PC4000 GZEBM08199-1 (Completo)Mm

SHOP 08199-upD-GB-1

Shop Manual

HYDRAULIC EXCAVATOR

PC4000-6 Diesel Serial Number 08199 and up

HYDRAULIC MINING EXCAVATOR PC4000-6D

Machine model

Serial numbers

PC4000-6D

08199 and up

00 Foreword

® Copyright 2009 KOMATSU MINING GERMANY GmbH

PC4000-6D

1

2

PC4000-6D

1.1 CONTENTS OF THE BINDER

1.1

CONTENTS OF THE BINDER

Assembled in this file are the Operation- and Maintenance Manuals for your KOMATSU Mining Shovel.

4

INTRODUCTION

INTRODUCTION

1.2

1.2 DIVISION OF THE BINDER

DIVISION OF THE BINDER

Part 1: Operation Manual Part 2: Maintenance Manual Part 3: Depending on the volume of Part 3 a second Binder "Volume 2" 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 Engine. 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 KOMATSU Shovel.

PERFORMANCE

of

your

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 and use as a transport vehicle) 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 ”General Assembly Procedure Manual” in Volume 2 Service Literature Binder. WARNING ●

Improper assembling of the Shovel can cause serious accidents with personal injury or death.

●

Personnel entrusted with work on the machine must have read the Assembly Manual, the Operation- 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 safe assembling procedure, contact your local Komatsu Service Organization.

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. In order to keep your Shovel in first-class operating condition use only genuine spare and wear parts. 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

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


Machine model

Serial numbers

PC4000-6D

08199 and up

01 Specification


PC4000-6D

1

2

PC4000-6D

OPERATING WEIGHT 385-397 ton 850,000-875,000 lb 22

m3

SHOVEL CAPACITY 29 yd3 SAE 2:1 heaped

BACKHOE CAPACITY 22 m3 29 yd3 SAE 1:1 heaped

PC4000 PC

4000

SUPER SHOVEL

PC 4000

S UPER S HOVEL

WALK-AROUND Quality ● Quality management ISO 9001 certified. ● Environmental Management ISO 14001 certified. ● High consistent quality through continuous investment in personnel, design and manufacturing systems and processes.

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.

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

2

PC 4000

SUPER SHOVEL

MATCHED FOR 150 to 240 U.S. ton TRUCKS

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 AND BACKHOE BUCKET CAPACITY 22 m3 29 yd3

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 Single Komatsu SDA16V160 engine ● Rated 1400 kW 1875 HP, at 1800 rpm. ● Electronic 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.

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. ● VHMS 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.

3

PC 4000

S UPER S HOVEL

SPECIFICATIONS DIESEL DRIVE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SDA16V160 Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rated power . . . . . . . . . . . . . . . . . . 1400 kW 1875 HP @ 1800 rpm (SAE 1995/J1349)

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronic The integrated engine oil and filter system combining the oil stabilising systems, Reserve and Centinel, with the Eliminator self cleaning oil filter extends, with oil analysis, the oil change interval to 4000 hours. (not available in Australia)

ELECTRIC DRIVE Type . . . . . . . . . . . . . . . . . . . . . . . . . Squirrel-cage induction motor Power output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350 kW Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6600 V* Amperage (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 A Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soft start Frequency (standard) . . . . . . . . . . . . . . . . . . . . . 50 Hz @ 1500 rpm Optional frequency . . . . . . . . . . . . . . . . . . . . . . . 60 Hz @ 1800 rpm *Other voltages available on request

UNDERCARRIAGE ELECTRICS System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V Batteries (series/parallel) . . . . . . . . . . . . . . . . . . . . . . . . 2x 3 x 12 V Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 A Standard working lights. . . . . . . . . . . . . . . . . . . . . . . 8 Xenon lights Standard service lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 lights

HYDRAULICS The power train consists of one main drive. Diesel engine or electric motor can be supplied. One gearbox drives four identical main pumps which draw hydraulic oil from an unpressurized hydraulic tank. Open circuit hydraulics provide maximum cooling and filtering efficiency. Rated flow (total output) . . . . . . . . . . . . 4140 ltr/min 1096 U.S. gal Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . 310 bar 4,495 psi Swing flow rate . . . . . . . . . . . . . . . . . . . . 1590 ltr/min 420 U.S. gal High pressure in line filters . . . . . . . . . . . . . . . . . . . . . . 200 microns

Undercarriage consists of one center carbody and two track frames, each side attached by 62 high torque bolts. Center frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-type Track frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel box-section

CRAWLER ASSEMBLY Track adjustment . . . . . . . . . . . . . . . . . . . Automatic hydraulic type Number of shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 each side Number of top rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 each side Number of bottom rollers. . . . . . . . . . . . . . . . . . . . . . . . 7 each side

COOLING SYSTEM The high capacity engine radiators are cooled by hydraulically driven fans for superior cooling efficiency and require little maintenance. The hydraulic system includes two large swing-out vertical air-to-oil hydraulic coolers with temperature-regulated hydraulically driven fans.

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 four large swing-out vertical air-to-oil hydraulic coolers with temperatureregulated hydraulically driven fans.

DRIVES AND BRAKES Travel control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 foot pedals Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 50% Travel speed (maximum) . . . . . . . . . . . . . . . . . . . 2.1 km/h 1.3 mph Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc

SWING SYSTEM Hydraulic motors and drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Swing brake, service . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake Swing brake, parking. . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc Swing ring teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Swing speed (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 rpm

4

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 VHMS. The central lube grease system is supplied from a refillable 200 litre 53 gal. barrel. A second, identical system supplies open gear lubricant to the swing ring teeth through a lube pinion. Replenishment of the barrels is through the service arm.

SERVICE CAPACITIES Hydraulic oil tank . . . . . . . . . . . . . . . . . . . 3900 ltr Hydraulic system . . . . . . . . . . . . . . . . . . . 5900 ltr Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400 ltr Engine coolant . . . . . . . . . . . . . . . . . . . . . . 475 ltr Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . 290 ltr Centinel engine oil make up tank . . . . . . . 460 ltr

1,030 U.S. gal 1,559 U.S. gal 1,691 U.S. gal 125 U.S. gal 77 U.S. gal 122 U.S. gal

PC 4000

SUPER SHOVEL

CAB Cab engineering standards are; • ISO 3449 Falling Objects Protection Structure • ISO 6396 Noise in operator´s cab is 73 dB(A) • ISO 2631-1/ 5349-1 Vibration and Shock • Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . .10kW 34120 Btu • Heater/Demister (Diesel version) . . . . . . . . . . . . .10kW 34120 Btu

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 VHMS 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.

CS

VEHICLE HEALTH MONITORING SYSTEM

VHMS is designed for Komatsu mining equipment to provide real time and stored information about the status of the operating machine. A touch sensitive flat screen color monitor gives a continuous display or can be activated to provide operator or service data. Non serious and critical faults are automatically announced, while for major malfunctions the engine is also shut down. The integrated digital storage provides a full event history, which can be down loaded by laptop computer or by wireless link. The ability to provide real time service information as messages, snap-shot or trend data automatically to mine control programmes can improve mechanical utilisation and reduce costs. (Electric drive version fitted with ECS Health Monitor)

OPERATING WEIGHTS PC 4000 Backhoe:

PC 4000 Front Shovel:

Operating weight including 9750 mm 32’0’’ boom, 4500 mm 14’9’’ stick, 22 m3 29 yd3 backhoe bucket, operator, lubricant, coolant, full fuel tank and standard equipment.

Operating weight including 7150 mm 23’6’’ boom, 4900 mm 16’1’’ stick, 22 m3 29 yd3 shovel bucket, operator, lubricant, coolant, full fuel tank and standard equipment.

Shoe Width

Operating Weight

Ground Pressure

Shoe Width

Operating Weight

Ground Pressure

1200 mm 47’’

392 t 865,000 lb

2.19 kg/cm2 31.2 psi

1200 mm 47’’

385 t 850,000 lb

2.15 kg/cm2 30.6 psi

1500 mm 59’’

397 t 875,000 lb

1.78 kg/cm2 25.3 psi

1500 mm 59’’

390 t 860,000 lb

1.75 kg/cm2 24.8 psi

4

5

3

Explanation 1 Operator´s Cab

7

10

2 Power Train 3 Hydraulic Pumps

6

4 Hydraulic Tank

2

9

5 Hydraulic Coolers 6 Valve Blocks 7 Swing Motor

7

10

8 Fuel Tank

8

9 Counterweight 10 Autolube System

6

1

11 Secondary Egress

11

Lower-Level Upper-Level SKZ4006_68

5

PC 4000

S UPER S HOVEL

PRODUCTIVITY-FEATURES

4006078

DIGGING FORCES Break-out force Tear-out force

1155 kN 1050 kN

260,000 lb 236,000 lb

Maximum reach at ground level . . . . . . . . .16.650 mm 54’8’’ Maximum digging depth . . . . . . . . . . . . . . . .8000 mm 26’3’’

BACKHOE BUCKET, STICK AND BOOM COMBINATION Bucket Capacity

Width

SAE Heaped 1 : 1 22 m3 29 yd3

Teeth

including Wear package -2 3790 mm 12’5’’

Alternative buckets / wear packages are available

6

Weight

23.4 t 51,590 lb

Boom Length 9750 mm 32’ 0’’ Stick Length 4500 mm 14’ 9’’

6

Material weight to 1.8 t/m3 3000 lb/yd3

SUPER SHOVEL

PC 4000

4006077

DIGGING FORCES Break-out force Crowd force

1250 kN 1330 kN

280,000 lb 300,000 lb

Level crowd at ground level . . . . . . . . . . . . . .5700 mm 18’8’’ Maximum dumping height . . . . . . . . . . . . . .12.000 mm 39’4’’

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

Heaped 1 : 1

22 m3 29 yd3

25 m3 32.7 yd3

Width

Weight

Teeth

including Wear package-3 4020 mm 13’2’’

38.8 t 76,700 lb

Boom Length 7150 mm 23’ 6’’ Stick Length 4900 mm 16’ 1’’

5

Material weight to 1.8 t/m3 3000 lb/yd3

Alternative buckets / wear packages are available

7

STANDARD EQUIPMENT Hydraulic Mining Shovel with Diesel Drive will comprise: ● FRONT SHOVEL ATTACHMENT 7.15 m 23'6" boom and 4.9 m 16'1" stick complete with cylinders. 22 m3 29 yd3 (SAE 2:1) shovel bucket with mechanical teeth and lip system. OR ● BACKHOE ATTACHMENT 9.75 m 32'0" boom and 4.5 m 14'9" stick with 22 m3 29 yd3 (SAE 1:1) bucket. ● CRAWLER UNDERCARRIAGE Heavy-duty shovel type undercarriage consisting of a center carbody and 2 heavy box-type track frames, each having 7 bottom rollers, 3 top rollers, and 1200 mm 47" cast steel track shoes. Hydraulic track adjustment and parking brake provided.

● SUPERSTRUCTURE Main frame mounted over an externally toothed swing circle carries the main drive module, including Komatsu SDA16V160 diesel engine, oil and fuel reservoirs, counterweight, operator’s cab and base.

AM-FM radio. Washbasin with running water (reservoir 50 ltr 13 gal). Refrigerator and storage cabinets. Left and right hand sliding windows. All windows tinted parsol green. ● LUBRICATION LINCOLN central lubrication for basic machine, attachment, and bucket. 200 ltr 53 gal refillable barrel. LINCOLN automatic pinion lubrication system for swing circle teeth with 200 ltr 53 gal refillable barrel.

● LIGHTING 8 Xenon high performance working lights. 11 service lights throughout platform. ● 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 fully suspended seat with lap-belt. Fold-away auxiliary seat. Full selection of controls, switches, and VHMS (Vehicle Health Monitoring System). Joystick and pedal-operated controls are electric over hydraulic. Windshield wash wipers with two speed and intermittent operation. (reservoir 7 ltr 1.8 gal).

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, cabwater 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 System. (Centinel, Reserve & Eliminator Systems)

OPTIONAL EQUIPMENT • 1500 mm 59’’ track shoes • Extra or alternative, lighting

• Electric drive • Cable reel (Electric Version)

• Low temperature package • Fire suppression system

DIMENSIONS

BASIC MACHINE WITH COUNTERWEIGHT

N M

OR

L

A B CA CB D E F G

1200mm 1500mm 6750mm 7050mm 2480mm 3380mm 6700mm 8842mm

47" 59" 22'2" 23'2" 8'2" 11'1" 22'0" 29'0"

H I J K L M N O OR

3017mm 3085mm 7600mm 8300mm 3175mm 4700mm 7975mm 6095mm 6500mm

9'11" 10'2" 24'11" 27'3" 10'5" 18'6" 26'2" 20'0" 21'4"

O

K

H

D

E

A B

F

CA

G

CB

Ground Clearance: 930mm 3'0"

QESS0046 01

I J

SKZ4006_67

SKZ4006_66

©2006 Komatsu Printed in Germany

www.komatsu-mining.com

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


Machine model

Serial numbers

PC4000-6D

08199 and up

10 Structure, Function


PC4000-6D

1

2

PC4000-6D

I.

II.

INTRODUCTION ............................................................................ I-1 I.I

CONTENTS OF THE BINDER ........................................................................................... I-2

I.II

FOREWORD ...................................................................................................................... I-3 1.2.1 IMPORTAND NOTE.............................................................................................. I-5

I.III

EXPLANATION OF ABBREVATIONS .............................................................................. I-7

SAFETY ......................................................................................... II-1 II.I

SAFETY INSTRUCTIONS ................................................................................................. II-2

II.II

GENERAL PREAUCTIONS .............................................................................................. II-3

II.III

PREPARATIONS FOR WORK ......................................................................................... II-4

II.IV

PRECAUTIONS DURING WORK ..................................................................................... II-5

II.V

PRECAUTIONS AFTER WORK ....................................................................................... II-6

1

1

III.

2

MAIN ASSEMBLY GROUPS............................................................ 1-1 1.1

GENERAL LAYOUT .......................................................................................................... 1-2

1.2

SUPERSTRUCTURE ......................................................................................................... 1-4

1.3

MACHINE HOUSE ............................................................................................................ 1-6

1.4

HYDRAULIC OIL RESERVOIR ......................................................................................... 1-8

1.5

HYDRAULIC OIL COOLER ............................................................................................. 1-10

1.6

FUEL TANK .................................................................................................................... 1-12

1.7

COUNTERWEIGHT.......................................................................................................... 1-14

1.8

CAB SUPPORT................................................................................................................ 1-16

1.9

OPERATOR’S CAB ......................................................................................................... 1-18

1.10

CONTROL BLOCKS ........................................................................................................ 1-20

1.11

SWING GEARS ................................................................................................................ 1-22

1.12

UNDERCARRIAGE.......................................................................................................... 1-24

1.13

BACKHOE ATTACHMENT (BHA) .................................................................................. 1-26

1.14

FRONT SHOVEL ATTACHMENT (FSA) ......................................................................... 1-28

SPECIFICATIONS ........................................................................ III-1 III.I

LIFTING GEARS .............................................................................................................. III-2

III.II

STANDARD TIGHTENING TORQUE CHART ................................................................ III-4

III.III

CONVERSION TABLE ..................................................................................................... III-5

III.IV

GENERAL SPECIFICATIONS ....................................................................................... III-12

2.

DRIVE............................................................................................... 2-1 2.1

PRIME DRIVE ASSEMBLY ............................................................................................... 2-2

2.2

ENGINE AND PTO MOUNTS ............................................................................................ 2-4 2.2.1 FLEXIBLE MOUNTS ............................................................................................ 2-5 2.2.2 TORQUE SUPPORT............................................................................................ 2-7

2.3

FAN DRIVE AND RADIATOR ASSEMBLY....................................................................... 2-8 2.3.1 RADIATOR FAN DRIVE SPEED ADJUSTMENT .............................................. 2-12

2.4

PUMP DISTRIBUTOR GEARBOX (PTO)........................................................................ 2.4.1 SPLINE SHAFT HOUSING ................................................................................ 2.4.2 PTO LUBRICATION AND COOLING................................................................. 2.4.3 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES .......

2.5

GEISLINGER COUPLING................................................................................................ 2-28

2.6

AIR FILTER ...................................................................................................................... 2-30

2-16 2-18 2-20 2-26

3

3.

4

HYDRAULIC OIL RESERVOIR ........................................................ 3-1 3.1

GENERAL LAYOUT ......................................................................................................... 3-2

3.2

MAIN OIL TANK, LOCATION OF ELECTRIC EQUIPMENT. ........................................... 3-4

3.3

SUCTION OIL RESERVOIR WITH STRAINERS ............................................................. 3-6

3.4

RETURN OIL COLLECTOR TUBE WITH STRAINER ..................................................... 3-8

3.5

BACK PRESSURE VALVE ............................................................................................. 3-10

3.6

TRANSFER PUMP .......................................................................................................... 3-12 3.6.1 EVACUATION OF THE SUCTION OIL RESERVOIR........................................ 3-15 3.6.2 EVACUATION OF THE RETURN OIL COLLECTOR PIPES AND COOLER CIRCUIT 3-17

3.7

RETURN AND LEAK OIL FILTER .................................................................................. 3-18

3.8

BREATHER FILTER ....................................................................................................... 3-20

4.

HYDRAULIC OIL COOLING ............................................................ 4-1 4.1

4.2 CIRCUIT 4.3

GENERAL .......................................................................................................................... 4-2 FUNCTION OF THE HYDRAULIC OIL COOLING 4-4 ADJUSTMENT OF THE BACK PRESSURE VALVE........................................................ 4-6

4.4 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL) 4-8 4.4.1 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING ......................... 4-10 4.4.2 PRESSURE RELIEF VALVES .......................................................................... 4-12 4.4.3 FAN SPEED CONTROL VALVE ARRANGEMENT........................................... 4-14 4.5

ADJUSTMENT OF THE COOLER FAN DRIVE SPEED ................................................. 4-16 4.5.1 FUNCTION CHECK OF FAN SPEED CONTROL ............................................. 4-21

5

5.

CONTROLLING.............................................................................. 5-23 5.1

GENERAL LAYOUT ........................................................................................................ 5-24

5.2 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS 5-26 5.3

PILOT PRESSURE SUPPLY AND ADJUSTMENTS ...................................................... 5.3.1 PILOT PRESSURE CIRCUIT (PPC) .................................................................. 5.3.2 CHECKS AND ADJUSTMENT OF PILOT PRESSURE..................................... 5.3.3 REMOTE CONTROL VALVES ARRANGEMENT..............................................

5-32 5-33 5-36 5-38

5.4 FUNCTION ELECTRO HYDRAULIC CONTROL SYSTEM 5-40

6

5.5

POTENTIOMETER CONTROL (LEVER, JOY STICK).................................................... 5-44

5.6

POTENTIOMETER CONTROL (PEDAL) ........................................................................ 5-46

5.7

PROPORTIONAL AMPLIFIER MODULE, TYPE A ......................................................... 5-48

5.8

PROPORTIONAL AMPLIFIER MODULE, TYPE B ......................................................... 5-50

5.9

RAMP TIME MODULE .................................................................................................... 5-52

5.10

ADJUSTMENTS OF AMPLIFIER MODULES ................................................................. 5.10.1 GENERAL .......................................................................................................... 5.10.2 ADJUSTING THE AMPLIFIERS TYPE B........................................................... 5.10.3 ADJUSTING THE AMPLIFIERS TYPE A...........................................................

5.11

ADJUSTING THE RAMP TIME MODULE ....................................................................... 5-62

5-54 5-55 5-56 5-60

6.

COMPONENTS ................................................................................ 6-1

6.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (FSA) 6-2 6.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (BHA) 6-4 6.3 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (FSA) 6-6 6.4 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (BHA) 6-8 6.5

SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM (FSA)................ 6-10

6.6

RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE........................................... 6-12

6.7

ANTI CAVITATION VALVE BLOCK................................................................................ 6-14

6.8

REMOTE CONTROL VALVES ........................................................................................ 6-16

6.9 DIRECTIONAL SOLENOID VALVES (THREE POSITIONS / 4-WAYS) 6-18 6.10

PROPORTIONAL SOLENOID VALVE ............................................................................ 6-20

6.11

HIGH PRESSURE FILTER .............................................................................................. 6-22

6.12

CONTROL BLOCKS AND VALVES................................................................................ 6-24

6.13

TRAVEL BRAKE VALVE................................................................................................. 6-36

6.14

PRESSURE REDUCING VALVE..................................................................................... 6-38

6.15 DIRECTIONAL SOLENOID VALVES (TWO POSITIONS / 4-WAYS) 6-40 6.16

PRESSURE INCREASING VALVE ................................................................................. 6-42

6.17

HYDRAULIC CYLINDER ................................................................................................. 6-44

6.18

SWING RING.................................................................................................................... 6-48

7

7.

MAIN HYDRAULIC PUMPS AND PUMP REGULATION................. 7-1 7.1

GENERAL .......................................................................................................................... 7-2

7.2

MAIN PUMPS ................................................................................................................... 7.2.1 LOCATION OF PUMPS ..................................................................................... 7.2.2 PUMP BEARING FLUSHING / LUBRICATION.................................................. 7.2.3 OPERATING PRINCIPLE .................................................................................. 7.2.4 CHECKS / ADJUSTMENTS ...............................................................................

7-12 7-13 7-14 7-16 7-34

7.3

ELECTRONIC PUMP REGULATION SYSTEM .............................................................. 7.3.1 ELECTRONIC LOAD LIMITING CONTROL - GENERAL .................................. 7.3.2 MICROCONTROLLER RC4-4............................................................................ 7.3.3 CHECKS AND ADJUSTMENTS ........................................................................

7-44 7-45 7-47 7-49

7.4

HYDRAULIC CONSTANT REGULATION SYSTEM ....................................................... 7-76 7.4.1 GENERAL .......................................................................................................... 7-77 7.4.2 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE)............................. 7-78

7.5 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE) 7-80

8

7.6

ENGINE SPEED SENSOR (PICK UP)............................................................................. 7-82 7.6.1 GENERAL .......................................................................................................... 7-83 7.6.2 ENGINE SPEED SENSOR (PICK UP) ADJUSTMENT ..................................... 7-83

7.7

ENERGY EFFICIENCY .................................................................................................... 7-84 7.7.1 GENERAL .......................................................................................................... 7-85 7.7.2 CHECKS AND ADJUSTMENTS ........................................................................ 7-86

8.

OPERATING HYDRAULIC............................................................... 8-1 8.1

GENERAL .......................................................................................................................... 8-2 8.1.1 FLOATING SYSTEM............................................................................................ 8-4

8.2

HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA............................... 8-6 8.2.1 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISING" FSA...................... 8-6 8.2.2 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISING" BHA ..................... 8-8 8.2.3 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" FSA ............... 8-10 8.2.4 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" BHA............... 8-12 8.2.5 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTENDING" FSA .............. 8-14 8.2.6 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTENDING" BHA.............. 8-16 8.2.7 ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACTING" FSA............ 8-18 8.2.8 ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACTING" BHA ........... 8-20 8.2.9 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET FILLING" FSA ................. 8-22 8.2.10 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET FILLING" BHA ................. 8-24 8.2.11 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET EMPTYING" FSA ............ 8-26 8.2.12 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET EMPTYING" BHA............ 8-28 8.2.13 ELECTRIC / HYDRAULIC FLOWCHART "CLAM OPENING" FSA ................... 8-30 8.2.14 ELECTRIC / HYDRAULIC FLOWCHART "CLAM CLOSING" FSA ................... 8-32 8.2.15 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (FSA) ......... 8-34 8.2.16 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (BHA)......... 8-36 8.2.17 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV) 8-38 8.2.17.1 BOOM CYLINDER "PISTON SIDE" FSA + BHA .............................. 8-39 8.2.17.2 BOOM CYLINDER "PISTON ROD SIDE" FSA +BHA ...................... 8-43 8.2.17.3 STICK CYLINDER "PISTON SIDE" FSA .......................................... 8-47 8.2.17.4 STICK CYLINDER "PISTON SIDE" BHA.......................................... 8-51 8.2.18 STICK CYLINDER "PISTON ROD SIDE" FSA .................................................. 8-55 8.2.18.1 STICK CYLINDER "PISTON ROD SIDE" BHA................................. 8-59 8.2.18.2 BUCKET CYLINDER "PISTON SIDE" FSA ...................................... 8-63 8.2.18.3 BUCKET CYLINDER "PISTON SIDE" BHA...................................... 8-67 8.2.18.4 BUCKET CYLINDER "PISTON ROD SIDE" FSA ............................. 8-71 8.2.18.5 BUCKET CYLINDER "PISTON ROD SIDE" BHA............................. 8-75 8.2.18.6 CLAM CYLINDER "PISTON ROD SIDE" FSA.................................. 8-79 8.2.18.7 CLAM CYLINDER "PISTON SIDE" FSA........................................... 8-81 8.2.18.8 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED ....... 8-83 8.2.18.9 BUCKET CYLINDER FSA ................................................................ 8-97 8.2.18.10 BUCKET CYLINDER BHA ................................................................ 8-99 8.2.18.11 CLAM CYLINDER BHA .................................................................. 8-101

8.3

HYDRAULIC FOR THE SWING CIRCUIT ..................................................................... 8.3.1 SWING CIRCUIT.............................................................................................. 8.3.2 SWING MOTOR .............................................................................................. 8.3.3 SWING GEAR BOX ......................................................................................... 8.3.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE) ...................................... 8.3.5 SWING BRAKE VALVE ................................................................................... 8.3.6 ELECTRIC / HYDRAULIC FLOWCHART "SWING LEFT" .............................. 8.3.7 ELECTRIC / HYDRAULIC FLOWCHART "SWING RIGHT" ............................ 8.3.8 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT......................... 8.3.9 FUNCTION CHECK FOR HYDRAULIC SWING BRAKE ................................ 8.3.10 FUNCTION CHECK FOR THE SWING PARKING BRAKE .............................

8-102 8-102 8-106 8-108 8-110 8-112 8-114 8-116 8-118 8-124 8-126

9

8.4

10

HYDRAULIC FOR THE TRAVEL CIRCUIT ................................................................... 8.4.1 TRAVEL CIRCUIT ............................................................................................ 8.4.2 TRAVEL MOTOR ............................................................................................. 8.4.3 ROTARY DISTRIBUTOR ................................................................................. 8.4.4 TRAVEL GEAR ................................................................................................ 8.4.5 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)..................................... 8.4.6 TRAVEL BRAKE VALVE.................................................................................. 8.4.7 ELECTRIC / HYDRAULIC FLOWCHART “TRAVELING FORWARD”............. 8.4.8 ELECTRIC / HYDRAULIC FLOWCHART “TRAVELING BACKWARD”........... 8.4.9 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT ....................... 8.4.10 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE ...........................

8-128 8-128 8-132 8-134 8-136 8-138 8-140 8-142 8-144 8-146 8-148

9.

HYDRAULIC TRACK TENSIONING SYSTEM ................................ 9-1 9.1

GENERAL .......................................................................................................................... 9-2

9.2

PRESSURE INCREASING VALVE ................................................................................... 9-6

9.3

TENSIONING CYLINDER .................................................................................................. 9-8

9.4

ADJUSTMENTS / CHECKS............................................................................................. 9-10

9.5

FUNCTIONAL TEST ........................................................................................................ 9-12

11

10. ACCESS LADDER HYDRAULICALLY OPERATED ...................... 10-1

12

10.1

GENERAL ........................................................................................................................ 10-2

10.2

FUNCTION OF HYDRAULICALLY OPERATED ACCESS LADDER............................. 10-4

10.3


11. CENTRAL REFILLING SYSTEM (SERVICE ARM) ....................... 11-1 11.1

GENERAL ........................................................................................................................ 11-2

11.2

FUNCTION ....................................................................................................................... 11-4

13

12. HINTS FOR READING THE HYDRAULIC DIAGRAM ................... 12-1

14

12.1

GENERAL ........................................................................................................................ 12-2

12.2

SYMBOLIC....................................................................................................................... 12-4 12.2.1 LINES, UNIONS ................................................................................................. 12-5 12.2.2 COMPONENTS, VALVES.................................................................................. 12-6 12.2.3 SENSORS .......................................................................................................... 12-7 12.2.4 VALVES, VALVE COMPONENTS ..................................................................... 12-8 12.2.5 PUMP, MOTOR, CYLINDER............................................................................ 12-12

13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM....... 13-1 13.1

DESIGNATION OF ELECTRICAL COMPONENTS ........................................................ 13-3

13.2

ELECTRIC SYMBOLS ..................................................................................................... 13-4

13.3

SYMBOLS ........................................................................................................................ 13-6

13.4

DRAWING CONCEPT...................................................................................................... 13-8

13.5

READING A CIRCUIT DIAGRAM.................................................................................. 13-12

13.6

COMPONENT LIST........................................................................................................ 13-16

15

14 VEHICLE HEALTH MONITORING SYSTEM ................................. 14-1

16

14.1

GENERAL ........................................................................................................................ 14-2

14.2

SPECIFICATIONS FOR OPERATORS .......................................................................... 14-4 14.2.1 SEQUENCE OF DISPLAYS............................................................................... 14-5 14.2.2 OPENING SCREEN ........................................................................................... 14-5 14.2.3 MAIN GAUGE SCREENS 1 TO 3 ...................................................................... 14-6 14.2.4 FUEL CONSUMPTION SCREEN .................................................................... 14-10 14.2.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR......................... 14-13 14.2.6 MAIN SCREEN - CHANCE TIME SMR DATE ................................................. 14-13 14.2.7 MAINTENANCE MONITOR ............................................................................. 14-14 14.2.8 SETTINGS FOR OPERATOR.......................................................................... 14-16 14.2.9 AUTOMATIC MESSAGES ............................................................................... 14-22 14.2.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM.................. 14-26 14.2.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES ..................................... 14-36

14.3

SPECIFICATIONS FOR SERVICE ................................................................................ 14.3.1 MAIN SCREEN FLOW CHART FOR THE OPERATER MODE ...................... 14.3.2 MAIN SCREEN FLOW CHART FOR THE SERVICE MODE .......................... 14.3.3 ENTERING THE SERVICE MENU .................................................................. 14.3.4 SERVICE MENU SELECT SCREEN ............................................................... 14.3.5 REAL TIME MENU SELECT SCREEN ............................................................ 14.3.5.1 ENGINE .......................................................................................... 14.3.5.2 PTO 1.............................................................................................. 14.3.5.3 HYDRAULIC ................................................................................... 14.3.5.4 ELECTRICAL EQUIPMENT............................................................ 14.3.5.5 EMERGENCY STOP ...................................................................... 14.3.5.6 MANUAL SW .................................................................................. 14.3.5.7 CENTRAL LUBRICATION SYSTEM 1 ........................................... 14.3.5.8 SLEW RING GEAR LUBE SYSTEM............................................... 14.3.5.9 OTHER............................................................................................ 14.3.5.10 OUTPUT SIGNALS......................................................................... 14.3.5.11 OUTPUT SIGNALS WITH DEACTIVATED PLC-EVALUATION .... 14.3.6 PM-CLINIC ....................................................................................................... 14.3.6.1 GENERAL ....................................................................................... 14.3.6.2 POWER CHECK ............................................................................. 14.3.7 SERIAL/GCC NO. SETTING............................................................................ 14.3.8 MEMORY CLEAR ............................................................................................ 14.3.8.1 INPUT MEMORY CLEAR ID........................................................... 14.3.8.2 MEMORY CLEAR SCREEN ........................................................... 14.3.9 FAILURE HISTORY ......................................................................................... 14.3.10 MAINTENANCE MONITOR ............................................................................. 14.3.11 SNAPSHOT...................................................................................................... 14.3.12 SETTINGS........................................................................................................ 14.3.12.1 CENTRAL LUBRICATION SYSTEM (CLS) .................................... 14.3.12.2 SWING LUBRICATION SYSTEM (SLS)......................................... 14.3.12.3 OTHER SETTINGS 1...................................................................... 14.3.12.4 OTHER SETTINGS 2...................................................................... 14.3.12.5 SHUTDOWN ON/OFF ....................................................................

14.4

WIRING OF THE MAIN COMPONENTS ....................................................................... 14-74

14-38 14-39 14-40 14-44 14-46 14-47 14-47 14-48 14-48 14-50 14-50 14-51 14-52 14-52 14-53 14-54 14-56 14-57 14-57 14-58 14-59 14-60 14-60 14-61 14-62 14-64 14-65 14-66 14-66 14-67 14-68 14-70 14-71

14.4.1 14.4.2 14.4.3 14.4.4

WIRING OF THE ENGINE ............................................................................... WIRING OF THE VHMS-CONTROLLER......................................................... WIRING OF THE CGD-MONITOR................................................................... WIRING OF THE PLC......................................................................................

14-76 14-78 14-82 14-84

14.5

GENERAL DESIGN OF THE PLC ................................................................................. 14.5.1 INPUT AND OUTPUT OF THE PLC ................................................................ 14.5.2 TASK ................................................................................................................ 14.5.3 PLC DIGSY PLUS ® ........................................................................................

14-86 14-89 14-89 14-90

14.6

HOW TO PROCEED THE MAINTENANCE AND INSTALLATION .............................. 14.6.1 MEANING OF THE +5 V STATUS LED........................................................... 14.6.2 MEANING OF THE DIAG STATUS LED ......................................................... 14.6.3 SHORT CIRCUIT MARKER-LED “MK”............................................................ 14.6.4 DIAGNOSTIC FOR ANALOGUE-MODULE “ANM” .........................................

14-92 14-93 14-95 14-98 14-98

14.7

FRONT CONNECTOR ARRANGEMENT...................................................................... 14-99 14.7.1 FRONT CONNECTOR ARRANGEMENT, BIM MODULE (DIGITAL INPUT / OUTPUT) 14-

99 14.7.2 14.7.3 14.7.4

FRONT CONNECTOR ARRANGEMENT, ANM-MODULE (ANALOGUES INPUT) 14-101 GROUND CONNECTION OF THE CONTROL UNIT .................................... 14-103 INTERFACE-CONNECTION VHMS-CONTROLLER .................................... 14-104

14.8

POWER SUPPLY......................................................................................................... 14.8.1 OPERATION VOLTAGES +24 V ................................................................... 14.8.2 SAFETY PRECAUTIONS FOR TROUBLESHOOTING................................. 14.8.3 CPU VOLTAGE RANGE AND ELECTRIC CLASSIFICATION ...................... 14.8.4 FUSE..............................................................................................................

14-106 14-107 14-108 14-109 14-109

14.9

FUNCTION EXPLANATIONS WITH ELECTRICAL DIAGRAM.................................. 14.9.1 GENERAL ...................................................................................................... 14.9.2 PRESSURE MEASURING (HYDRAULIC SYSTEM) ..................................... 14.9.3 TEMPERATURE MEASURING AND TROUBLESHOOTING........................ 14.9.4 TEMPERATURE – RESISTANCE CHART PT100 ........................................

14-111 14-111 14-112 14-114 14-116

14.10 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS..................................... 14-117 14.10.1 GENERAL ...................................................................................................... 14-117 14.10.2 EXAMPLE: MONITORING THE X1-PRESSURE FOR PUMP CONTROL .... 14-118

17

15. LUBRICATION SYSTEMS ............................................................. 15-1

18

15.1

INTRODUCTION .............................................................................................................. 15-3

15.2

CENTRAL LUBRICATION SYSTEM (CLS) .................................................................... 15-4 15.2.0.1 CLS LUBRICATION SYSTEM ELECTRIC LAYOUT ........................ 15-8

15.3

LUBRICATION PUMP STATION (SLS) ........................................................................ 15.3.0.1 SLS LUBRICATION SYSTEM ELECTRIC LAYOUT ...................... 15.3.1 HYDRAULICALLY DRIVEN LUBE PUMP........................................................ 15.3.2 VENT VALVE ................................................................................................... 15.3.3 END OF LINE SWITCH.................................................................................... 15.3.4 IN-LINE FILTER ............................................................................................... 15.3.5 LUBRICANT LEVEL SENSOR......................................................................... 15.3.6 LUBRICANT PRESSURE SENSOR ................................................................ 15.3.7 LUBRICANT INJECTOR .................................................................................. 15.3.7.1 FUNCTION STEPS:........................................................................ 15.3.7.2 INLINE CONNECTION OF INJECTORS ........................................ 15.3.8 LUBRICATION PINION ....................................................................................

15.4

OPERATING AND CONTROLLING .............................................................................. 15-33 15.4.1 OPERATING FLOW, ELECTRICAL FLOW ..................................................... 15-34

15.5

ADJUSTMENTS ............................................................................................................. 15.5.1 PUMP SPEED AND WORKING PRESSURE .................................................. 15.5.1.1 ADJUSTMENTS LUBRICATING PUMP SPEED............................ FIG. 15-20ADJUSTMENTS LUBRICATING PUMP PRESSURE .................... 15.5.2 INJECTORS ..................................................................................................... 15.5.3 END OF LINE SWITCH SETTING CLS ........................................................... 15.5.4 END OF LINE SWITCH SETTING SLS ...........................................................

15.6

TROUBLESHOOTING ................................................................................................... 15-48

15.7

COMMISSIONING .......................................................................................................... 15.7.1 COMMISSIONING OF THE CLS ..................................................................... 15.7.2 FINE ADJUSTMENT ........................................................................................ 15.7.3 COMMISSIONING OF THE SLS......................................................................

15-10 15-14 15-16 15-18 15-20 15-22 15-24 15-25 15-26 15-28 15-30 15-31

15-38 15-39 15-39 15-41 15-42 15-44 15-46 15-52 15-52 15-53 15-53

Table of Contents I.

INTRODUCTION ............................................................................ I-1 I.I

CONTENTS OF THE BINDER ........................................................................................... I-2

I.II

FOREWORD ...................................................................................................................... I-3

I.III

RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS ...................................................... I-4

I.IV

EXPLANATION OF ABBREVATIONS .............................................................................. I-5

I.V

DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL ................................................... I-6

SAFETY............................................................................................ II-1 CONTENTS ........................................................................................................................ II-2 OVERVIEW ........................................................................................................................ NORMAL OPERATIONS ..................................................................................... REGULAR MAINTENANCE................................................................................. TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...................................... ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR ................

II-3 II-3 II-3 II-3 II-3

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........... II-4 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR .... II-4 PREPARATIONS FOR SAFE OPERATION ........................................................ II-4 FIRE PREVENTION............................................................................................. II-6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE........................ II-8 BURN PREVENTION........................................................................................... II-9 PRECAUTIONS WHEN CLEANING CAB GLASS............................................... II-9 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ........................ II-10 PRECAUTIONS AT JOBSITE............................................................................ II-11 STARTING ENGINE .......................................................................................... II-17 OPERATION ...................................................................................................... II-18 PRECAUTION FOR MAINTENANCE.............................................................................. II-24 PRECAUTIONS FOR INSPECTION AND MAINTENANCE .............................. II-30 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS................................................................................................................ II-36 SPECIAL SAFETY EQUIPMENT..................................................................................... II-38

III.

SPECIFICATIONS ........................................................................ III-1 III.I

LIFTING GEARS .............................................................................................................. III-2

III.II

SAFETY HINTS FOR SLING ACCESSORY ................................................................... III-4

III.III

STANDARD TIGHTENING TORQUE CHART ................................................................ III-5

III.IV

CONVERSION TABLE ..................................................................................................... III-6

III.V

BLIND PLUGS ............................................................................................................... III-13

III.VI

CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH .................................... III-15

III.VII PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353 .............................. III-16

3

1.

2.

3.

4

MAIN ASSEMBLY GROUPS............................................................ 1-1 1.1

GENERAL LAYOUT .......................................................................................................... 1-2

1.2

SUPERSTRUCTURE ......................................................................................................... 1-4

1.3

MACHINE HOUSE ............................................................................................................ 1-6

1.4

HYDRAULIC OIL TANK..................................................................................................... 1-8

1.5

HYDRAULIC OIL COOLER ............................................................................................. 1-10

1.6

FUEL TANK ..................................................................................................................... 1-12

1.7

COUNTERWEIGHT.......................................................................................................... 1-14

1.8

CAB SUPPORT................................................................................................................ 1-16

1.9

OPERATOR’S CAB ......................................................................................................... 1-18

1.10

CONTROL BLOCKS ........................................................................................................ 1-20

1.11

SWING MACHINERY....................................................................................................... 1-22 1.11.1 SWING MACHINERY L&S ................................................................................. 1-22 1.11.2 SWING MACHINERY SIEBENHAAR................................................................. 1-24

1.12

UNDERCARRIAGE.......................................................................................................... 1-26

1.13

BACKHOE ATTACHMENT (BHA) .................................................................................. 1-28

1.14

FRONT SHOVEL ATTACHMENT (FSA) ......................................................................... 1-30

DRIVE............................................................................................... 2-1 2.1

PRIME DRIVE ASSEMBLY ............................................................................................... 2-2

2.2

ENGINE AND PTO MOUNTS ............................................................................................ 2-4 2.2.1 ENGINE MOUNTS ............................................................................................... 2-5 2.2.2 TORQUE SUPPORT............................................................................................ 2-6

2.3

GEISLINGER COUPLING.................................................................................................. 2-8

2.4

FAN DRIVE AND RADIATOR ASSEMBLY..................................................................... 2-10 2.4.1 RADIATOR FAN DRIVE SPEED ADJUSTMENT .............................................. 2-14

2.5

PUMP DISTRIBUTOR GEARBOX (PTO) ........................................................................ 2.5.1 PUMP DRIVE SHAFT HOUSING....................................................................... 2.5.2 PTO LUBRICATION AND COOLING................................................................. 2.5.3 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES .......

2.6

AIR FILTER ...................................................................................................................... 2-28

2-18 2-20 2-22 2-26

HYDRAULIC OIL TANK.................................................................... 3-1 3.1

GENERAL LAYOUT ......................................................................................................... 3-2

3.2

HYDRAULIC OIL TANK, LOCATION OF THE ELECTRIC EQUIPMENT ........................ 3-4

3.3

SUCTION OIL TANK WITH STRAINERS ......................................................................... 3-6

3.4

RETURN OIL COLLECTOR PIPE WITH STRAINER ....................................................... 3-8

3.5

BACK PRESSURE VALVE ............................................................................................. 3-10

3.6

TRANSFER PUMP FOR HYDRAULIC OIL ..................................................................... 3-12

3.7

RETURN AND LEAK OIL FILTER .................................................................................. 3-14

3.8

BREATHER FILTER ....................................................................................................... 3-16

4.

5.

6.

HYDRAULIC OIL COOLING ............................................................ 4-1 4.1

OVERALL VIEW OF THE HYDRAULIC OIL COOLING ................................................... 4-2

4.2

FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT ............................................ 4-4

4.3

ADJUSTMENT OF THE BACK PRESSURE VALVE........................................................ 4-6

4.4

FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL)........................................... 4-8 4.4.1 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING ......................... 4-10 4.4.2 PRESSURE RELIEF VALVE ............................................................................ 4-12 4.4.3 SOLENOID VALVE ............................................................................................ 4-14

4.5

ADJUSTMENT OF THE COOLER FAN DRIVE SPEED ................................................. 4.5.1 MAXIMUM SPEED............................................................................................. 4.5.2 MEDIUM SPEED................................................................................................ 4.5.3 FUNCTION CHECK OF FAN SPEED CONTROL .............................................

4-16 4-16 4-19 4-20

CONTROLLING.............................................................................. 5-23 5.1

GENERAL LAYOUT ........................................................................................................ 5-24

5.2

VALVE CARTRIDGE BLOCK.......................................................................................... 5-26

5.3

PILOT PRESSURE SUPPLY AND ADJUSTMENTS ...................................................... 5.3.1 PILOT PRESSURE CONTROL (PPC) CIRCUIT ............................................... 5.3.2 CHECKS AND ADJUSTMENT OF PILOT PRESSURE .................................... 5.3.3 REMOTE CONTROL VALVES ARRANGEMENT .............................................

5.4

FUNCTION OF THE ELECTRO HYDRAULIC CONTROL SYSTEM .............................. 5-40

5.5

HAND LEVER (JOYSTICK) CONTROL .......................................................................... 5-44

5.6

FOOT PEDAL CONTROL................................................................................................ 5-46

5.7

PROPORTIONAL AMPLIFIER MODULE, TYPE A......................................................... 5-48

5.8

PROPORTIONAL AMPLIFIER MODULE, TYPE B......................................................... 5-50

5.9

RAMP TIME MODULE ..................................................................................................... 5-52

5.10

ADJUSTMENTS OF AMPLIFIER MODULES ................................................................. 5.10.1 GENERAL .......................................................................................................... 5.10.2 ADJUSTING THE AMPLIFIERS TYPE A........................................................... 5.10.3 ADJUSTING THE AMPLIFIERS TYPE B...........................................................

5.11

ADJUSTING THE RAMP TIME MODUL ......................................................................... 5-60

5-32 5-33 5-36 5-38

5-54 5-55 5-56 5-58

COMPONENTS ................................................................................ 6-1 6.1

MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (FSA)................................ 6-2

6.2

MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (BHA) ............................... 6-4

6.3

DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (FSA) ................................................................................... 6-6

6.4

DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (BHA)................................................................................... 6-8

6.5

SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM (FSA)................ 6-10

6.6

RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE........................................... 6-12

6.7

ANTI CAVITATION VALVE BLOCK................................................................................ 6-14

6.8

REMOTE CONTROL VALVES ........................................................................................ 6-16 5

7.

8.

6

6.9

4/3 DIRECTIONAL SOLENOID VALVES ........................................................................ 6-18

6.10

PROPORTIONAL SOLENOID VALVES.......................................................................... 6-20

6.11

HIGH PRESSURE FILTER .............................................................................................. 6-22

6.12

CONTROL BLOCKS AND VALVES................................................................................ 6-24

6.13

TRAVEL BRAKE VALVE................................................................................................. 6-36

6.14

PRESSURE REDUCING VALVE ..................................................................................... 6-38

6.15

4/2 DIRECTIONAL SOLENOID VALVES ........................................................................ 6-40

6.16

PRESSURE DOUBLE STAGE VALVE ........................................................................... 6-42

6.17

HYDRAULIC CYLINDER ................................................................................................. 6-44

6.18

SLEW RING ..................................................................................................................... 6-48

MAIN HYDRAULIC PUMPS AND PUMP REGULATION................. 7-1 7.1

GENERAL .......................................................................................................................... 7-2

7.2

MAIN PUMPS ................................................................................................................... 7.2.1 LOCATION OF PUMPS ..................................................................................... 7.2.2 PUMP BEARING FLUSHING / LUBRICATION.................................................. 7.2.3 OPERATING PRINCIPLE .................................................................................. 7.2.4 CHECKS / ADJUSTMENTS ...............................................................................

7-10 7-11 7-12 7-14 7-30

7.3

ELECTRONIC PUMP REGULATION SYSTEM .............................................................. 7.3.1 ELECTRONIC LOAD LIMITING CONTROL - GENERAL .................................. 7.3.2 MICROCONTROLLER RC4-4............................................................................ 7.3.3 CHECKS AND ADJUSTMENTS ........................................................................

7-38 7-39 7-41 7-43

7.4

HYDRAULIC CONSTANT REGULATION SYSTEM ....................................................... 7-50 7.4.1 GENERAL .......................................................................................................... 7-51 7.4.2 X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE) ............................. 7-52

7.5

DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE) ........................ 7-54

7.6

ENGINE SPEED SENSOR (PICK-UP) ............................................................................ 7-56 7.6.1 GENERAL .......................................................................................................... 7-57 7.6.2 ENGINE SPEED SENSOR (PICK-UP) ADJUSTMENT ..................................... 7-57

7.7

ENERGY EFFICIENCY .................................................................................................... 7-58 7.7.1 GENERAL .......................................................................................................... 7-59 7.7.2 CHECKS AND ADJUSTMENTS ........................................................................ 7-60

OPERATING HYDRAULICS ............................................................ 8-1 8.1

GENERAL .......................................................................................................................... 8-2 8.1.1 FLOATING SYSTEM............................................................................................ 8-4

8.2

HYDRAULICS FOR THE ATTACHMENT CYLINDER FSA AND BHA ............................ 8-6 8.2.1 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISE" FSA .......................... 8-6 8.2.2 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISE" BHA ......................... 8-8 8.2.3 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" FSA ............... 8-10 8.2.4 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" BHA............... 8-12 8.2.5 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTEND" FSA .................... 8-14 8.2.6 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTEND" BHA .................... 8-16 8.2.7 ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACT" FSA .................. 8-18

8.2.8 8.2.9 8.2.10 8.2.11 8.2.12 8.2.13 8.2.14 8.2.15 8.2.16 8.2.17

8.2.18

ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACT" BHA.................. ELECTRIC / HYDRAULIC FLOWCHART "BUCKET CURL" FSA ..................... ELECTRIC / HYDRAULIC FLOWCHART "BUCKET CURL" BHA..................... ELECTRIC / HYDRAULIC FLOWCHART "BUCKET DUMP" FSA .................... ELECTRIC / HYDRAULIC FLOWCHART "BUCKET DUMP" BHA .................... ELECTRIC / HYDRAULIC FLOWCHART "CLAM OPEN" FSA ......................... ELECTRIC / HYDRAULIC FLOWCHART "CLAM CLOSE" FSA ....................... CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (FSA) ......... CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (BHA)......... CHECKS AND ADJUSTMENTS OF THE SECONDARY RELIEF VALVES (SRV)................................................................................................... 8.2.17.1 BOOM CYLINDER "PISTON SIDE" FSA + BHA .............................. 8.2.17.2 BOOM CYLINDER "PISTON ROD SIDE" FSA +BHA ...................... 8.2.17.3 STICK CYLINDER "PISTON SIDE" FSA .......................................... 8.2.17.4 STICK CYLINDER "PISTON SIDE" BHA.......................................... STICK CYLINDER "PISTON ROD SIDE" FSA .................................................. 8.2.18.1 STICK CYLINDER "PISTON ROD SIDE" BHA................................. 8.2.18.2 BUCKET CYLINDER "PISTON SIDE" FSA ...................................... 8.2.18.3 BUCKET CYLINDER "PISTON SIDE" BHA...................................... 8.2.18.4 BUCKET CYLINDER "PISTON ROD SIDE" FSA ............................. 8.2.18.5 BUCKET CYLINDER "PISTON ROD SIDE" BHA............................. 8.2.18.6 CLAM CYLINDER "PISTON ROD SIDE" FSA.................................. 8.2.18.7 CLAM CYLINDER "PISTON SIDE" FSA........................................... 8.2.18.8 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED .......

8-20 8-22 8-24 8-26 8-28 8-30 8-32 8-34 8-36 8-38 8-39 8-43 8-47 8-51 8-55 8-59 8-63 8-67 8-71 8-75 8-79 8-81 8-83

8.3

HYDRAULICS FOR THE SWING CIRCUIT................................................................... 8.3.1 SWING CIRCUIT.............................................................................................. 8.3.2 SWING MOTOR .............................................................................................. 8.3.3 SWING GEARBOX (L&S)................................................................................ 8.3.4 SWING GEARBOX (SIEBENHAAR)................................................................ 8.3.5 SLEW PARKING BRAKE (L&S) ...................................................................... 8.3.6 SLEW PARKING BRAKE (SIEBENHAAR) ...................................................... 8.3.7 SWING BRAKE VALVE ................................................................................... 8.3.8 ELECTRIC / HYDRAULIC FLOWCHART "SWING LEFT" .............................. 8.3.9 ELECTRIC / HYDRAULIC FLOWCHART "SWING RIGHT" ............................ 8.3.10 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT......................... 8.3.11 FUNCTION CHECK FOR THE HYDRAULIC SWING BRAKE ........................ 8.3.12 FUNCTION CHECK FOR THE SLEW PARKING BRAKE...............................

8-102 8-102 8-106 8-108 8-110 8-112 8-114 8-116 8-118 8-120 8-122 8-128 8-130

8.4

HYDRAULICS FOR THE TRAVEL CIRCUIT ................................................................ 8.4.1 TRAVEL CIRCUIT............................................................................................ 8.4.2 TRAVEL MOTOR ............................................................................................. 8.4.3 ROTARY JOINT ............................................................................................... 8.4.4 TRAVEL GEARBOX (L&S).............................................................................. 8.4.5 TRAVEL GEARBOX (ZOLLERN)..................................................................... 8.4.6 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE) .................................... 8.4.7 TRAVEL BRAKE VALVE.................................................................................. 8.4.8 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL FORWARD” ................... 8.4.9 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL BACKWARDS” .............. 8.4.10 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT ....................... 8.4.11 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE ...........................

8-132 8-132 8-136 8-138 8-140 8-142 8-144 8-146 8-148 8-150 8-152 8-154

7

9.

HYDRAULIC TRACK TENSIONING SYSTEM................................. 9-1 9.1

GENERAL .......................................................................................................................... 9-2

9.2

FUNCTIONAL DESCRIPTION ........................................................................................... 9-4

9.3

PRESSURE DOUBLE STAGE VALVE ............................................................................. 9-6

9.4

TENSIONING CYLINDER .................................................................................................. 9-8

9.5


10. ACCESS LADDER, HYDRAULICALLY OPERATED ..................... 10-1 10.1

GENERAL ........................................................................................................................ 10-2

10.2

FUNCTION OF HYDRAULICALLY OPERATED ACCESS LADDER............................. 10-4

10.3


11. CENTRAL REFILLING SYSTEM (SERVICE ARM) ....................... 11-1 11.1

GENERAL ........................................................................................................................ 11-2

11.2

FUNCTION ....................................................................................................................... 11-4

12. HINTS FOR READING THE HYDRAULIC DIAGRAM ................... 12-1 12.1

GENERAL ........................................................................................................................ 12-2

12.2

HYDRAULIC SYMBOLS .................................................................................................. 12-4 12.2.1 LINES, UNIONS ................................................................................................. 12-5 12.2.2 COMPONENTS, VALVES.................................................................................. 12-7 12.2.3 SENSORS .......................................................................................................... 12-7 12.2.4 VALVES, VALVE COMPONENTS ..................................................................... 12-8 12.2.5 PUMP, MOTOR, CYLINDER............................................................................ 12-12

13. HINTS FOR READING THE ELECTRIC WIRING DIAGRAM........ 13-1

8

13.1

GENERAL ........................................................................................................................ 13-2

13.2

REFERENCE DESIGNATION OF THE ELECTRICAL COMPONENTS ......................... 13-3 13.2.1 AREA CODE ...................................................................................................... 13-3 13.2.2 COMPONENT IDENTIFYING LETTER.............................................................. 13-5

13.3

GRAPHICAL SYMBOLS.................................................................................................. 13-6

13.4

DRAWING CONCEPT.................................................................................................... 13-10

13.5

CABLE MARKING ......................................................................................................... 13-20

13.6

TABLE OF NEW AND OLD COMPONENT DESIGNATIONS ...................................... 13-21

14. VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM ...................................................................... 14-1 14.1

GENERAL ........................................................................................................................ 14-2

14.2

SPECIFICATIONS FOR OPERATORS ........................................................................... 14-4 14.2.1 SEQUENCE OF DISPLAYS............................................................................... 14-5 14.2.2 OPENING SCREEN........................................................................................... 14-5 14.2.3 MAIN GAUGE SCREENS 1 TO 3 ...................................................................... 14-6 14.2.4 FUEL CONSUMPTION SCREEN .................................................................... 14-11 14.2.5 FAILURE MESSAGE SCREEN FOR THE OPERATOR ................................. 14-13 14.2.6 MAIN GAUGE SCREENS - CHANGING OF TIME / SMR / DATE .................. 14-15 14.2.7 MAINTENANCE MONITOR ............................................................................. 14-16 14.2.8 SETTINGS FOR OPERATORS ....................................................................... 14-18 14.2.9 AUTOMATIC MESSAGES ............................................................................... 14-26 14.2.10 TABLES OF ALL MESSAGES PROVIDED BY THE SYSTEM ....................... 14-29 14.2.10.1 TABLE OF G-CODES .................................................................... 14-30 14.2.10.2 TABLE OF C-CODES - DIESEL ENGINES WITH EMISSION STANDARD TIER 2 ..................................................... 14-39 14.2.10.3 TABLE OF C-CODES - DIESEL ENGINES WITH EMISSION STANDARD TIER 1 ..................................................... 14-46 14.2.10.4 TABLE OF AVAILABLE INSTRUCTION MESSAGES ................... 14-52

14.3

FLOW CHARTS (1-4) VHMS MAIN SCREENS............................................................. 14-55

14.4

VHMS SERVICE LEVEL ................................................................................................ 14.4.1 EXPLANATION OF THE BUTTON SYMBOLS (SERVICE LEVEL) ................ 14.4.2 SERVICE MENU SELECT SCREEN ............................................................... 14.4.3 REAL TIME MENU SELECT SCREEN............................................................ 14.4.3.1 REAL TIME MENU, OPTION: 01 ENGINE 1 .................................. 14.4.3.2 REAL TIME MENU, OPTION: 02 PTO 1 ........................................ 14.4.3.3 REAL TIME MENU, OPTION: 03 HYDRAULIC .............................. 14.4.3.4 REAL TIME MENU, OPTION: 04 SLEW ........................................ 14.4.3.5 REAL TIME MENU, OPTION: 05 ELECTRICAL EQUIPMENT ...... 14.4.3.6 REAL TIME MENU, OPTION: 06 EMERGENCY STOP................. 14.4.3.7 REAL TIME MENU, OPTION: 07 MANUAL SWITCH .................... 14.4.3.8 REAL TIME MENU, OPTION: 08 CENTRAL LUBE SYSTEM 1..... 14.4.3.9 REAL TIME MENU, OPTION: 09 SLEW RING GEAR LUBE SYSTEM ............................................................................... 14.4.3.10 REAL TIME MENU, OPTION: 10 WINDSCREEN WIPER ............. 14.4.3.11 REAL TIME MENU, OPTION: 11 LADDER .................................... 14.4.3.12 REAL TIME MENU, OPTION: 12 SERVICE ARM .......................... 14.4.3.13 REAL TIME MENU, OPTION: 13 PILOT CONTROL...................... 14.4.3.14 REAL TIME MENU, OPTION: 14 OTHER ITEMS .......................... 14.4.3.15 REAL TIME MENU, OPTION: 15 OUTPUT SIGNALS ................... 14.4.3.16 OUTPUT SIGNALS WITH DEACTIVATED MTC-EVALUATION.... 14.4.4 PM-CLINIC ....................................................................................................... 14.4.4.1 GENERAL ....................................................................................... 14.4.4.2 POWER CHECK ............................................................................. 14.4.5 SERIAL/GCC NO. SETTING............................................................................ 14.4.6 MEMORY CLEAR ............................................................................................ 14.4.6.1 INPUT MEMORY CLEAR ID .......................................................... 14.4.6.2 MEMORY CLEAR SCREEN ...........................................................

14-59 14-60 14-61 14-62 14-62 14-63 14-64 14-65 14-65 14-65 14-66 14-67 14-67 14-68 14-68 14-69 14-70 14-71 14-72 14-77 14-78 14-78 14-79 14-80 14-81 14-81 14-82 9

14.4.7 14.4.8 14.4.9 14.4.10

FAILURE HISTORY ......................................................................................... MAINTENANCE MONITOR ............................................................................. SNAPSHOT...................................................................................................... SETTINGS........................................................................................................ 14.4.10.1 CENTRAL LUBRICATION SYSTEM (CLS 1), SCREEN 1/8 .......... 14.4.10.2 SWING LUBRICATION SYSTEM (SLS), SCREEN 2/8.................. 14.4.10.3 QMIN - QMAX - SETTING, SCREEN 3/8 ....................................... 14.4.10.4 OTHER SETTINGS 1/2, SCREEN 4/8............................................ 14.4.10.5 OTHER SETTINGS 2/2, SCREEN 5/8............................................ 14.4.10.6 SHUTDOWN BYPASS ON/OFF .....................................................

14-83 14-84 14-85 14-86 14-86 14-87 14-88 14-88 14-90 14-92

14.5

INTERFACE-CONNECTION VHMS-CONTROLLER .................................................... 14-94 14.5.1 VHMS-CONTROLLER ..................................................................................... 14-95

14.6

WIRING OF THE VHMS-CONTROLLER....................................................................... 14-96

14.7

GLOBAL LAYOUT OF THE MTC CONTROL SYSTEM ............................................. 14.7.1 MTC (MASTER TURBO CONTROLLER) ...................................................... 14.7.1.1 MTC-FLOWCHART ...................................................................... 14.7.1.2 MTC FEATURES .......................................................................... 14.7.1.3 MTC-FIRMWARE AND SOFTWARE............................................ 14.7.1.4 VIEW ONTO THE MTC UNIT AND ITS CONNECTORS .............

14-100 14-102 14-102 14-102 14-103 14-104

14.8

GLOBAL LAYOUT OF THE INTERNAL CAN BUS .................................................... 14.8.1 GENERAL INFORMATION ABOUT A CAN BUS SYSTEM........................... 14.8.1.1 GENERAL CAN BUS DESCRIPTION .......................................... 14.8.1.2 CAN BUS TROUBLESHOOTING ................................................. 14.8.1.3 CAN BUS WIRING........................................................................ 14.8.1.4 CAN BUS END RESISTOR ..........................................................

14-106 14-106 14-107 14-107 14-108 14-110

14.9

THE NODES IN THE CAN BUS SYSTEM ................................................................... 14.9.1 GLOBAL LAYOUT.......................................................................................... 14.9.2 INTRODUCTION ............................................................................................ 14.9.2.1 ICN-V FEATURES ........................................................................ 14.9.2.2 ICN-D FEATURES ........................................................................ 14.9.3 NODE DIP-SWITCHES .................................................................................. 14.9.4 NODE BOX..................................................................................................... 14.9.5 NODE LOCATIONS ON THE MACHINE ....................................................... 14.9.5.1 NODE & LOCATION CHART........................................................ 14.9.5.2 EXEMPLARY VIEW ONTO LOCATION 11 (CAB BASE).............

14-112 14-112 14-113 14-114 14-115 14-116 14-117 14-118 14-119 14-120

15. AUTOMATIC LUBRICATION SYSTEMS ....................................... 15-1

10

15.1

GENERAL OVERVIEW CLS & SLS ................................................................................ 15-2 15.1.1 GENERAL DESCRIPTION................................................................................. 15-3

15.2

BASIC FUNCTION OF THE LUBRICATION SYSTEMS ................................................. 15-4

15.3

CENTRAL LUBRICATION SYSTEM (CLS) .................................................................... 15-6 15.3.1 GENERAL INFORMATION ON CLS.................................................................. 15-8

15.4

LUBRICATION PUMP STATION (SLS) ........................................................................ 15-10 15.4.1 GENERAL INFORMATION ON SLS ................................................................ 15-12

15.5

LUBRICATION CYCLE.................................................................................................. 15.5.1 OPERATION AND CONTROL ......................................................................... 15.5.2 LUBRICATION CYCLE - COMPONENTS ....................................................... 15.5.3 LUBRICATION CYCLE - PROCESSING ......................................................... 15.5.4 TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE ........... 15.5.5 LUBRICATION MODES ................................................................................... 15.5.5.1 AUTOMATIC LUBRICATION MODE .............................................. 15.5.5.2 MANUAL LUBRICATION MODE .................................................... 15.5.5.3 VHMS SERVICE MODE .................................................................

15-13 15-13 15-14 15-16 15-17 15-18 15-18 15-18 15-18

15.6

HYDRAULICALLY DRIVEN LUBE PUMP .................................................................... 15.6.1 ADJUSTMENT OF LUBE PUMP SPEED & WORKING PRESSURE ............. 15.6.1.1 STROKE SPEED ADJUSTMENT ................................................... 15.6.1.2 WORKING PRESSURE ADJUSTMENT ........................................

15-20 15-22 15-23 15-23

15.7

LUBRICANT INJECTORS ............................................................................................. 15.7.1 TIGHTENING TORQUE FOR FITTINGS AT THE GREASE INCETORS ....... 15.7.2 DESCRIPTION................................................................................................. 15.7.3 ADJUSTMENT OF THE LUBRICANT OUTPUT .............................................. 15.7.4 OPERATION PRINCIPLE OF LUBRICANT INJECTORS ............................... 15.7.4.1 FUNCTION DESCRIPTION ............................................................ 15.7.5 CONNECTION OF ONE OR MORE INJECTORS...........................................

15-24 15-25 15-25 15-25 15-26 15-28 15-29

15.8

VENT VALVE ................................................................................................................. 15-30 15.8.1 DESCRIPTION................................................................................................. 15-31

15.9

END-LINE SWITCH........................................................................................................ 15.9.1 DESCRIPTION................................................................................................. 15.9.2 CLS END-LINE SWITCH ADJUSTMENT ........................................................ 15.9.3 SLS END-LINE SWITCH ADJUSTMENT ........................................................

15-32 15-33 15-34 15-36

15.10 IN-LINE FILTER ............................................................................................................. 15-38 15.10.1 DESCRIPTION................................................................................................. 15-39 15.10.2 MAINTENANCE PROCEDURE ....................................................................... 15-39 15.11 LUBRICANT LEVEL SENSOR ...................................................................................... 15-40 15.11.1 DESCRIPTION................................................................................................. 15-41 15.11.1.1 LEDS AT THE SONAR SENSOR ................................................... 15-41 15.12 LUBRICATION PINION (SLS) ....................................................................................... 15-44 15.12.1 DESCRIPTION................................................................................................. 15-45 15.13 COMMISSIONING.......................................................................................................... 15.13.1 COMMISSIONING OF THE CLS LUBRICATION SYSTEM ............................ 15.13.2 FINE ADJUSTMENT ........................................................................................ 15.13.3 COMMISSIONING OF THE SLS LUBRICATION SYSTEM ............................

15-46 15-46 15-47 15-48

11

12

I. INTRODUCTION

Version 2010/1

I-1

I.I


Assembled in this file are the Service Manual with explanation and adjustment of the major components and circuits for your KOMATSU Hydraulic Mining Shovel PC4000-6 Diesel with X2 controller and the enhanced VHMS system.

I-2

Version 2010/1

I.II

FOREWORD

Observe the instructions in these manuals for: WARNING z

your Personal SAFETY

z


z

READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major systems of the Hydraulic Excavator PC 4000-6D. We describe for you all functions and how to carry out the inspections and adjustments.

How do you find "your" desired information? In the TABLE OF CONTENT all the functions and components are shown in their sequence of the description. 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.

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 to work. Reading the instructions after work has begun is too late.

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. In order to keep your Shovel in first-class operating condition use only genuine spare and wear parts. 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.

Replace damaged graphics and symbols at the machine. Observe safety precautions to prevent injury and damage. 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 Buscherhofstr. 10 40599 Düsseldorf GERMANY

FROM THE PRACTICE - FOR THE PRACTICE -

Version 2010/1

I-3

I.III

RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS

Operation z

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.

z

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.

z

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

Maintenance and repair z

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

z

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.

z

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

.

I-4

Version 2010/1

I.IV

EXPLANATION OF ABBREVATIONS

Abbre.

Definition

AC

Alternating Current

A/C

Air Condition

ACV

Anti-Cavitation Valve

API


BHA

Backhoe Attachment

°C

Degree Celsius

CCW

Counterclockwise

CW

Clockwise

CLS


CO

Cut off function (main pump)

DC

Direct Current

FSA

Front Shovel Attachment

GET

Ground Engaging Tools

HP

High Pressure

LED


L.H.

Left Hand

MH801

VHMS monitor

MRV

Main Relief Valve

MTC

Master Turbo Controller

PTO


Qmax

Maximum pump delivery = maximum swash plate angle

Qmin

Minimum pump delivery = minimum swash plate angle

1/2 Qmax

1/2 pump delivery

R.H.

Right Hand

RPM

Revolutions Per Minute

SLS


SRV

Secondary Relief Valve

VHMS

Vehicle Health Monitoring System

Version 2010/1

I-5

I.V

DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL

Wiring Diagrams & Hydraulic Diagrams z

During work or troubleshooting always make sure to use your Wiring Diagrams and Hydraulic Diagrams which are assigned to your machine.

z

Due to variable requirements in many respects, the samples of diagrams shown in this manual can not meet the actual state of each machine in every case.

Illustrations & technical drawings

I-6

z

The illustrations and technical drawings shown in this manual correspond to state of the technology at the time of press date.

z

Modifications of shown components are possible prior notice.

Version 2010/1

This page was left blank intentionally.

Version 2010/1

I-7

I-8

Version 2010/1

III. SPECIFICATIONS

Version 2010/1

III-1

III.I

LIFTING GEARS CAUTION

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

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

WIRE ROPES Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:

z

Wire popes (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

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

z

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.

z

Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.

Fig. III-1 III-2

Version 2010/1

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 can result in a dangerous accident.

z

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) where hoisting g is made with two ropes, each of which is allowed to sling up to 1000kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000kg of total weight can be suspended. This weight becomes 1000kg when two ropes make a 120° hanging angle. On the other hand two ropes are subject to an excessive force as large as 4000kg if they sling a 2000kg load at a lifting angel of 150°.

Fig. III-2

Version 2010/1

III-3

III.II

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. ISO 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 a Starpoint hoist ring disengage the star key. Adjust the ring plane in direction of pull before attaching any 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.Install the lifting equipment at the correct places.

z

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.

III-4

Version 2010/1

III.III STANDARD TIGHTENING TORQUE CHART

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

z

(1 kgm = 9,806 Nm)

z

Insert all bolts lubricated with multi purpose grease MPG (Multi Purpose Grease) (same grease as used in the central lubrication system)

Version 2010/1

III-5

III.IV CONVERSION TABLE Millimeter - Inch & Kilogram - Pound 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 5 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.

III-6

Version 2010/1

Version 2010/1

III-7

Liter - U.S. Gallon & Liter - U.K. Gallon

III-8

Version 2010/1

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

III-9

bar - PSI / PSI - bar

Conversion Table bar / PSI bar - PSI bar 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

PSI 14,5033 73 145 218 290 363 435 508 580 653 725 798 870 943 1015 1088 1160 1233 1305 1378 1450 1523 1595 1668 1740 1813 1885 1958 2030 2103 2175 2248 2321 2393 2466 2538 2611 2683 2756 2828 2901

PSI - bar bar 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

PSI 2973 3046 3118 3191 3263 3336 3408 3481 3553 3626 3698 3771 3843 3916 3988 4061 4133 4206 4278 4351 4424 4496 4569 4641 4714 4786 4859 4931 5004 5076 5149 5221 5294 5366 5439 5511 5584 5656 5729 5801

PSI 1 75 150 225 300 375 450 525 600 675 750 825 900 975 1050 1125 1200 1275 1350 1425 1500 1575 1650 1725 1800 1875 1950 2025 2100 2175 2250 2325 2400 2475 2550 2625 2700 2775 2850 2925 3000

bar 0,06895 5,17 10 16 21 26 31 36 41 47 52 57 62 67 72 78 83 88 93 98 103 109 114 119 124 129 134 140 145 150 155 160 165 171 176 181 186 191 197 202 207

PSI 3075 3150 3225 3300 3375 3450 3525 3600 3675 3750 3825 3900 3975 4050 4125 4200 4275 4350 4425 4500 4575 4650 4725 4800 4875 4950 5025 5100 5175 5250 5325 5400 5475 5550 5625 5700 5775 5850 5925 6000

bar 212 217 222 228 233 238 243 248 253 259 264 269 274 279 284 290 295 300 305 310 315 321 326 331 336 341 346 352 357 362 367 372 378 383 388 393 398 403 409 414

PSI bar

x

14,5033 = PSI

=

bar

14,5033

III-10

Version 2010/1

Basic values in Ohm according to IEC 751 / EN 60751 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

III-11

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 degrees Fahrenheit or Centigrade . If it is desired to convert from degrees Fahrenheit to Centigrade, 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 degrees Centigrade to Fahrenheit, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

III-12

Version 2010/1

III.V BLIND PLUGS Dummy plates for SAE–flanges

Fig. III-3

Forms / types of dummy plates for SAE–flanges

Up to 3000 PSI (207 bar)

SAE size

Form / type according to Fig. III-3

Part Number

DN (Diameter Nominal) (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

Version 2010/1

III-13

Up to 6000 PSI (414 bar)

III-14

SAE size

Form / type according to Fig. III-3

Part Number

DN (Diameter Nominal) (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

III.VI CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH Heavy class (up to 6000 PSI / 414 bar)

Light class (up to 3000 PSI / 207 bar)

Size

Ra

DN (nominal width)

Ra

DN (nominal width)

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 appropriate plugs and fittings according to Table III.VII on page 16. 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 III.VII on page 16.

NOTE: The column "Size" indicates the thread-size for the ROV-fittings.

Version 2010/1

III-15

III.VII PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353 Up to 3000 PSI / 207 bar BUZ (plugs)

Part Number

ROV (fittings)

Part Number

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 / 414 bar

III-16

BUZ (plugs)

Part Number

ROV (fittings)

Part Number

-

-

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


Version 2010/1

III-17

III-18

Version 2010/1

MAIN ASSEMBLY GROUPS

1. MAIN ASSEMBLY GROUPS

Version 2010/1

1-1

General Layout

1.1

GENERAL LAYOUT

Fig. 1-1

General layout

1-2


Version 2010/1


General Layout

Legend for Fig. 1-1: (1)

Superstructure

(2)

Undercarriage

(3)

Front shovel attachment (FSA)

(4)

Backhoe attachment (BHA)

Version 2010/1

1-3

Superstructure

1.2

SUPERSTRUCTURE

Fig. 1-2

Superstructure

1-4


Version 2010/1


Superstructure


Hydraulically operated access ladder

(2)

Battery main switches (batteries G1-G4)

(2a)


(3)

Lift cylinder for access ladder

(4)

Batteries, location below the catwalk (batteries G1-G4)

(5)

Control switch for access ladder

(6)

Emergency engine shut down switch

(7)

Fuel tank

(8)

Cab base, contains the electronic components of the VHMS system, the electrical switch boards, and the batteries G8 & G9

(9)

Side window of operator’s cab

(10)

Swing circle guard

(11)

Emergency escape ladder

(12)

Engine air cleaners

(13)

Exhaust mufflers

(14)

Air duct

(15)

Extinguishing agent tank assemblies, only on machines equipped with a fire detection, actuation and suppression system.

(16)

Counterweight

(17)

Main control valves & remote control valves with high pressure in-line filters

(18)

Hydraulic oil reservoir

(19)

Return oil filters and leak oil filter

(20)

Hydraulic oil cooler

(21)

Swing machinery

(22)

Distributor manifold

(23)

Swing circle pinion Lubrication System (SLS)

(24)

Central Lubrication System (CLS)

(25)

Node box, location 40

(26)


(27)


Version 2010/1

1-5

Machine House

1.3

MACHINE HOUSE

Fig. 1-3

Machine house

1-6


Version 2010/1


Machine House


Engine air cleaners

(2)

Exhaust air duct

(3)

Exhaust muffler housing

(4)

Rain cap for exhaust muffler

(5)

Expansion tank for radiator

(6)

Coolant radiator

(7)

Hydraulic motor for radiator fan drive

(8)

Oil tank for engine oil reserve system

(9)

Engine oil filler tube

(10)

Engine oil eliminator filter

(11)

Diesel engine

(12)

Flexible coupling, oil-filled (Geislinger)

(13)

Suction oil manifold

(14)

Hydraulic pump for the hydraulic oil cooler fan drive

(15)

Hydraulic pump for the coolant radiator fan drive

(16)

Gear pumps, installed at the drive through shaft of the main hydraulic pumps

(17)

Main hydraulic pumps

(18)

Pump distributor gear (PTO)

(19)

Valve cartridge block

(20)


Version 2010/1

1-7

Hydraulic Oil tank

1.4

HYDRAULIC OIL TANK

Fig. 1-4

Hydraulic oil tank

1-8


Version 2010/1


Hydraulic Oil tank

Legend for Fig.1-4: (1)

Breather filter

(2)

Back pressure valve, temperature controlled

(3)

Drain coupling of the hydraulic oil tank

(4)

Return oil filters

(5)

Leak oil filter

(6)

Main shut-off valve (gate valve) with compensator

(7)

Return oil collector pipe

(8)

Drain coupling of the return oil collector pipe

Version 2010/1

1-9

Hydraulic Oil Cooler

1.5

HYDRAULIC OIL COOLER

Fig. 1-5


1-10


Version 2010/1


Hydraulic Oil Cooler


Cooler frame with swing out facility

(2)

Hydraulic motor of upper fan

(3)

Upper fan

(4)

Fan guard

(5)

Outer part of the upper radiator set

(6)

Inner part of the upper radiator set

(7)

Hydraulic motor of lower fan

(8)

Lower fan

(9)

Fan guard

(10)

Outer part of the lower radiator set

(11)

Inner part of the lower radiator

(12)

Swing out doors

(13)

Lock bars to secure the swing out doors in open position

Version 2010/1

1-11

Fuel Tank


1.6

FUEL TANK

Fig. 1-6

Fuel tank

1-12

Version 2010/1


Fuel Tank

Legend for Fig. 1-6 : (1)

Fuel tank

(2)

Fuel tank breather valve

(3)

Main shut-off cock valve

(4)

Drain coupling with protection cap

(5)

Shut-off cock valve for fuel pressure transducer

(6)

Fuel pressure transducer (31B063)

(7)

Fuel shut-off solenoid (31Q599)

Version 2010/1

1-13

Counterweight

1.7

COUNTERWEIGHT

Fig. 1-7

Counterweight

1-14


Version 2010/1


Counterweight


Counterweight

(2)

Mounting bolts

(3)

Instruction label

(4)

Lifting points for horizontal transport

(5)

Lifting points for vertical transport

(6)

Lifting points for raising up the counterweight

NOTE: For information about bolt connections see OPERATION & MAINTENANCE MANUAL, section Maintenance.

Version 2010/1

1-15

Cab Support

1.8

CAB SUPPORT

Fig. 1-8

Cab support

1-16


Version 2010/1


Cab Support


Cab support (location of the electrical switch board “X2”)

(2)

Mounting bolts

(3)

Mounting bolts

(4)

Door

(5)

Door seal

(6)

Door handle (adjustable)

NOTE: For information about bolt connections see OPERATION & MAINTENANCE MANUAL, section Maintenance.

Version 2010/1

1-17

Operator’s Cab

1.9

OPERATOR’S CAB

Fig. 1-9

Operator’s cab

1-18


Version 2010/1


Operator’s Cab


VHMS monitor (20P047)

(2)

Switch panel

(3)

Operator’s seat

(4)

Lock lever (20S105)

(20S019)

Control lever

(20S020)

Control lever

(20S021a)

Control pedal: left track

(20S021b)

Control pedal: right track

(20S022)

Control pedal: swing brake

(20S023)

Control pedal: clam closing

(20S024)

Control pedal: clam opening

Version 2010/1

1-19

Control Blocks


1.10 CONTROL BLOCKS

Fig. 1-10 Control blocks 1-20

Version 2010/1


Control Blocks


Control block carrier

(2)

Remote control valves

(3)

Main control blocks

(4)

High pressure filter

Version 2010/1

1-21

Swing machinery


1.11 SWING MACHINERY 1.11.1 SWING MACHINERY L&S

Fig. 1-11 Swing machinery (L&S) 1-22

Version 2010/1


Swing machinery


Oil dip stick (gearbox)

(2)

Oil filler plug (gearbox)

(3)

Breather filter (gearbox)

(4)

Oil dip stick (motor adapter housing)

(5)

Breather filter (motor adapter housing)

(6)

Oil drain plug (motor adapter housing)

(7)

Drain plug (gearbox)

(8)

Pinion

(60.1 + 60.2)

Swing motors

(61.1 + 61.2)

Swing brake valve blocks

(48.1 + 48.2)

Swing gearbox (L&S) with integrated spring loaded multi disc brakes

Version 2010/1

1-23

Swing machinery


1.11.2 SWING MACHINERY SIEBENHAAR

Fig. 1-12 Swing machinery (Siebenhaar)

1-24

Version 2010/1


Swing machinery


Swing gearbox SIEBENHAAR

(2)

Oil drain coupling

(3)

Compensator oil tank for swing machinery

(4)

Brake housing

(5)

Oil level gauge, motor adaper housing

(6)

Oil level gauge and oil drain plug, brake housing

(7)

Oil drain plug and breather filter, motor adapter housing

(8)

Breather filter, brake housing

(9)

Dipstick, swing machinery housing

(10)

Breather filter, oil tank

(48.1 + 48.2)

Multi-disc slew parking brake

(60.1 + 60.2)

Swing motor

(61.1 + 61.2)

Hydraulic swing brake

Version 2010/1

1-25

Undercarriage


1.12 UNDERCARRIAGE

Fig. 1-13 Undercarriage

1-26

Version 2010/1


Undercarriage


Undercarriage center body

(2)

Crawler carrier R.H.-side

(3)

Crawler carrier L.H.-side

(4)

Screws, connecting center body and crawler carriers

(5)

Crawler tracks

(6)

Rotary joint

(7)

Travel brake valves

(8)

Travel motors

(9)

Parking brakes, spring loaded disk type brakes

(10)

Travel gearbox

(11)

Sprocket

(12)

Track rollers

(13)

Carrier rollers

(14)

Guide wheel (idler)

(15)

Track tensioning cylinder

Version 2010/1

1-27

Backhoe Attachment (BHA)


1.13 BACKHOE ATTACHMENT (BHA)

Fig. 1-14 Backhoe attachment (BHA)

1-28

Version 2010/1


Backhoe Attachment (BHA)


Boom

(2)

Boom cylinders

(3)

Stick

(4)

Stick cylinders

(5)

Bucket

(6)

Bucket cylinders

(7)

Steering

(8)

Rod

Version 2010/1

1-29

Front Shovel Attachment (FSA)


1.14 FRONT SHOVEL ATTACHMENT (FSA)

Fig. 1-15 Front shovel attachment (FSA)

1-30

Version 2010/1




Boom

(2)

Boom cylinders

(3)

Stick

(4)

Stick cylinders

(5)

Bucket backwall

(6)

Bucket cylinders

(7)

Clam

(8)

Clam cylinders

Version 2010/1

1-31


1-32


Version 2010/1

DRIVE

2. DRIVE

Version 2010/1

2-1

Prime Drive Assembly

2.1

PRIME DRIVE ASSEMBLY

Fig. 2-1

Prime drive assembly

2-2

DRIVE

Version 2010/1

DRIVE

Prime Drive Assembly


Engine, Komatsu SDA16V160

(2)

Front damper

(3)

Coupling adapter flange

(4)

Coupling (Geislinger)

(5)

Pump distributor gear (PTO)

(6)

Power frame

General description The drive unit consists of the Komatsu engine SDA16V160, the fexible coupling, the front damper, and the PTO gear. The drive unit is bolted to the power frame with engine mounts and PTO mounts. Two damping elements, which complement each other, are installed at the prime drive in order to eliminate exessive rotation torques at the crankshaft of the engine (Fig. 2-1, Pos. 1). The damping elements are the front damper (Fig. 2-1, Pos. 3) at the front and rear side of the engine as well as the flexible coupling (Fig. 2-1, Pos. 4) which is connected to the PTO (Fig. 2-1, Pos. 5). It is very important that both damping elements are working properly. In case of any damage or wear at either the front damper or at the flexible coupling also always check the damping element at the opposite side of the engine for proper function as well. For further information about the Geislinger coupling refer to section 2.3 GEISLINGER COUPLING.

Version 2010/1

2-3

Engine and PTO Mounts

2.2

ENGINE AND PTO MOUNTS

Fig. 2-2

Engine and PTO mounts

2-4

DRIVE

Version 2010/1

DRIVE


Legend for Fig. 2-2: Quantity

Size

Grade

WS*

Torque

(1)

Flexible bearing

14

(2)

Bolt with self-locking nut

4 per mount

M10x35

8.8

17

43

(3)

Tie bolt

4

M24x400

10.9

36

handtight

(4)

Rubber-bounded metal bar

4

(5)

Self locking nut

4

M24

8

36

handtight

(6)

Bolt with self locking nut

28

M16x80

10.9

24

265

(7)

Cup springs

7 per bolt

(8)

Stop bolt

2

M36x250

10.9

55

-

(9)

Nut

2

M36

10

55

-

(10)

Bolt

10

M24x200

10.9

36

880

(11)

Bolt

16

M20x120

10.9

30

510

(12)

Resilient sleeve

16

(13)

Bolt

4

M30x200

10.9

46

1770

(14)

Resilient sleeve

4 * Wrench Size

2.2.1

ENGINE MOUNTS

The flexible mounts are installed to absorb the vibrations and the torsional forces. They carry the total weight of the engine and the pump distributor gear with all hydraulic pumps. For this reason, all connections must be checked frequently (every 3000 hs) according to PARTS & SERVIVE NEWS "AH01521b" (latest edition), or after the engine, the coupling, or the PTO has been replaced. In the case of wear or damage of any metal rubber guide (Fig. 2-2, Pos. 1), all metal rubber guides and their fastening bolts (Fig. 2-2, Pos. 2) including nuts must be replaced. Also inspect the metal-rubber-bar (Fig. 2-2, Pos. 4) for wear or damage and replace if necessary. The bolt (Fig. 2-2, Pos. 3) should not have any axial play. If necessary, re-tighten the nut (Fig. 2-2, Pos. 5) until the rubber is squeezed slightly out of the rubber bar (Fig. 2-2, Pos. 4).

Version 2010/1

2-5


2.2.2

DRIVE

TORQUE SUPPORT

To absorb the torque force, the front engine support is additionally supported by a cup spring package. Check the cup springs (Fig. 2-2, Pos. 7) of both supports for fatigue or damage regularly and replace them if necessary. Turn the bolt (Fig. 2-2, Pos. 8) down until it slightly pre-stresses the cup spring and secure it with the lock nut. (Distance between engine torque support and bolt head "B" = 29 mm)

2-6

Version 2010/1


DRIVE


2-7

Version 2010/1

Geislinger Coupling

2.3

GEISLINGER COUPLING

Fig. 2-3

Geislinger coupling

2-8

DRIVE

Version 2010/1

DRIVE

Geislinger Coupling


Coupling assembly

(2)

Input drive flange

(3)

Leaf spring assembly

(4)

Output drive flange

(5)

Dip stick

(6)

Bleeder plug

(7)

O-rings

(8)

Spacer

(E)

Engine input flange

(G)

Gearbox output flange

Description of the oil-filled GEISLINGER coupling The combination of the high elasticity of the leaf springs together with viscous damping by oil displacement ensures that the GEISLINGER-COUPLING removes major critical speeds outside the engine speed range and dampens minor torsional vibrations effectively. The widest engine speed range free of vibration periods and dangerous resonance is thus obtained. Furthermore, the employment of this coupling with its highly dampening characteristics generally results in lower stress in all engine driving shafts and gears as well as in the crankshaft, permitting further power development on standard components. In any similar application, a simple vibration damper and/or a pure flexible coupling would not confer the same advantages. The springs (Fig. 2-3, Pos. 3) together with the inner driving and outer driven member, form the chambers A and B (Fig. 2-3, Pos. A and B), which are filled with oil. If the outer member is displaced in relation to the inner member, the deflection of the leaf springs displaces oil from one chamber to the next. By this action the relative movements of the two members of the coupling are braked and the vibrations are dampened. The spacer (Fig. 2-3, Pos. 8) limits the movement of the leaf springs.

Version 2010/1

2-9

Fan Drive and Radiator Assembly

2.4

FAN DRIVE AND RADIATOR ASSEMBLY

Fig. 2-4

Fan drive and radiator assembly

2-10

DRIVE

Version 2010/1

DRIVE



Radiator

(2)

Fan motor (axial piston motor)

(3)

Intake air fan

(4)

Bearing group carrier

(5)

Ball bearings

(6)

Breather filter

(7)

Oil level plug

(8)

Check valve (anti-cavitation valve)

NOTE: For service intervals and procedures refer to the OPERATION & MAINTENANCE MANUAL of the corresponding machine. The fan direction is counterclockwise viewed from the engine to the radiator. The fan aspirates air through the cooler into the engine house => The air flows from the outside to inside.

Version 2010/1

2-11


Fig. 2-5

2-12

DRIVE

Fan drive and radiator assembl

Version 2010/1

DRIVE



Radiator

(2)

Intake air fan

(5.2)

Axial piston pump (fixed displacement pump, with variable setting)

(23)


(31.2)

Pressure relief valve - engine radiator fan drive

(34.2)

Pressure filter

(41)

Hydraulic oil tank

(52)

Check valve – (anti cavitation valve for fan drive motor)

(57K636-1)

Proportional solenoid valve - Engine radiator fan speed (infinitely variable)

(L)

Leak oil tank

(P)

Pressure to motor

(R)

Return oil to tank

Function description From the pump (Fig. 2-5, Pos. 5.2) the oil flows through the filter (Fig. 2-5, Pos. 34.2) to the fan motor (Fig. 2-5, Pos. 23) and then back to the oil tank. The check valve (Fig. 2-5, Pos. 52) acts as an anti-cavitation valve and is installed, because the fan motor drive is stopped by a cutt-off of the pressure and the fan keeps on running for a short period due to its own torque. The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief valve (Fig. 2-5, Pos. 31.2). This valve works together with the proportional solenoid valve (Fig. 2-5, Pos. 57K636-1). The proportional solenoid valve (Fig. 2-5, Pos. 57K636-1) operates dependent on the engine coolant temperature. The ECM (Electronic Control Module) passes the engine coolant temperature on to the MTC controller, which regulates the fan speed via proportional solenoid valve (Fig. 2-5, Pos. 57K636-1) by sending variable current signals. With a low current signal to the proportional solenoid the fans are running with the max. set-speed. With a high current signal to the proportional solenoid the fans are running with a very low speed.

Version 2010/1

2-13


2.4.1

RADIATOR FAN DRIVE SPEED ADJUSTMENT

Fig. 2-6

Radiator fan drive speed adjustment

2-14

DRIVE

Version 2010/1

DRIVE



Dust cap

(2)

Lock nut

(3)

Set screw

(5.2)


(6)

Torque adjustment bolt

(6.1)

Lock nut

(7)

Qmax stop bolt

(7.1)

Lock nut

(10)

Positioning pin (mover)

(31.2)

Pressure relief valve - engine radiator fan drive

(57K636-1)

Proportional solenoid valve - engine radiator fan speed

(L1)

Measurement of torque adjustment bolt

(L2)

Measurement of Qmax stop bolt

(M7)

Pressure check point - engine radiator fan drive operating pressure

Basic Adjustment NOTE: Basic adjustment has to be carried out whenever one of the following components has been replaced: z

pump

z

relief valve

z

hydraulic motor

1. Reduce the output flow of pump (Fig. 2-6, Pos. 5.2) by adjusting the minimum possible swivel angle, to avoid over speeding the fan: To do this, loosen both lock nuts (Fig. 2-6, Pos. 6.1+7.1) and turn out bolt (Fig. 2-6, Pos. 6) and turn in bolt (Fig. 2-6, Pos. 7) the same length. This is necessary to avoid a loose positioning pin (Fig. 2-6, Pos. 10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts. 2. Remove the protection cap (Fig. 2-6, Pos. 1) from the relief valve (Fig. 2-6, Pos. 31.2), loosen the lock nut (Fig. 2-6, Pos. 2) and turn the set screw (Fig. 2-6, Pos. 3) fully clockwise and then half turn counterclockwise. 3. Isolate the function of the proportional solenoid valve (Fig. 2-6, Pos. 57K636-1), by disconnecting the plug connector, to ensure that the full flow of the pump (Fig. 2-6, Pos. 5.2) will be delivered to the fan motor. 4. Connect a pressure gauge to the check point (Fig. 2-6, Pos. M7). 5. Start the engine and let it run at high idle. 6. Check the fan speed with a non-contact rev counter, required fan speed: 1200 ± 50 rpm

WARNING Be careful not to get caught in the fan or other rotating parts.

Version 2010/1

2-15


DRIVE

7. If the speed can not be raised by increasing the pressure then increase the output flow of the pump (Fig. 2-6, Pos. 5.2). If necessary increase the output flow of the pump (Fig. 2-6, Pos. 5.2), by adjusting the swivel angle, until the fan speed will be 20 rpm higher than required: To do this, loosen both lock nuts (Fig. 2-6, Pos. 6.1 + 7.1), turn in the bolt (Fig. 2-6, Pos. 6), and turn out the bolt (Fig. 2-6, Pos. 7) the same length. This is necessary to avoid a loose positioning pin (Fig. 2-6, Pos. 10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts (Fig. 2-6, Pos. 6.1 + 7.1).

WARNING Do not exceed the maximum permissible operating pressure of max 230 bar.

NOTE: Note down the lengths (Fig. 2-6, Pos. L1) and (Fig. 2-6, Pos. L2) as reference measurements. 8. Loosen the lock nut (Fig. 2-6, Pos. 2) of the relief valve (Fig. 2-6, Pos. 31.2), and decrease the pressure with the set screw (Fig. 2-6, Pos. 3) until the correct fan speed is obtained. 9. Tighten the lock nut (Fig. 2-6, Pos. 2) and fix the protection cap (Fig. 2-6, Pos. 3). 10. Activate the function of the proportional solenoid valve (Fig. 2-6, Pos. 57K636-1), by connecting the connector (fan speed is controlled in relation to the engine temperature). 11. Disconnect the pressure gauge from the check point (Fig. 2-6, Pos. M7). Fan speed check If the fan speed is out of the adjustment range, first increase or decrease the pressure at the relief valve (Fig. 2-6, Pos. 31.2), in order to change the speed.

2-16

Version 2010/1

DRIVE



Version 2010/1

2-17

Pump Distributor Gearbox (PTO)

2.5

PUMP DISTRIBUTOR GEARBOX (PTO)

Fig. 2-7

Pump distributor gearbox (PTO)

2-18

DRIVE

Version 2010/1

DRIVE



Oil level dip stick

(2)

Oil filler plug

(3)

Breather filter

(4)

Oil collector reservoir for auxiliary pump drive shaft housing

(5)

Breather filter with oil level dip stick

(6)

Main pump drive shaft housings

(7)

Oil level plug of main pump drive shaft housing

(8)

Oil filler plug with breather pipe of main pump drive shaft housing

(9)

Oil drain plug of main pump drive shaft housing

(10)

Oil drain plug of PTO gear

(11)

Flange for heater studs

(12)

Mounting bore for sensor "Trouble totally loss gear oil" (option)

(13)

Gear oil temperatur sensor mounting bore

(14)

Suction line connection for gear oil cooling

(15)

Return line connection from gear oil cooler

(16)

Return line connection from cooling system relief valve

(D)

Drive flange

(M)

Power take off for main pumps

(R)

Power take-off for engine radiator fan drive pump

(C)

Power take-off for hydraulic oil cooler fan drive pump

Description The pump distribution gear (PTO gear) is a spur gear design and driven by a Diesel engine. 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. O-rings included in the supply enable the unit to be reliably sealed statically. The gearbox housing is a one-piece design and made of grey cast iron. The gearbox has been provided with connections for a separate cooling system or, as an option, a heating system.

Version 2010/1

2-19


2.5.1

PUMP DRIVE SHAFT HOUSING

Fig. 2-8

Pump drive shaft housing

2-20

DRIVE

Version 2010/1

DRIVE




(2)


(M)

Configuration, main pump drives

(A)

Configuration, auxiliary pump drives

The gear oil in the drive shaft housings is different to the gear oil in the pump distributor gear. There are two reasons for to have seperate housings: 1. To lubricate the multi-spline connections in order to prevent wear and corrosion. 2. It makes it easier to determine a seal ring leak at one of the drive shaft connections.

Function description z

(Fig. 2-8, Pos. M): If the oil level increases, the oil drops out of the breather pipe (Fig. 2-8, Pos. 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 during an oil level check a loss of oil is found, the cause may be worn or defective radial seal rings.

z

(Fig. 2-8, Pos. A): The oil is filled in via the oil collector reservoir (Fig. 2-8, Pos. 2). All auxiliary drive shaft housings are connected to the reservoir by pipes. The reservoir is filled approx. one half with oil. If the oil level in the reservoir increases due to leakage, the oil drops out from the breather filter (with oil level gauge) on top of the reservoir. In this case a check has to be done, to find out which one of the drive shafts seals is damaged. It can be done by disconnecting the pipe to the reservoir temporarily. Disconnect the pipe at the drive shaft housing, plug the pipe and leave the union open. Start the motor or engine and run it at high idle. After a while monitor the open drive shaft housings. The housing with continuous oil leak has a pump seal defect. Otherwise check all auxiliary drives one after the other.

Version 2010/1

2-21


2.5.2

PTO LUBRICATION AND COOLING

Fig. 2-9

PTO Lubrication and cooling

2-22

DRIVE

Version 2010/1

DRIVE



Line to the cooler (hot oil)

(2)

Return line from the cooler (cooled oil)

(3)

Return line from the valve (cooler by-pass)

(4)

Control line (x)

(5)

Leak oil line (y)

(P)

Spray nozzle port

(8.2)

Gear pump - PTO gearbox lubrication

36

Pressure filter - PTO gearbox lubrication

(57B027-1)

Filter clogging sensor (5 bar)

(29)

Pressure relief valve (10 bar)

(M3)

Pressure check point

(57B017-1)

Pressure switch (0.5 bar)

(51.1 & 51.2)

Oil cooler, part of the hydraulic oil cooler

(57B049-1)

Temperature sensor

(M34)


(57K553-1)

Solenoid valve (by-pass control)

Function description An external gear pump (Fig. 2-9, Pos. 8.2) feeds gear oil from the gearbox sump and pumps it through the oil coolers (Fig. 2-9, Pos. 51.1 & 51.2) back to the gearbox. The lubrication and cooling circuit is protected by a filter (Fig. 2-9, Pos. 36) and a pressure relief valve (Fig. 2-9, Pos. 29). The gear oil coolers (Fig. 2-9, Pos. 51.1 & 51.2) are small parts of the hydraulic oil cooler elements, thus the gear oil is getting cooled by the same air stream as the hydraulic oil. From the coolers the oil flows to the spray nozzle port (Fig. 2-9, Pos. P) of the gearbox via return line (Fig. 2-9, Pos. 2). The spray nozzle insures proper and adequate distribution of the oil in order to lubricate and cool down the gears and bearings. The circuit is monitored by the pressure switch (Fig. 2-9, Pos. 57B017-1). If the lube oil pressure is too low (<0.5 bar) a fault message will be displayed at the monitor. The gear oil temperature is monitored by the temperature sensor 57B049-1. If the temperature increases to the specified limit temperature, a fault message will be displayed at the monitor. During the warm up period, the solenoid valve (Fig. 2-9, Pos. 57K553-1) is energized in order to reduce the release pressure of the pressure relief valve (Fig. 2-9, Pos. 29). So the main oil flow will by-pass the oil coolers and the oil flows back to the gearbox via the relief line (Fig. 2-9, Pos. 5). This causes the oil to reach its optimum operating temperature faster.

Version 2010/1

2-23


DRIVE

Fig. 2-10 PTO lubrication and cooling

2-24

Version 2010/1

DRIVE



Pilot operated relief valve

(1a)

Protection cap

(1b)

Lock nut

(1c)

Set screw

(2)

Plug screw

(3)

Valve piston

(4)

Port for pressure switch 57B017-1

(5)

"Y"- port (external return to tank)

(5a)

"X"- port (external return to tank via solenoid valve 57K553-1)

(6)

Port for pressure check stud

(7)

Jet bore

(8)

Valve spring

(9)

Seal rings

(M3)


(57B027-1)

Filter clogging switch

(29)

Pressure relief valve

(A)

Pressure port

(T)

Return from valve

57K553-1

Solenoid valve (reduced pressure if energized)

Adjustments

CAUTION z

The adjustment of the maximum permissible PTO lube pressure has to be carried out with cold oil in order to avoid serious damages to the coolers.

Setting the Pressure Relief Valve (Fig. 2-10, Pos. 29) at cold oil: 1. Connect a pressure gauge to the check point (M3). 2. Disconnect the plug of the solenoid valve (57B553-1). 3. Start the engine and run it at high idle. 4. Required pressure: 10±1 bar. If adjustment is required: z

Remove the protection cap (1a).

z

Loosen the lock nut (1b).

z

Set the pressure with the set screw (1c).

z

Tighten the lock nut (1b) and re-install the protection cap (1a).

z

Reconnect the plug of the solenoid valve (57B553-1).

Version 2010/1

2-25


2.5.3

DRIVE

HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES

Fig. 2-11 Hydraulic pumps

2-26

Version 2010/1

DRIVE


Legend for Fig. 2-11: (1-4)

(5.1)

(5.2)

(8.1)

(8.2)

Axial piston pump (swash plate type) theoretical or all working motions Flow rate, each Drive speed*

1034 Liter/min n = 1378 rpm

Axial piston pump for oil cooler fan drive theoretical flow rate Drive speed*


Axial piston pump for radiator fan drive Theoretical flow rate Drive speed*


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


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


NOTE: * at 1800 rpm input drive speed

Version 2010/1

2-27

Air Filter

2.6

DRIVE

AIR FILTER

Fig. 2-12 Air filter 2-28

Version 2010/1

DRIVE

Air Filter


Wing nut

(2)

Washer

(3)

Seal ring

(4)

Main filter element

(5)

Cotter pin

(6)

Wing nut with service indicator

(7)

Safety element

(8)

Maintenance switch

(9)

Flap for pre-separator

(10)

Air intake with pre-separation

The air is filtered by a dry-air-filter with pre-separator for coarse impurities. One air cleaner housing includes 2 air filters. Each one consists of a main air filter element (Fig. 2-12, Pos. 4) and a safety element (Fig. 2-12, Pos. 7). The air cleaner condition is monitored by a maintenance switch (Fig. 2-12, Pos. 8). A fault message as "Engine air filter restricted" is displayed at the VHMS display as soon as the air cleaner restriction is too high. The safety air cleaner element incorporates a service indicator inside of the wing nut of the safety filter mounting. z

Green indication = OK.

z

Red indication = safety element (Fig. 2-12, Pos. 7) requires replacement.

To reset the indicator after air cleaner replacement, blow with your mouth through the nut against the normal air flow. The indicator should move to the green position. NOTE: For service intervals and procedures refer to the OPERATION & MAINTENANCE MANUAL of the corresponding machine.

Version 2010/1

2-29

Air Filter

2-30

DRIVE

Version 2010/1

HYDRAULIC OIL TANK

3. HYDRAULIC OIL TANK

Version 2010/1

3-1

General Layout

3.1

GENERAL LAYOUT

Fig. 3-1

Overall view of the hydraulic oil tank

3-2

HYDRAULIC OIL TANK

Version 2010/1

HYDRAULIC OIL TANK

General Layout


Filter cover retainer

(2)

Filter cover

(3)

Filter element (A) - Return oil filter - 10 µm (B) - Leak oil filter - 3 µm

(4)

Man hole cover

(24)

Pressure switch 40B024 – monitors items (92.1) & (92.2)

(30)

Hydraulic oil level gauge

(41)

Main oil reservoir

(54)

Return oil collector tube with pressure check point M10

(55)

Back pressure valve

(67)

Dust cap for item (77)

(77)

Oil drain, quick release coupling

(87)

Shut-off valve with switch 40B031 (gate valve)

(88)

Compensator

(91.1 + 92.2)

Breather filter

The hydraulic oil tank is a welded sheet-metal construction. The tank has a filling volume of approx. 3900 litres. The tank contains four return oil filters (Fig. 3-1, Pos. A) and one leak oil filter (Fig. 3-1, Pos. B). The breather filter (Fig. 3-1, Pos. 92.1 + 92.2) cleans the air that streams into the tank. The back pressure valve (Fig. 3-1, Pos. 55) and the pressure check point (Fig. 3-1, Pos. M10) are located at the collector pipe (Fig. 3-1, Pos. 54) for return oil. The connection to the suction tank can be closed with the shut-off valve (Fig. 3-1, Pos. 87) in order to prevent oil flow during repairs on the hydraulic pumps. This gate valve is controlled by the switch 40B031. It ensures that engine start is not possible while the shut-off valve is closed. Fault message ”Start blocked because of main ShutOff (gate) Valve” is displayed at the VHMS monitor.

Version 2010/1

3-3

Hydraulic Oil Tank, Location of the Electric Equipment

HYDRAULIC OIL TANK

3.2

HYDRAULIC OIL TANK, LOCATION OF THE ELECTRIC EQUIPMENT

Fig. 3-2

Hydraulic oil tank

3-4

Version 2010/1

HYDRAULIC OIL TANK

Hydraulic Oil Tank, Location of the Electric Equipment

Legend for Fig. 3-2: (40B004)

Oil level sensor “Hydraulic oil level too low”

(40B015)

Temperatur sensor

(40B024)

Breather filter pressure switch

(40B050)

Oil level sensor “Hydraulic oil refill level”

(40B105)

Pressure transducer – Hydraulic oil level

(40B163)

Pressure transducer – Pressure return oil chamber

(40B164)

Pressure transducer – Pressure leak oil chamber

(40B165)

Pressure transducer – Pressure oil cooler

(40B166)

Pressure transducer – Pressure pre-load (back pressure) valve

Version 2010/1

3-5

Suction Oil Tank with Strainers

3.3

SUCTION OIL TANK WITH STRAINERS

Fig. 3-3

Suction oil tank

3-6

HYDRAULIC OIL TANK

Version 2010/1

HYDRAULIC OIL TANK

Suction Oil Tank with Strainers


Suction oil tank

(2)

Drain coupling

(3)

Pressure transducer (59B162) – pressure suction oil tank

(4)

Hydraulic oil temperature sensor (59B015)

(5)

Bolt M 20

(6)

Nut

(7)

Gaskets

(8)

Main suction oil strainer

(9)

Intermediate pipe

(10)

Gaskets

(11)

Suction strainer – one for each main pump

(12)

Suction hose connection pipe

(13)

Bolt M16

(14)

Lock nuts

(14a)

Resilient sleeve

(15)

Bolt M 20

(16)

Resilient sleeve

(17)

Bolt M 18

NOTE: For information about bolt connections see the OPERATION& MAINTENANCE MANUAL, section Maintenance. The suction oil tank (Fig. 3-3, Pos. 40) is a welded sheet-metal construction. The suction lines of all hydraulic pumps are connected to the suction tank.

Version 2010/1

3-7

Return Oil Collector Pipe with Strainer

HYDRAULIC OIL TANK

3.4

RETURN OIL COLLECTOR PIPE WITH STRAINER

Fig. 3-4


3-8

Version 2010/1

HYDRAULIC OIL TANK

Return Oil Collector Pipe with Strainer


Return oil collector pipe - Part 1 -

(2)


(3)


(4)

Strainer

(5)

Bolt M20

(6)

Bolt M20

(7)

Self locking nut

(8)

Gasket

NOTE: For information about bolt connections see the OPERATION& MAINTENANCE MANUAL, section Maintenance.

Fig. 3-5

Hydraulic diagram

Task: The strainer (Fig. 3-5, Pos. 1) is installed to prevent the hydraulic oil coolers from getting clogged up in case of contamination in the main return oil circuit. 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.

Version 2010/1

3-9

Back Pressure Valve

3.5

BACK PRESSURE VALVE

Fig. 3-6

Back pressure valve

3-10

HYDRAULIC OIL TANK

Version 2010/1

HYDRAULIC OIL TANK

Back Pressure Valve


Back pressure valve assembly

(2)

Solenoid valve (40K601)

Fig. 3-7

Hydraulic diagram

Task: The back pressure valve (Fig. 3-7, Pos. 1) 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 anti-cavitaton 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 the solenoid valve 40K601. z

Low temperature => low volume through the coolers

z

High temperature => high volume through the coolers

NOTE: For further information about the function principle, refer to section 4.2 on page 4-4. For further information about adjustment, refer to section 4.3 on page 4-6.

Version 2010/1

3-11

Transfer Pump for hydraulic oil

3.6

TRANSFER PUMP FOR HYDRAULIC OIL

Fig. 3-8

Transfer pump for hydraulic oil

3-12

HYDRAULIC OIL TANK

Version 2010/1

HYDRAULIC OIL TANK

Transfer Pump for hydraulic oil

REMARK The illustration shows the transfer pump arrangement viewed from the center of the platform. Legend for Fig. 3-8 1

Cock for the suction oil tank (11)

2

Cock for the collector pipe (13)

3

Cock for the return oil collector pipe (12)

4

Electric motor of the transfer pump (40G018)

5

Transfer pump (40G018)

6

Operating switch (40S035) for the transfer pump (5)

7

Suction line to the suction oil manifold (11)

8

Suction line to the collector pipe (13)

9

Suction line to the return oil manifold (12)

10

Hand wheel of the main shut-off gate valve

11

Suction oil manifold

12

Return oil manifold

13

Collector pipe

14

Back pressure valve

General description 1. Transfusing oil from the suction manifold into the main hydraulic oil tank. This is required for the evacuation of the suction oil manifold when replacing the hydraulic oil. Before servicing the main hydraulic pumps, it is recommended to empty the suction oil manifold partially. 2. Transfusing oil from the return oil manifold and from the collector pipe into the main hydraulic oil tank. This is required when replacing the hydraulic oil and before servicing the high-pressure filters, the main control valves, or the hydraulic oil cooler (oil return system). NOTE: For the operating instructions of the transfer pump refer to the OPERATION & MAINTENANCE MANUAL.

Version 2010/1

3-13

Return and Leak Oil Filter

3.7

RETURN AND LEAK OIL FILTER

Fig. 3-9

Return and leak oil filter

3-14

HYDRAULIC OIL TANK

Version 2010/1

HYDRAULIC OIL TANK

Return and Leak Oil Filter



(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)

Bypass valve, 2.3 bar

(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

(A)

Filter chamber

Function The return oil flows into the filter chamber (Fig. 3-9, Pos. A) of the hydraulic oil tank (the drawing is showing a section of it 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 then passes on its way to the tank the filter element (Fig. 3-9, Pos. 7) "Inside to outside filtration". The filter element condition is monitored by pressure switches (40B164 for the leak oil filter and 40B163 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 VHMS monitor. In this case the filter elements must be replaced. For safety precautions the filter is equipped with a bypass valve. As the filter chamber pressure increases the by-pass valve opens at 2.3 + 0.5 bar and protects the element from bursting. But the oil does not flow totally unfiltered into the tank because it is forced to flow through the strainer (Fig. 3-9, Pos. 8).

Version 2010/1

3-15

Breather Filter

3.8

HYDRAULIC OIL TANK

BREATHER FILTER

Fig. 3-10 Breather filter 3-16

Version 2010/1

HYDRAULIC OIL TANK

Breather Filter


Nut

(2)

Cover

(3)

Filter element

(4)

Filter pot

(5)

Pressure sensor

Two breather filters are installed in order to clean the air which streams into the tank at any time when the oil level decreases during the extension of the attachment cylinders. The filter element condition is monitored by a vacuum type pressure switch (40B024, 0.08 bar). NOTE: Refer to the OPERATION & MAINTENANCE MANUAL for further information.

CAUTION Only use steel filter elements.

Version 2010/1

3-17

Breather Filter

3-18

HYDRAULIC OIL TANK

Version 2010/1

HYDRAULIC OIL COOLING

4. HYDRAULIC OIL COOLING

Version 2010/1

4-1

Overall view of the hydraulic oil cooling


4.1

OVERALL VIEW OF THE HYDRAULIC OIL COOLING

Fig. 4-1


4-2

Version 2010/1




Cooler door

(2)

Cooler (radiator)

(3)

Cooler frame

(4)

Fan

(5)


(6)

Bolt

(7)

Bolt

(8)

Drive shaft

(9)

Shaft protecting sleeve

(10)

Drive shaft seal

(11)

Ball bearings

(12)

Seeger clip ring

(13)


(14)

Oil level plug

(15)

Breather filter

(16)

Bolt

The hydraulic oil cooling system keeps the hydraulic oil in the normal operating temperature range. Design There are four hydraulic oil coolers in front of the hydraulic tank on the R.H. side of the platform. They are in pairs mounted in one frame, one above the other. The air stream needed for the cooling is produced by hydraulic driven fans. The air flows from the inside to the outside through the coolers. For cleaning, the cooler frame must be moved to the side ("swing out cooler"). The bearing group carrier is filled with oil (CLP 220) in order to lubricate the bearings and the spline shaft connection. The oil change interval is 3000 hours.

Version 2010/1

4-3

Function of the Hydraulic Oil Cooling Circuit


4.2

FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT

Fig. 4-2

Function of the hydraulic oil cooling circuit

4-4

Version 2010/1


Function of the Hydraulic Oil Cooling Circuit

Legend for Fig. 4-2: (32.1 - 32.4)

Restrictor, shock absorbers for the hydraulic oil cooler 22mm.

(39.1 + 39.2)


(41)

Main oil reservoir

(54)


(55)

Back pressure valve

(L6 + L7)

Return line from control blocks

(L13 + L14)

Supply line for the anti cavitation circuit of the swing motors

(M10)


(40K601)

Solenoid valve – 4/2-directional control valve

(H)

Lines to cooler (hot oil)

(C)

Lines to tank (cold oil)

Function description The returning oil from the system flows via the lines (Fig. 4-2, Pos. L6 - L7) into the return oil collector pipe (Fig. 4-2, Pos. 54). A pressure relief valve, also called back pressure valve (Fig. 4-2, Pos. 55) is installed on top of it. The back pressure valve (Fig. 4-2, Pos. 55) causes a back pressure which forces most of the relative hot oil through the lines (Fig. 4-2, Pos. H) to the cooler (Fig. 4-2, Pos. 39.1 - 39.2). During its flow through the coolers the oil gets cooled and then it flows through the restrictors (Fig. 4-2, Pos. 32.1 - 32.4) and the lines (Fig. 4-2, Pos. C) into the filter chamber of the main hydraulic oil tank (Fig. 4-2, Pos. 41). The restrictors are acting as shock absorbers in order to prevent cooler cracking at pressure peaks. The back pressure valve (Fig. 4-2, Pos. 55) also acts as an oil flow control valve as long as the oil temperature has not reached its normal operating temperature. During the warm up period (1/2 Qmax) the back pressure valve (Fig. 4-2, Pos. 55) is wide open because the solenoid valve 40K601 is energized. As a results smaller oil flow volume passes through the coolers, which causes the oil to reach its optimum operating temperature faster. With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously the solenoid valve 40K601 will be de-energized. As a result the valve piston is more closed by the force of the spring so that a larger oil volume may pass the coolers. NOTE: Refer to the sectional drawing in (Fig. 4-3).

Version 2010/1

4-5

Adjustment of the Back Pressure Valve


4.3

ADJUSTMENT OF THE BACK PRESSURE VALVE

Fig. 4-3

Back pressure valve

4-6

Version 2010/1


Adjustment of the Back Pressure Valve


Control oil port

(2)

"Y"- port (external return to tank)

(2a)

"X"- port (external return to tank via solenoid valve 40K601)

(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

Checks and settings only at normal operating temperature of the hydraulic oil and main pumps in maximum flow position (Qmax activated via VHMS). 1. Connect a pressure gauge to the check point (Fig. 4-3, Pos. M10). 2. Disconnect the plug connector (Fig. 4-3, Pos. 13) of the solenoid valve 40K601. 3. Activate the Qmax function via VHMS. 4. Start the engine and run it at high idle. 5. Required pressure: 10 ± 1.0 bar If adjustment is required: z

Remove the protective cap (Fig. 4-3, Pos. 12).

z

Loosen the lock nut (Fig. 4-3, Pos. 5).

z

Adjust the pressure with the set screw (Fig. 4-3, Pos. 6).

z

Tighten the lock nut (Fig. 4-3, Pos. 5) and refit the protective cap (Fig. 4-3, Pos. 12).

6. Disconnect the pressure gauge, reconnect the solenoid valve 40K601, and switch off the Qmax function via VHMS.

Version 2010/1

4-7

Fan Drive (Two Stage Cooler Fan RPM Control)


4.4

FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL)

Fig. 4-4

Fan drive

4-8

Version 2010/1



Legend for Fig. 4-4: (5.1)

Axial piston pump (fixed displacement pump with variable setting)

(31.1)

Pressure relief valve, pilot controlled (maximum fan speed)

(34.1)

Pressure filter

(37.1)

Fan motor top (axial piston motor)

(37.2)

Fan motor bottom (axial piston motor)

(38)

Check valve – (anti-cavitation valve for fan drive motor)

(124)

Pressure relief valve (medium fan speed)

(57K506a/b-1)

Solenoid valve

(M6)


Function From the pump (Fig. 4-4, Pos. 5.1) the oil flows through the pressure filter (Fig. 4-4, Pos. 34.1) to the fan motors (Fig. 4-4, Pos. 37.1 + 37.2) and then back to the tank. The check valve (Fig. 4-4, Pos. 38) acts as an anti-cavitation valve. It is installed because the fan motor (driven by inertial force) keeps on running for a short period after the oil flow is interrupted by the solenoid valve (Fig. 4-4, Pos. 57K506a/b-1). The fan drive circuit is protected by the pilot controlled pressure relief valves ( Fig. 4-4, Pos. 31.1) and (Fig. 4-4, Pos. 124). These valves are working together with the solenoid valve (Fig. 4-4, Pos. 57K506a/b-1), controlled by the VHMS system, depending on the hydraulic oil temperature. z

With de-energized solenoids 57K506a-1 and 57K506b-1 the relief valve (Fig. 4-4, Pos. 31.1) is operating and the fans are running with max. adjusted speed (1250 ± 50 rpm).

z

With solenoid 57K506a-1 energized the relief valve (Fig. 4-4, Pos. 31.1) is not operating and the fans are running with a very low speed caused by the flow resistance only.

z

With solenoid 57K506b-1 energized the relief valve (Fig. 4-4, Pos. 124) is controlling the relief valve (Fig. 4-4, Pos. 31.1) and the fans are running with medium speed (1000 ± 10 rpm) only.

Version 2010/1

4-9



4.4.1

FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING

Fig. 4-5

Fixed displacement pump

4-10

Version 2010/1




Drive shaft

(2)

Bearings

(3)

Cylinder with pistons

(4)

Center pin

(5)

Control lens

(6)


(7)

Qmax 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 into the suction port. The rotary group is a robust self aspirating unit. 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 an decrease in the swivel angel, the pump output decreases together with the necessary drive torque.

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

Version 2010/1

4-11


4.4.2

PRESSURE RELIEF VALVE

Fig. 4-6


4-12


Version 2010/1




Valve cartridge

(2)

Spring

(3)

Spring chamber

(4)

"X" port

(5)

Jet bore, pilot poppet

(6)

Jet bore, main piston

(7)

Main valve piston

(8)

Valve housing

(9)

Pilot valve cone

(A)

Pressure port

(B)

Return oil port

(X)

Remote control port

(Y)

External leak oil port

Function description Pressure input (A) affects the main piston (Fig. 4-6, Pos. 7). At the same time pressure acts via the jet bore (Fig. 4-6, Pos. 6) onto the spring-loaded side of the main piston, and via the jet bore (Fig. 4-6, Pos. 5) onto the pilot poppet (Fig. 4-6, Pos. 9) of the relief valve cartridge (Fig. 4-6, Pos. 1). If the system pressure in line (A) exceeds the value which is set at the spring (Fig. 4-6, Pos. 2), the pilot poppet (Fig. 4-6, Pos. 9) opens. The signal for this action comes from line (A) via the jet bores (Fig. 4-6, Pos. 6) and (Fig. 4-6, Pos. 5). The oil on spring-loaded side of the main piston (Fig. 4-6, Pos. 7) now flows via the jet bore (Fig. 4-6, Pos. 5) and poppet (Fig. 4-6, Pos. 9) into the spring chamber (Fig. 4-6, Pos. 3). From here it is fed internally by means of the control line (Fig. 4-6, Pos. Y) to the tank (Fig. 4-6, Pos. B). Due to the state of equilibrium at the main piston (Fig. 4-6, Pos. 7), the oil flows from line (A) to (B), while the adjusted operating pressure is maintained. The pressure relief valve can be unloaded (remote controlled) by means of the port (X) and the function of the solenoid valve (Fig. 4-7, Pos. 124). For the operating function of the solenoid valve refer to section 4.4.3 on page 4-14.

Version 2010/1

4-13


4.4.3

SOLENOID VALVE

Fig. 4-7

Solenoid valve

4-14


Version 2010/1



Function description With de-energized solenoids (Fig. 4-7, Pos. 57K506a/b-1) the spool (Fig. 4-7, Pos. 3) keeps the "X" connection of valve (Fig. 4-7, Pos. 31.1) and port “B“ to port “P“ closed. The pressure relief valve (Fig. 4-7, Pos. 31.1) operates normally. • Fan speed: maximum speed. The energized solenoid 57K506b-1 operates the spool (Fig. 4-7, Pos. 3) and a connection is made between port “P“ and port “B“ and port "X" of the valve (Fig. 4-7, Pos. 31.1) The system pressure now opens the main piston (Fig. 4-6, Pos. 7) of the pressure relief valve (Fig. 4-7, Pos. 31.1), because via the solenoid 57K506b-1 (P to B) the oil from the rear side of the piston (Fig. 4-6, Pos. 7) flows from the "X"-port to the “P“ connection of the valve (Fig. 4-7, Pos. 124). The normal valve function is now remote controlled by the pressure adjusted at the valve (Fig. 4-7, Pos. 124). • Fan speed: medium speed The energized solenoid 57K506a-1 operates the spool (Fig. 4-7, Pos. 3) and a connection is made between port “P“ and port “A” and port "X" of the relief valve (Fig. 4-7, Pos. 31.1). The system pressure now opens the main piston (Fig. 4-6, Pos. 7) of the relief valve (Fig. 4-7, Pos. 31.1) because via the "X"-port the oil from the rear side of piston (Fig. 4-6, Pos. 7) flows to the tank. The normal relief valve function is eliminated. • Fan speed: minimum speed

Version 2010/1

4-15

Adjustment of the Cooler Fan Drive Speed


4.5

ADJUSTMENT OF THE COOLER FAN DRIVE SPEED

4.5.1

MAXIMUM SPEED

Fig. 4-8

Adjustment of the cooler fan drive maximum speed

4-16

Version 2010/1



Legend for Fig. 4-8: (a + d)

Dust cap

(b + e)

Lock nut

(c + f)

Set screw

(5.1)


(6)


(6.1)

Lock nut

(7)

Qmax stop bolt

(7.1)

Lock nut

(10)

Positioning pin (mover)

(31.1)

Pressure relief valve – Hydraulic oil cooler fan drive

(34.1)

Pressure filter

(124)

Pressure relief valve (medium fan speed)

(57K506a/b-1)

Solenoid valve

(L1)

Measurement of torque adjustment bolt

(L2)

Measurement of Qmax stop bolt

(M6)


NOTE: Basic adjustment has to be carried out whenever one of the following components has been replaced: z

pump

z

relief valve

z

hydraulic motor

Precaution when the fan pump was replaced: The pump must be bleeded properly and the spline housing must be filled with oil, refer to the OPERATION & MAINTENANCE MANUAL. Basic Adjustment – Maximum Speed 1. For safety reason reduce the output flow of the pump (Fig. 4-8, Pos. 5.1) by adjusting the minimum possible swivel angle, to avoid over-speeding the fan: To do this, loosen both lock nuts (Fig. 4-8, Pos. 6.1 + 7.1), turn out the torque adjustment bolt (Fig. 4-8, Pos. 6). Turn in the Qmax bolt (Fig. 4-8, Pos. 7) the same length. This is necessary to avoid a loose positioning pin (Fig. 4-8, Pos. 10) which would result in oscillating of the cylinder barrel. Tighten the lock nuts. Adjust the relief valve to a higher setting as required in order to eliminate the pressure relief valve influence. 2. Remove the protection cap (Fig. 4-8, Pos. a) from the relief valve (Fig. 4-8, Pos. 31.1), loosen the lock nut (Fig. 4-8, Pos. b) and turn the set screw (Fig. 4-8, Pos. c) fully clockwise and then a half turn counterclockwise. 3. Isolate the function of the solenoid valve (Fig. 4-8, Pos. 57K506a/b-1) by disconnecting both connectors, to ensure that the full flow capacity of pump 5.1 will be delivered to the fan motor. 4. Connect a pressure gauge to the check point (Fig. 4-8, Pos. M6).

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5. Start the engine and run it at high idle. 6. Check the fan speed with a non-contact revolution counter.

WARNING Be careful not to get caught in the fan or other rotating parts.

7. Increase the output flow of pump (Fig. 4-8, Pos. 5.1) by adjusting the swivel angle, until the fan speed will be 20 - 50 rpm higher as required: To do this, loosen both lock nuts (Fig. 4-8, Pos. 6.1 + 7.1) and turn in the bolt (Fig. 4-8, Pos. 6). Turn out the bolt (Fig. 4-8, Pos. 7) the same length while the engine and the fan are in operation. This is necessary to avoid a loose positioning pin (Fig. 4-8, Pos. 10) which would result in oscillating of the cylinder barrel. Tighten the lock nuts (Fig. 4-8, Pos. 6.1 + 7.1).

WARNING Do not exceed the maximum permissible operating pressure of p = 230 +30 bar.

NOTE: Note down the lengths ”L1” and ”L2” as reference measurements. 8. Loosen the lock nut (Fig. 4-8, Pos. b) of the relief valve (Fig. 4-8, Pos. 31.1), and decrease the pressure with the set screw (Fig. 4-8, Pos. c) until the correct fan speed is obtained. 9. Tighten the lock nut (Fig. 4-8, Pos. b) and fix the protection cap (Fig. 4-8, Pos. a). NOTE: Both fans have to be checked. A speed difference of 50 rpm is normal due to the higher resistance of the air stream for the lower fan. If the speed difference between both fans is higher than 50 rpm, a possible cause could be a worn hydraulic motor or defective bearings.

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4.5.2

MEDIUM SPEED

Fig. 4-9

Adjustment of the cooler fan drive medium speed

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Basic Adjustment – Medium Speed 10. Activate the function of the pressure relief valve (Fig. 4-9, Pos. 124) by connecting the connector of the solenoid valve 57K506b-1 only. 11. Use the REAL TIME MONITOR of the VHMS system and check the condition of the solenoid valve 57K506b-1 (0 or 1).

Fig. 4-10 VHMS screen with 57K506b-1 NOTE: For the operating instructions of the VHMS system refer to section 14. 12. Loosen the lock nut (Fig. 4-9, Pos. e) of the relief valve (Fig. 4-9, Pos. 124) and turn the set screw (Fig. 4-9, Pos. f) fully counterclockwise and then clockwise until the correct fan speed is obtained. z

Required fan speed: 1000 ± 10 rpm.

13. Tighten the lock nut (Fig. 4-9, Pos. e) and fix the protection cap (Fig. 4-9, Pos. d). 14. Note down the pressure as reference value (expected ~ 150 bar). 15. Disconnect the pressure gauge from the check point (Fig. 4-9, Pos. M6). 16. Connect the connector of the solenoid valve 57K506a-1.

4.5.3

FUNCTION CHECK OF FAN SPEED CONTROL

Connect/disconnect the plugs of the solenoids 57K506a/b-1 and check the following fan speeds: 57K506a-1 - 0 57K506b-1 - 0

nmaximum ≈ 1250 ± 50 rpm

57K506a-1 - 0 57K506b-1 - 1

nmedium ≈ 1000 ± 10 rpm

57K506a-1 - 1 57K506b-1 - 0

nminimum ≈ 0 - 50 rpm

NOTE: At minimum speed condition the fan may spin at low revolution or it may stop completely.

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5. CONTROLLING

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General layout

5.1

GENERAL LAYOUT

Fig. 5-1

Overall view of the controlling system

5-24

CONTROLLING

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CONTROLLING

General layout

Legend for Fig. 5-1 (20S019)

Electro proportional joystick control

(20S020)


(20S021a)

Electro proportional pedal control, travelling of left crawler

(20S021b)

Electro proportional pedal control, travelling of right crawler

(20S022)

Electro proportional pedal control, swing brake

(20S023)

Electro proportional pedal control, closing of the clam

(20S024)

Electro proportional pedal control, opening of the clam

(M1.1)

Pressure test port, X4 pressure. (Pump bearing lubrication, pump support pressure (60 bar)) CLS SLS

(M1.2)

Pressure test port, X2 pressure. Pilot pressure (45 bar), bracke control, pump regulation.

(8.1)

Gear pump for pilot pressure, pump regulation and pump bearing lubrication

(14.1/.2 + 15.1/.2)

Remote control valve blocks

(33)

Pressure filter

(35)


(41)

Main hydraulic oil tank

(85)

Bladder accumulator – 10 liters, 10 bar (located underneath the catwalk in front of the PTO)

(252.1)

Pressure relief valve for pilot pressure X2 (45 bar)

(252.2)

Pressure relief valve for pump support pressure X4 (60 bar)

General The control circuit is fed by one gear pump, and splitted in two pressure lines X4 and X2. The controlling includes the pilot pressure system and the pump regulation system. The pump (Fig. 5-1, Pos. 8.1) forces the oil through the filter (Fig. 5-1, Pos. 33) to all involved valves. The pressure accumulator ensures that under any circumstances enough pilot pressure oil is available. The accumulator (Fig. 5-1, Pos. 85) also serves as a hydraulic back-up system for a certain time when the engine was shut down, or to relieve the system pressure for repair works. The remote control valves are constantly supplied with the pilot pressure X2 (45 bar). When the operator is using the control elements, an electric signal is sent to electric system which energises and controls the relevant proportional valve(s) of the remote control valves (Fig. 5-1, Pos. 14.1/.2+15.1/.2). As a consequence of this, hydraulic oil runs to the corresponding component.

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5.2

VALVE CARTRIDGE BLOCK

Fig. 5-2

Valve cartridge block, location of components

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CONTROLLING

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Legend for Fig. 5-2: Solenoid valves (57Q505)

Slew parking brake operating pressure

(57K506a-1)

Cooler fan RPM control, minimum speed

(57K506b-1)

Cooler fan RPM control, medium speed

(57Q516)

Travel parking brake operating pressure

(57K517)

Qmin control (pump control system)

(57K517a)

½ Qmax (reduced oil flow at cold oil [below T2])

(57K553-1)

”Reduction pre-load pressure PTO gear lubrication - oil cooler”

(57K561-1)

X1 pressure, pumps 1 – 4

(57K620)

Hydraulic swing brake, operating pressure

(57Q623a)

Ladder, raise

(57Q623b)

Ladder, lower

(57Q624a)

Refilling arm, raise

(57Q624b)

Refilling arm, lower

(57Q624c)

Refilling arm stop, hold position

(57Q625)

Ladder, fast movement

(57K626)

Flow reduction swing (pump 1)

(57Q627)

Proportional swing brake pressure

(57K630)

Fixed pump No. 1 (max. flow, X1 = 45 bar)

(57K631)


(57K636)

Engine radiator fan speed (proportional valve)

(57K646)

Energy Efficiency (pump No. 2 + No. 4)

(57K647)

Energy Efficiency (pump No. 3)

(57K648)

Energy Efficiency (pump No. 1) Filter

(33)

Pilot pressure

(34.1)

Hydraulic oil cooler fan drive

(34.2)

Engine radiator fan drive

(36)

PTO gear lubrication

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Fig. 5-3

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CONTROLLING


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Miscellaneous (29)

Pressure relief valve – PTO gear lubrication

(31.1)

Pressure relief valve – hydraulic oil cooler fan drive, with solenoid valve 57K506a/b-1 for fan RPM control

(31.2)

Pressure relief valve - engine radiator fan drive, with proportional solenoid valve 57K636-1 for fan RPM control

(47)

Pressure reducing valve – track tensioning system (35 bar)

(124)

Pressure relief valve medium speed cooler fan

(152)

Pressure reducing valve – Energy Efficiency (X3 ~ 18 bar, pre-adjustment)

(252.1)

Pressure reducing valve for pilot pressure X2 (45 bar)

(252.2)


(253.1)

Change-over valve – electronic pump regulation or hydraulic constant regulation

(253.2)

Pressure reducing valve – hydraulic constant regulation

(255.4)

Pressure reducing valve – ½ Qmax

(257.1)

Pressure relief valve – safety valve for travel brake / track tensioning system (55 bar)

(258.3)

Pressure relief valve – safety valve for hydraulic access ladder (70 bar)

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Fig. 5-4

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CONTROLLING


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Legend for Fig. 5-4: Pressure switches (57B017-1)

PTO gear lubrication pressure

(57B027-1)

PTO gear lubrication - filter element monitoring

(57B085-1)

Pressure transducer – X1 pressure

(57B086)

Pressure transducer – X2 pressure Pressure test ports

(M1.1)

X4, pump support pressure, pump bearing lubrication (60 bar)

(M1.2)

X2 pressure, pilot pressure (45 bar)

(M2)

Bladder accumulator, pilot pressure (45 bar)

(M3)

PTO gear lubrication pressure

(M4)

Travel parking brake operating pressure (35 bar)

(M5)

Slew parking brake operating pressure (45 bar)

(M6)

Hydraulic oil cooler fan drive operating pressure

(M7)

Engine radiator fan drive operating pressure

(M15)

X1 pressure, hydraulic constant regulation only

(M18)

X1 pressure – general (electronic or hydraulic constant regulation general)

(M19)

X3 pressure – Energy Efficiency (~18 bar pre-adjustment)

(M23)

Travel parking brake safety pressure (55 bar)

(M30)

X4 pressure (60 bar)

(M31)

Option operating pressure: “fast motion for travel” not used

(M32)

X3 pressure – pumps No. 2 to No. 4

(M33)

Reduced X3 pressure – to pump No. 1 – ½ Qmax (~15 bar)

(M35.1)

Hydraulic cylinder access ladder “piston side”

(M35.2)

Hydraulic cylinder access ladder “rod side”

(M38.1)

Hydraulic cylinder refilling arm “piston side”

(M38.2)

Hydraulic cylinder refilling arm “rod side”

(M39)

Proportional pressure to hydraulic swing brake

(M41)

X1 pressure – fixed pump No. 3 (max. flow, X1 = 45 bar)

(M42)

X1 pressure – fixed pump No. 1 (max. flow, X1 = 45 bar)

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Pilot pressure supply and adjustments

CONTROLLING

5.3

PILOT PRESSURE SUPPLY AND ADJUSTMENTS

Fig. 5-5


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Legend for Fig. 5-5: (20S019)


(20S020)


(20S021a)

Electro proportional pedal control, travelling of left crawler

(20S021b)

Electro proportional pedal control, travelling of right crawler

(20S022)

Electro proportional pedal control, swing brake

(20S023)

Electro proportional pedal control, closing of the clam

(20S024)

Electro proportional pedal control, opening of the clam

(M1.1)

Pressure test port, X4 pressure. (Pump bearing lubrication, pump support pressure (60 bar)) CLS SLS

(M1.2)

Pressure test port, X2 pressure. Pilot pressure (45 bar), bracke control, pump regulation.

(8.1)

Gear pump for pilot pressure, pump regulation and pump bearing lubrication

(14.1/2+15.1/.2)


(33)

Pressure filter

(35)


(41)


(85)


(252.1)

Pressure relief valve for pilot pressure X2 (45 bar)

(252.2)


5.3.1

PILOT PRESSURE CONTROL (PPC) CIRCUIT

The pilot pressure oil is used for the following functions: To operate 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 drive the grease pumps and to supply the hydraulic track tensioning system. Function NOTE: For further details refer to the hydraulic circuit diagram! The pump (Fig. 5-5, Pos. .8.1) delivers the oil through the pressure filter (Fig. 5-5, Pos. 33) to port "A" of the pressure relief valve (Fig. 5-5, Pos. 252.2) to limit the pump support pressure X4 (60 bar). The pressure reducing valve (Fig. 5-5, Pos. 252.1) maintains the adjusted pressure of 45 bar (X2) for the pilot pressure system, the pump regulation system and the supply for some auxiliary systems. The pressure accumulator (Fig. 5-5, Pos. 85) holds a certain 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.

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Fig. 5-6

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CONTROLLING


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(85)


(PX2)

Pilot pressure line

(LX2)

Leak / return oil line from the remote control valve blocks

Function The pilot pressure oil (X2 pressure) flows via a line (Fig. 5-6, Pos. PX2) to the pressure port of each remote control valve block. These solenoid valves are energized when operating the electro proportional controls (joysticks or pedals). The soleniod valves direct the pilot pressure oil to the respective spools of the main control blocks. The pressure correlates to the deflection of the controls corresponding to the adjustments of the amplifiers and the ramp time module. NOTE: For the location and designation of the proportional and directional solenoid valves of the remote control blocks refer to section 5.3.3 on page 5-38.

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5.3.2

CHECKS AND ADJUSTMENT OF PILOT PRESSURE

Fig. 5-7

Checks and adjustment of pilot pressure

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Legend for Fig. 5-7: (1), (3)

Lock nut

(2), (4)

Set screw, pressure relief valve

(85)

Bladder accumulator – 10 liters, 10 bar pre-charge pressure

(252.1)


(252.2)


(M1.1)

Pressure test port X4, pump support pressure (60 bar)

(M1.2)

Pressure test port X2 pressure, pilot pressure (45 bar)

(M2, M40)

Pressure test ports for accumulator

NOTE: Carry out oil pressure testing and adjustment only at hydraulic oil temperature T3. X4 pressure (60 bar), valve 252.2: 1. Connect a pressure gauge to the appropriate test port (Fig. 5-7, Pos. M1.1). 2. Start the engine, run at high idle. 3. Read pressure, required = 60 bar (±1.0 bar). If readjustment is required, proceed as follows: z

Loosen the lock nut (Fig. 5-7, Pos. 1).

z

Set pressure with the set screw (Fig. 5-7, Pos. 2).

z

Tighten the lock nut (Fig. 5-7, Pos. 1).

X2 pressure (45 bar), valve 252.1: 1. Connect a pressure gauge to the appropriate test port (Fig. 5-7, Pos. M1.2). 2. Start the engine, run at high idle. 3. Read pressure, required = 45 bar (±1.0 bar). If readjustment is required proceed as follow: z

Loosen lock nut (Fig. 5-7, Pos. 3).

z

Set pressure with the set screw (Fig. 5-7, Pos. 4).

z

Tighten the lock nut (Fig. 5-7, Pos. 3).

Checking the accumulator function: 1. Connect a pressure gauge to the appropriate test port (Fig. 5-7, Pos. M2). 2. Start the engine, run at high idle. 3. After build-up of pressure stop the drive engine, but do not turn the key switch to zero position. 4. Watch the pressure gauge. Pressure should remain constant for at least 5 minutes. NOTE: If the pressure drops, the system must be checked for leakages. To check the accumulator charging pressure, refer to PARTS & SERVICE NEWS “AH01531”, latest edition.

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5.3.3

REMOTE CONTROL VALVES ARRANGEMENT

Fig. 5-8

Remote control valves arrangement

5-38

CONTROLLING

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Legend for Fig. 5-8: Remote control unit schematic code

Directional solenoid

Proportional solenoid

61K540

Function BHA

FSA Boom raising

61K573 61K541

Boom lowering

61K538

Stick extending

Clam closing

Stick retracting

Clam opening

Bucket filling

Bucket filling

Bucket dump

Stick extending

61K572 61K539 (15.1) 61K536 61K571 61K537 61K534

L.H. crawler reverse 61K570

61K535

L.H. crawler forward

61K524

L.H. swing 61K565

61K525

R.H. swing

61K522 (14.1)

Bucket filling (curl) 61K564

61K523

Bucket emptying

61K520

Boom raising 61K563

61K521

Boom lowering

61K526

R.H. swing 61K566

61K527

L.H. swing

61K532 (14.2)

Boom lowering

Bucket filling

Boom raising

Boom raising

61K569 61K533 61K530

Stick extending 61K568

61K531

Stick retracting

61K546

Boom raising 61K576

61K547

Boom lowering

61K544


61K545

Bucket emptying

(15.2) 61K542


61K543

Stick retracting

61K528

R.H. crawler forward 61K567

61K529

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R.H. crawler reverse

5-39

Function of the electro hydraulic control system

5.4

FUNCTION OF THE ELECTRO HYDRAULIC CONTROL SYSTEM

Fig. 5-9

Electro hydraulic control system

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CONTROLLING



Control lever (joystick)

(2)

MTC controller (zero position and direction recognition)

(3)

Node

(4)

Proportional solenoid valve

(5)

Directional solenoid valve, a side

(6)

Directional solenoid valve, b side

(7)

Main control valve block

(8)

Pump

(9)

Filter

(10)


(11)

Check valve

(12)

Pressure accumulator

Function The electric-hydraulic control system is used to control the direction and volume of the oil flow to the operating cylinders and motors via the main control valve blocks. Hydraulically The oil volume of the pump (Fig. 5-9, Pos. 8) flows through the filter (Fig. 5-9, Pos. 9) into the pilot pressure system. The pressure is limited by the pressure relief valve (Fig. 5-9, Pos. 10). With the pressurized oil stored in accumulator (Fig. 5-9, Pos. 12), a limited number of control valve spool movements can be carried out with the main drive motor at standstill. When a lever (or pedal) is actuated, the proportional solenoid valve (Fig. 5-9, Pos. 4) and one of the directional solenoid valves (Fig. 5-9, either Pos. 5 or 6) are energized, the pilot pressure moves the spools of the main control valve blocks. Electrical Whenever a lever or a pedal is moved out of its neutral position, an amplifier will create a current between 0 and 1000 mA. (For detailed information see next page.) Depending on the lever direction, one of the directional solenoid valves (Fig. 5-9, either Pos. 6 or 7) is energized to select the main valve direction. The proportional solenoid valve alters the pilot pressure according to the lever deflection, effecting a spool movement between neutral and full stroke position.

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CONTROLLING

Fig. 5-10 Electro hydraulic proportional control

5-42

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Legend for Fig. 5-10 (exemplary illustration of the function of two axis with one amplifier only): (1)


(2)

Capacitor module

(3)

Ramp time module

(4)

Proportional amplifier module

(5)

Relay (supply voltage)

(6)


(7)

Directional solenoid valve

(8)

Control block spool

General Function The control lever (Fig. 5-10, Pos. 1) is supplied with 24 VDC battery voltage for the switch contacts and with capacitor supported 24 VDC to create a stable signal voltage. When moving the the lever (Fig. 5-10, Pos. 1) out of his neutral position, 24 VDC battery voltage is applied to the relay (Fig. 5-10, Pos. 5) and energizes the proportional amplifier (Fig. 5-10, Pos. 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 „X-axis“ (left/right direction). The polarity of the output signal from the joystick (Fig. 5-10, Pos. 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 (Fig. 5-10, Pos. 3) at terminal 5 which will arrive after the adjusted ramp time delay via terminal 7 at the proportional amplifier (Fig. 5-10, Pos. 4), terminal 5. This input signal (between 0 and 10 VDC) is amplified to an output signal between 0 to 1000 mA and is simultaneously sent via terminal 7 (negative) or terminal 8 (positive) to the proportional solenoid valve (Fig. 5-10, Pos. 6) and the directional solenoid valve (Fig. 5-10, Pos. 7) via terminal 3 (negative) or terminal 9 (positive) to the “a” or “b”-side. The proportional solenoid valve (Fig. 5-10, Pos. 6) alters the pilot pressure (“X2”) of max. 45 bar to a value proportional to the current signal. This pressure controls the movement of the control block spool (Fig. 5-10, Pos. 8) between neutral and full stroke position.

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Hand lever (joystick) control

5.5

CONTROLLING

HAND LEVER (JOYSTICK) CONTROL

Fig. 5-11 Potentiometer control

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Hand lever (joystick) control



(2)

Control unit

(3)

Deutsch connector

(4)

Inductive linear transmitter

(5)

Push pin

(6)

Coil

(7)

Direction monitoring

(8)

Zero position monitoring

(9)

Electronics of the control unit

(10)

Direction contacts

(11)

Zero position contacts

* Alternative application The non-contacting lever control (inductive linear transmitter) contains both the electronic and mechanical components which convert the lever movement into a proportional electrical voltage. The lever can be operated in two axes: z

Axis "Y", splitted into the half axis Y- and Y + (backward and forward)

z

Axis "X", splitted into the half axis X- and X + (left and right)

Of course the lever can be moved in any combined direction (joystick function). In order to be able to monitor the direction of the lever movement and the neutral position, the electronics (Fig. 5-11, Pos. 9) sends a 24 V signal as soon as the lever gets moved out of its neutral position. For one axis two inductive linear transmitter (Fig. 5-11, Pos. 4) are used. The motion of the coil core connected to the push pin (Fig. 5-11, Pos. 5) causes a variation of the induction in the coil (Fig. 5-11, Pos. 6). The electronics converts this inductive signal into a proportional output signal of -10...0...+10 V for the amplifiers. In order to be able to monitor the direction of the lever movement and its neutral position, two switches (Fig. 5-12, Pos. 7 and 8) are fitted, which are actuated by the switch actuator attached to the push pin (Fig. 5-12, Pos. 5) as soon as the lever gets moved out of its neutral position. The monitoring of the neutral position and the direction of the lever is carried out by the MTC controller.

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5-45

Foot pedal control

5.6

CONTROLLING

FOOT PEDAL CONTROL

Fig. 5-12 Foot pedal control

5-46

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CONTROLLING

Foot pedal control


Pedal control unit

(2)

Foot pedal

(3)

Connection cable

(4)

Deutsch connector

(5)

Push pin

(6)

Coil

(7)

Direction monitoring

(8)

Direction contacts

(9)

Electronics

(10)

Switch actuator

(11)

Neutral (zero) position contacts

(12)

Neutral (zero) position monitoring

Application for: (A)

Clam opening/closing

(B)

Travelling

(C)

Swing foot brake

The foot pedal control (inductive, linear travel transmitter) contains both the electronic and mechanical components which convert the pedal movement into a proportional electrical voltage. In order to be able to electrically monitor the pedals (Fig. 5-12, Pos. A-C) action, neutral position switches are fitted. These switches close when the pedal is moved out of the neutral position. In order to be able to monitor the direction of the pedal movement and the neutral position of travel unit (Fig. 5-12, Pos. B), two switches (Fig. 5-12, Pos. 7 and 12) are fitted, which are actuated by the switch actuator (Fig. 5-12, Pos. 10) as soon as the pedal gets moved out of its neutral position.

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Proportional amplifier module, type A

5.7

CONTROLLING

PROPORTIONAL AMPLIFIER MODULE, TYPE A

Fig. 5-13 Proportional amplifier module, type A

5-48

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CONTROLLING

Proportional amplifier module, type A

Legend for Fig. 5-13: Type A

Usage: Swing brake :

11T016

(1)

LED for solenoid A or B

(2)

Set potentiometer R1 and R2 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 channel A or channel B is operated. Both channels outputs are combined. 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. Input signals up to 1 V generate no output signal (ouput current = 0). From 1 V to 9 V, the output current rises linearly from 40 mA to 350 mA. For input signals above 9 V, the ouptut current is fixed to the maximum of 1000 mA. The module also generates a direction-dependent voltage signal (solenoid A - solenoid B) as soon as the solenoid current reaches the lowest set value. Both endpoints for the linear increase (proportinal area) are set externally via the potentiometer R1 and R2. NOTE: For adjustment of the type A amplifier refer to section 5.10.2 on page 5-56.

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Proportional amplifier module, type B

5.8

CONTROLLING

PROPORTIONAL AMPLIFIER MODULE, TYPE B

Fig. 5-14 Proportional amplifier module, type B

5-50

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CONTROLLING

Proportional amplifier module, type B

Legend for Fig. 5-14: Type B

Usage: Boom Stick Bucket Clam Swing Travel, left Travel, right

: : : : : : :

11T010… (4 Pcs.) 11T008… (2 Pcs.) 11T009… (3 Pcs.) 11T011 11T007… (2 Pcs.) 11T012 11T013

(LED) Ax: AS: Bx: BS: Power: Fault:

Proportional output Ax active Switched output AS active Proportional output Bx active Switched output BS active Internal supply voltage Fault indication (P)

(P)

Set potentiometer: z 10% for the lowest current value z J2 for the highest current value

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% jumps may be set separately for the proportional outputs Ax and Bx via external potentiometers. As the signal voltage rises, the solenoid current for the proportional outputs increases linearly. A further step in the 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 potentiometers. 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. A fault is indicated by the LED „Fault“.

Version 2010/1

5-51

Ramp time module

5.9

CONTROLLING

RAMP TIME MODULE

Fig. 5-15 Ramp time module

5-52

Version 2010/1

CONTROLLING

Ramp time module

Legend for Fig. 5-15: Ramp time module

Usage: Boom Stick Travel

: : :

Swing : Swing brake : Bucket :

11T049 11T048 11T051 (left) 11T052 (right) 11T050/50a 11T050b 11T059

Potentiometer "t1" to "t5"

Ramp time adjustment (t5 not used)

"w1" to "w4"

Command value call-ups (not used)

"G"

Zero point matching

"Z"

Amplitude attenuation for the differential input

LED Displays (1)

green => operational power

(2)

"4-Q" => quadrant recognition (not used)

(3)

"INV" => inversion active (not used)

(4)

yellow => display for potentiometer t1 to t4

(5)

yellow => display for potentiometer w1 to w4

(6)

Measurement sockets: z z z

"t" - Actual ramp time (tension signal) "w" - Internal adjustment variable (not used) "⊥" - 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 be changed from 0% to approx. 110% via potentiometer "G". 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 illuminated. Version 2010/1

5-53

Adjustments of amplifier modules

CONTROLLING

5.10 ADJUSTMENTS OF AMPLIFIER MODULES

Fig. 5-16 Adjustments of amplifier modules

5-54

Version 2010/1

CONTROLLING




(2)

Terminal with a separating possibility

(3)

Ramp time module

(4)

Amplifier

(5)

Solenoid valve (Proportional valve)

(6)

Service module

5.10.1 GENERAL Introduction Fig. 5-16 is a simplified illustration of the signal voltage route from the joystick control (Fig. 5-16, Pos. 1) to the solenoid valve (Fig. 5-16, Pos. 5): (A)

With ramp time module FSA & BHA – Boom, stick, bucket, travel, swing brake and swing function NOTE: For adjustment data, please also refer to the Parts & Service News "AH09525" (latest edition).

(B)

Without ramp time module FSA only – Clam function

The ramp time modules (Fig. 5-16, Pos. 3) and the amplifiers (Fig. 5-16, Pos. 4) are adjustable. Adjustments are required: Ramp Time Modules z z

When commissioning the machine. When replacing a module.

Amplifiers z z

When replacing a proportional solenoid valve. When replacing an amplifier.

For checking and setting the signal current at the proportional-amplifier (Fig. 5-16, Pos. 4), both separating terminal (Fig. 5-16, Pos. 2) before and behind the amplifier (Fig. 5-16, Pos. 4) must be opened. For the setting procedure the signal voltage from the potentiometer control (Fig. 5-16, Pos. 1) can be simulated with the potentiometer of the service module (Fig. 5-16, Pos. 6) installed on the X2 board.

Version 2010/1

5-55


CONTROLLING

5.10.2 ADJUSTING THE AMPLIFIERS TYPE A

Fig. 5-17 Adjusting the amplifiers type A

5-56

Version 2010/1

CONTROLLING


NOTE: The adjustment of the amplifier for the swing brake is slightly different from the adjustment procedures for the amplifiers of the other foot pedals and the joysticks, also refer to section 5.10.3 on page 5-58. Adjustment procedure for the amplifier of the swing brake (foot pedal): 1. Open* the respective separating terminal (Fig. 5-17, Pos. T1) between the pedal unit and the amplifier module to be set. 2. Open* the respective separating terminal (Fig. 5-17, Pos. T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from the amplifier, terminal 5. 4. Connect the positive output of the service module with terminal 5 of the amplifier module using a test lead (Fig. 5-17, Pos. 2). 5. Attach a multimeter for voltage reading to the service module using test leads (Fig. 5-17, Pos. 3). 6. Attach a multimeter (in series) for ampere reading to the terminals between the amplifier module and the solenoid valve using test leads (Fig. 5-17, Pos. 3). 7. Press the swing brake pedal fully down, or manually override the relay supplying the amplifier module with 24 VDC operating voltage. (Thus, the amplifier gets 24 V operating voltage.) 8. Turn the potentiometer (Fig. 5-17, Pos. P) of the service module until the multimeter for voltage reading shows 1 VDC; the multimeter for the current reading will show a value that should correspond to the value given in the circuit diagram, e.g. 40 mA (10% value). If necessary correct the value with the potentiometer (Fig. 5-17, Pos. R1). 9. Turn the potentiometer (Fig. 5-17, Pos. P) of the service module until the multimeter for voltage reading shows 10 VDC; the multimeter for the current reading will show a value that should correspond to the value given in the circuit diagram, e.g. 350 mA (100% value). If necessary correct the value with the potentiometer (Fig. 5-17, Pos. R2). NOTE: It is important that the pilot pressure for the pressure increasing valve is 24 ±1 bar. For more information refer to section 8.3 on page 8-102. * How to open and close the terminal: Push the yellow stud (Fig. 5-17, Pos. 1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. Then a spring pushes the stud outwards and the contacts are either open or closed.

Version 2010/1

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CONTROLLING

5.10.3 ADJUSTING THE AMPLIFIERS TYPE B

Fig. 5-18 Adjusting the amplifiers type B

5-58

Version 2010/1

CONTROLLING


Procedure applicable for all amplifiers except the one for the swing brake: NOTE: Used respective electric circuit diagram to identify the required terminals, components and valves. NOTE: Do not start the engine, only turn the key switch into ON-position. 1. Open* the respective separating terminal (Fig. 5-18, Pos. T1) between the lever unit and the amplifier module. 2. Open* the respective separating terminal (Fig. 5-18, Pos. T2) between the amplifier module and the proportional solenoid valve. 3. Disconnect the wire from terminal 5. 4. Connect the positive output of the service module with terminal 5 of the amplifier module using a test lead (Fig. 5-18, Pos. 2). 5. Attach a multimeter for voltage reading to the service module using test leads (Fig. 5-18, Pos. 3). 6. Attach a multimeter (in series) for ampere reading to the terminal between the amplifier module and the solenoid valve using test leads (Fig. 5-18, Pos. 3). 7. Move the lever 20S105 into operating position, or manually override the relay supplying the amplifier module with 24 VDC operating voltage. Thus the amplifier gets 24 V operating voltage. Simultaneously the power LED and either LED A(+) or B(-) light up, depending on the polarity. 8. Turn the potentiometer (Fig. 5-18, Pos. P) of the service module until the multimeter shows 1 VDC (it may be either positive or negative); the multimeter for the current reading should show a value corresponding to the value given in the circuit diagram, e.g. 300 mA (first step / 10% value [R1]). The LED’s show which channel (positiv A or negativ B) is activated. For adjustment use always potentiomenter in horizontal line to the activated LED’s. If necessary correct the value with the potentiometer (Fig. 5-18, Pos. R1). 9. Turn the potentiometer (Fig. 5-18, Pos. P) of the service module further until the multimeter shows 9 VDC; the multimeter for the current reading should show a value corresponding to the value given in the circuit diagram, e.g. 550 mA (second step / 90% value [R2]). The LED’s show which channel (positiv A or negativ B) is activated. For adjustment use always potentiomenter in horizontal line to the activated LED’s. If necessary correct the value with potentiometer (Fig. 5-18, Pos. R2). 10. Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other. 11. If the setting with either positive or negative potential was successful, turn the potentiometer (Fig. 5-18, Pos. P) of the service module into the opposite direction and check the settings with the other polarity. 12. Repeat the setting as described in steps 7 to 10. 13. Remove the multimeter, test leads, 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 (Fig. 5-18, Pos. 1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. Then a spring pushes the stud outwards and the contacts are either open or closed.

Version 2010/1

5-59

Adjusting the ramp time modul

CONTROLLING

5.11 ADJUSTING THE RAMP TIME MODUL

Fig. 5-19 Adjusting the ramp time module

5-60

Version 2010/1

CONTROLLING



Capacitor module

(2)

Service module

(3)

Ramp time module

(P)

Potentiometer

NOTE: 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. The following step numbers corespond to the boldface numbers in Fig. 5-19. Basic adjustment: 1. Connect a multimeter for voltage reading to the service module (Fig. 5-19, Pos. 6) and, if required, set voltage to 0 V by turning the potentiometer "P". Connect another multimeter for voltage reading to terminal 7 (+) and terminal 8 (-) of the ramp time module (Fig. 5-19, Pos. 3). Connect the red (positive) terminal of the service module with terminal 5 of the ramp time module using a test lead. If the multimeter at the ramp time module does not show "0 V", adjust the value by turning potentiometer "Z" at the ramp time module. 2. Now set the output voltage of the service module to 10 V. Check the voltage reading of the multimeter connected to the ramp time module; if neccessary, adjust to "10 V" by turning the potentiometer "G". NOTE: Repeat settings of item 1 and 2 until both values are stabilized, because "Pot Z" and "Pot G" influence each other. Disconnect the test lead after the setting is done. NOTE: The factory setting of potentiometer "w1" to "w4" must not be adjusted!

Version 2010/1

5-61


CONTROLLING

Fig. 5-20 Adjusting the ramp time module

5-62

Version 2010/1

CONTROLLING



Capacitor module

(2)


(3)

Ramp time module

(4)

Proportional amplifier module

(5)

Relay (supply voltage)

(6)

Extract from the circuit diagram

(7)

Designation of the amplifier connected to the ramp time module to be set

Ramp time adjustment in relation to the operating movements: 3. Disconnect the cables at terminal 3 and terminal 5 of the respective module. Connect a multimeter for voltage reading to the ramp time module terminals marked "t" (+) and "⊥" (-). 4. For setting the ramp times "t1" to "t4" one after another: Apply +24 VDC to the corresponding terminal (9 to 12, see Fig. 5-20) of the ramp time module using a test lead. (+24 VDC can be taken from terminal 1 of the ramp time module itself.) Take the set value for the ramp time(s) from the corresponding table in the circuit diagram and set the voltage by adjusting the appropriate potentiometer marked "t1" to "t4" at the ramp time module. NOTE: The ramp time "t" corresponds to the voltage "Ut"set as desribed above, see following table and examples. Voltage Ut measured at socket "t" [V]

Ramp time (±20%) [ms]

t = 100 Vms / Ut

5

20

Quick reaction

3

33

2

50

1

100

0.5

200

0.3

333

0.2

500

0.1

1000

0.05

2000

0.03

3333

0.02

5000

Example: Measured value Ut = 5 V

⇒ Resulting ramp time t = 100 V ms / 5 V = 20 ms

Example: Requested ramp time = 50 ms ⇒ Voltage to be set Ut = 100 V ms / 50 ms = 2 V

Slow reaction

NOTE: Through the new release of the PM Clinic procedure (and adjustment of the Energy Efficiency), the ramp time modules (except swing and travel circuit) are basically adjusted to 20 ms / 5 V. For more details refer to your electric circuit diagram. The amplifiers and ramp time modules will soon be replaced with a closed control module for controlling.

Version 2010/1

5-63


CONTROLLING

5-64

Version 2010/1

COMPONENTS

6. COMPONENTS

Version 2010/1

6-1

Main control blocks and high pressure filter (FSA)

COMPONENTS

6.1

MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (FSA)

Fig. 6-1


6-2

Version 2010/1

COMPONENTS


NOTE: Legend for Fig. 6-1: Pump Circuit No. I (10 / I)

Main control block (swing [fast] L.H. & R.H., bucket fill / boom raise, stick retract / extend)

(13.2)


(68.1)

Anti cavitation valve – stick cylinder piston side

(66.4)

Service-line relief valve – stick cylinder rod side Pump Circuit No. II

(11 / II)

Main control block (boom, clam, bucket fill / stick extend, L.H. travel)

(13.3)


(45)

SRV clam cylinder piston side

(66.5)

SRV boom cylinder piston side

(68.2)

ACV clam cylinder rod side

(68.3 + 68.4)

ACV travel motors Pump Circuit No. III

(9 / III)

Main control block (swing [slow], clam, bucket, boom [lower])

(13.1)

High pressure filter (with differential pressure switch B7)

(66.1)

SRV bucket cylinder piston side

(66.2)

SRV bucket cylinder rod side Pump Circuit No. IV

(12 / IV)

Main control block (R.H. travel, boom / bucket, stick)

(12.3)


(66.7)


(66.8)

SRV boom cylinder rod side

(66.9)

SRV bucket cylinder piston side

(66.10)

SRV bucket cylinder rod side

(66.11)

SRV stick cylinder piston side

(66.12)

SRV stick cylinder rod side

(68.5)

ACV stick cylinder piston side

(68.6 + 68.7)

ACV travel motors

NOTE: There is one main relief valve in each control block.

Version 2010/1

6-3

Main control blocks and high pressure filter (BHA)

COMPONENTS

6.2

MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (BHA)

Fig. 6-2


6-4

Version 2010/1

COMPONENTS


Legend for Fig. 6-2: Pump Circuit No. I (10 / I)

Main control block (swing [fast], boom, stick)

(13.2)


(66.4)

Service-line relief valve – Stick cylinder rod side Pump Circuit No. II

(11 / II)

Main control block (boom, bucket, stick, L.H. travel)

(13.3)


(66.5)


(66.6)

SRV clam cylinder rod side

(68.3 + 68.4)

ACV travel motors Pump Circuit No. III

(9 / III)

Main control block (swing [slow], bucket, boom)

(13.1)


(66.3)

SRV bucket cylinder rod side Pump Circuit No. IV

(100 / IV)

Main control block (boom, bucket, stick, R.H. travel)

(13.4)


(66.7)


(66.8)

SRV boom cylinder rod side

(66.12)

SRV stick cylinder rod side

(68.6 + 68.7)

ACV travel motors

NOTE: There is one main relief valve in each control block.

Version 2010/1

6-5

Distributor manifold - location of restrictor blocks and anti cavitation valves (FSA)

COMPONENTS

6.3

DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (FSA)

Fig. 6-3


6-6

Version 2010/1

COMPONENTS


Legend for Fig. 6-3: (SB)

Synchronization (equalization) block

(SL)

Synchronization (equalization) lines

(SRV)

Secondary relief valve

(M)


(42)


(64.1)

ACV block section A, boom cylinder rod side

(70.1 + 70.2)

Restrictor blocks section B, boom cylinder piston side with SRVs and pressure check points M16.1 + M16.2

(65.1)

SRV section C, bucket cylinder piston side with SRV and pressure check point M17.1

(70.4)

Restrictor block section C, bucket cylinder piston side with pressure check point M17.2

(64.2)

ACV block section C, bucket cylinder piston side

(64.3)

ACV block section D, bucket cylinder rod side

(70.6)

Restrictor block section E, clam cylinder rod side with SRV and pressure check point M19

(64.4)

ACV block section F, stick cylinder rod side

(65.2)

SRV section G, stick cylinder piston side with pressure check point M20

(64.5)

ACV block section H, stick cylinder rod side

(70.8 + 70.9)

Restrictor blocks section J, stick cylinder piston side with SRVs and pressure check points M21.1 + M21.2

(18)

SRV section K, clam cylinder piston side with pressure check points M22

(64.6)

ACV block section K, clam cylinder piston side

(64.7)

ACV block section L, bucket cylinder rod side

(64.8)

ACV block section M, bucket cylinder piston side

(70.12)

Restrictor block section M, bucket cylinder piston side with SRV and pressure check point M24

(65.3)

SRV section N, bucket cylinder piston side with pressure check point M25

(65.4)

SRV section O, boom cylinder piston side with pressure check point M26.2

(70.13)

Restrictor blocks section O, boom cylinder piston side with SRV and pressure check point M26.1

(64.9)

ACV block section P, boom cylinder rod side

Version 2010/1

6-7

Distributor manifold - location of restrictor blocks and anti cavitation valves (BHA)

COMPONENTS

6.4

DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (BHA)

Fig. 6-4

Distributor Manifold - Location of restrictor blocks and anti cavitation valves (BHA)

6-8

Version 2010/1

COMPONENTS

Distributor manifold - location of restrictor blocks and anti cavitation valves (BHA)

Legend for Fig. 6-4: (SL)

Synchronization (equalization) lines

(SRV)


(M)


(42)


(64.1)

ACV block section A, boom cylinder rod side

(70.1 + 70.2)

Restrictor blocks section B, boom cylinder piston side with SRVs and pressure check points M16.1 + M16.2

(70.3)

Restrictor block section C, bucket cylinder piston side with SRV and pressure check point M17.1

(70.4)

Restrictor block section C, bucket cylinder piston side with SRV and pressure check point M17.2

(64.2)

ACV block section C, bucket cylinder piston side

(64.3)

ACV block section D, bucket cylinder rod side

(70.5)

Restrictor block section D, bucket cylinder rod side with SRV and pressure check point M18

(64.4)

ACV block section F, stick cylinder piston side

(70.7)

Restrictor block section G, bucket cylinder rod side with SRV and pressure check point M20

(64.5)

ACV block section H, stick cylinder piston side

(70.8 + 70.9)

Restrictor blocks section J, stick cylinder rod side with SRVs and pressure check points M21.1 + M21.2

(70.10)

Restrictor blocks section K, stick cylinder rod side with SRVs and pressure check points M22

(64.6)

ACV block section K, stick cylinder rod side

(70.11)

Restrictor blocks section L, stick cylinder rod side with SRVs and pressure check points M23

(64.7)

ACV block section L, bucket cylinder rod side

(70.12)

Restrictor block section M, bucket cylinder piston side with SRV and pressure check point M24

(64.8)

ACV block section M, bucket cylinder piston side

(70.13)


(70.14)


(64.9)

ACV block section P, boom cylinder rod side

Version 2010/1

6-9

Single control blocks (floating) for stick and boom (FSA)

COMPONENTS

6.5

SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM (FSA)

Fig. 6-5


6-10

Version 2010/1

COMPONENTS


Legend for Fig. 6-5: (60Q632)

Single control block - Stick lowering function Floating position

(60Q633)


(60Q634)


(61Q635)

Single control block - Boom lowering function Floating position

Function (only Front Shovel Attachment) The additionally installed single control blocks connect the piston side of the cylinders with the rod side and also with the hydraulic oil tank: z

60Q632, 60Q633 and 60Q634 for the stick cylinders

z

61Q635 for the boom cylinders

In normal operation mode (floating position) the pilot pressure oil holds the spool in the single control blocks (via de-energized solenoid valves) open when lowering the boom or stick. If a pressurized lowering of the cylinders is required, the pilot pressure oil is switched via energized solenoid valves to the main control blocks. The solenoid valves (4/2-directional control valves) are controlled by push buttons located in the control levers (joysticks).

Version 2010/1

6-11

Restrictor block with pressure relief valve

COMPONENTS

6.6

RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE

Fig. 6-6

Restrictor block with secondary relief valve

6-12

Version 2010/1

COMPONENTS

Restrictor block with pressure relief valve


Adjustment pin

(2 + 3)

O-ring with back-up ring

(4)

Retainer

(5 + 6)

O-ring with back-up ring

(7)

Spring

(8)

Spring cup

(9)

Valve poppet

(10)

O-ring

(11)

Housing

(12)

Return line port, T

(13)


(14)

Allen bolt

(15)

Clip ring

(16)

Lock nut

(A + B)

Line ports

M


Y

Control oil drain port

NOTICE A restrictor block is used for limiting cylinder lowering speeds.

z z

A secondary relief valve is installed to limit the maximum system pressure due to external forces.

Function Setting of the maximum permissible cylinder speed (flow B to A) is carried out by the adjustment pin (Fig. 6-6, Pos. 1). Depending on the setting, the radial holes (Fig. 6-6 Pos. 9.1) in the valve poppet (Fig. 6-6, Pos. 9) will be partially opened to achieve the required throttling of the oil flow. The extra holes (fixed throttle 9.2) prevent the valve from becoming completely closed. For the lifting operation (flow A to B), the valve poppet (Fig. 6-6 Pos. 9), which is guided by the pin (Fig. 6-6, Pos. 1), is pressed against the spring (Fig. 6-6, Pos. 7) so that the valve will be completely open. NOTE: Ex factory the throttle valves are pre-adjusted, refer to PM-Clinic.

Version 2010/1

6-13

Anti cavitation valve block

6.7

ANTI CAVITATION VALVE BLOCK

Fig. 6-7


6-14

COMPONENTS

Version 2010/1

COMPONENTS


Legend for Fig. 6-7 (type 64.1 to 64.9 of the hydraulic circuit diagram): (1)

Housing

(2)

Valve cone

(3)

Spring

(4)

O-ring

(5)

Control and leak oil bore

(6)

Cap screw (torque: 900 Nm)

(S)

Supply line

(A + B)

Line connections

NOTE: ACVs are installed to avoid cavitation damages on hydraulic cylinders by compensating a possible lack of oil when the SRV at the opposite side of the cylinder opens (see circuit diagram). Function The circuit pressure in lines A and B hold the valve cone (Fig. 6-7, Pos. 2) closed. Pressure of the supply line S is put on 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 necessary oil supply into the circuit.

Version 2010/1

6-15


6.8

REMOTE CONTROL VALVES

Fig. 6-8


6-16

COMPONENTS

Version 2010/1

COMPONENTS



Pilot pressure supply port (marked with P)

(2)

Pilot pressure return port to tank (marked with L)

(3)

Pilot pressure output lines to the control block

(4)


(5)

4/3 Directional solenoid valve

NOTE: Remote control valves are part of the electric-hydraulic control system. 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 (Fig. 6-8, Pos. 4) and one of the directional solenoid valves (Fig. 6-8, Pos. 5 / either Ax or Bx) are energized, allowing 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, resulting in a spool movement in the main control block between neutral and full stroke position.

Version 2010/1

6-17

4/3 Directional solenoid valves

6.9

4/3 DIRECTIONAL SOLENOID VALVES

Fig. 6-9


6-18

COMPONENTS

Version 2010/1

COMPONENTS



Control spool

(2)

Plunger

(3)

Solenoids

(4)

Reset springs

(5)

Housing

NOTE: This solenoid operated directional spool valves are installed to control the start, stop and direction of an oil flow. Function In un-operated condition the control spool (Fig. 6-9, Pos. 1) is held in the neutral position by the reset springs (Fig. 6-9, Pos. 4). Operation of the control spool takes place by means of oil immersed solenoids (Fig. 6-9, Pos. 3). The force of the solenoid (Fig. 6-9, Pos. 3) acts via the plunger (Fig. 6-9, Pos. 2) on the control spool (Fig. 6-9, Pos. 1) and pushes it from its neutral position into the required end position. This results in the required flow from P to A and B to T, or from P to B and A to T. When the solenoid (Fig. 6-9, Pos. 3) is de-energised, the control spool (Fig. 6-9, Pos. 1) is returned to its original position by the reset springs (Fig. 6-9, Pos. 4).

Version 2010/1

6-19

Proportional solenoid valves

6.10

PROPORTIONAL SOLENOID VALVES

Fig. 6-10


6-20

COMPONENTS

Version 2010/1

COMPONENTS



Connector socket

(2)

Bleed screw

(3)


(4)

Valve housing

(5)

Piston stop

(6)

Pressure spool

(7)

Control piston

(8)

Pressure spool

NOTE: These valves are responsible for the creation of a variable control pressure proportional to the electrical signal output of an amplifier. Function In neutral condition the control piston (Fig. 6-10, Pos. 7) is held in the neutral or starting position by reset springs. The control piston (Fig. 6-10, Pos. 7) is directly operated by the proportional solenoid (Fig. 6-10, Pos. 3). If the solenoid is energised, it produces a force to operate the control piston (Fig. 6-10, Pos. 7) via the pressure spool (Fig. 6-10, Pos. 8) 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 piston (Fig. 6-10, Pos. 7) to the inner end of the pressure spool (Fig. 6-10, Pos. 4). The force generated by the pressure now works against the solenoid force and pushes the control piston (Fig. 6-10, Pos. 7) to the right (closing direction) until a balance is achieved between the two forces. In order to achieve this, the pressure spool (Fig. 6-10, Pos. 4) moves to the left in the direction of the piston stop (Fig. 6-10, Pos. 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 piston (Fig. 6-10, Pos. 7). 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, while port P is blocked from both ports A and B.

Version 2010/1

6-21


6.11

HIGH PRESSURE FILTER

Fig. 6-11


6-22

COMPONENTS

Version 2010/1

COMPONENTS



Hexagon

(2)

Drain plug

(3)

Packing ring

(4)

Spring

(5)

Filter element

(6)

Filter case

(7)

Filter head

(8)

Back-up ring

(9)

O-ring

(10)

Spring

NOTE: High pressure filters are installed in each pump line. 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.

Version 2010/1

6-23

Control blocks and valves

6.12

CONTROL BLOCKS AND VALVES

Fig. 6-12


6-24

COMPONENTS

Version 2010/1

COMPONENTS



Control block housing

(2)

Main relief valve (MRV)

(3)

Boom lifting / lowering spool (special)

(4)

Long cap ("B" side)

(5)

"B" side service line ports

(6)

Centering springs

(7)

Solid spool

(8)

Short cap ("A" side)

(9)

"A" side service line ports

(10)

Load check valves

(11)

Pilot oil warm up and flushing grooves

(12)

Fine controlling grooves

(13)

Type plate

NOTE: Principle drawing, showing valve block II and IV. The control blocks are "Open Center Blocks". Control blocks I and III are 3 spool blocks, control blocks II and IV are 4 spool blocks. See hydraulic circuit diagram for spool details. Each spool is provided with "Fine Controlling Grooves", ring grooves for hydraulically centering of the spool and “Pilot oil warm up and flushing“ grooves. Pilot pressure between 8 and 19 bar moves the spools in their fine control range. The spool (Fig. 6-12, Pos. 3) is especially designed to keep the pressure channel connected to the center channel during the function “Boom lowering“ is selected, so that pump flow is available for other functions. The Load Holding Valves are installed beneath a plug from the service port side of the control block. The MRV is a pilot operated pressure relief valve.

Version 2010/1

6-25


Fig. 6-13

6-26

COMPONENTS


Version 2010/1

COMPONENTS



Main relief valve (MRV) control block housing

(2)

Load check valve

(3)

Anti cavitation valve (ACV)

(4)

Secondary relief valve (SRV)

Explanation of the schematic drawing of the control block: The hydraulic oil flows (Qmin = 190 liters/min) through the control block from port P to T, if all spools are in neutral position ("open center“). z

Fig. 6-13 ,Pos. A: E.g. the spools pilot pressure is built up in the control pipe line a1. (Imagine the upper symbol box moves to the center position.) Now pump oil flows through check valve (Fig. 6-13, Pos. 2) to the user port A1 because the free flow circulation to the hydraulic reservoir is closed. The main relief valve (Fig. 6-13, Pos. 1) limits the maximum operation pressure in this circuit. Via port B1 the return oil from the user is flowing back to the hydraulic reservoir. During down hill travelling motion and stopping procedure (e.g. travel motors) the anti cavitation valves (Fig. 6-13, Pos. 3) prevent 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.

z

Fig. 6-13, Pos. B: E.g. spool #3 moves up when pilot pressure is built up in the control pipe b3. Now the user port B3 is supplied with pump pressure. Via port A3 the return oil from the user is flowing back to the hydraulic reservoir. The secondary relief valve (Fig. 6-13, Pos. 4) is additional installed in this circuit to protect the circuit against extreme pressure. The short-time extreme pressure also closes the check valve (Fig. 6-13 Pos. 2) which protects the hydraulic pump against extreme pressure peaks. The check valves (Fig. 6-13, Pos. 2) also have the function of load holding valves, because during the fine controlling period all lines are interconnected (negative over-lapping). For a moment, the load pressure is higher than the pump pressure.

Version 2010/1

6-27


COMPONENTS

Spool in "neutral position"

Pilot pressure connected to spool cab "a"

Fig. 6-14

6-28


Version 2010/1

COMPONENTS




(2)

Reset springs

(3)

Fine control grooves

(4)

Spool

Function Reset springs (Fig. 6-14, Pos. 2) move the spool (Fig. 6-14, Pos. 4) into neutral position. Fine control grooves (Fig. 6-14, Pos. 3) provide for sensitive controlling, because a motion is always started while the pressure oil and the return oil first pass these fine control grooves before the spool (Fig. 6-14, Pos. 4) is interconnecting the entire groove to the user channel. In neutral position of spool (Fig. 6-14, Pos. 4) the pump oil is flowing back via port PU to the tank. Lower Picture Example: The spool is moved to left position: Port PU is closed and the connection through the check valve RP1 to the user (port A) is open. In addition, the connection from the other user side (port B return) is connected to the port T (return line to tank). The return line of the pressure relief valve MRV (Fig. 6-14, Pos. 1) is also connected to the port T.

Version 2010/1

6-29


Fig. 6-15 6-30

COMPONENTS

Control blocks and valves Version 2010/1

COMPONENTS



Secondary relief valve (SRV)

(2)

Anti cavitation valve

(3)


(4)

Closing plate

(5)

Plug screw

(6)

Spring

(7)

Valve cone

(8)

Dust cap

(9)

Set screw

(10)

Lock nut

(11)

Spring, pilot part

(12)

Poppet

(13 + 16)

Jet bore

(14)

Spring, main cone

(15)

Main valve cone

(17)

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. z

Function: The circuit pressure P pushes the piston surface A of the main valve cone (Fig. 6-15, Pos. 15) with the force F1. Because there is the same pressure on the back side of the main cone via the jet bore (Fig. 6-15, Pos. 16), this, together with the spring (Fig. 6-15 Pos. 14) force, results in a force F2 that keeps the main cone closed. Via the jet bore (Fig. 6-15, Pos. 13) the circuit pressure is in front of the poppet (Fig. 6-15, Pos. 12). When the circuit pressure exceeds the setting value of the spring (Fig. 6-15, Pos. 11), the poppet opens against the force of the spring (Fig. 6-15, Pos. 11). As a result, force F2 decreases and there is no more balance condition between F1 and F2. The valve cone (Fig. 6-15, Pos. 15) is moved upwards by the greater force F1. That means now there is a direct connection from port P to T (tank).

ACVs serve for compensating a possible lack of oil when the SRV at the opposite port is actuated (see circuit diagram) and for avoiding cavitation damages. In addition, they serve to supply a user in case it is continuously moved by acceleration forces at zero position of the control spool. z

Function: The circuit pressure inside the spring chamber closes the valve cone (Fig. 6-15, Pos. 7). The back pressure of the return line acts on the surface of the valve cone (Fig. 6-15, Pos. 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 additionally supplied.

Version 2010/1

6-31


Fig. 6-16

6-32

COMPONENTS


Version 2010/1

COMPONENTS


Legend for Fig. 6-16 (load holding valve): (1)

Valve cone guide

(2)

Valve spring

(3)

Valve cone

(4)

Valve block housing

(5)

Passage from pump (P)

(6)

Passage to control block spool A/B

Control blocks II and IV (4 spool blocks) The load holding valves are fitted into separate spaces of the control block housing, one valve for each spool. The load holding valves have three tasks: 1. When the circuit pressure is higher than pump pressure due to the attachment weight, these valves prevent dropping of the attachment, within their sensitive (fine controlling) range. 2. Due to sudden pressure peaks in the service-lines the valves also protect the pump. 3. When two pump flows are used for one user, the valves ensure that at least the flow of one pump reaches the user in case one MRV is defect or no longer properly 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 The system pressure pushes onto the front area of the valve cone (Fig. 6-16 Pos. 1). This force moves the valve cone against the spring (Fig. 6-16 Pos. 2) and allows the oil to flow from the pump to the spool. In neutral position of the spool no further flow is possible (see circuit diagram). If the spool is no longer in neutral position, the flow continues to the user. If, due to an external force, the pressure directed to the pump overcomes the pump line pressure, this pressure forces the valve onto its seat (closed position).

Version 2010/1

6-33


Fig. 6-17 6-34

COMPONENTS

Control blocks and valves Version 2010/1

COMPONENTS


Legend for Fig. 6-17 (load holding valve): (1)

Spool

(2)

Valve cone

(3)

Valve spring

(4)

Passage from P to A

(5)

Passage from B to T

NOTE: This is a principle drawing only, showing the location of load holding valves in valve block I and III. Control blocks I and III (3 Spool Blocks) The load holding valves are directly fitted into the spools (one on each side). The load holding valves have three tasks: When circuit pressure is higher than pump pressure due to attachment weight, these valves prevent dropping of the attachment, within their sensitive (fine controlling) range. Due to sudden pressure peaks in the service lines, the valves also protect the pump. When two pumps flows are used for one user, the load holding valves ensure that at least the flow of one pump reaches the user in case one MRV is defect or no longer properly 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 (Fig 6-17, Pos. 1) both valve cones (Fig. 6-17, Pos. 2) are closed by the springs (Fig. 6-17, Pos. 3). In a switched position (lower picture), the circuit pressure pushes onto the front area of the valve piston (Fig. 6-17, Pos. 2). This force moves the piston against the spring (Fig. 6-17, Pos. 3) and allows the oil to flow from the pump supply (Fig. 6-17, Pos. 4) to the user port (A) and from port B via boring (Fig. 6-17, Pos. 5) to the return oil passage. 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).

Version 2010/1

6-35

Travel brake valve

6.13

TRAVEL BRAKE VALVE

Fig. 6-18

Travel brake valve

6-36

COMPONENTS

Version 2010/1

COMPONENTS

Travel brake valve

Task Travel brake valves control the oil flow from the hydraulic motor to the tank depending on the 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 or B to B1, depending on the selected travel motion.

Example The operating pressure at port A moves spool (Fig. 6-18, Pos. 1) against the force of the spring (Fig. 6-18, Pos. 2) and opens the way for the return oil (Fig. 6-18, Pos. B1 to B). The check valve (Fig. 6-18, Pos. 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.

Version 2010/1

6-37

Pressure reducing valve

6.14

PRESSURE REDUCING VALVE

Fig. 6-19


6-38

COMPONENTS

Version 2010/1

COMPONENTS



Set screw

(2)

Threaded sleeve

(3)

Compression spring

(4)

Spring chamber

(5)

Spool

(6)

Non-return valve

(7)

Cone

(8)

Control line

NOTE: Pressure reducing valves are installed to reduce the common 45 bar pilot pressure to a lower pressure for other systems, e.g. the track tensioning system or the travel parking brake. 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 oil can flow from port P to A. Pressure in port A is also present on the end of the spool (Fig. 6-19, Pos. 5) via control line (Fig. 6-19, Pos. 8), opposing the compression spring (Fig. 6-19, Pos. 3). When the pressure in port A reaches the pressure level set at spring (Fig. 6-19, Pos. 3), the spool (Fig. 6-19, Pos. 5) moves to the control position and holds the pressure in port A constant. Oil to control the valve is taken from port A via the control line (Fig. 6-19, Pos. 8). If the pressure in port A still rises further due to external forces, the spool (Fig. 6-19, Pos. 5) is moved further towards the compression spring (Fig. 6-19, Pos. 3). This causes a flow path to be opened over the cone (Fig. 6-19, Pos. 7) of the control spool (Fig. 6-19, Pos. 5) to tank. Sufficient fluid then flows to tank to prevent any further rise in pressure. An optional non-return valve (Fig. 6-19, Pos. 6) is available to allow free flow from A to P.

Version 2010/1

6-39


6.15

4/2 DIRECTIONAL SOLENOID VALVES

Fig. 6-20

Directional solenoid valves

6-40

COMPONENTS

Version 2010/1

COMPONENTS



Housing

(2)

Control spool

(3)

Plunger

(4)

Solenoid

(5)

Dust cap with stem for manual operation

(6)

Return spring

NOTE: These solenoid operated directional spool valves are installed to control the start, stop, and direction of an oil flow. Function When there is no flow through the valve, the control spool (Fig. 6-20, Pos. 2) is held in neutral or output position by means of the return springs (Fig. 6-20, Pos. 6). The control spool (Fig. 6-20, Pos. 2) is operated by means of oil immersed solenoid (Fig. 6-20, Pos. 4). The force of the solenoid (Fig. 6-20, Pos. 4) effects the control spool (Fig. 6-20, Pos. 2) by means of the plunger (Fig. 6-20, Pos. 3) 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 the solenoid (Fig. 6-20, Pos. 4) is de-energized, the control spool (Fig. 6-20, Pos. 2) is moved back to its resting position by means of return springs (Fig. 6-20, Pos. 6). An optional emergency operating device for manual operation (Fig. 6-20, Pos. 5) allows movement of the control spool (Fig. 6-20, Pos. 2) without energizing the solenoid.

Version 2010/1

6-41

Pressure double stage valve

6.16

PRESSURE DOUBLE STAGE VALVE

Fig. 6-21


6-42

COMPONENTS

Version 2010/1

COMPONENTS



Pilot valve with valve seat

(2)

Valve poppet

(3)

Compression spring

(4)

Main valve with sleeve

(5)

Main piston

(6)

Closing spring

(7 + 8)

Set screws

(9)

Piston

(10)

Pin

(11 + 12)

Jet bore

(13 + 14)

Lock nut

NOTE: The pressure double stage valve is a remote controlled pressure relief valve, actuated by hydraulic pressure. The individual relieve pressure is determined by the pilot pressure. Function The valve poppet (Fig. 6-21, Pos. 2) is connected via the jet bores (Fig. 6-21, Pos. 11 and Pos. 12) with port P. If static pressure increases above the set pressure value, the valve poppet (Fig. 6-21 Pos. 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 (Fig. 6-21, Pos. 6) is cancelled, and the main piston (Fig. 6-21, Pos. 5) opens to allow the pump 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 (Fig. 6-21, Pos. 9) via port X, the pre-tensioning of the pressure spring (Fig. 6-21, Pos. 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 (Fig. 6-21, Pos. 7) and lock nut (Fig. 6-21, Pos. 13); 1 turn of the screw = 150 bar.

Version 2010/1

6-43

Hydraulic cylinder

6.17

HYDRAULIC CYLINDER

Fig. 6-22

Hydraulic cylinder, layout

6-44

COMPONENTS

Version 2010/1

COMPONENTS

Hydraulic cylinder


Bushing

(2)

Grease fitting

(3)

Cylinder head with rod guide and rod seal

(4)

Snap ring

(5)

Piston rod

(6)

Piston seal

(7)

Cylinder barrel

(8)

Main piston seal

(9)

Back up ring

(10)

Piston

(11)

Piston nut

(12)

Bushing

(13)

Hydraulic port to piston side

(14)

Set screw connection of piston nut and piston

(15)

Set screw secured with a prick-punch (acc. to works standard)

(16)

Rod seal to piston

(17)

Back up ring

(18)

O-ring

(19)

Hydraulic port to rod side

(20)

Cylinder head seal to barrel

(21)

O-ring

(22)

Back up ring

(23)

Buffer ring

(24)

Rod seal

(25)

Back up ring for rod buffer ring

(26)

Rod packing

(27)

Rod seal

(28)

Back up ring

(29)

Dust seal

(30)

Dust seal

(31)

Snap ring

Version 2010/1

6-45

Hydraulic cylinder

COMPONENTS

Function Hydraulic cylinders (also called linear hydraulic motors) are actuators which convert fluid power into mechnical power. The cylinders get their power from pressurized hydraulic fluid, typically oil. Hydraulic cylinders are used at high pressures to produce large forces and presice movements. Therefore they are constructed of strong materials and designed to withstand large forces. The hydraulic cylinder is the the actuator or "motor" side of the system. The "generator"side of the system is the hydraulic pump which brings in a regulated flow of oil to the bottom side of the cylinder to move the piston rod outwards. The oil in the chamber on the rod side is pushed back to the oil tank. The force of the cylinder depends on the hydraulic oil pressure and the piston face. The force F is given by the formula F = p A, where p is the pressure (in N/m²) and A is the face (in m²) of the piston the pressure acts on. That means, that the force of the hydraulic oil can be multiplied as needed, the maxium force is only limited by the dimension of the piston face. Structure The layout of the hydraulic cylinder is shown in Fig. 6-22. The piston (Fig. 6-22, Pos. 10) separates the two sides of the cylinder barrel internally. To prevent leakage from one side to the other, the piston is fitted with the piston seal (Fig. 6-22, Pos. 6) and the rod seal (Fig. 6-22, Pos. 16). At the other side of the cylinder, there are 4 different seal packages: – a dust seal (Fig. 6-22, Pos. 29) the prevent dirt beeing drawn into the cylinder – a rod packing (Fig. 6-22, Pos. 26) as the main seal to the outside – a buffer ring (Fig. 6-22, Pos. 23) to prevent leakage between the cylinder head and the piston rod – a cylinder head seal (Fig. 6-22, Pos. 20) to prevent the leakage from the fit between cylinder head and barrel. The cylinder head (Fig. 6-22, Pos. 10) is bolted to the cylinder barrel (Fig. 6-22, Pos. 7).

WARNING During commissioning and when new hydraulic cylinders are installed, first of all, the air has to be bled from the cylinders, refer to the ’air bleeding’ procedure described in the TROUBLESHOOTING MANUAL.

NOTE: In case abnormal movements of the hydraulic cylinder are noticed, carry out a cylinder bypass test, refer to the TROUBLESHOOTING MANUAL.

6-46

Version 2010/1

COMPONENTS

Hydraulic cylinder

Cylinder data markings, with the following information, are located at the piston rod side (sealing area) of the cylinder tube.

Fig. 6-23

Hydraulic cylinder, data markings

Legend for Fig. 6-23 (example for cylinder data markings): (1)

Piston diameter in [mm]

(2)

Piston rod diameter in [mm]

(3)

Piston stroke in [mm]

(4)

Symbol of producer

(5)

Consecutive number (serial number) for each year of production

(6)

Month of production (06 = June)

(7)

Last two digits of the year of production (10 = 2010)

(8)

Part-no.

Version 2010/1

6-47

Slew ring

COMPONENTS

6.18

SLEW RING

Fig. 6-24

Slew ring

6-48

Version 2010/1

COMPONENTS

Slew ring


Seal ring

(2)

Outer ring gear

(3)

Thread for mounting to car body

(4)

Axial roller bearing, bottom

(5)

Lower internal bearing ring

(6)

Radial roller bearing

(7)

Axial roller bearing, top

(8)

Upper internal bearing ring

(9)

Bore for mounting to superstructure

Function The slew ring is the movable connection between the superstructure and the undercarriage. The bearing is from a cylindrical roller design with three roller paths, two for axial guiding (Fig. 6-24, Pos. 4 and 7) and one for radial guiding (Fig. 6-24, Pos. 6). The outer gear is directly machined to the outer bearing ring (Fig. 6-24, Pos. 2). The slew ring bearing is connected to the central lubrication system. The outer ring gear is lubricated by a separate lubrication system SLS for which a special open gear lubricant is used. NOTE: For assembly and additional checks refer to Parts & Service News AH00511, AH01532, and AH02513 (latest edition).

Version 2010/1

6-49

Slew ring

6-50

COMPONENTS

Version 2010/1

MAIN HYDRAULIC PUMPS AND PUMP REGULATION

7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION

Version 2010/1

7-1

General


7.1

GENERAL

Fig. 7-1

Circuit diagram of the main hydraulic pumps and pump regulation

7-2

Version 2010/1


General

General layout (hydraulic only) Legend for Fig. 7-1: (1-4)


(8.1)

Pilot pressure pump

(33)

Pilot pressure filter unit

(152)

Pressure relief valve – energy efficiency (X3: ~18 bar)

(252.1)

45 bar pressure relief valve

(252.2)


(253.1)

Cchange-over valve: "Electronic or hydraulic pump regulation"

(253.2)

Pressure relief valve: " Pump regulation pressure X1 at hydraulic pump regulation" (hydraulic constant regulation mode)

(255.4)

Pressure relief valve: "Remote control pressure" ½ Qmax flow reduction for the warming-up period and flow reduction for pump #1

(57K517)

Solenoid valve:Qmin flow for all main pumps

(57K517a)

Solenoid valve: "Remote control pressure" ½ Qmax flow reduction for all main pumps

(57K561-1)

Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation" (Standard operation mode)

(57K626)

Solenoid valve: "Remote control pressure" ½ Qmax flow reduction for pump #1 only

(57K630)

Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #1" (fixed pump for swing)

(57K631)

Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #3" (fixed pump for swing)

(57K646)

Flow reduction (pump No. 2 + No. 4)

(57K647)

Flow reduction (pump No. 3)

(57K648)

Flow reduction (pump No. 1)

Version 2010/1

7-3

General

Fig. 7-2

7-4



Version 2010/1


General

Pump regulation system ("open sensing system") General z

The system controls the output flow of the main pumps, dependent on engine power, most efficiently.

z

It limits the power request of the hydraulic pumps according to the maximum engine power (Electronic pump regulation with micro-controller RC4-4).

z

For additional functions, such as rotating dependent or temperature-dependent 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 XLR to the spring chamber of the power control valve. The start of destroking can be varied in proportion to the applied pressure X1. X2 – Pilot Pressure (45 bar): Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix pump #1 and # 3 in Qmax position when swinging. X3 – Remote Control Pressure (0 / 15 / 45 bar): Basic setting Qmin (0 bar), the flow rate increases with the pilot pressure X3 at port Pst, up to Qmax (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: Qmin:

X3 = 0 bar

½ Qmax:

X3 = 15 bar

Qmax:

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.

Version 2010/1

7-5

General

Fig. 7-3

7-6



Version 2010/1


General

Pump regulation system general Function Solenoid Valve 57K517: If de-energized pumps #1-4 are in Qmin 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 57K517a: 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 #1-4 are in ½ Qmax. 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 with 2 seconds delay whenever all controls are in neutral position.

Pump flow control (i.e. pause = not moving the joysticks and pedals OFF

ON

ON

OFF

OFF

ON

Oil temperature

Flow reduction 2 seconds after pause



Oil flow

Fig. 7-4

Version 2010/1

7-7

General


Solenoid Valve 57K626: If energized, pump #1 is in the same regulation mode like pumps #2, #3 and #4. If de-energized, the flow of pump#1 is limited to ½ Qmax by the function of pressure relief valve (255.4). It gets de-energized when the swing function in main control block 1 is activated, or when the hydraulic oil temperature is below „T2“. Normal operating conditions without swinging

Normal operating conditions with swinging (fast speed)

57K517

1

1

57K517a

1

1

57K626

1

0

(1) = Energized (0) = De-energized Proportional solenoid valve 57K561-1: This valve, connected to the RC4-4 micro-controller (electronic pump regulation), creates a X1-pressure depending on the load of the engine. This X1-pressure is the information for the pumps to destroke from Qmax into Qmin position, to keep the engine at rated speed of approx. 1800 rpm. Solenoid valve 57K630: If energized, pump regulation pressure X1 = 45 bar for pump #1 (fixed pump for swinging) Solenoid valve 57K631: If energized, pump regulation pressure X1 = 45 bar for pump #3 (fixed pump for swinging with fast speed) Pressure relief valve 255.4: "Remote control pressure" (X3) z

½ Qmax flow reduction during the warming-up period for all pumps by the function of solenoid valve 57K517a.

z

½ Qmax flow reduction only for pump #1 while swinging with max. speed by the function of solenoid valve 57K626.

Pressure relief valve 253.2: Pump regulation pressure X1 at "Hydraulic pump regulation" (hydraulic constant regulation mode) by the function of change-over valve (22). Change-over valve 253.1: Change-over three way cock valve to select "Electronic or constant regulation mode".

7-8

Version 2010/1


General

Pressure relief valve 152: "Remote control pressure" (Energy efficiency ~ 18 bar) Pressure relief valve 152 in connection with the MTC controlled solenoid valves 57K646, 57K647 and 57K648 increases the energy efficiency by optimizing the oil flow of all main pumps under definite combinations of working movements. Solenoid valve 57K646: If energized, main pumps #2 and #4 with optimized oil flow. Solenoid valve 57K647: If energized, main pump #3 with optimized oil flow. Solenoid valve 57K648: If energized, main pump #1 with optimized oil flow.

Version 2010/1

7-9

Main pumps


7.2

MAIN PUMPS

Fig. 7-5

Main pumps

7-10

Version 2010/1


7.2.1

Main pumps

LOCATION OF PUMPS

Legend for Fig. 7-5: (1-4)

(5.1)

(5.2)

(8.1)

(8.2)

Axial piston pump (swash plate type) theoretical for all working motions Flow rate, each Drive speed*

1034 Liters/min n = 1378 rpm

Axial piston pumpfor oil cooler fan drive Theoretical flow rate Drive speed*


Axial piston pump for radiator fan drive Theoretical flow rate Drive speed*


Gear pumpfor pilot pressure supply Theoretical flow rate Drive speed*


Gear pump PTO gear lubrication Theoretical flow rate Drive speed*


NOTE: * at 1800 rpm input drive speed

Version 2010/1

7-11

Main pumps


7.2.2

PUMP BEARING FLUSHING / LUBRICATION

Fig. 7-6

Pump bearing flushing / lubrication

7-12

Version 2010/1


Main pumps

Legend for Fig. 7-6: (1 – 4)

Main pumps

(20.1 – 20.4)

Orifice (one for each main pump)

(33)

Filter for pilot pressure

(B-E)

Ports for X4-pressure (pump support pressure)

(U)

Port for the pump bearing lubrication

The installed main pumps are provided with an external lubrication system for flushing the drive shaft bearing and shaft seal. Oil supply is provided from the X4-pressure circuit. To reach the restricted guidance of the external bearing lubrication, 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.

Fig. 7-7

Circuit diagram

Version 2010/1

7-13

Main pumps


7.2.3

OPERATING PRINCIPLE

Fig. 7-8

Main hydraulic pump A4VSLO 750 LR3DN / 30L

7-14

Version 2010/1


Main pumps


Drive shaft

(11)

Drive through (auxiliary pump drive)

(2)

Cylindrical roller bearing

(12)

Swash plate

(3)

Slide shoes

(13)

Qmin stop bolt

(4)

Angle indicator

(14)

Power control valve

(5)

Servo piston

(15)

Pressure balance valve

(6)

Rocker cam

(16)

Power curve correction

(7)

Barrel with pistons

(17)

Pressure cut-off valve

(8)

Case (rear)

(18)

Qmax stop bolt

(9)


(19)

Remote control valve

(10)

Impeller pump

Main hydraulic pump A4VSO750i Type code explanation: A4VSO

750

i

L Rotation

Series 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: z

The A4VSO750i variable displacement axial piston pump in swash plate design is intended for drives in open circuit operation.

z

The flow volume is proportional to the drive speed and the displacement. By adjusting the swash plate an infinitely variable flow adjustment is possible.

z

Pumps of the same nominal size can be built onto the trough drive. Combinations with gear pumps are also possible.

Version 2010/1

7-15

Main pumps


Symbol of main hydraulic pump A4VSO750i

Fig. 7-9

7-16

Symbol of main hydraulic pump A4VSO750i

Version 2010/1


Main pumps


Main pump (swash plate pump, variable displacement)

(2)

Impeller pump

(3)

Pump bearing

(4)

Drive shaft

(5)

Non-return valves

(6)


(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)

Throttle valve

(9)

Power control valve

(10)

Throttle valve

(11)


(12)

Auxiliary pump (gear pump)

(13)

Servo piston

(14)

Slipper pad piston

(15)

Lever

(16)

Cam

(17)

Through drive shaft

NOTE: * Factory side adjusted, no field adjustment required (B/B1)

Pressure port

(S)

Suction line

(MB)

Operating pressure test port

(ML)

Charging pressure test port

(MST)

Control pressure test port

(R)

Filler and bleeder port

(P)

Pump support pressure (”X4”-pressure)

(PST)

Remote control pressure port (”X3”-pressure)

(U)

Bearing lubrication port

(XLR)

Regulating pressure port (”X1”-pressure)

Version 2010/1

7-17

Main pumps


Sectional drawing of regulating valves

Fig. 7-10

7-18

Sectional drawing of regulating valves

Version 2010/1


Main pumps



(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)


(13)

Positioning piston

(14)

Slipper pad piston

(15)

Lever

NOTE: Also refer to Fig. 7-9.

Version 2010/1

7-19

Main pumps


Main pump at Qmin (190 l/min, no lever or pedal activated)

Fig. 7-11

7-20

Operating principle

Version 2010/1


Main pumps

Qmin position: When are the pumps in Qmin position? A

Engine at standstill

B

Engine running and the controls are not used for 20 sec. or longer at temperature state between T1 and T3.

C

Engine running and via (VHMS Service Menu) 57K517 activated (Qmin position)

Example C with the following conditions: z

Engine running (high idle)

z

Pump circuit pressure less than X4 = 60 bar (pump support pressure).

z

X1 = 34 bar (pump regulation pressure), this pressure will not influence the Qmin position under these conditions.

z

X3 = 0 bar (remote control pressure); 57K517 de-energized (Qmin activated) for pumps #2, #3 and #4. For pump #1, 57K517 de-energized and 57K626 energized.

z

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 exceeds the spring force, since the oil behind nozzle (Fig. 7-11, Pos. 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 than 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 Qmin position. NOTE: The pump remains in Qmin position.

Version 2010/1

7-21

Main pumps


Main pump at Qmax

Fig. 7-12

7-22

Operating principle

Version 2010/1


Main pumps

Qmax position: (remember Q means volume) When does the pump move into Qmax position? z

Engine running

z

and hydraulic oil at normal operating temperature (>T2) (57K517a is energized)

z

and the controls individually used for individual movements (or 57K517 activated via VHMS – Qmax position)

z

and a pump pressure below start of de-stroking.

Example with the following conditions: z

Engine running (>1800 rpm)

z

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

z

X1 = 34 bar (pump regulation pressure via 57K561-1 or constant pressure XLR in hydraulic mode)

z

X3 = 45 bar (remote control pressure); 57K517 + 57K517a energized and 57K646 + 57K647 de-energized for pumps #2, #3 and #4. For pump #1, 57K517 + 57K517a energized and 57K648 de-energized

z

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 (Fig. 7-12, Pos. 9) position "a" and pressure balance valve (Fig. 7-12, Pos. 7) position "a", to the return oil line. The pump moves into Qmax position, because the pump pressure acts only at the small area side of positioning piston #13. NOTE: The pump moves into Qmax position

Version 2010/1

7-23

Main pumps


Main pump at ½Qmax

Fig. 7-13

7-24

Operating principle

Version 2010/1


Main pumps

½Qmax position: When does the pumps move into ½Qmax position? z

Engine running

z

and hydraulic oil below normal operating temperature (< T2)

z

and the controls frequently used within 20 sec.

z

or the controls not used at a temperature state between T3 and T4

z

and a pump pressure below start of de-stroking.


Engine running (> 1800 rpm)

z

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

z

X1 = 34 bar (pump regulation pressure via 57K561-1)

z

X3 = 15 bar (remote control pressure); 57K517 energized and 57K517a de-energized for pumps #2, #3 and #4. For pump #1, 57K517 energized and 57K626 de-energized or energized.

z


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 (Fig. 7-13, Pos. 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 (Fig. 7-13, Pos. 9) position "a" and pressure balance valve (Fig. 7-13, Pos. 7), to the return oil line. The pump moves into ½Qmax position, because the return oil flow through pressure balance valve (Fig. 7-13, Pos. 7) is restricted (due to its intermediate position), resulting in a pressure at the large area side of the positioning piston (Fig. 7-13, Pos. 13). NOTE: The pump moves into ½Q-max position.

Version 2010/1

7-25

Main pumps


Main pump destroking

Fig. 7-14

7-26

Operating principle

Version 2010/1


Main pumps

Destroking: (pump moves from Qmax into of Qmin direction) When does the pumps start to destroke? z

Engine running

z

and hydraulic at normal operating temperature (> T2)

z

and VHMS Service Menu "Qmax" deactivated

z

and the load stalls the engine RPM below 1800 rpm. (The electronic pump regulation system will reduce the X1-pressure.)

z

or with pump pressure above ≈180 bar (hydraulic constant regulation) (constant X1-pressure of approximately 13 bar).


Engine running (> 1800 rpm)

z

Pump pressure 180 bar at the main relief valve, present at the slipper pad of piston #14 and the small area side of the positioning piston #13.

z

X1 = 13 bar (constant regulation pressure adjustable at pressure relief valve 253.2) Change-over valve (253.1) switched to hydraulic mode.

z

X3 = 45 bar (remote control pressure); 57K517 energized and 57K517a energized for pumps #2, #3 and #4. For pump #1, 57K517 energized and 57K626 energized.

z


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 (Fig. 7-14, Pos. 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 than 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 direction. NOTE: The pump de-strokes until the forces at positioning piston #13 are balanced.

Version 2010/1

7-27

Main pumps


Main pump – pressure cut-off

Fig. 7-15

7-28

Operating principle

Version 2010/1


Main pumps

Pressure cut-off valve: (DR control valve, Pump moves into Qmin position) When is the pressure cut-off valve active? z

Engine running

z

and with pump pressure above ≈300 bar

Example with the following conditions: Engine running (> 1800 rpm) Pump pressure 300 bar X1 = 34 bar (pump regulation pressure via 57K561-1) X3 = 45 bar (remote control pressure via 57K517 / 57K517a) 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 Qmin 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 than 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. NOTE: The pump moves into Qmin position.

Version 2010/1

7-29

Main pumps


7.2.4

CHECKS / ADJUSTMENTS

Fig. 7-16

Checks / adjustments

7-30

Version 2010/1


Main pumps



(2)


(3)

Pressure balance valve

(4)

Start of destroking

(5)

Power curve correction

(6)


(7)

Qmax stop bolt

(8)

Angle indicator

Average length "L" of the adjustment bolts: Location:

1

2

3

4

5

6

7

Length (mm)

13.8

26.9

8.0

8.1

---

6.0

34.4

NOTE: The length "L" is an orientation only if the adjustment is totally out of requirements. They must not be used for final adjustments.

CAUTION The detail for (Fig. 7-16, Pos. 5) shows the position of the housing edge and the edge of the excentric set bolt. The example shows them in parallel position which is mostly not the case. The adjustment should never be altered.

Pressure balance valve (Fig. 7-16, Pos. 3)

CAUTION The pressure balance valve is bench adjusted. There is no field setting with a sufficient result possible.

Version 2010/1

7-31

Main pumps

Fig. 7-17

7-32



Version 2010/1


Main pumps

Start of destroking (LR valve), (Fig. 7-17) The purpose 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. Connect a 400 bar pressure gauge to the pressure test port at the respective high pressure filter for the pumps being checked. 2. Connect a 60 bar pressure gauge to pressure test port M18 at the control and filter panel (X1-pressure). 3. Move the change-over valve into position “Hydraulic” (constant regulation mode). 4. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of destroking. 5. Start the engine, let it run in high idle and adjust the X1-pressure to 13 bar at pressure relief valve (253.2). 6. Stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV 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 follows: z

With the MRV, adjust the operating pressure to 180 bar.

z

Loosen lock nut #6 (power control valve).

z

Turn set bolt #7 so that the pump is still in Qmax position, but just at the beginning of destroking.

z

Tighten lock nut #6.

7. Readjust the operating pressure at the MRV to 310+5 bar and the X1-pressure at the pressure relief valve (253.2) to approx. 15 bar. (For exact values refer to the final test report.) 8. Remove Allen key and gauges. 9. Move the change-over valve back to eletronic pump regulation.

Version 2010/1

7-33

Main pumps

Fig. 7-18

7-34



Version 2010/1


Main pumps

Pressure cut-off valve (DR control valve), (Fig. 7-18) The purpose of this check is to make sure that the pump is in Qmin position at an operating pressure 300±10 bar. 1. Connect a 400 bar pressure gauge to the pressure test port at the respective high pressure filter for the pumps being checked. 2. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of destroking. 3. Start the engine and run in high idle, stall the hydraulic for the pump that is to be checked and alter the operating pressure ± 20 bar from the starting pressure of 310+5 bar. 4. The angle indicator must indicate Qmin position at a pressure of 300±10 bar shown at the gauge connected to the high pressure filter. If readjustment is required proceed as follow: z


z

Turn set bolt (Fig. 7-18, Pos. 9), so that the pump is in Qmin position at the required value.

z

Tighten lock nut (Fig. 7-18, Pos. 8).

5. Re-adjust the operating pressure at the MRV to 310+5 bar 6. Remove Allen key and gauges.

Version 2010/1

7-35

Main pumps

Fig. 7-19

7-36



Version 2010/1


Main pumps

Qmax and torque adjustment bolt (Fig. 7-19) 1. Unscrew cap nut (Fig. 7-19, Pos. 10 or 14). 2. Loosen the lock nut (Fig. 7-19, Pos. 11 or 13). 3. Turn the stop bolt (Fig. 7-19, Pos. 12 or 15) in or out until required length "X" or "Y" is obtained. 4. Tighten the lock nut and screw on cap nut (Fig. 7-19, Pos. 10 or 14).

NOTE: If, in exceptional cases the necessary high pressure, required for the secondary valve adjustment, can not be obtained, the cause could be insufficient pump delivery. To enable the adjustment, screw in the torque adjustment bolt (Fig. 7-19, Pos. 15) two turns. After the adjustments are finished the torque adjustment bolt (Fig. 7-19, Pos. 15) must be reset to the initial setting.

WARNING Do not turn the torque adjustment bolt (Fig. 7-19, Pos. 15) too far out, because this 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.

NOTE: If the machine works at an altitude above 3600 meters, the maximum displacement of the pumps must be reduced by changing the Qmax stop bolt setting according to PARTS & SERVICE NEWS AH05515 (latest edition).

Version 2010/1

7-37

Electronic Pump Regulation System


7.3

ELECTRONIC PUMP REGULATION SYSTEM

Fig. 7-20

Electronic pump regulation system

7-38

Version 2010/1


7.3.1


ELECTRONIC LOAD LIMITING CONTROL - GENERAL

The drive train of the excavator consists of a Diesel engine, 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 Diesel engine. Fig. 7-20 shows the principle of the electronic load limiting control. The RC4-4 (10K032) processes the following input signals: z

Diesel engine speed (Pin 33) from magnetic pick-up (52B064).

z

Switch signal (Pin 37) from engine control (25K014-1), 24 V if n > 300 rpm.

The RC4-4 (10K032) processes the following output signals: z

Signal value to control the proportional solenoid valve 57K561-1 (Pin 31).

z

Switch signals (Pin 15 and 29), diagnostic of the RC4-4 (10K032).

The Diesel engine drives four variable displacement pumps by means of a PTO-gearbox. Each pump is equipped with a hydraulic power controller (HPC). This controller limits the input torque of the pump to an adjusted command value (X1-pressure, for start of destroking). The command value (X1-pressure) is present via proportional solenoid valve 57K561-1 at the hydraulic power controllers of each pump. The actual speed of the engine is measured with a speed sensor at the flywheel. NOTE: The auxiliary hydraulic pumps and other consumers can be operated without being directly affected by the load limiting control. The control algorithm of the load limiting control always compares the actual engine speed with the rated load speed. With increasing load the engine torque will rise and the engine speed will drop. For this reason the electronic load limiting control will be initiated when the load speed falls below 1800 rpm, i.e. the torque of the main pumps will be lowered (by reducing the X1-pressure) until the rated speed of 1800 rpm is attained again.

Version 2010/1

7-39


Fig. 7-21

7-40


Electronic pump regulation system

Version 2010/1


7.3.2


MICROCONTROLLER RC4-4

The RC4-4 microcontroller is used for the programmable control of a maximum of four proportional solenoids and four additional switching functions. As input signals, the microprocessor processes analog voltages in the 0 V to 5 V range and switching information. All inputs are protected against overvoltage and electrical interference. As output signals, the output stages of the RC4-4 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 z

Closed loop control of solenoid currents, i.e. independent of voltage and temperature.

z

Pulse width modulated (PWM) solenoid currents for minimal hysteresis.

z

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 a PC w ith the BODEM 24 software.

Fig. 7-22

RC4-4 - Unit dimensions

Fig. 7-23

RC4-4 - Block circuit diagram

Version 2010/1

7-41


Fig. 7-24

7-42


Checks and adjustments

Version 2010/1


7.3.3


CHECKS AND ADJUSTMENTS

Microcontroller RC4-4 (Fig. 7-24) The adjustment of the X1-pressure can be done with two different methods: 1. "A" : with 24 V supply to separating terminals at the X2-board, 2. "B" : with a laptop and the BODEM 24 software connected to the serial interface 20X110 (located in the operators cab)

NOTE: Procedure 2 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 only the necessary setups are described. If additional information is required, please contact KMG-Service department.

Version 2010/1

7-43


Fig. 7-25

7-44



Version 2010/1



Microcontroller RC4-4 (Fig. 7-25) Method "A" X1-pressure adjustment with 24 V supply to separating terminals at the X2-switch over the 11X_09 board. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. Make sure the change-over valve is in position “Electronic Pump Regulation”. 2. Connect a pressure gauge to test port (M18), using a long pressure gauge hose to be able reading the pressure in front of the 11X_09 board. 3. Selection of adjusting mode: Turn the main key switch in on position and activate the adjusting mode as follows: Connect 24 V, simultaneously to terminals 11X_09-4 and -5 for 10 seconds, using two test leads and disconnect the voltage thereafter. 4. Selection of the required proportional solenoid valve: With the main key switch still in ON position, the output terminal of proportional solenoid valve 57K561-1 is directly selected. Since there is only one engine with one proportional solenoid valve installed, a 24 V connection is not required. 5. Adjusting the X1-pressure: Start the engine, let it run with maximum speed. Read the pressure, required = 34±0,5 bar. If necessary, increase the X1-pressure as follows: Connect 24 V to terminal 4. NOTE: 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 X1-pressure. NOTE: Example: Keeping voltage supply for two seconds will increase the X1-pressure of approximately 1 bar. 6. To decrease the X1-pressure connect 24 V to terminal 5 and proceed as described under item 5; keeping voltage supply for two seconds will decrease the X1-pressure of approximately 1 bar. 7. After the adjustment is finished, remove the test leads and the pressure gauge, and turn the main key switch in OFF position to deactivate the adjusting mode.

Version 2010/1

7-45


Fig. 7-26

7-46



Version 2010/1



Method "B"

With a laptop and BODEM/24 software connected to the serial interface 20X110 (located in the operators cab). Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air.

Fig. 7-27 BODEM/24 software CD 1. Make sure the change-over valve is in position “Electronic Pump Regulation”. 2. Connect a pressure gauge to test port (M18). 3. Connect the laptop computer to the data link adapter 20X110, with key switch (20S001) in OFF position. 4. Make sure that the USB dongle is connected to the laptop computer.

Fig. 7-28 USB dongle BODEM/24 software 5. Turn key switch (20S001) in ON position. 6. Switch on the laptop computer. 7. Click on the BODEM/24 icon to start the program (see Fig. 7-29). NOTE: For information about the BODEM/24 software, please refer to the software user’s guide.

Fig. 7-29

Version 2010/1

7-47



8. Open menu "Display/Edit parameters" and, from the Device list, select the required excavator type. Confirm saving the parameters with "OK". 9. Open menu "Display/Edit parameters" and select "Max current" from the shortlist. 10. Adjust the required pressure with the engine running at high idle, and move the slide control to the required pressure. Confirm with OK.

Fig. 7-30 11. After adjusting the pressure, confirm saving the parameters with OK.

7-48

Version 2010/1




Version 2010/1

7-49

Hydraulic Constant Regulation System

7.4


HYDRAULIC CONSTANT REGULATION SYSTEM

Pilot pressure (X2) Pump support pressure (X4) Pump regulation pressure (X1) Pump regulation pressure (X1) or pilot pressure (X2), depending on the position of 57K6350 and 57K631 respectively Fig. 7-31

7-50

Hydraulic constant regulation system

Version 2010/1


7.4.1


GENERAL



(8.1)

Pilot pressure pump

(33)

Pilot pressure filter unit

(252.2)


(252.1)


(253.1)

Change-over valve: "Electronic or hydraulic pump regulation"

(253.2)

Pressure relief valve: " Pump regulation pressure X1 at hydraulic pump regulation" (hydraulic constant regulation mode)

(57K561-1)

Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation" (standard operation mode)

(57K630)

Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #1" (fixed pump for swinging)

(57K631)

Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #3" (fixed pump for swinging)

The pilot pressure pump (Fig. 7-31, Pos. 8.1) delivers the oil via the pressure filter (Fig. 7-31, Pos. 33) to port A of the pressure relief valve (Fig. 7-31, Pos. 252.2) for limiting the pump support pressure X4 (60 bar). The pilot pressure oil X2 (45 bar) maintained at pressure relief valve (Fig. 7-31, Pos. 252.1) flows through the manifold to the pressure relief valve (Fig. 7-31, Pos. 253.2), which reduces the X2 pressure to the necessary constant X1 pressure to prevent the engine from overloading. NOTE: 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. NOTE: The standard operation mode of the pump regulation system is the Electronic Operation Mode.

Version 2010/1

7-51



7.4.2

X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE)

Fig. 7-32

X1 pressure adjustment

7-52

Version 2010/1



1. Connect gauges to test ports (M11, M12, M13; and M14) at the high pressure filters. 2. Connect pressure gauge to the X1 pressure test port M18. 3. Unplug solenoid valves 57K506a/b-1 and 57K636-1 to ensure that all fans are running with maximum speed. 4. Shift the three way cock valves (Fig. 7-32, Pos. 253.1) to position “Hydraulic (constant) regulation mode”. 5. Actuate the "Qmax" position via the VHMS Service Menu. 6. Start the engine and let it run at high idle. 7. Set the XLR pressure at pressure relief valve (Fig. 7-32, Pos. 253.2) to approx. 6 bar** 8. Apply max. load to all pumps z

(e.g. BHA: retract the bucket and stick cylinders to the stop position until the hydraulic system stalls. e.g. FSA: extend the bucket cylinders to the stop position until the hydraulic system stalls),

z

and adjust the pressure at all 4 MRV’s* equally to 260 bar.

z

Check the engine speed. Required = 1840 rpm.

z

If necessary, correct the XLR pressure at pressure relief valve (Fig. 7-32, Pos. 253.2), until the required engine speed is obtained. Record the XLR pressure.

9. Shift the cock valves (Fig. 7-32, Pos. 253.1) to position “Electronic regulation“. 10. Switch back "Qmax" via the VHMS Service Menu. 11. Adjust the MRV’s * to 310+5 bar and remove the gauges. *Altering the MRV-setting: z

Remove the dust cap (Fig. 7-32, Pos. a).

z

Loosen the lock nut (Fig. 7-32, Pos. b).

z

Turning the set screw (Fig. 7-32, Pos. c) - cw the pressure will increase.

z

Turning the set screw - ccw the pressure will decrease.

**Altering the XLR-setting: z

Loosen the lock nut (Fig. 7-32, Pos. e).

z

Turning the set screw (Fig. 7-32, Pos. f) - cw the pressure will increase.

z


Version 2010/1

7-53

Determination of the peak point (engine performance)


7.5

DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)

Fig. 7-33

Determination of the peak point

7-54

Version 2010/1


Determination of the peak point (engine performance)

1. Connect pressure gauges to test ports M11, M12, M13, M14 at the high pressure filter. 2. Connect a pressure gauge to the XLR pressure test port M18. 3. Unplug solenoid valves 57K506a-1 and 57K506b-1 to ensure that the hydraulic oil cooler fans are running at maximum speed. 4. Unplug the solenoid valve 57K636-1 to ensure that the engine radiator fan is running at maximum speed. 5. Start the engine and let it run at high idle. 6. Check high idle speed = 1900±10 rpm. 7. Set the MRV individually to approx. 120 bar* to prevent the engine from overloading during the test. 8. Shift the cock valve (Fig. 7-33, Pos. 253.1) to position "hydraulic regulation". 9. Actuate the "Qmax" position via the VHMS Service Menu. 10. Set the XLR pressure at pressure relief valve (Fig. 7-33, Pos. 253.2) > 34 bar** to ensure that the pumps remain in Qmax flow position during the test. 11. Apply max. load to all pumps z

(e.g. BHA: retract the bucket and stick cylinders to the stop position until the hydraulic system stalls. e.g. FSA: extend the bucket cylinders to the stop position until the hydraulic system stalls),

z

and adjust the pressure at all 4 MRV’s *equally until the engine speed is 1800±10 rpm.

z

Record this pressure for other tests. Required: 4 times 157±5 bar.

NOTE: If either the operating pressure or the engine speed is higher than required, there is probably not the full volume available. NOTE: If either the operating pressure or the engine speed is lower than required, there is probably not the full engine power available. 12. Re-set the XLR pressure at pressure relief valve (Fig. 7-33, Pos. 253.2) as recorded**. 13. Shift the cock valve (Fig. 7-33, Pos. 253.1) to position “Electronic regulation“ 14. Switch back "Qmax" via the VHMS Service Menu. 15. Adjust the MRV’s * to 310+5 bar and remove the gauges. * Altering the MRV-Setting: z

Remove the dust cap (Fig. 7-33, Pos. a).

z

Loosen the lock nut (Fig. 7-33, Pos. b).

z

Turning the set screw (Fig. 7-33, Pos. c) - cw the pressure will increase.

z


** Altering the X1-Setting: z

Loosen the lock nut (Fig. 7-33, Pos. e).

z

Turning the set screw (Fig. 7-33, Pos. f) - cw the pressure will increase.


Version 2010/1

7-55

Engine speed sensor (pick-up)


7.6

ENGINE SPEED SENSOR (PICK-UP)

Fig. 7-34

Engine speed sensor

7-56

Version 2010/1


Engine speed sensor (pick-up)


Speed sensor (pick-up)

(2)

Flywheel housing

(3)

Flywheel

(4)

Look nut

(5)

RPM-module

7.6.1

GENERAL

The engine speed sensor 52B064-1 (pick-up), together with the RPM-module 51T018-1, use the flywheel teeth to count RPM. With running engine, each tooth induces a coltage in the pick-up coil. That causes an alternative voltage at the pick-up coil wire. With engine at stand still, there is no voltage at the pick-up wire. The frequency of this alternative voltage will increase or decrease proportional to the engine RPM. The RPM-module converts the frequency into a proportional milliampere signal. This signal is used for different components, e.g. pump regulation, display, VHMS.

7.6.2

ENGINE SPEED SENSOR (PICK-UP) ADJUSTMENT

1. Stop the engine. 2. Disconnect plug at the pick-up wire. 3. Loosen the look nut. 4. Turn out the pick-up completely ccw. 5. Check front end of the pick-up and clean it from magnetic chips and dirt. 6. Turn the pick-up completely in (cw) until it touches the flywheel (Fig. 7-34, Pos. A). 7. Turn the pick-up ¾ turn out (ccw) (Fig. 7-34, Pos. B). 8. Secure the pick-up with look nut (Fig. 7-34, Pos. C). 9. Connect the plug. Final Check 10. Start engine and let it run at high idle. 11. Check the voltage (AC) of the pick-up. Insert the T-box on the sensor connector and connect between pick-up and RPM-module 51T018-1. 12. The voltage should be 10±2.5 volts AC.

WARNING z

Avoid pick-up contact with the flywheel while engine is running!

z

The induced AC voltage must be measured with connected pick-up to the RPM-module.

Version 2010/1

7-57

Energy Efficiency

7.7

ENERGY EFFICIENCY

Fig. 7-35

Energy efficiency

7-58


Version 2010/1


Energy Efficiency


Main pumps

(11K301)

MTC (Master Turbo Controller)

M19

Test port, pressure control valve

M55

Test port, output 57K646

M56


M57


(57K517)

„Idle time“ control (pump control system)

(57K517a)

½ Qmax (reduced oil flow if oil is too cold)

(57K626)

Flow control (pump 1, when swinging with fast speed)

(57K646)

Flow control (pump No. 2 + No. 4)

(57K647)

Flow control (pump No. 3)

(57K648)


(152)

Pressure control valve – controlled pump flow

(255.4)

Pressure relief valve – ½ Qmax (X3 = 15 bar)

7.7.1

GENERAL

Energy which is not used for active movements can be considered as a loss of energy. Although energy can not be destroyed, it can be converted into heat, which is useless for performing work by means of hydraulics. With the following measures the energy efficiency in your machines is optimized, the oil delivery takes place through specified pumps corresponding to the definite movements of the excavator. NOTE: If individual movements (single movements) are selected, the pumps will have maximum flow, but with one exception. Pump No. 1 will have half flow when high speed swinging is selected (important for PMclinic and other tests). z

Individual movements of the attachment are selected: => 57K646 OFF + 57K647 OFF + 57K648 OFF + 57K626 ON

z

Only travel is selected: => 57K646 OFF + 57K647 OFF + 57K648 OFF + 57K626 ON

z

Only swinging (low speed) is selected: => 57K646 ON + 57K647 OFF + 57K648 ON + 57K626 ON

z

Only swinging (high speed) is selected: => 57K646 ON + 57K647 OFF + 57K648 OFF + 57K626 OFF

Version 2010/1

7-59

Energy Efficiency

7.7.2

CHECKS AND ADJUSTMENTS

Fig. 7-36


7-60


Version 2010/1


Energy Efficiency

Legend for Fig. 7-36: (a)

Lock nuts

(b)

Set screws

(M19)

Test port, pressure control valve – X3-pressure

(57K646)

Flow control (pump No. 2 + No. 4)

(57K647)


(57K648)


(152)

Pressure relief valve – reduced pump flow (X3 ~ 18 to 19 bar)

To check the function of the Energy Efficiency System it is necessary to follow the instructions below. Adjusting the flow control: 1. Connect a pressure gauge (0-60 bar) to test port M19. 2. Turn the superstructure 90° to the travel direction. 3. Apply the slew parking brake. 4. Move the bucket close to the side frame and raise one track off the ground just enough to get the track free. 5. Activate the travel pedal of the lifted track fully in one direction. Make sure there is no other function activted. 6. Test of max. pump flow: 57K646, 57K647 and 57K648 must be de-energized, and 57K626 must be energized. Check the time of five (5) sprocket revolutions, see table Fig. 7-38. 7. Test of optimized pump flow: Activate the swing function (against the brake). 8. Let the sprocket turn with the swing function still applied (slew parking brake closed). 9. Measure the time for five (5) sprocket revolutions; see table Fig. 7-38 for the required value.

CAUTION Values are based for machine working from see level up to 3600 m. Machines working on higher altitude require a reduced Qmax setup which influences the test values.

NOTE: 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.

Version 2010/1

7-61

Energy Efficiency

Fig. 7-37

7-62



Version 2010/1


Energy Efficiency

If adjustment is required: Change the setting at pressure control valve (152): 1. Loosen lock nut (Fig. 7-36, Pos. a) of the pressure control valve. 2. Turn the set screw (b) of the pressure control valve (152) clockwise to reduce or counterclockwise to increase the sprocket speed. Adjust the sprocket speed according to the table below. 3. Lock set screw by tightening the lock nut.

Pump flow control test values No.

Function

57K646

57K647

57K648

57K626

Left sprocket Time/5 revs.

Right sprocket Time/5 revs.

1

Travel right only

0V

0V

0V

24 V

50±1 sec

50±1 sec

2

Travel right and swing (low speed)

24 V

24 V

24 V

24 V

65±1 sec

65±1 sec

3

Travel right and swing (high speed)

24 V

0V

0V

0V

65±1 sec

65±1 sec

4

Travel left only

0V

0V

0V

24 V

50±1 sec

50±1 sec

5

Travel left and swing (low speed)

24 V

24 V

24 V

24 V

65±1 sec

65±1 sec

6

Travel left and swing (high speed)

24 V

0V

0V

0V

65±1 sec

65±1 sec

Fig. 7-38

Pump flow control test values

NOTE: Switch swing speed between low and high with switch 20S154 at the left control lever. 5 revolutions of the sprocket within 65 seconds are mandatory to determine the optimized pump flow. The pressure control valve (152) is factory preset to 18 bar, a field test / adjustment after comissoning is necessary.

Version 2010/1

7-63

Energy Efficiency

7-64


Version 2010/1

OPERATING HYDRAULICS

8. OPERATING HYDRAULICS

Version 2010/1

8-1

General


8.1

GENERAL

Fig. 8-1

Overall view of the hydraulic system

8-2

Version 2010/1


General

Legend for Fig. 8-1: (1 - 4)

Main pumps

(5)

High pressure filters

(6)

Main control blocks

(7)

Distributor maniflod

(8)

Attachment cylinders

(9)

Swing motors

(10)

Rotary joint

(11)

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: NOTE: Also refer to the circuit diagram. NOTE: The following numbering refers to the hydraulic circuit diagram. Each main pump (Fig. 8-1, Pos. 1 to 4) delivers oil trough the high pressure filter (13.1 to 13.4) to port P of the main control blocks (I to IV). This results in four main circuits. If all spools of the control blocks (I to IV) are in neutral position, the oil flows through the blocks at port T and returns via return oil pipes, return oil collector manifold (107), return oil pipes (L6 and L7), return oil collector pipe (54), back pressure valve (55) and the return oil filters (49.1 - 49.4) into the tank. The function of back pressure valve (55) ensures: z

sufficient oil supply for all anticavitation valves

z

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 flows via the return oil circuit back into the tank. Each circuit is provided with one MRV (Main Relief Valve), at least one SRV (Secondary Relief Valve) and at least one flow restrictor.

Version 2010/1

8-3

General


8.1.1

FLOATING SYSTEM

Fig. 8-2

Floating function of boom and stick cylinders, FSA

8-4

Version 2010/1


General

The excavator operates automatically with the floating position for boom and stick activated. That means the lowering movement of boom and stick is always done in the floating position. For deactivation of the floating position, two push-buttons are installed: z

20S095 in the right joystick (20S019) for the boom function,

z

20S098 in the left joystick (20S020) for the stick function.

Press the respective button and keep it depressed as long as the floating position shall be deactivated. When releasing the button, the floating position is activated again. Function: The additionally installed single control blocks (Fig. 8-2, Pos. 60Q632, 60Q633, 60Q634 and 61Q635) connect the piston side of the cylinders with the rod side and also with the tank: z

60Q632, 60Q633 and 60Q634 for the stick cylinders,

z

61Q635 for the boom cylinders.

In normal operation mode (i.e. floating position) the pilot pressure oil is directed via 60Q632, 60Q633 and 61Q635 to the single control blocks when lowering the boom or stick. If a pressurised lowering of the cylinders is required, the pilot pressure oil is directed via 60Q632, 60Q633 and 61Q635 to the main control blocks. The solenoid valves 60Q632, 60Q633 and 61Q635 (4/2-directional control valves) are controlled by push-buttons 20S095 and 20S098. Boom:

20S095 ON => 61K635 ON => Floating position deactivated 20S095 OFF => 61K635 OFF => Floating position activated

Stick:

20S098 ON => 61K632 + 61K633 OFF => Floating position deactivated 20S098 OFF => 61K632 + 61K633 OFF => Floating position activated

NOTE: Due to the two different operation modes for lowering, the lowering speed of boom and stick cylinder must be adjusted twice: • floating position deactivated, • floating position activated.

Version 2010/1

8-5

Hydraulics for the attachment cylinder FSA and BHA


8.2

HYDRAULICS FOR THE ATTACHMENT CYLINDER FSA AND BHA

8.2.1

ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISE" FSA

Fig. 8-3

Electric / hydraulic flowchart "boom raise", FSA

8-6

Version 2010/1





(YD)

Direction (axis) of joystick

(-10V)

Signal voltage (maximum)

(11X_...)

Terminal rail with number

(11T049)

Ramp time module

(11T010)

Amplifier module - boom

(11T010a)


(11T010b)

Amplifier module - boom up or bucket fill when not raising the boom

(11T010c)


(11K058)

Relay - pilot control: Contacts 6/10 and 7/11 only closed while lifting the boom.

(11K076)

Relay - pilot control: Contacts 8/12 only closed while travelling, left crawler.

(11K078)

Relay - pilot control: Contacts 6/10 only closed while travelling, right crawler.

(14.1 + 14.2) (15.1 + 15.2)


(61K563) (61K569) (61K573) (61K576)


(61K533) (61K540) (61K546)


(I - IV)

Main control blocks I - IV

(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-3, Pos. 20S019) goes via ramp time module (Fig. 8-3, Pos. 11T049) to terminal 5 of the amplifier modules (Fig. 8-3, Pos. 11T010 to 11T010c) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-3, Pos. 14.1, 14.2, 15.1 and 15.2). 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. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I ; II ; IV) and, via distributor manifold (Fig. 8-3, Pos. 42), arrives at the hydraulic cylinders.

Version 2010/1

8-7



8.2.2

ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISE" BHA

Fig. 8-4

Electric / hydraulic flowchart "boom raise", BHA

8-8

Version 2010/1





(YD)


(-10V)


(11X_…)


(11T049 – 11T049c)

Ramp time module

(11T010 – 11T010c)

Amplifier module – boom

(11K076)

Relay – pilot control: Contacts 8/12 only closed while travelling, left crawler.

(11K078)

Relay – pilot control: Contacts 6/10 only closed while travelling, right crawler.

(14.1 + 14.2) (15.1 + 15.2)


(61K563) (61K569) (61K573) (61K576)


(61K533) (61K540) (61K546)


(I - IV)


(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-4, Pos. 20S019) goes via ramp time modules (Fig. 8-4, Pos. 11T049 to 11T049c) to terminal 5 of the amplifier modules (Fig. 8-4, Pos. 11T010 to 11T010c) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-4, Pos. 14.1, 14.2, 15.1 and 15.2). 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. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I ; II ; IV) via distributor manifold (Fig. 8-4, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-9



8.2.3

ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" FSA

Fig. 8-5

Electric / hydraulic flowchart "boom lowering", FSA

8-10

Version 2010/1





(YC)


(+10V)


(11X_…)


(11T049)

Ramp time module

(11T010)


(11T010a)


(11T010b)

Amplifier module - boom or bucket

(11T010c)


(11K058)

Relay – pilot control: Contacts 6/10 only closed while lifting the boom.

(11K076)


(11K078)


(14.1 + 14.2) (15.1 + 15.2)


(61K563) (61K573) (61K576)


(61K521) (61K541) (61K547) (61K635)


(61Q635)

Single control block

(I - IV)


(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-5, Pos. 20S019) goes via ramp time module (Fig. 8-5, Pos. 11T049) to terminal 5 of the amplifier modules (11T010, 11T010a and 11T010c) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-5, Pos. 14.1, 15.1 and 15.2). 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 and single control block (Fig. 8-5, Pos. 61Q635). Hydraulic oil flow Now piston and piston rod side of the boom cylinders are connected, so that the boom lowers only by gravity. The excess oil flows via distributor manifold (Fig. 8-5, Pos. 42) through the main control blocks (II and III) and single control block (Fig. 8-5, Pos. 61Q635) back to tank.

Version 2010/1

8-11



8.2.4

ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" BHA

Fig. 8-6

Electric / hydraulic flowchart "boom lowering", BHA

8-12

Version 2010/1





(YC)


(+10V)


(11X_…)


(11T049 11T049c)

Ramp time module

(A10)


(A10a)


(A10b)

Amplifier module – boom or bucket

(A10c)


(K76)


(K78)


(14.1 + 14.2) (15.1 + 15.2)


(61K563) (61K569) (61K573) (61K576)


(61K521) (61K532) (61K541) (61K547)


(I - IV)


(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-6, Pos. 20S019) goes via ramp time modules (Fig. 8-6, Pos. 1T049 to 11T049c) to terminal 5 of the amplifier modules (Fig. 8-6, Pos. 11T010 to 11T010c) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-6, Pos. 14.1, 14.2, 15.1 and 15.2). 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. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to IV) and via distributor manifold (Fig. 8-6, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-13



8.2.5

ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTEND" FSA

Fig. 8-7

Electric / hydraulic flowchart "stick extend", FSA

8-14

Version 2010/1





(YC)


(+10V)


(11X_61…)


(11T048)

Ramp time module

(11T008)

Amplifier module – stick

(11T008a)


(11T009)

Amplifier module – stick extend or bucket fill

(11K074)

Relay – pilot control: Contacts 5/9 only closed while extending the stick.

(11K076)


(11K078)


(14.2) (15.1 + 15.2)


(61K568) (61K571) (61K574)


(61K530) (61K537) (61K542)


(60Q632) – (60Q634)

Single control blocks (closed ports while extending the stick)

(I, II + IV)

Main control blocks

(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-7, Pos. 20S020) goes via ramp time module (Fig. 8-7, Pos. 11T048) to terminal 5 of the amplifier modules (Fig. 8-7, Pos. 11T008, 11T008a and 11T009) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-7, Pos. 14.2, 15.1 and 15.2). 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 . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, IV) and via distributor manifold (Fig. 8-7, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-15



8.2.6

ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTEND" BHA

Fig. 8-8

Electric / hydraulic flowchart "stick extend", BHA

8-16

Version 2010/1





(YC)


(+10V)


(11X_00…)


(11T048)

Ramp time module

(11T008)


(11T008a)


(11T011)


(11K076)


(11K078)


(14.2) (15.1 + 15.2)


(61K568) (61K572) (51K574)


(61K530) (61K538) (61K542)


(61K632) – (61K634)

Single control blocks (closed ports while extending the stick)

(I, II + IV)

Main control blocks

(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-8, Pos. 20S020) goes via ramp time module (Fig. 8-8, Pos. 11T048) to terminal 5 of the amplifier modules (Fig. 8-8, Pos. 11T008, 11T008a and 11T011) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-8, Pos. 14.2, 15.1 and 15.2). 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. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, IV) and via distributor manifold (Fig. 8-8, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-17



8.2.7

ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACT" FSA

Fig. 8-9

Electric / hydraulic flowchart "stick retract", FSA

8-18

Version 2010/1





(YD)


(-10V)


(11X_00…)


(11T048)

Ramp time module

(11T008)


(11T008a)


(11T009)

Amplifier module – stick extend or bucket fill

(11K074)


(11K076)


(11K078)


(14.1 + 15.2)


(99.5)

Check valve (necessary for combined operation of travel right crawler and retracting the stick)

(61K568) (61K574)


(61K531) (61K632) (61K633) (61K542) (61K543)


(60Q632) – (60Q634)

Single control blocks (ports A-B-T connected while retracting the stick)

(I + IV)

Main control blocks I + IV

(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-9, Pos. 20S020) goes via ramp time module (Fig. 8-9, Pos. 11T048) to terminal 5 of the amplifier modules (Fig. 8-9, Pos. 11T008, 11T008a) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-9, Pos. 14.2 and 15.2). 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 single control blocks (Fig. 8-9, Pos. 60Q632, 60Q633 and 60Q634). Hydraulic oil flow Now piston and piston rod side of the stick cylinders are connected, so that the stick lowers only by gravity. The excess oil flows via distributor manifold (Fig. 8-9, Pos. 42) through the single control blocks (Fig. 8-9, Pos. 60Q632, 60Q633 and 60Q634) back to tank.

Version 2010/1

8-19



8.2.8

ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACT" BHA

Fig. 8-10

Electric / hydraulic flowchart "stick retract", BHA

8-20

Version 2010/1





(YD)


(-10V)


(11X_00…)


(11T048)

Ramp time module

(11T008)


(11T008a)


(11T011)


(11K076)

Relay – pilot control: Contacts 7/11 only closed while traveling the left crawler.

(11K078)

Relay – pilot control: Contacts 8/12 only closed while traveling the right crawler.

(14.2) (15.1 + 15.2)


(61K568) (61K572) (61K574)


(61K531) (61K539) (61K543)


(I, II + IV)

Main control blocks I, II + IV

(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-10, Pos. 20S020) goes via ramp time module (Fig. 8-10, Pos. E48) to terminal 5 of the amplifier modules (Fig. 8-10, Pos. 11T008, 11T008a and 11T011) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-10, Pos. 14.2, 15.1 and 15.2). 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 . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, IV) and via distributor manifold (Fig. 8-10, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-21



8.2.9

ELECTRIC / HYDRAULIC FLOWCHART "BUCKET CURL" FSA

Fig. 8-11

Electric / hydraulic flowchart "bucket curl", FSA

8-22

Version 2010/1





(XB)


(-10V)


(11X_00…)


(11T009) (11T009a) (11T009b)

Amplifier module – bucket

(11T010b)

Amplifier module – boom up or bucket fill when not raising the boom.

(11K050)

Relay – pilot control: bucket cut-off. Contacts 11/12 only closed if the hydraulic oil is overheated.

(11K058)

Relay – pilot control: Contacts 6/10 and 5/9 only closed while lifting the boom.

(11K071)

Relay – pilot control: Contacts 6/10 and 5/9 only closed while filling the bucket.

(11K074)


(11K076)


(11K078)


(14.1 + 14.2) (15.1 + 15.2)


(61K569) (61K564) (61K571) (61K575)


(61K522) (61K532) (61K536) (61K544)


(I - IV)


(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-11, Pos. 20S019) goes via relay contacts at terminal 5 of the amplifier modules (Fig. 8-11, Pos. 11T009, 11T009a, 11T009b and 11T010b) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-11, Pos. 14.1, 14.2, 15.1 and 15.2). 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. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to IV) and via distributor manifold (Fig. 8-11, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-23



8.2.10

ELECTRIC / HYDRAULIC FLOWCHART "BUCKET CURL" BHA

Fig. 8-12

Electric / hydraulic flowchart "bucket curl", BHA

8-24

Version 2010/1





(XB)


(-10V)


(11X_00…)


(11T009) (11T009a) (11T009b)


(11K050)

Relay – pilot control: Bucket cut-off. Contacts 11/12 only closed if the hydraulic oil is overheated.

(11K076)


(11K078)


(14.1) (15.1 + 15.2)


(61K564) (61K571) (61K575)


(61K522) (61K536) (61K544)


(II, III + IV)

Main control blocks II, III + IV

(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-12, Pos. 20S019) goes via relay contacts to terminal 5 to the amplifier modules (Fig. 8-12, Pos. 11T009, 11T009a, 11T009b) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-12, Pos. 14.1, 15.1 and 15.2). 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 . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and via distributor manifold (Fig. 8-12, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-25



8.2.11

ELECTRIC / HYDRAULIC FLOWCHART "BUCKET DUMP" FSA

Fig. 8-13

Electric / hydraulic flowchart "bucket dump", FSA

8-26

Version 2010/1





(XA)


(+10V)


(11X_00…)


(11T009a) (11T009b)


(11K050)


(11K058)

Relay – pilot control: Contacts 5/9 only closed while lifting the boom.

(11K071)

Relay – pilot control: Contacts 5/9 only closed while filling the bucket.

(11K078)


(14.1 + 15.2)


(61K564) (61K575)


(61K523) (61K545)


(III + IV)

Main control blocks III + IV

(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-13, Pos. 20S019) goes via relay contacts to terminal 5 of the amplifier modules (Fig. 8-13, Pos. 11T009a and 11T009b) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-13, Pos. 4.1 and 15.2). 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. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (III + IV) and via distributor manifold (Fig. 8-13, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-27



8.2.12

ELECTRIC / HYDRAULIC FLOWCHART "BUCKET DUMP" BHA

Fig. 8-14

Electric / hydraulic flowchart "bucket dump", BHA

8-28

Version 2010/1





(XA)


(+10V)


(11X_00…)


(11T009a) (11T009b)


(11K050)


(11K076)


(11K078)


(14.1) (15.1 + 15.2)


(61K564) (61K571) (61K575)


(61K523) (61K537) (61K545)


(II, III + IV)

Main control blocks II, III + IV

(42)


Electrical signal flow Signal voltage of joystick (Fig. 8-14, Pos. 20S019) goes via relay contacts to terminal 5 of the amplifier modules (Fig. 8-14, Pos. 11T009, 11T009a, 11T009b) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-14, Pos. 14.1, 15.1 and 15.2). 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. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and via distributor manifold (Fig. 8-14, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-29



8.2.13

ELECTRIC / HYDRAULIC FLOWCHART "CLAM OPEN" FSA

Fig. 8-15

Electric / hydraulic flowchart "clam open", FSA

8-30

Version 2010/1




Control pedal

(-10V)


(11X_00…)


(11T011)

Amplifier module – clam

(11K076)

Relay – pilot control: Contacts 7/11 only closed while travelling the left crawler.

(15.1)


(61K572)


(61K539)


(II)

Main control block II

(42)


Electrical signal flow Signal voltage of control pedal (Fig. 8-15, Pos. 20S024) goes via relay contact to terminal 5 of the amplifier module (Fig. 8-15, Pos. 11T011) and further to the proportional and directional solenoid valves of the remote control block (Fig. 8-15, Pos. 15.1). Hydraulic signal flow (pilot pressure) When the proportional and directional solenoid valves are energized, pilot pressure oil flows to the pilot pressure port of the main control block. Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and via distributor manifold (Fig. 8-15, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-31



8.2.14

ELECTRIC / HYDRAULIC FLOWCHART "CLAM CLOSE" FSA

Fig. 8-16

Electric / hydraulic flowchart "clam close", FSA

8-32

Version 2010/1




Control pedal

(+10V)


(11X_00…)


(11T011)

Amplifier module – clam

(11K076)


(15.1)


(61K572)


(61K538)


(II)

Main control block II

(42)


Electrical signal slow Signal voltage of control pedal (Fig. 8-16, Pos. 20S023) goes via relay contact to terminal 5 of the amplifier module (Fig. 8-16, Pos. 11T011) and further to the proportional and directional solenoid valves of the remote control block (Fig. 8-16, Pos. 15.1). Hydraulic signal flow (pilot pressure) When the proportional and directional solenoid valves are energized, pilot pressure oil flows to the pilot pressure port of the main control block. Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and via distributor manifold (Fig. 8-16, Pos. 42) to the hydraulic cylinders.

Version 2010/1

8-33



8.2.15

CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (FSA)

Fig. 8-17

Checks and adjustments of the main relief valves (FSA)

8-34

Version 2010/1



There are four main relief valves (MRV) installed, one in each main control block, to limit the maximum pump supply pressure (operating pressure). MRV in control block

Test port

Pump circuit I

I

M14

Pump circuit II

II

M12

Pump circuit III

III

M11

Pump circuit IV

IV

M13

Functions FSA Swing Boom

Clam Swing

Boom

Bucket

Bucket filling Boom raise

Stick

Bucket filling Stick extend

Travel

Bucket

Boom

Stick

Travel

Each pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit. Checking: 1. Connect the gauge to the required test port M11 - M14. 2. Start engine and let it run at high idle. 3. Extend or retract the cylinder to the stop position for the valve being tested until the hydraulic system stalls. 4. Read the pressure. Required: 310+5 bar. If the pressure is not correct, carry out a comparative measurement with another function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system. Adjusting: 1. Remove protective cap (Fig. 8-17, Pos. a). 2. Loosen lock nut (Fig. 8-17, Pos. b). 3. Turn set-screw (Fig. 8-17, Pos. c) clockwise to increase pressure, or counter-clockwise to decrease pressure. 4. Tighten lock nut (Fig. 8-17, Pos. b) and install cap (Fig. 8-17, Pos. a).

NOTE: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly, which results in loud flow noises and wrong adjustments.

Version 2010/1

8-35



8.2.16

CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (BHA)

Fig. 8-18

Checks and adjustments of the main relief valves (BHA)

8-36

Version 2010/1



There are four main relief valves (MRV) installed, one in each main control block, to limit the maximum pump supply pressure (operating pressure). MRV in control block

Test port

Pump circuit I

I

M14

Pump circuit II

II

M12

Pump circuit III

III

M11

Pump circuit IV

IV

M13

Functions BHA Swing Boom

Stick Swing

Boom

Bucket

Boom

Stick

Bucket

Travel

Bucket

Boom

Stick

Travel

Each pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit. Checking: 1. Connect the gauge to the required test port M11 - M14. 2. Start engine and let it run at high idle. 3. Extend or retract the cylinder to the stop position for the valve being tested until the hydraulic system stalls. 4. Read the pressure. Required: 310+5 bar. Adjusting: 1. Remove protective cap (Fig. 8-18, Pos. a). 2. Loosen lock nut (Fig. 8-18, Pos. b). 3. Turn set-screw (Fig. 8-18, Pos. c) clockwise to increase pressure, counter-clockwise to decrease pressure. 4. Tighten lock nut (Fig. 8-18, Pos. b) and install cap (Fig. 8-18, Pos. a).


Version 2010/1

8-37



8.2.17

CHECKS AND ADJUSTMENTS OF THE SECONDARY RELIEF VALVES (SRV)

Fig. 8-19

Checks and adjustments of the secondary relief valves (SRV)

8-38

Version 2010/1


8.2.17.1


BOOM CYLINDER "PISTON SIDE" FSA + BHA

There are 6 secondary relief valves (SRV) installed, 4 at the distributor manifold (Fig. 8-19, Pos. 42), 1 in main control block II and 1 in block IV, to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve

Pressure Test Port

Location

SRV 66.5

M12 (High pressure filter)

Control block II, section A1

SRV 66.7


Control block IV, section A1

SRV 65.7

M26.2

Manifold (Fig. 8-19, Pos. 42), section O

SRV 70.13

M26.1

Manifold (Fig. 8-19, Pos. 42), section O

SRV 70.2

M16.2

Manifold (Fig. 8-19, Pos. 42), section B

SRV 70.1

M16.1

Manifold (Fig. 8-19, Pos. 42), section B

MRV circuit II


Control block II

MRV circuit IV


Control block IV

1. Connect gauges to all above listed test ports. 2. Start engine and let it run at high idle. 3. Extend the boom cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-19, Pos. 3) of both MRVs in control block II and IV while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston side of the boom cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments, it is necessary to further increase the setting of both MRVs. 5. Remove protective cap (Fig. 8-19, Pos. 1) of the MRV. 6. Loosen lock nut (Fig. 8-19, Pos. 2). 7. Turn set-screw (Fig. 8-19, Pos. 3) of both MRVs ½ a turn further in, the gauge pointers will remain at the value shown in step 4 (350±5 bar). 8. Tighten lock nut (Fig. 8-19, Pos. 2) and install cap (Fig. 8-19, Pos. 1).

Version 2010/1

8-39


Fig. 8-20

8-40



Version 2010/1



9. Adjust all 6 SRVs equally, until all gauges show a pressure of 350 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-20, Pos. 3) in the following sequence: z

70.1Ö 70.2 Ö 70.13 Ö 65.4 Ö 66.5 Ö 66.7

z

Remove protective cap (Fig. 8-20, Pos. 1) of the SRVs.

z


z

Turn set-screw (Fig. 8-20, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.

z

Tighten lock nut (Fig. 8-20, Pos. 2) and install cap (Fig. 8-20, Pos. 1).

NOTE: Now all gauges will show the same value of 350±5 bar. 10. Proceed with the other valves in the same manner.

WARNING Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all six secondary relief valves.

11. Reset the MRVs to 310+5 bar after the check / adjustment is finished, as follows: z

Remove protective cap (Fig. 8-20, Pos. 1).

z


z


z



Version 2010/1

8-41


Fig. 8-21

8-42



Version 2010/1


8.2.17.2


BOOM CYLINDER "PISTON ROD SIDE" FSA +BHA

There is 1 secondary relief valve (SRV) installed in the main control blocks, to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs), it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve

Pressure Test Port

Location

SRV 66.3


Control block III, section B3

SRV 66.8


Control block IV, section B1

MRV circuit III


Control block III

MRV circuit IV


Control block IV

1. Connect gauges to all above listed test ports. 2. Start engine and let it run at high idle. 3. Retract the boom cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-21, Pos. 3) of the MRVs in the control blocks, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: If the piston rod side of the boom cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments it is necessary to further increase the setting of both MRVs. 5. Remove protective cap (Fig. 8-21, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-21, Pos. 2). 7. Turn set-screw (Fig. 8-21, Pos. 3) of both MRV's ½ a turn further in. 8. Tighten lock nut (Fig. 8-21, Pos. 2) and install cap (Fig. 8-21, Pos. 1).

Version 2010/1

8-43


Fig. 8-22

8-44



Version 2010/1



9. Adjust all SRVs equally, until all gauges show a pressure of 350 bar. z

Adjust in steps of ¼ turn of set-screw (Fig. 8-22, Pos. 3).

z

Remove protective cap (Fig. 8-22, Pos. 1) of SRVs.

z


z


z


NOTE: All gauges will show the same value of 350 bar. 10. Proceed with the other valves in the same manner.

WARNING Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be avoided. Otherwise, the internal sealing is not properly, which results in loud flow noises and wrong adjustments.

11. Reset the MRV's to 310+5 bar after the check / adjustment is finished, as follows: z


z


z


z



Version 2010/1

8-45


Fig. 8-23

8-46



Version 2010/1


8.2.17.3


STICK CYLINDER "PISTON SIDE" FSA

There are 4 secondary relief valves (SRV) installed, 3 at the distributor manifold (Fig. 8-23, Pos. 42) and 1 in main control block IV, to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRV), it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve

Press. test port

Location

SRV 66.11



SRV 65.2

M20

Manifold (Fig. 8-23, Pos. 42), section G

SRV 70.8

M21.1

Manifold (Fig. 8-23, Pos. 42), section J

SRV 70.9


Control block IV

1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Extend the stick cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-23, Pos. 3) of the MRV in control block IV, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston side of the stick cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments, it is necessary to further increase the setting of the MRVs. 5. Remove protective cap (Fig. 8-23, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-23, Pos. 2). 7. Turn set-screw (Fig. 8-23, Pos. 3) of the MRV ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (350±5 bar). 8. Tighten lock nut (Fig. 8-23, Pos. 2) and install cap (Fig. 8-23, Pos. 1).

Version 2010/1

8-47


Fig. 8-24

8-48



Version 2010/1



9. Adjust all 4 SRVs equally, until all gauges show a pressure of 350 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-24, Pos. 3) in the following sequence: z

65.2 Ö 70.8 Ö 70.9 Ö 66.11

z


z


z


z


NOTE: Now all gauges will show the same value of 350±5 bar. 10. Proceed with the other valves in the same manner in the following sequence: z

70.8 Ö 70.9 Ö 66.11

WARNING Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all four secondary relief valves.

11. Reset the MRV to 310+5 bar after the check / adjustment is finished, as follows: z


z


z


z


NOTE: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.

Version 2010/1

8-49


Fig. 8-25

8-50



Version 2010/1


8.2.17.4


STICK CYLINDER "PISTON SIDE" BHA

There are 3 secondary relief valves (SRVs) installed in main control blocks I, II and IV to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs), it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve

Press. test port

Location

SRV 66.4


Control block I, section B3

SRV 66.6


Control block II, section B2

SRV 66.12



MRV circuit I


Control block I

MRV circuit II


Control block II

MRV circuit IV


Control block IV

1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the stick cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-25, Pos. 3) of the MRVs in the control blocks, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston side of the stick cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments, it is necessary to further increase the setting of the MRVs. 5. Remove protective cap (Fig. 8-25, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-25, Pos. 2). 7. Turn set-screw (Fig. 8-25, Pos. 3) of the MRV's ½ a turn further in, the gauge pointers will remain at the value shown at step 4 (350±5 bar). 8. Tighten lock nut (Fig. 8-25, Pos. 2) and install cap (Fig. 8-25, Pos. 1).

Version 2010/1

8-51


Fig. 8-26

8-52



Version 2010/1



9. Adjust all 3 SRVs equally, until all gauges show a pressure of 350 bar. z

Adjust in steps of ¼ turn of set-screw (Fig. 8-26, Pos. 3) in the following sequence:

z

66.4 Ö 66.6 Ö 66.12

z

Remove protective cap (Fig. 8-26, Pos. ) of SRVs.

z


z

Turn set-screw (Fig. 8-26, Pos. ) clockwise to increase pressure, or counter-clockwise to decrease pressure.

z



66.6 Ö 66.12

WARNING 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 3 secondary relief valves.

11. Reset the MRV to 310+5 bar after the check/adjustment is finished, as follows: z


z


z


z


NOTE: It is important that the valve bodies of MRV and SRV are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.

Version 2010/1

8-53


Fig. 8-27

8-54



Version 2010/1


8.2.18


STICK CYLINDER "PISTON ROD SIDE" FSA

There are 2 secondary relief valves (SRVs) installed in main control blocks I and IV to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs), it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve

Pressure Test Port

Location

SRV 66.4


Control block I, section B3

SRV 66.12



MRV circuit I


Control block I

MRV circuit IV


Control block IV

1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the stick cylinder to the stop position until the hydraulic system stalls. (Switch 20S098) 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-27, Pos. 3) of MRVs in the control blocks, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston rod side of the stick cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments, it is necessary to further increase the setting of both MRVs. 5. Remove protective cap (Fig. 8-27, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-27, Pos. 2). 7. Turn set-screw (Fig. 8-27, Pos. 3) of both MRV's ½ a turn further in. 8. Tighten lock nut (Fig. 8-27, Pos. 2) and install cap (Fig. 8-27, Pos. 1).

Version 2010/1

8-55


Fig. 8-28

8-56



Version 2010/1



9. Adjust both SRVs equally, until all gauges show a pressure of 350 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-28, Pos. 3) in the following sequence: z

66.4 Ö 66.12

z

Remove protective cap (Fig. 8-28, Pos. ) of SRVs.

z


z


z


NOTE: Now all gauges will show the same value of 350±5 bar. 10. Proceed with the other valves in the same manner.

WARNING Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all secondary relief valves.



z


z


z



Version 2010/1

8-57


Fig. 8-29

8-58



Version 2010/1


8.2.18.1


STICK CYLINDER "PISTON ROD SIDE" BHA

There are 3 secondary relief valves (SRVs) installed at the distributor manifold (Fig. 8-29, Pos. 42) to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs), it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve

Pressure Test Port

Location

SRV 70.8

M21.1


SRV 70.9

M21.2


SRV 70.10

M22

Manifold (Fig. 8-29, Pos. 42), section K

MRV circuit I


Control block I

1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the stick cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-29, Pos. 3) of MRVs in the control blocks while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston rod side of the stick cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments, it is necessary to further increase the setting of both MRVs. 5. Remove protective cap (Fig. 8-29, Pos. 1) of the MRV. 6. Loosen lock nut (Fig. 8-29, Pos. 2). 7. Turn set-screw (Fig. 8-29, Pos. 3) of both MRVs ½ a turn further in. 8. Tighten lock nut (Fig. 8-29, Pos. 2) and install cap (Fig. 8-29, Pos. 1).

Version 2010/1

8-59


Fig. 8-30

8-60



Version 2010/1



9. Adjust all SRVs equally, until all gauges show a pressure of 350±5 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-30, Pos. 3) in the following sequence: z

70.8 Ö 70.9 Ö 70.10

z


z


z


z



70.9 Ö 70.10




z


z


z

Tighten lock nut (Fig. 8-30, Pos.2) and install cap (Fig. 8-30, Pos. 1).

NOTE: It is important that the valve bodies of MRV and SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.

Version 2010/1

8-61


Fig. 8-31

8-62



Version 2010/1


8.2.18.2


BUCKET CYLINDER "PISTON SIDE" FSA

There are 6 secondary relief valves (SRVs) installed, 4 at the distributor manifold (Fig. 8-31, Pos. 42), 1 in main control block III, and 1 in block IV, to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs), it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve

Pressure Test Port

Location

SRV 66.1


Control block III, section A2

SRV 66.9



SRV 65.1

M17.1

Manifold (Fig. 8-31, Pos. 42), section C

SRV 70.4

M17.2


SRV 70.12

M24

Manifold (Fig. 8-31, Pos. 42), section M

SRV 65.3

M25

Manifold (Fig. 8-31, Pos. 42), section N

MRV circuit III


Control block III

MRV circuit IV


Control block IV

1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Extend the bucket cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the MRV pressure by turning in set-screws (Fig. 8-31, Pos. 3) of both MRVs in control blocks III and IV, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 360–370 bar. NOTE: Since the piston side of the bucket cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments, it is necessary to further increase the setting of both MRVs. 5. Remove protective cap (Fig. 8-31, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-31, Pos. 2). 7. Turn set-screw (Fig. 8-31, Pos. 3) of both MRVs ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (360–370 bar). 8. Tighten lock nut (Fig. 8-31, Pos. 2) and install cap (Fig. 8-31, Pos. 1).

Version 2010/1

8-63


Fig. 8-32

8-64



Version 2010/1



9. Adjust all 6 SRVs equally until all gauges show a pressure of 350±5 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-32, Pos. 3) in the following sequence: z

65.1 Ö 70.4 Ö 70.12 Ö 65.3 Ö 66.1 Ö 66.9

z


z


z


z


10. Reduce the pressure, at SRV 65.1 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. NOTE: Now all gauges will show the same value of 350±5 bar, but only SRV 65.1 has the correct setting. 11. Proceed with the other valves in the same manner in the following sequence: z

70.4 Ö 70.12 Ö 65.3 Ö 66.1 Ö 66.9

WARNING Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all 6 secondary relief valves.



z


z


z



Version 2010/1

8-65


Fig. 8-33

8-66



Version 2010/1


8.2.18.3


BUCKET CYLINDER "PISTON SIDE" BHA


Pressure Test Port

Location

SRV 70.3

M17.1


SRV 70.4

M17.2


SRV 70.12

M24

Manifold (Fig. 8-33, Pos. 42), section M

MRV circuit III


Control block III

1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Extend the bucket cylinder to the final stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-33, Pos. 3) of MRV in control block III, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston side of the bucket cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments, it is necessary to further increase the setting of both MRVs. 5. Remove protective cap (Fig. 8-33, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-33, Pos. 2). 7. Turn set-screw (Fig. 8-33, Pos. 3) of both MRVs ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (350±5 bar ). 8. Tighten lock nut (Fig. 8-33, Pos. 2) and install cap (Fig. 8-33, Pos. 1).

Version 2010/1

8-67


Fig. 8-34

8-68



Version 2010/1




70.3 Ö 70.4 Ö 70.12

z


z


z


z


10. Reduce the pressure at SRV 70.3 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. NOTE: Now all gauges will show the same value of 350±5 bar, but only SRV 70.3 has the correct setting. 11. Proceed with the other valves in the same manner in the following sequence: z

70.4 Ö 70.12




z


z


z


NOTE: It is important that the valve bodies of MRV and the SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.

Version 2010/1

8-69


Fig. 8-35

8-70



Version 2010/1


8.2.18.4


BUCKET CYLINDER "PISTON ROD SIDE" FSA

There are 2 secondary relief valves (SRVs) installed, 1 in main control block III, and 1 in block IV, to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs), it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve

Pressure Test Port

Location

SRV 66.2


Control block III, section B2

SRV 66.10



MRV circuit III


Control block III

MRV circuit IV


Control block IV

1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the bucket cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-35, Pos. 3) of MRVs in the control blocks, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston rod side of the bucket cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments, it is necessary to further increase the setting of the MRVs. 5. Remove protective cap (Fig. 8-35, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-35, Pos. 2). 7. Turn set-screw (Fig. 8-35, Pos. 3) of both MRVs ½ a turn further in. 8. Tighten lock nut (Fig. 8-35, Pos. 2) and install cap (Fig. 8-35, Pos. 1).

Version 2010/1

8-71


Fig. 8-36

8-72



Version 2010/1



9. Adjust both SRVs equally until all gauges show a pressure of 350±5 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-36, Pos. 3) in the following sequence: z

66.2 Ö 66.10

z


z


z


z


10. Reduce the pressure at SRV 66.2 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. NOTE: Now all gauges will show the same value of 350±5 bar, but only SRV 66.2 has the correct setting. 11. Proceed with the other valve in the same manner.




z


z


z



Version 2010/1

8-73


Fig. 8-37

8-74



Version 2010/1


8.2.18.5


BUCKET CYLINDER "PISTON ROD SIDE" BHA


Pressure Test Port

Location

SRV 70.5

M18

Manifold (Fig. 8-37, Pos. 42), section D

SRV 70.7

M20

Manifold (Fig. 8-37, Pos. 42), section G

SRV 70.11

M23

Manifold (Fig. 8-37, Pos. 42), section L

MRV circuit IV


Control block III

1. Connect gauges to all above listed test ports. 2. Start engine and let it run at high idle. 3. Extend the bucket cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-37, Pos. 3) of MRV in control block III, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston rod side of the bucket cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if the gauges show the required pressure, it is possible that one or more valves have a higher setting. To ensure that only the SRVs open during checks and adjustments, it is necessary to further increase the setting of the MRV. 5. Remove protective cap (Fig. 8-37, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-37, Pos. 2). 7. Turn set-screw (Fig. 8-37, Pos. 3) of both MRVs ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (350±5 bar). 8. Tighten lock nut (Fig. 8-37, Pos. 2) and install cap (Fig. 8-37, Pos. 1).

Version 2010/1

8-75


Fig. 8-38

8-76



Version 2010/1




70.5 Ö 70.7 Ö 70.11

z


z


z


z


10. Reduce the pressure at SRV 70.5 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. NOTE: Now all gauges will show the same value of 350±5 bar, but only SRV 70.5 has the correct setting. 11. Proceed with the other valves in the same manner in the following sequence: z

70.7 Ö 70.11


12. Reset the MRVs to 310+5 bar after the check/adjustment is finished, as follows: z


z


z


z


NOTE: It is important that the valve bodies of MRVs and SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.

Version 2010/1

8-77


Fig. 8-39

8-78



Version 2010/1


8.2.18.6


CLAM CYLINDER "PISTON ROD SIDE" FSA

There is one secondary relief valve (SRV) installed at the distributor manifold (Fig. 8-39, Pos. 42) to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRV is higher than the setting of the main relief valves (MRVs), it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve

Pressure Test Port

Location

SRV 70.6

M19

Manifold (Fig. 8-39, Pos. 42), section E

MRV cicuit II


Control block II

1. Connect gauges to the test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the clam cylinder (open the bucket) to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-39, Pos. 3) of MRV in control block II, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. If necessary, correct the adjustment as follows: 1. Remove protective cap (Fig. 8-39, Pos. 1) of MRV. 2. Loosen lock nut (Fig. 8-39, Pos. 2). 3. Turn set-screw (Fig. 8-39, Pos. 3) of the MRV ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (350±5 bar). 4. Tighten lock nut (Fig. 8-39, Pos. 2) and install cap (Fig. 8-39, Pos. 1). 5. Reduce the pressure at SRV 70.6 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. 6. Reset the MRV to 310+5 bar after adjustment is finished, as follows: z


z


z


z



Version 2010/1

8-79


Fig. 8-40

8-80



Version 2010/1


8.2.18.7


CLAM CYLINDER "PISTON SIDE" FSA

There are 2 secondary relief valves (SRVs) installed, 1 at distributor manifold (Fig. 8-40, Pos. 42), and 1 in main control block II, to limit the maximum possible pressure in the lines when closing the bucket. To avoid damages at the clam shell due to improper operation, the SRVs should be adjusted in a way that the pressure is just sufficient to keep the bucket closed. Valve

Pressure Test Port

Location

SRV 18

M18

Manifold (Fig. 8-40, Pos. 42), section K

SRV 45


Control block II

1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Raise the attachment and bring the back wall of the bucket into horizontal position. 4. Press the 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 SRVs as follows: z


z


z


z


5. Adjust both SRVs equally until the gauges show a pressure of 150±30 bar. NOTE: Since the piston side of the clam cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. For standard buckets the pressure is 150 bar, reinforced or with heavy wear package attached, the pressure may be raised up to 180 bar. ###

Version 2010/1

8-81


Fig. 8-41

8-82


Checks and adjustments of the lowering speed

Version 2010/1


8.2.18.8


CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED

General On excavators equipped with face shovel attachment (FSA), there are two different operation modes for lowering the boom and stick: 1. Floating position activated, the lowering speed is restricted by the stroke limiters (Fig. 8-41, Pos. 1) of the single control blocks (Fig. 8-41, Pos. 2). (Standard adjustment: ’fully open’) 2. Floating position deactivated, the lowering speed has to be adjusted at the the flow restrictors (throttle valves) at the distributor manifold (Fig. 8-41, Pos. 42). On excavators equipped with backhoe attachment (BHA), the lowering speed has to be adjusted at the flow restrictors only (no floating system installed). Purpose of the flow restrictors: z

To avoid an interruption (stops during movements) of the pump delivery.

z

To provide smooth cylinder movement.

z

To limit the return oil flow through the control block to the maximum permissible volume.

Checks and adjustments: z

Standard test method is measuring the total cylinder running time (from start to final stop) by using a stop watch.

z

Basic adjustment of all restrictors as follows: z

For easy turning of set-screw (Fig. 8-41, Pos. 3), lower the attachment to ground, stop motor and allow pressure equalising by moving the joysticks several times.

z

Loosen the lock nut (Fig. 8-41, Pos. 4) and turn the bolt (Fig. 8-41, Pos. 3) cw. for more restriction and ccw. for less restricton. If more than one restrictor is used for one movement make sure all set-screws are equally adjusted.

NOTE: For the values to be set, refer to column "Nominal" in the PM-CLINIC data sheet for the respective attachment (FSA / BHA), see following illustrations (extracts – sample only). FSA:

BHA:

Version 2010/1

8-83



NOTE: During commissioning, a standard throttle valve adjustment has to be carried out. For safety reasons, the throttle valves are basically adjusted before the machine is leaving the factory. For more information, refer to PM CLINIC.

Fig. 8-42

8-84

Checks and adjustments of the lowering speed (boom cylinder FSA)

Version 2010/1



Boom cylinder FSA Due to the 2 different operation modes for lowering the boom, the lowering speed must be adjusted twice: 1. Floating position activated 2. Floating position deactivated Maximum permissible lowering speed Refer to the PM-CLINIC sheet for your machine. Adjustments / checks (floating position activated): 1. Use a stop watch to measure the time for the cylinder movement (from start to final stop). NOTE: Pay attention to measure the time of the cylinder movement only. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-42, Pos. A). 3. Run the engine at high idle. 4. Lower the attachment; do not press button 20S095 (floating position switch). Rapidly move the control lever 20S019 to the front end position (start stop watch when the boom starts moving) and hold the control lever in this position until the final position (Fig. 8-42, Pos. B) is reached (stop the stop watch). NOTE: Lower the boom so that the bucket stops just above the ground. 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the stroke limiter of the single control block (Fig. 8-42, Pos. 61Q635). Adjust as follows: z

To decrease the lowering speed, loosen the lock nut (Fig. 8-42, Pos. 2) and turn the bolt (Fig. 8-42, Pos. 1) clockwise.

z

To increase the lowering speed, loosen the lock nut (Fig. 8-42, Pos. 2) and turn the bolt (Fig. 8-42, Pos. 1) counter-clockwise.

6. Check the lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-42, Pos. 2).

Version 2010/1

8-85


Fig. 8-43

8-86


Checks and adjustments of the lowering speed (boom cylinder FSA)

Version 2010/1



Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks (floating position deactivated). 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-43, Pos. A). 3. Run the engine at high idle. 4. Press push-button 20S095 and keep it depressed while lowering the attachment. Rapidly move the control lever (Fig. 8-43, Pos. 20S019) to the front end position (start the stop watch) and hold it in this position until the final position (Fig. 8-43, Pos. B) is reached (stop the stop watch). NOTE: Lower the boom so that the bucket stops just above the ground. 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.1, 70.2 and 70.13 at the distributor manifold (Fig. 8-43, Pos. 42). Adjust as follows: z


z


NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions.

6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-43, Pos. 2).

Version 2010/1

8-87


Fig. 8-44

8-88


Checks and adjustments of the lowering speed (boom cylinder BHA)

Version 2010/1



Boom cylinder BHA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-44, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-44, Pos. 20S019) to the front end position (start the stop watch) and hold it in this position until the final position of the boom (Fig. 8-44, Pos. B) is reached.(stop the stop watch). NOTE: Lower the boom so that the bucket stops just above the ground. 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.1, 70.2 , 70.13 and 70.14 at the distributor manifold (Fig. 8-44, Pos. 42). Adjust as follows: z


z


NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-44, Pos. 2).

Version 2010/1

8-89


Fig. 8-45

8-90


Checks and adjustments of the lowering speed (stick cylinder FSA)

Version 2010/1



Stick cylinder FSA Due to the two different operation modes for lowering the stick, the lowering speed must be adjusted twice: 1. Floating position activated 2. Floating position deactivated Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks (floating position activated): 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-45, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-45, Pos. 20S020) to the rear end position (start the stop watch) and hold it in this position until the final position (Fig. 8-45, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the stroke limiter of the single control block (Fig. 8-45, Pos. 60Q632, 60Q633 and 60Q634). Adjust as follows: z


z


NOTE: Since there are several single control blocks used for the stick movement, make sure that all stroke limiters are equally adjusted. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-45, Pos. 2).

Version 2010/1

8-91


Fig. 8-46

8-92


Checks and adjustments of the lowering speed (stick cylinder FSA)

Version 2010/1



Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks (floating position deactivated with push-button 20S098): 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-46, Pos. A). 3. Run the engine at high idle. 4. Press push-button 20S098 and keep it depressed while lowering the stick. Rapidly move the control lever (Fig. 8-46, Pos. 20S020) to the rear end position (start the stop watch) and hold it until the final position (Fig. 8-46, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.8 and 70.9 at the distributor manifold (Fig. 8-46, Pos. 42). Adjust as follows: z


z



Version 2010/1

8-93


Fig. 8-47

8-94


Checks and adjustments of the lowering speed (stick cylinder BHA)

Version 2010/1



Stick cylinder BHA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-47, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-47, Pos. 20S020) to the rear end position (start the stop watch) and hold it until the final position (Fig. 8-47, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.8, 70.9 and 70.10 at the distributor manifold (Fig. 8-47, Pos. 42). Adjust as follows: z


z



Version 2010/1

8-95


Fig. 8-48

8-96


Checks and adjustments of the lowering speed (bucket cylinder FSA)

Version 2010/1



Bucket cylinder FSA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-48, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-48, Pos. 20S019) to the r.h. end position (start the stop watch) and hold it until the final position (Fig. 8-48, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.4 and 70.12 at the distributor manifold (Fig. 8-48, Pos. 42). Adjust as follows: z


z


NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished tighten lock nut (Fig. 8-48, Pos. 2).

Version 2010/1

8-97


Fig. 8-49

8-98


Checks and adjustments of the lowering speed (bucket cylinder BHA)

Version 2010/1



Bucket cylinder BHA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-49, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-49, Pos. 20S019) to the r.h. end position (start the stop watch) and hold it until the final position (Fig. 8-49, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.3, 70.4 and 70.12 at the distributor manifold (Fig. 8-49, Pos. 42). Adjust as follows: z


z



Version 2010/1

8-99


Fig. 8-50

8-100


Checks and adjustments of the lowering speed (clam cylinder FSA)

Version 2010/1



Clam cylinder BHA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Open the clam of the empty bucket to the maximum height position (Fig. 8-50, Pos. A). 3. Run the engine at high idle. 4. Rapidly push the control pedal (Fig. 8-50, Pos. 20S023) to the end position (start the stop watch) and hold it until the final position (Fig. 8-50, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valve 70.6 at the distributor manifold (Fig. 8-50, Pos. 42). Adjust as follows: z


z



Version 2010/1

8-101

Hydraulics for the swing circuit


8.3

HYDRAULICS FOR THE SWING CIRCUIT

8.3.1

SWING CIRCUIT

Fig. 8-51

Swing circuit

8-102

Version 2010/1



Legend for Fig. 8-51: (1 + 3)

Main pumps

(9/III)

Control block

(10/I)

Control block

(16.1 + 16.2)

Manifold

(60.1 + 60.2)

Swing motors

Brief description (service circuits) The machine is equipped with a two speed swing system (also refer to the hydraulic and electric circuit diagram). The swing motors (Fig. 8-51, Pos. 60.1 + 60.2) are driven by the pumps (Fig. 8-51, Pos. 1 + 3). The oil flows from the pumps through high pressure filters to the control block (Fig. 8-51, Pos. 9/III) and (Fig. 8-51, Pos. 10/I). With the spools in neutral position, oil flows via the return oil line into the collector pipe (107) and further via the return oil lines (L6 + L7) back to the tank. On the way back to the tank the oil must flow through the back pressure valve (55) and the return oil filters (59.1 59.4). (For the back pressure valve function, refer to section 4.2 on page 4-4). When operating the control lever for "swinging", the pump line is connected in the control blocks (Fig. 8-51, Pos. 9/III and 10/I) with the corresponding service line (A1 or B1) to the swing motors (Fig. 8-51, Pos. 60.1 + 60.2). The oil flows from the control block through each of the swing brake valves (61.1 + 61.2; for description refer to section 8.3.7 on page 8-116) and the swing motors (Fig. 8-51, Pos. 60.1 + 60.2). Each swing gear includes one spring loaded multi-disk brake for locking the superstructure. The leak oil (case drain) flows through the lines (L18 + L19) and the leak oil filter (53) back to the tank.

Version 2010/1

8-103


Fig. 8-52

8-104


Swing circuit

Version 2010/1



Main pumps

(9/III)

Control block

(10/I)

Control block

(14.1 + 14.2)

Remote control valve block

(16.1 + 16.2)

Manifold

(60.1 + 60.2)

Swing motors

(61K524) (61K525) (61K526) (61K527)


(61K565) (61K566)


(57K620) (57K626)


(57Q627)


(57K630) (57K631)



If swing speed switch 20S154 is activated, also proportional solenoid valve 61K566 and, depending on the swinging direction, directional solenoid valves 61K526 (swing right) or 61K527 (swing left) are energized. Simultaneously solenoid valves 57K630 and 57K626 (pump #1 fixed in ½ Qmax position) are energized, so that only a reduced oil flow from pump #1 will be added to increase the swing speed. I.e.: Swing speed fast = oil flow of pump #3 + reduced oil flow of pump #1

Description When the lever (Fig. 8-53, Pos. 20S020) is moved out of its neutral position, proportional solenoid valve 61K565 and solenoid valve 57K631 (pump #3 fixed in Qmax position) are energized. Simultaneously the directional solenoid valves 61K524 (swing right) or 61K525 (swing left) are energized. At the same time, by the function of proportional solenoid valve 57Q627, pilot pressure is present at port "X" of each brake valve block.

Fig. 8-53

I.e.: Swing speed low = only oil flow of pump #3

Version 2010/1

8-105


8.3.2

SWING MOTOR

Fig. 8-54

Axial piston motor A2FLM (with SL-bearing)

8-106


Version 2010/1


Legend for Fig. 8-54:


Description of the SL-bearing (SL = Slipper Bearing)

(1)

Drive shaft

(2)

Housing

(3)

Case drain port

(4)

Retaining plate

(5)

Piston

(5a)

Pivot (center) pin

(6a)

Upper dead point

(6b)

Lower dead point

The slipper pads support themselves on the thrust washer (Fig. 8-54, Pos. 14) and discharge axially the tapered roller bearing (Fig. 8-54, Pos. 11). Without pressure, the slipper pads are kept on the thrust washer by means of spring (Fig. 8-54, Pos. 12).

(7)

Cylinder

Function

(8)

Control lens

(9)

End plate

(10)

Centering spring

The pressure oil inlet (Fig. 8-54, Pos. A or B) and consequent oil outlet (Fig. 8-54, Pos. B or A) determine the output drive direction of the drive shaft (Fig. 8-54, Pos. 1).

(11)

Taper roller bearing

Direction of rotation:

(12)

Spring

(13)

Slipper pads

(14)

Thrust washer

(15)

Roller bearing

(16)

Circlip

(17)

Sealing flange

(18)

Radial seal ring

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.

Version 2010/1

The main part of the axial forces is supported by the slipper pads (Fig. 8-54, Pos. 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 (Fig. 8-54, Pos. 5).

"Clockwise" = Direction of flow A to B "Counter-clockwise" = Direction of flow B to A with view onto drive shaft! Via the control lens (Fig. 8-54, Pos. 8), the oil is directed to the cylinder bores. The piston (Fig. 8-54, Pos. 5) is moved from the lower (Fig. 8-54, Pos. 6b) to the upper dead point (Fig. 8-54, Pos. 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 (Fig. 8-54, Pos. 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.

8-107


8.3.3

SWING GEARBOX (L&S)

Fig. 8-55

Swing gearbox (L&S)

8-108


Version 2010/1



Drive housing

(2)

Drive shaft

(3)

Sun gear shaft

(4)

Multi-disk brake

(5)

Breather filter Drive shaft housing

(6)

Oil level gauge (dipstick) Drive shaft housing

(7)

Disk brake housing

(8)


(9)

Internal ring gear

(10)


(11)

Bearing ring

(12)

Cartridge

(13)

Spherical roller bearing

(14)

Oil drain plug, gearbox

(15)


(16)

Oil level gauge (dipstick) Gearbox

(17)

First planetary stage

(18)

Drive shaft to second stage

(19)

Second planetary stage

(20)

Radial seal ring

(21)

Drive pinion

(22)

Grease line port

Version 2010/1


The swing gear is of compact design with a two stage planetary gear including a multi-disk brake. The gear is bolted to the superstructure and fits firmly due to the machined diameter (Fig. 8-55, Pos. A) and the bolt torque. The torque loaded on the hydraulic motor is transmitted by drive shafts (Fig. 8-55, Pos. 2) and sun gear shaft (Fig. 8-55, Pos. 3) to the first planetary stage (Fig. 8-55, Pos. 17). The sun shaft of the first planetary stage (Fig. 8-55, Pos. 17) transmits the torque into the second planetary stage (Fig. 8-55, Pos. 19). By the planetary gears, the output drive shaft is rotated and transmits the torque to the pinion (Fig. 8-55, Pos. 21). The drive housing and the gearbox are filled with gear oil. Aeration is done by breather filters. To lubricate the pinion, the grease line port (Fig. 8-55, Pos. 22) is connected to the central lubrication system.

8-109


8.3.4

SWING GEARBOX (SIEBENHAAR)

Fig. 8-56

Swing gearbox (Siebenhaar)

8-110


Version 2010/1



Drive housing

(2)

Drive shaft

(3)

Sun gear shaft

(4)

Multi-disk brake

(5)

Equalizing reservoir

(6)

Oil level gauge (dipstick), gearbox

(7)

Oil level gauge (diptick), parking brake

(8)

Adapter (gearbox / brake housing)

(9)

First planetary stage

(10)

Sun wheel (drive shaft to second stage)

(11)

Annulus gear

(12)

Spherical roller bearing

(13)

Oil drain plug, gearbox

(14)

Bearing center

(15)

Grease line port

(16)


(17)

Drive pinion

(18)

Shaft sealing rings

(19)

Fixed bearing bushing

(20)

Second planetary stage

(21)

Cylindrical roller bearings

(22)

Cylindrical roller bearings

(23)

Oil drain plug, parking brake

(24)

Pressure oil port, parking brake

(25)

Oil drain plug, motor

(26)

Oil filler pipe, gearbox

(27)

Oil level gauge (dipstick), motor

Version 2010/1


The swing gear is of compact design with a two stage planetary gear including a multi-disk brake. The gear is bolted to the superstructure and fits firmly due to the machined diameter (Fig. 8-56, Pos. A) and the bolt torque. The torque loaded on the hydraulic motor is transmitted by drive shaft (Fig. 8-56, Pos. 2) and sun gear shaft (Fig. 8-56, Pos. 3) to the first planetary stage (Fig. 8-56, Pos. 9). Through the pivot carrier of the planetary wheels, the torque is transmitted to sun wheel (Fig. 8-56, Pos. 10) of the second planetary stage (Fig. 8-56, Pos. 20). By the planetary gears of the second stage, the output drive shaft is rotated and transmits the torque to the pinion (Fig. 8-56, Pos. 17). Drive housing, gearbox and brake housing are filled with oil. Aeration is done by breather filters. NOTE: In opposition to the parking brake installed to the L&S swing gear, the SIEBENHAAR slew parking brake is not splash lubricated through gearbox oil. To lubricate the pinion, the grease line port (Fig. 8-56, Pos. 15) is connected to the central lubrication system.

8-111


8.3.5

SLEW PARKING BRAKE (L&S)

Fig. 8-57

Sew parking brake (L&S)

8-112


Version 2010/1




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-ring with back-up rings

(9)

Springs

(10)

Thrust washer

(11)

Circlip

(12)

Drive shaft

(13)

Oil pressure port

The spring loaded multi-disk brake is a safety brake; applied by spring force and released by oil pressure. The slew parking brake is a "wet brake", because the brake housing is splash lubricated by the gearbox oil. Function Brake applied: The outer disks (Fig. 8-57, Pos. 4) engaged to the housing by serration and the inner disks (Fig. 8-57, Pos. 3) in serrated connection with drive shaft (Fig. 8-57, Pos. 12) are pressed together by the springs (Fig. 8-57, Pos. 9). This results in a fixed connection between housing and drive shaft. Brake released: Oil pressure via port (Fig. 8-57, Pos. 13) reaches the bottom of the piston (Fig. 8-57, Pos. 6) and forces the piston upwards against the thrust washer (Fig. 8-57, Pos. 10). This function eliminates the spring force onto the disks so that the sinus (spacing) rings can keep the outer disks (Fig. 8-57, Pos. 4) apart, thus the brake is released. The releasing pressure is 19-20 bar, the maximum permissible pressure 60 bar.

Version 2010/1

8-113


8.3.6

SLEW PARKING BRAKE (SIEBENHAAR)

Fig. 8-58

Slew parking brake (Siebenhaar)

8-114


Version 2010/1



Outer disk (lamella)

(2)

Inner disk (lamella)

(3)

Oil drain plug

(4)

Pressure oil port

(5)

Piston

(6)

Springs

(7)

Ball bearing seal

(8)

Inner piston seal

(9)

Outer piston seal

(10)

Disk housing

(11)

Through-hole for attaching gearbox

(12)

Rotary shaft seal

(13)

Drive shaft


Function Brake applied: The outer disks (Fig. 8-58, Pos. 1) engaged to the housing by serration and the inner disks (Fig. 8-58, Pos. 2) in serrated connection with drive shaft (Fig. 8-58, Pos. 13) are pressed together by the springs (Fig. 8-58, Pos. 6). This results in a fixed connection between housing (Fig. 8-58, Pos. 11) and drive shaft. Brake released: Pressure oil runs through port (Fig. 8-58, Pos. 4) to the chamber between the piston (Fig. 8-58, Pos. 5) and the brake housing ring. The oil moves the piston upwards away from the brake disks (Fig. 8-58, Pos. 1 and 2) when the resulting force exceeds the force of the springs (Fig. 8-58, Pos. 6). When the piston is lifted, the spring force onto the disks is eliminated. The required releasing pressure is 19-20 bar, the maximum permissible pressure 60 bar.

The spring loaded multi-disk brake is a safety brake; applied by spring force and released by oil pressure. The slew parking brake is a "wet brake", because the brake disks are lubricated by the oil filling in the brake housing.

Version 2010/1

8-115


8.3.7

SWING BRAKE VALVE

Fig. 8-59

Swing brake valve

8-116


Version 2010/1




(Fig. 8-59, Pos. 1 or 2) and opens the check valves (Fig. 8-59, Pos. 3 or 4). That means by the check valves (Fig. 8-59, Pos. 3 or 4) the service lines are connected to the pressure increasing valve.

(1)

Anti-carvitation valve circuit A

(2)

Anti-cavitation valve circuit B

(3)

Check valve circuit B

(4)

Check valve circuit A

(5)

Pressure increasing valve (item 6 - 13)

(6)

Pilot pressure piston

(7)

Intermediate piston

(8)

Spring

(9)

Valve poppet

(10)

Jet bore

(11)

Spring of main piston

(12)

Jet bore of main piston plug

(13)

Main piston

Function of the double stage valve

(Y)

Leak oil

When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (Fig. 8-59, Pos. 5) at port "X". The pilot pressure pre-loads these valves.

(T)

Return oil

(A)

Service line from control block

(A’)

Service line to the motor

(B)

Service line from control block

(B’)


Ports:

Pressure test ports: (MA)

Circuit A

(MB)

Circuit B

Function When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives at the pressure increasing valve (Fig. 8-59, Pos. 5) at port "X". The pilot pressure pre-loads these low stages. The oil for the hydraulic motor from the control block arrives at the service line port A or B, depending if a R.H. or a L.H. swing motion is carried out with max. MRV pressure.

Whenever the pressure is higher than the setting of the pressure increasing valve, this valve opens and dumps the oil into the return line (Fig. 8-59, Pos. T) to tank. The pressure can be checked at the test ports MA or MB. If after a swing motion the joystick 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 line, and oil is forced through the anti-cavitation valves into the service line.

By applying pilot pressure via the external port X to piston (Fig. 8-59, Pos. 6), the pre-tensioning of the pressure spring (Fig. 8-59, Pos. 8) 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 (Fig. 8-59, Pos. 13) and via the jet bore (Fig. 8-59, Pos. 12) also in the chamber of the spring (Fig. 8-59, Pos. 11) and via the jet bore (Fig. 8-59, Pos. 10) at the pressure relief valve poppet (Fig. 8-59, Pos. 9). Due to the force balance, the piston (Fig. 8-59, Pos. 13) is kept in its position supported by the spring (Fig. 8-59, Pos. 11). Does the system pressure exceed the setting of the valve (Fig. 8-59, Pos. 9), this valve opens a channel to the dump line port (Fig. 8-59, Pos. Y). Due to the drop of force, the piston (Fig. 8-59, Pos. 13) is moved to the right. The pressure line gets connected with the return line (Fig. 8-59, Pos. T). The shuttle valves 270.1 and 270.2 stabilize the pilot pressure for the double stage valve (lower stage) to avoid pressure sequences when starting swinging.

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, either at port A or B closes the anti-cavitation valves Version 2010/1

8-117



8.3.8

ELECTRIC / HYDRAULIC FLOWCHART "SWING LEFT"

Fig. 8-60

Electric / hydraulic flowchart "swing left"

8-118

Version 2010/1





(20S022)

Control pedal swing brake

(-X)


(-10V)


(11X_…)


(11T050 / 50a / 50b)

Ramp time modules

(11T007)

Amplifier module – swing (61K565 + 61K524 / 61K525 - Block III)

(11T007a)

Amplifier module – swing (61K566 + 61K526 / 61K527 - Block I)

(11T016)

Amplifier module – swing brake

(11K080)

Relay - Contacts 7/11 only closed while rotating with swing speed switch 20S154 activated and not lifting the boom.

(11Q190)

Relay - Swing brake without ramp time - Contacts 5/9 and 6/10 only closed while using the brake pedal

(14.1 + 14.2)


(61K565 + 61K566)


(61K524 + 61K526)


(61QK627)


(I + III)

Main control blocks I + III

(16.2)


(61.1 + 61.2)

Swing brake valve block

(DSV)

Double stage valve

(60.1 + 60.2)

Swing motor

(270.1 + 270.2)

Shuttle valve

The electrical signal Signal voltage of joystick (Fig. 8-60, Pos. 20S020) arrives via ramp time modules (Fig. 8-60, Pos. 11T050/a) at terminal 5 of the amplifier modules (Fig. 8-60, Pos. 11T007 + 11T007a) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-60, Pos. 14.1 + 14.2). Simultaneously, signal voltage arrives via ramp time modules (Fig. 8-60, Pos. 11T050b) at terminal 5 of the amplifier modules (Fig. 8-60, Pos. 11T016) and further to the proportional valve (Fig. 8-60, Pos. 57Q627). Pilot pressure When the proportional and directional solenoid valves are energized, pilot pressure oil flows to the pressure ports of the main control blocks and to the double stage valves (Fig. 8-60, Pos. DSV). Main hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (Fig. 8-60, Pos. I + III) and arrives via swing brake valves (Fig. 8-60, Pos. 61.1 + 61.2) at the swing motors (Fig. 8-60, Pos. 60.1 + 60.2).

Version 2010/1

8-119



8.3.9

ELECTRIC / HYDRAULIC FLOWCHART "SWING RIGHT"

Fig. 8-61

Electric / hydraulic flowchart "swing right"

8-120

Version 2010/1





(20S022)

Control pedal swing brake

(+X)


(+10V)


(11X_…)


(11T050 / 50a / 50b)

Ramp time modules

(11T007)

Amplifier module – swing (61K565 + 61K524/61K525 - Block III)

(11T007a)

Amplifier module – swing (61K566 + 61K526/61K527 - Block I)

(11T016)

Amplifier module – swing brake

(11K080)

Relay – Contacts 7/11 only closed while rotating with swing speed switch 20S154 activated and not lifting the boom.

(11Q190)

Relay – Swing brake without ramp time – Contacts 5/9 and 6/10 only closed while using the brake pedal

(14.1 + 14.2)


(61K565 + 61K566)


(61K524 + 61K526)


(57Q627)


(I + III)

Main control blocks I + III

(16.1)


(61.1 + 61.2)

Swing brake valve block

(DSV)

Double stage valve

(60.1 + 60.2)

Swing motor

(270.1 + 270.2)

Shuttle valve

The electrical signal Signal voltage of joystick (Fig. 8-61, Pos. 20S020) arrives via ramp time modules (Fig. 8-61, Pos. 11T0E50,-a) at terminal 5 of the amplifier modules (Fig. 8-61, Pos. 11T007 + 11T007a) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-61, Pos. 14.1 + 14.2). Simultaneously, signal voltage arrives via ramp time modules (Fig. 8-61, Pos. 11T050b) at terminal 5 of the amplifier modules (Fig. 8-61, Pos. 11T016) and further to the proportional valve (Fig. 8-61, Pos. 57Q627). Pilot pressure When the proportional and directional solenoid valves are energized, pilot pressure oil flows to the pressure ports of the main control blocks and to the double stage valves (Fig. 8-61, Pos. DSV). Main hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (Fig. 8-61, Pos. I + III) and arrives via swing brake valves (Fig. 8-61, Pos. 61.1 + 61.2) at the swing motors (Fig. 8-61, Pos. 60.1 + 60.2).

Version 2010/1

8-121



8.3.10

CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT

Fig. 8-62

Checks and adjustments for the swing circuit

8-122

Version 2010/1


Legend for Fig. 8-62: (M33)

Test port – pressure increasing valve

(M41)

"X1" pressure – fixed pump No. 3 (X1 = 45 bar)

(M42)

"X1" pressure – fixed pump No. 1 (X1 = 45 bar)

(M32)

Reduced "X3" pressure – to pump No. 1

(255.4)

Pressure reducing valve – reduced "X3" pressure (½ Qmax)

(57K626)

Solenoid valve – flow reduction (pump No. 1)

(57K630)

Solenoid valve – fixed pump (pump No. 1)

(57K631)

Solenoid valve – fixed pump (pump No. 3)


4. Read pressure while swinging. Required values at 5 turns: 20S154 = ON (fast)

20S154 = OFF (slow)

M33 = 15 bar

M33 = 45 bar

M41 = 45 bar

M41 = 45 bar

M42 = 45 bar

M42 = 34 bar

time = 75–80 sec

time = 150–160 sec

WARNING WARNING Do not exceed the maximum permissible swing speed of 5 turns within 75 sec.

NOTE: Note down the pressures and speeds in sec. as reference values. If adjustment is necessary:

1. Connect pressure gauges to test ports M33, M41 and M42. 2. Start the engine and let it run at high idle. 3. Move the control lever (Fig. 8-63, Pos. 20S020) to the end position (L.H. or R.H.) with activated and deactivated swing speed switch (Fig. 8-63, Pos. 20S154). Swing 5 turns and start counting the time in seconds .

5. Loosen lock nut (Fig. 8-62, Pos. 2). 6. Adjust the pressure with set-screw (Fig. 8-62, Pos. 1). 7. Tighten lock nut and remove the gauges.

Fig. 8-63 Version 2010/1

8-123


Fig. 8-64

8-124



Version 2010/1



NOTE: It is important that the complete MRV and the double stage valve is firmly tightened (with 300 Nm). Otherwise, internal leaks could occur which result in: problems of incorrect adjustment, loud flow noises, abnormal swing movements and high temperatures. NOTE: Whenever pressure checks are carried out, they must be carried out for both, R.H. and L.H. swinging to make sure the shuttle valves in the control lines and the check valves in the brake valve blocks are in good condition. NOTE: Because the swing motors are working hydraulically in combined operation, the pressure gauge shows the pressure of the double stage valve with the lowest setting. Even if 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 valve in the same manner. High pressure check / adjustment 1. Connect gauges to test ports M11 and M14 at the high pressure filters. 2. Disconnect the pilot pressure lines from the double stage valve and close the lines with a suitable plug (Fig 8-64, Pos. 6). 3. Loosen lock nut (Fig. 8-64, Pos. 3) of both double stage valves (DSV) and screw in set-screw (Fig. 8-64, Pos. 4) until piston (Fig. 8-64, Pos. 5) comes to stop. 4. Start the engine and let it run at high idle. 5. Lower attachment to ground and apply the slew parking brake with switch 20S029. 6. Adjust the MRVs to ~350 bar. 7. Actuate either L.H. or R.H. rotation (20S154 ON) until the hydraulic system stalls. Read the pressure, required = 330±5 bar. 8. If the gauge shows a lower or higher value, the valves must be adjusted: z

Loosen lock nut (Fig. 8-64, Pos. 1) of the second stage (330 bar) of the DSV.

z

Adjust pressure with set-screw (Fig. 8-64, Pos. 2) to ~340 bar. If the pressure can not be raised, turn set-screw (Fig. 8-64, Pos. 2) of the second DSV a ¼ turn (cw.) further in.

z

Secure by tightening lock nut (Fig. 8-64, Pos. 1).

z

Reduce the pressure with set-screw (Fig. 8-64, Pos. 2) to a value of ~320 bar, and then raise the pressure up to the required value of 330 bar.

z

Secure adjusted set-screw (Fig. 8-64, Pos. 2) by tightening lock nut (Fig. 8-64, Pos. 1).

z

Reduce the pressure with set-screw (Fig. 8-64, Pos. 2) of the first DSV to a value of ~320 bar, and then raise the pressure up to the required value of 330 bar.

z


Version 2010/1

8-125



Ho

Fig. 8-65

8-126


Version 2010/1



Low pressure check / adjustment (swing brake pedal with pilot pressure line still disconnected) 9. Actuate either L.H. or R.H. rotation (20S154 ON) until the hydraulic system stalls. z

Loosen lock nut (Fig. 8-65, Pos. 3) of both DSVs and reduce the pressure equally with set-screws (Fig. 8-65, Pos. 4) to a value of 130±5 bar, secure setting with lock nut (Fig. 8-65, Pos. 3).

z

Loosen lock nut (Fig. 8-65, Pos. 3) of the first DSV.

z

Reduce the pressure with set-screw (Fig. 8-65, Pos. 4) of the first DSV to a value of about 110 bar, and then raise up to the required pressure of 130±5 bar.

z


z

Loosen lock nut (Fig. 8-65, Pos. 3) of the second DSV.

z

Reduce the pressure with set-screw (Fig. 8-65, Pos. 4) of the second DSV to a value of about 110 bar, and then raise up to the required pressure of 130±5 bar.

z


10. Re-plug and connect the pilot pressure lines. 11. Re-set MRVs to 310+5 bar and remove the gauges after the check / adjustment is finished.

WARNING Strong pulsation of the return line hoses indicates deviation in opening pressure of DSVs and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via both double stage valves.

Brake pilot pressure – check / adjustment 1. Connect the gauge to test port M27. 2. Start the engine and let it run at high idle. 3. Press down the swing brake pedal (20S022) fully and read the pressure. The pressure must be 24±1 bar. If adjustment is required: 4. Adjust the output (mA) of the amplifier (11T016) with potentiometer R2 until the pressure of 24±1 bar is reached. NOTE: For basic values for the amplifiers, refer to the electric circuit diagram of your shovel.

Version 2010/1

8-127



8.3.11

FUNCTION CHECK FOR THE HYDRAULIC SWING BRAKE

Fig. 8-66

Function check for hydraulic swing brake

8-128

Version 2010/1



Legend for Fig. 8-66: (M39)

Test port

(20S022)

Switch – position of acces ladder

(20S105)

Switch – lock lever

(57K620)

Solenoid valve – hydraulic swing brake ON - OFF

(57Q627)

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 upper position and/or if the lock lever is not in the lower end position. Brake apply pressure 1. Connect a gauge to test port M39 (Fig. 8-66). 2. Start the engine and let it run at high idle. 3. Lift the access ladder to the upper end position. 4. Check the pressure at test port M39 under the following conditons: z

Lock lever in lower end position and ladder completely up. No message should appear on the monitor.

0 bar => released.

z

Lock lever in lower end position and ladder completely down. Message G00091 "Pilot control cut out" should appear.

45 bar => applied.

z

Lock lever in upper end position and ladder completely up. Message G00091 "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 a counter action of the joystick is required. As a result, proportional valve 57Q627 will vary the pilot pressure at the double stage valves (DSV) in relation to the lever deflection. 5. Apply the slew parking brake. Therefore, move switch (Fig. 8-68, Pos. 20S029) into 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. NOTE: In case of malfunction, check the electrical control system and the function of solenoid valve 57K6120 and/or 57Q627.

Version 2010/1

8-129



8.3.12

FUNCTION CHECK FOR THE SLEW PARKING BRAKE

Fig. 8-67

Function check for the slew parking brake

8-130

Version 2010/1


Legend for Fig. 8-67: (20P047)

Monitor MH 801

(M1.2)

Pressure test port (X2 – pilot pressure)

(57Q505)

Solenoid valve – slew parking brake ON - OFF

(252.1)


Parking brake release pressure 1. Connect gauge to test port (Fig. 8-67, Pos. M1.2). 2. Start engine, let it run at high idle and read the pressure. Required = 45±1 bar. If not, the pilot pressure adjustment must be corrected (refer to section 5.3.2 on page 5-36). 3. Apply the slew parking brake. Therefore, move switch (Fig. 8-68, Pos. 20S029) into position "1", now the following message G00247 should appear:


4. Actuate either L.H. or R.H. swinging, the machine should not turn.

WARNING WARNING If the machine turns, the parking brakes must be repaired.

5. Release the slew parking brake. Therefore, move switch (Fig. 8-68, Pos. 20S029) into position "0"; now the swing function must be executable again, and message G00247 should disappear from the monitor. NOTE: In case of malfunction, check the electrical control system and the function of solenoid valve 57Q505. Function check of relays 56K250a & b 1. Connect a pressure gauge to test port (Fig. 8-67, Pos. M5).

z

Slew ring gear house brake

2. Start the engine and let it run at high idle. Pilot pressure X2 = 45±1 bar.

z

Instruction message 26: Slew ring gear house brake ON

3. Move switch position "0".

(Fig. 8-68,

Pos. 20S029)

into

4. Unplug / reconnect solenoid valve 57Q505 to allow pressure relief / increase from pilot pressure line to slew parking brake. 5. Select the "Real Time Monitor Menu" at the monitor and check whether the signal of 57Q505 has changed from "1" to "0". NOTE: 20S029 in position "0" Ö 57Q505= 1 = 45 bar Ö at Real Time Monitor 56K250a = 1 and 56K250b = 1 Ö Slew parking brake OFF 20S029 in position "1" Ö 57Q505= 0 = 0 bar Ö at Real Time Monitor 56K250a = 0 and 56K250b = 0 Ö Slew parking brake ON

Fig. 8-68

Version 2010/1

8-131

Hydraulics for the travel circuit


8.4

HYDRAULICS FOR THE TRAVEL CIRCUIT

8.4.1

TRAVEL CIRCUIT

Fig. 8-69

Travel circuit

8-132

Version 2010/1



Main pumps

(II + IV)

Control blocks

(15.1 + 15.2)


(19)

Rotary distributor

(21.1 + 21.2)

Travel motors

(41)

Main oil reservoir

(55)

Back pressure valve

(56.1 + 56.2)

Travel brake valves

(57.1 + 57.2)

Travel parking (house) brakes

(M4)

Pressure test port for parking brake release pressure

(57Q516)

Solenoid valve for travel parking brake

(L9)

Case drain (leak oil) line

(St)

Pilot pressure line to the travel parking brake


Description (control circuits) (Also use the hydraulic and electric circuit diagram). When the pedals 20S021a and 20S021b are moved out of their neutral position, the proportional solenoid valves 61K567 & 61K570 and the directional solenoid valves 61K528 or 61K529 (R.H. crawler) and 61K534 or 61K535 (L.H. crawler) are energized simultaneously.

Fig. 8-70

Version 2010/1

(20S021a) Control pedal – left track

A – forward => 61K570 + 61K535

(20S021b) Control pedal – right track

A – forward => 61K567 +61K528

B – reverse => 61K570 + 61K534

B – reverse => 61K567 +61K529

8-133


Fig. 8-71

8-134


Travel circuit

Version 2010/1



Description (Also use the hydraulic and electric circuit diagram.) The travel motors (Fig. 8-71, Po. 21.1 and 21.2) are driven by the pumps (Fig. 8-71, Pos. 2 and 4). The oil flows from the pumps through the high pressure filters to the control blocks (Fig. 8-71, Pos. II and IV). In neutral position of the spools the oil flows via the return oil lines into the return manifold (107) and further via the return oil lines (L6 and L7) into the collector pipe (54), and further through the filter back to the tank. On its way to the tank the oil must flow through the back pressure valve (Fig. 8-71, Pos. 55) and the return oil filter (59.1 - 59.4). (For back pressure valve function refer to section 4.2 on page 4-4.) 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 (Fig. 8-71, Pos. 19) and travel brake valves (Fig. 8-71, Pos. 56.1 and 56.2) to the travel motors (Fig. 8-71, Pos. 21.1 and 21.2). 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 brake (house brakes 57.1 and 57.2). They are used as parking brakes, automatically applied by the function of 57Q516 whenever the engine is switched OFF, or the ladder or the refilling arm is in bottom position. The leak oil (case drain) flows through the line (Fig. 8-71, Pos. L9) and the leak oil filter (53) back to the tank.

Version 2010/1

8-135


8.4.2

TRAVEL MOTOR

Fig. 8-72

Travel motor

8-136


Version 2010/1




Function The pressure oil inlet (Fig. 8-72, Pos. A or B) and consequent oil outlet (Fig. 8-72, Pos. B or A) determine the output drive direction of the drive shaft (Fig. 8-72, Pos. 1).

(1)

Drive shaft

(2)

Housing

(3)

Case drain port

(4)

Retaining plate

(5)

Piston

"Clockwise"

= Direction of flow A to B

(5a)

Pivot (center) pin

"Counter-clockwise"

= Direction of flow B to A

(6a)

Upper dead point

(6b)

Lower dead point

(7)

Cylinder

(8)

Control lens

(9)

End plate

(10)

Taper roller bearing

(11)

Roller bearing

(12)

Thrust washer

(13)

Circlip

(14)

Circlip

(15)

Sealing flange

(16)

Radial seal ring

Direction of rotation:

with view onto drive shaft! Via the control lens (Fig. 8-72, Pos. 8), the oil is directed to the cylinder bores. The piston (Fig. 8-72, Pos. 5) is moved from the lower (Fig. 8-72, Pos. 6b) to the upper point (Fig. 8-72, Pos. 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 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 are interchanged, the output drive direction of the drive shaft is changed. By means of the angled arrangement of the cylinder (Fig. 8-72, Pos. 7) (bent axis design), a certain piston stroke is produced which results in a fixed displacement per revolution of the drive shaft.

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.

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.

The output torque increases with the pressure drop between high and low pressure side. The motor converts hydrostatic energy into mechanical energy.

Version 2010/1

8-137


8.4.3

ROTARY JOINT

Fig. 8-73

Rotary joint

8-138


Version 2010/1



Rotor

(2)

Rotary distributor housing

(3)

Cover

(4)

Bearing ring (splitted)

(5)

Sealing element

(6)

Seal

(7)

Rotor guide rings

(8)

O-ring

(9)

Plug screws

(10)

Mover

Ports: (A - D)

Service lines

(K1 / K2)

Control oil track tensioning

(L)

Leak oil

(ST)

Control oil

(T)

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 (Fig. 8-73, Pos. A - D) of the housing (Fig. 8-73, Pos. 2). The oil flows to the outlet ports (Fig. 8-73, Pos. A - D), of the rotor (Fig. 8-73, Pos. 1), 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 (Fig. 8-73, Pos. 5). The hydraulic connection for case drain, house brake and the track tensioning cylinders is done via the ports (Fig. 8-73, Pos. L, St, K1 and K2). Entering of dirt is prevented by the seal ring (Fig. 8-73, Pos. 6) and the collar of the cover (Fig. 8-73, Pos. 3). The rotor (Fig. 8-73, Pos. 1) is at the top and bottom section guided in the housing by the guide rings (Fig. 8-73, Pos. 7).

The letters punch marked, beside the ports are marked as they are used in the hydraulic diagram. Task The rotary distributor (joint) permits a hydraulic connection between the superstructure and the undercarriage, that means between the rotating and the stationary part.

Version 2010/1

8-139


8.4.4

TRAVEL GEARBOX (L&S)

Fig. 8-74

Travel gearbox (L&S)

8-140


Version 2010/1




Input drive shaft

(2)

Spur gear

(3)

Sun gear first stage

(4)

Planetary ring gear first stage

(5)

Planetary carrier first stage

(6)

Planetary ring gear second stage

(7)

Sun gear second stage

(8)

Planetary carrier second stage

(9)

Side frame mounting flange

(10)

Motor adapter and brake housing

(11)

Multi-disk house brake

The travel gear consists of one spur gear set and two planetary stages. The travel gearbox is fitted to the side frame with bolts. Function The spur gear (Fig. 8-74, Pos. 2) is driven by a hydraulic motor and the input drive shaft (Fig. 8-74, Pos. 1). The planetary carrier (Fig. 8-74, Pos. 5) of the fist stage is driven by the sun gear (Fig. 8-74, Pos. 3) which is connected to the spur gear (Fig. 8-74, Pos. 2). The planetary gears are revolving in the planetary ring gear of the housing. As a result of the fixed housing, the planetary carrier will be turned. The planetary carrier (Fig. 8-74, Pos. 8) of the second stage is turned by the sun gear (Fig. 8-74, Pos. 7) which is connected to the sprocket drive shaft.

Version 2010/1

8-141


8.4.5

TRAVEL GEARBOX (ZOLLERN)

Fig. 8-75

Travel gearbox (Zollern)

8-142


Version 2010/1




Input drive shaft

(2)

Parking brake housing

(3)

Motor adapter

(4)

Spur gear

(5)

Sun gear, first stage

(6)

Planetary ring gear, first stage

(7)

Planetary carrier, first stage

(8)

Planetary ring gear, second stage

(9)

Sun gear, second stage

(10)

Planetary carrier, second stage

(11)

Side frame mounting flange

The travel gear consists of one spur gear set and two planetary stages. The travel gearbox is fitted to the side frame with bolts. Function The spur gear (Fig. 8-75, Pos. 4) is driven by a hydraulic motor connected to the input drive shaft (Fig. 8-75, Pos. 1) by means of the hollow shaft ot the parking brake (Fig. 8-75, Pos. 2) . The planetary carrier (Fig. 8-75, Pos. 7) of the first stage is driven by the sun gear (Fig. 8-75, Pos. 5) which is connected to the spur gear (Fig. 8-75, Pos. 4). The planetary gears are revolving in the planetary ring gear (Fig. 8-75, Pos. 6) of the housing. As a result of the fixed housing, the planetary carrier (Fig. 8-75, Pos. 7) will be turned. The planetary carrier of the first stage propels the sun gear (Fig. 8-75, Pos. 9) of the second stage. Like in the first stage, the planetary gears are revolving in a planetary ring gear (Fig. 8-75, Pos. 8) of the housing. The planetary carrier of the second stage (Fig. 8-75, Pos. 10) simultaneously acts as the sprocket drive hub.

Version 2010/1

8-143



8.4.6

TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)

Fig. 8-76

Travel parking brake (gear house brake) ZOLLERN (exemplarily)

8-144

Version 2010/1



Outer disk carrier (brake housing)

(2)

Intermediate ring (hydraulic unit with piston)

(3)

Seals

(4)

Piston

(5)

Pressure oil port

(6)

Motor flange

(7)

Compression spring

(8)

Travel gear housing

(9)

Inner disk carrier / drive sleeve

(10)

Inner brake disk

(11)

Outer brake disk

The spring loaded multi-disk brake is a safety brake; applied by spring force and released by oil pressure.


Function Brake applied: By means of toothings, the outer disks (Fig. 8-76, Pos. 11) are engaged to the housing (Fig. 8-76, Pos. 1), the inner disks (Fig. 8-76, Pos. 10) to the disk carrier / drive sleeve (Fig. 8-76, Pos. 9). Inner and outer disks are pressed together by the piston (Fig. 8-76, Pos. 4) with the force of the springs (Fig. 8-76, Pos. 7). This results in a fixed connection between housing and inner disk carrier / drive sleeve (Fig. 8-76, Pos. 11). Brake released: Pressure oil runs through port (Fig. 8-76, Pos. 5) to the chamber between intermediate ring (Fig. 8-76, Pos. 2) and piston (Fig. 8-76, Pos. 4). When the resulting force of the oil pressure exceeds the force of the compression springs, the piston is moved away form the brake disks to the motor flange. Now the disk are not longer pressed against each other, the brake is released. The minimum releasing pressure is 19-20 bar, the maximum permissible pressure 60 bar. The ZOLLERN parking brake is a "dry brake", no oil is permissible in the housing / on the brake disks.

WARNING WARNING The parking brake in the L&S gearbox has a similar design, but is a so called "wet brake" with an oil filling in the brake housing.

NOTE: For more information refer to the OPERATION AND MAINTENANCE MANUAL of the corresponding machine.

Version 2010/1

8-145


8.4.7

TRAVEL BRAKE VALVE

Fig. 8-77

Travel brake valve

8-146


Version 2010/1



Task Travel brake valves control the oil flow from the hydraulic motor to the tank depending on the operating pressure. This braking action prevents the motors from overspeeding and cavitation. 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 and from B to B1 respectively, depending on the selected travel motion. Example Operating pressure at port A moves the spool (Fig. 8-77, Pos. 1) against the force of the spring (Fig. 8-77, Pos. 2) and opens the way for the return oil (Fig. 8-77, Pos. B1 to B). The check valve (Fig. 8-77, Pos. 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 the travel motion of the machine.

Version 2010/1

8-147



8.4.8

ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL FORWARD”

Fig. 8-78

Electric / hydraulic flowchart “travel forward”

8-148

Version 2010/1



Legend for Fig. 8-78: (20S021a)

Foot pedal left crawler

(20S021b)

Foot pedal right crawler

(+10V)


(11X_…)


(11T051) (11T052)

Ramp time module

(11T012)

Amplifier module – left crawler

(11T013)

Amplifier module – right crawler

(15.1 + 15.2)


(61K567) (61K570)


(61K528) (61K535)


(II + IV)

Main control blocks

(19)

Rotary joint

(21.1 + 21.2)

Hydraulic motors

(56.1 + 56.2)

Travel brake valves

Electrical signal flow The signal voltage of the foot pedals (Fig. 8-78, Pos. 20S021a + 20S021b) arrives via ramp time module (Fig. 8-78, Pos. 11T051 + 11T052) at terminal 5 of the amplifier modules (Fig. 8-78, Pos. 11T012 and 11T013) and runs further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-78, Pos. 15.1 and 15.2). 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 according to the amplifier output signal [mA]. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (Fig. 8-78, Pos. II and IV) and arrives via rotary joint (Fig. 8-78, Pos. 19) and travel brake valves (Fig. 8-78, Pos. 56.1 and 56.2) at the hydraulic travel motors.

Version 2010/1

8-149



8.4.9

ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL BACKWARDS”

Fig. 8-79

Electric / hydraulic flowchart “travel backwards”

8-150

Version 2010/1



Legend for Fig. 8-79: (20S021a)

Foot pedal left crawler

(20S021b)

Foot pedal right crawler

(-10V)


(11X_…)


(11T051) (11T052)

Ramp time module

(11T012)

Amplifier module – left crawler

(11T013)

Amplifier module – right crawler

(15.1 + 15.2)


(61K567) (61K570)


(61K529) (61K534)


(II + IV)

Main control blocks

(19)

Rotary joint

(21.1 + 21.2)

Hydraulic motors

(56.1 + 56.2)

Travel brake valves

Electrical signal flow The signal voltage of the foot pedals (Fig. 8-79, Pos. 20S021a + 20S021b) arrives via ramp time module (Fig. 8-79, Pos. 11T051 + 11T052) at terminal 5 of the amplifier modules (Fig. 8-79, Pos. 11T012 and 11T013) and runs further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-79, Pos. 15.1 and 15.2). 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. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (Fig. 8-79, Pos. II and IV) and arrives via rotary joint (Fig. 8-79, Pos. 19) and travel brake valves (Fig. 8-79, Pos. 56.1 and 56.2) at the hydraulic travel motors.

Version 2010/1

8-151



8.4.10

CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT

Fig. 8-80

Checks and adjustments for the travel circuit

8-152

Version 2010/1




Adjusting the SRVs: 1. Set the MRVs to 310+5 bar.

(1)

Protective cap

(2)

Lock nut

(3)

Set-screw

(19)

Rotary joint

(56.1 + 56.2)

Travel brake valves

(68.3 + 68.4)

Anti-cavitation valves L.H.

3. Lower the pressure at the required SRV to 290 bar, and then increase it up to the required pressure of 310 bar. Proceed with next valves in the same manner.

(68.3 + 68.4)

Anti-cavitation valves R.H.

4. Replug solenoid valve 57Q516.

(M12 – M28.4)

Pressure test ports

2. Carefully engage the desired travel motion and keep the pedal in final position to built up max. pressure.

How to adjust MRVs and SRVs:

Pressure check of the secondary relief valves (SRV)

1. Remove protective cap (Fig. 8-80, Pos. 1) and loosen lock nut (Fig. 8-80, Pos. 2).

1. Connect pressure gauge to the required test ports:

2. Adjust pressure with set-screw (Fig. 8-80, Pos. 3).

z

z

L.H. track M12 = Operating pressure for the L.H. motor M28.1 = SRV pressure L.H., travel forward M28.2 = SRV pressure L.H., travel backward R.H. track M13 = Operating pressure for the R.H.-motor M28.3 = SRV pressure R.H., travel forward M28.4 = SRV pressure R.H., travel backward

2. Unplug solenoid valve 57Q516 (located at the valve cartridge block) to keep the parking brake applied.

3. Secure the adjustment by tightening lock nut (Fig. 8-80, Pos. 2) and replace cap (Fig. 8-80, Pos. 1). 4. Re-check pressure setting. NOTE: It is important that the complete MRV valve and the SRV valve is firmly tightened (with 300 Nm). Otherwise internal leaks could occur, which result in: problems of correct adjustment, loud flow noises and hydraulic temperatures higher than normal.

3. Start the engine and let it run at high idle. 4. Carefully engage the desired travel motion and keep the pedal in final position to built up max. pressure. 5. Slowly increase the MRV pressure while observing the pressure gauge. The displayed value must remain at 310+5 bar. If the gauge shows a smaller or greater value, the SRV must be adjusted. NOTE: A faulty anti-cavitation valve (Fig. 8-80, Pos. 68.3 + 68.4, 68.6 + 68.7) or a leaking seal of the rotary joint (Fig. 8-80, Pos. 19) can influence the SRV pressure reading / setting. Repair or replace faulty parts, if necessary.

Version 2010/1

8-153



8.4.11

FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE

Fig. 8-81

Function check for the travel parking brake

8-154

Version 2010/1



Legend for Fig. 8-81: (252.1)


(20P047)

Monitor MH 801

(M1.2 – M4)

Pressure test ports

(57Q516)

Solenoid valve

Travel parking brake release pressure 1. Connect a pressure gauge to test port (M1.2). 2. Start the engine and let it run at high idle. 3. Read the pressure (required = 45±1 bar). If differing from the nominal value, the pilot pressure adjustment must be corrected (refer to section 5.3 on page 5-32). 4. Disconnect solenoid valve 57Q516. Now the following message should appear over 56K251a/b: z

G00175 "Trouble travel gear house brake"

5. Operate the travel pedals; the machine should not travel.

WARNING If the machine moves, the travel parking brake is defective and must be repaired.

6. Replug solenoid valve 57Q516. Now the trouble message should disappear and travelling should be possible again. NOTE: In case of malfunction check the electrical control system and the function of the solenoid valve 57Q516. NOTE: If the signals for 56K251a/b on the Real Time Monitor screen show "1", the travel parking brake should be released by the pressurized oil: Real Time Monitor "0" Ù Travel parking brake applied (ON) Real Time Monitor "1" Ù Travel parking brake released (OFF)

Version 2010/1

8-155


8-156


Version 2010/1

HYDRAULIC TRACK TENSIONING SYSTEM

9. HYDRAULIC TRACK TENSIONING SYSTEM

Version 2010/1

9-1

General


9.1

GENERAL

Fig. 9-1

Overall view of the hydraulic track tensioning system

9-2

Version 2010/1


General


Rotary joint

(62.1)

Shut-off cock at the track tensioning valve block (130)

(62.2)

Service / transport shut-off cock for L.H. side

*("O" = open / "C" = closed)

(62.3)

Service / transport shut-off cock for R.H. side

*("O" = open / "C" = closed)

(82.1 + 82.2)

Bladder accumulator, 5 liters (pre-charge gas pressure: 150 bar)

(83.1 – 83.4)

Track tensioning cylinders

(89.1 + 89.2)

Membrane accumulator, 0,7 liter (pre-charge gas pressure: 31 bar)

(130)

Track tensioning valve block

(L11)

Supply line (travel parking brake circuit)

(M29.1 + M29.5)

Bleeder and hydraulic pressure test ports at the tensioning cylinders, L.H. side

(M29.2 + M29.6)

Bleeder and hydraulic pressure test ports at the tensioning cylinders, R.H. side

(M29.3)

Bleeder and hydraulic pressure test port at the bladder accumulator (82.1), L.H.-side.

(M29.4)

Bleeder and hydraulic pressure test port at the bladder accumulator (82.2), R.H.-side.

General information The hydraulic track tensioning system automatically ensures the correct tension of the tracks. The track tensioning pressure (35 bar) provides the force to move the guide wheels to the front until the correct track tension is obained. The track safety function is controlled by valve block 130 with a double stage valve (35/310 bar). Pressure peaks due to external forces acting on the idlers will be absorbed by means of the pressure accumulators of the first (31 bar / 89.1 + 89.2) and second stage (150 bar / 82.1 + 82.2). Heavy shocks and high pressure peaks will be eliminated by the double stage valve of the 310 bar section in the valve block (130).

CAUTION After the assembly and during comissioning, before the shovel moves for the first time, each track tensioning cylinder has to be bled via the test ports (29.1 / 29.2 / 29.5 / 29.6) until air-free oil is draining off.

CAUTION Under normal operating conditions, the shut-off cocks (62.2 & 62.3) inside the side frames must always be open. Only for service or repair reasons, the cocks may be shut.

CAUTION The accumulators (89.1, 89.2, 82.1, 82.2) are to be maintained frequently (every 3000 hours) because of the gas pressure charge. See KMG tool catalogue for the charging tool box. After 30,000 hours, the accumulators are to be replaced by new ones.

Version 2010/1

9-3

Functional description

9.2

FUNCTIONAL DESCRIPTION

Fig. 9-2

Circuit diagram of the hydraulic track tensioning system

9-4


Version 2010/1


Functional description

X2 pressure (45 bar) is supplied by the travel parking brake circuit via valve 57Q516 in case the access ladder and the refilling arm are in upper end position. The pressure for the track tensioning system is limited to 35 bar by the pressure reducing valve (47) with a built-in non-return valve to prevent high pressure peaks in the pilot pressure circuit. When the tensioning cylinders (83.1 – 83.4) are moved in by external forces, the non-return valves (137.1 & 137.2) will be closed. A certain amount of the displaced oil from 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 membrane accumulators (89.1 & 89.2) mounted at the side frames. Second stage: At a pressure higher than 150 bar, oil is taken up by the bladder accumulators (82.1 & 82.2) in the middle of the car body. The system pressure can rise up to 310 bar according to the setting of the double stage valve (140) inside the valve block (130). When the external forces fall below the forces of the track tensioning cylinders, the oil taken up by the accumulators is pushed back into the track tensioning cylinders (83.1 – 83.4). If not the whole amount of oil could be taken up the accumulators beforehand, oil is added from the pilot pressure circuit (35 bar) when the tensioning cylinders move in their initial position.

Version 2010/1

9-5



9.3

PRESSURE DOUBLE STAGE VALVE

Fig. 9-3


9-6

Version 2010/1




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 (35 bar)

(8)

Set screw – high pressure (310 bar)

(9)

Piston

(10)

Pin

(11 + 12)

Jet bore

(13 +14)

Lock nut

Description The pressure double stage valve is a remote controlled secondary relief valve at 310 bar. Function The valve poppet (Fig. 9-3, Pos. 2) is connected to port "P" via jet bores (Fig. 9-3, Pos. 11 and 12). If static pressure increases above the set pressure value, the valve poppet (Fig. 9-3, Pos. 2) opens and allows the oil to flow freely to the tank (Fig. 9-3, Pos. T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (Fig. 9-3, Pos. 6) is cancelled, and the main piston (Fig. 9-3, Pos. 5) opens to allow the oil flow to the tank (Fig. 9-3, Pos. T2).

Version 2010/1

9-7

Tensioning cylinder

9.4

TENSIONING CYLINDER

Fig. 9-4

Tensioning cylinder

9-8


Version 2010/1


Tensioning cylinder


Cylinder tube

(2)

Piston

(3)

Piston guide ring

(4)

Piston guide strap

(5)

Seal ring

(6)

O-ring

(7)

Scraper

(8)

Retracting device

(M)

Bleeder port

(P)

Oil supply

Version 2010/1

9-9

Adjustments / checks

9.5

ADJUSTMENTS / CHECKS

Fig. 9-5

Adjustments / checks on hydraulic track tensioning system

9-10


Version 2010/1





(57Q516)

Solenoid valve – travel parking brake

(257.1)

Safety relief valve (SRV) – safety valve for travel parking brake / track tensioning system (55 bar)

(M4)

Test port – travel parking brake operating pressure (35 bar)

Basic check 1. Connect a pressure gauge to test port M4. 2. Start the engine and let it run at high idle. 3. Ensure that the access ladder and the refilling arm are in the upper end position (as the pre-condition for releasing the travel parking brake). 4. Read the pressure (nominal value: 55 bar). 5. Stop the engine. 6. The pressure should now drop to 0 bar because solenoid valve is de-energized, allowing the oil to flow back to the tank. 7. Disconnect the pressure gauge. NOTE: If the pressure reading differs substantially from the nominal value, the pre-set pressure reducing valve is presumably defective and should be replaced.

Version 2010/1

9-11


9-12


Version 2010/1

ACCESS LADDER, HYDRAULICALLY OPERATED

10. ACCESS LADDER, HYDRAULICALLY OPERATED

Version 2010/1

10-1

General


10.1

GENERAL

Fig. 10-1

Overall view of the hydraulic access ladder

10-2

Version 2010/1


General

Legend for Fig. 10-1: (A)

Access ladder in upper position (working position)

(B)

Access ladder in lowered position

(1)

Stop bar

(2)

Pull chain for emergency lowering of the access ladder

(3)

Hydraulic cylinder

(70B091)

Monitor and control sensor This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (70B122) fails to function properly, the sensor (70B091) prevents unintended movement of the ladder.

(70B122)

Safety sensor, located on ladder pivot bracket Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position.

(70S084)

Ladder control switch for lowering and lifting the ladder

(70S084a)

Safety switch for emergency lowering of the access ladder. When the chain (Fig. 10-12. Pos. 2) is being pulled down with the engine running, the pilot control system is made inoperative preventing further movement of the shovel.

The access ladder is hydraulically operated by the hydraulic cylinder (Fig. 10-1, Pos. 3) with the pilot pressure X2 of 45 bar. The movement of the ladder is controlled by the function of switch (70S084). Lifting the ladder is only possible with the engine running. The lowering movement is possible by hydraulic force with the engine running or by force of gravity with the engine at standstill. NOTE: If the ladder is not in the upper end position (70S122 not activated), the pilot control is switched off via relais 11K111a and 11K111b. Solenoid valve 57K620 activates the hydraulic slew parking brake and a message appears on the display in the operators cab.

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10-3

Function of Hydraulically Operated Access Ladder


10.2

FUNCTION OF HYDRAULICALLY OPERATED ACCESS LADDER

Fig. 10-2

Function of hydraulically operated access ladder


Main pump

(258.3)

Pressure relief valve (safety valve 70 bar)

(8.1)

Pilot pump

(258.4)

Shuttle valve

(33)

Pilot pressure filter

(258.5+.6)

Check valve

(101)

Hydraulic cylinder

(258.7)

Orifice

(157)

Solenoid valve 57Q623a/b

(57Q625)

Solenoid valve (lowering speed control) (OFF => reduced speed)

(252.1)

Pressure relief valve (45+3 bar), X2 pressure

(57Q623a)

Solenoid valve (ON => ladder up)

(252.2)

Pressure relief valve (60+3 bar), X4 pressure

(57Q623b)

Solenoid valve (ON => ladder down)

(258.1)

Solenoid valve 57Q625

10-4

Version 2010/1



Prime drive is running The pump (Fig. 10-2, Pos. 8.1) delivers the oil through the filter (Fig. 10-2, Pos. 33) to port A of the pressure relief valve (Fig. 10-2, Pos. 252.2). The pressure relief valve (Fig. 10-2, Pos. 252.2) maintains the adjusted pressure of 60+3 bar, called "X4“-pressure. By the function of pressure relief valve (Fig. 10-2, Pos. 252.1), the “X4“-pressure will be reduced to 45+3 bar (called "X2“-pressure) and is present at port P of solenoid valve 57Q623a/b. If solenoid valve 57Q623a or b is energized, the oil flows to the cylinder, and the ladder will move up or down. By the function of shuttle valve (Fig. 10-2, Pos. 258.4) both service lines are connected to safety valve (Fig. 10-2, Pos. 258.3), which limits the pressure to 70 bar. Return oil from cylinder (Fig. 10-2, Pos. 101) flows back via solenoid valve 57Q623a/b to solenoid valve 57Q625. 57Q625 = ON => Maximum cylinder speed, return oil flow is not restricted when both proximity switches 70B122 and 70B091 are not activated (ladder between top and bottom end position) 57Q625 = OFF => Reduced cylinder speed, return oil flow is restricted by orifice (Fig. 10-2, Pos. 258.7) when one of the proximity switches 70B122 (ladder up) or 70B091 (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 70B122 de-energizes 57Q625 and energizes 57Q623a, with the result that the cylinder of the ladder is always charged (held) with pressure in this position. If switch 70S084 is in neutral position and the ladder is in “bottom position”, sensor 70B091 de-energises all solenoids (Fig. 10-2, Pos. 57Q625 and 57Q6123 a+b) and the ladder is “blocked”.

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10-5


Fig. 10-3

10-6


Electric circuit diagram of the hydraulically operated access ladder

Version 2010/1



Engine is not running and the ladder is in the “final upper position” With switch (70S084) activated in position "ladder down", the solenoid valves 57Q623b and 57Q625 are energized. 57Q6123b connects the piston side of the cylinder to the return line, so that the oil can return to the tank without resistance. Now the ladder can move down on its own (due to the force of gravity). The operator has to push the ladder slightly until it starts moving down on its own. In case the operator switches off the key switch (20S001), the "ladder down" function will be available via the MTC for approx. 30 min. After this time, the self-holding circuit (11Q100) switches off the MTC, and the travel alarm sounds twice. After that, the key switch (20S001) has to be switched on again for lowering the ladder. In case the operator switches off the key switch (20S001), and acitvates switch (70S084) in position "ladder down" until the ladder reaches the bottom end position (70B091 active), the self-holding circuit (11Q100) switches off the MTC after 2 minutes, the travel alarm will then sound twice.

WARNING z

Make sure that there are no obstacles in the moving range of the ladder! Stop raising the ladder by releasing the control switch (70S084) if there are any obstacles in the moving range!

z

Mount the ladder only in completely lowered position!

z

Do not lift persons or objects (tools) with the hydraulic access ladder! Serious injury or death could occur!

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10-7

Adjustments / Checks

10.3

ADJUSTMENTS / CHECKS

Fig. 10-4


10-8


Version 2010/1




Stop bar

(2)

Inner pivot bracket of the access ladder

(3)


(4) + (6)

Lock nut

(5) + (7)

Set screw

(A)


(B)


(M1.1)

Test port – X4 pressure (60+3 bar)

(M1.2)

Test port – X2 pressure, pilot pressure (45+3 bar)

(M35.1)

Test port – hydraulic cylinder pressure, access ladder “piston side”

(252.1)

Pressure relief valve (45+3 bar) – X2 pressure (pilot pressure)

(252.2)

Pressure relief valve (60+3 bar) – X4 pressure (pump support pressure)

(258.3)

Pressure relief valve (safety valve 70 bar)

(70S084)


(70SS84a)

Pull switch for emergency lowering of the access ladder. When the chain (3) is being pulled down with the engine running, the pilot control system is made inoperative preventing further movement of the shovel. (Operator warning system)

(70B091)

Monitor and control sensor, located on ladder pivot bracket. This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (70B122) fails to function properly, the sensor (70B091) prevents unintended movement of the ladder.

(70B122)

Safety sensor, located on ladder pivot bracket. Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position.

1. Connect pressure gauges to test ports (M1.1), (M1.2) and (M35.1). 2. Start the engine and let it run at high idle. 3. Lift the access ladder to the upper end position using switch (70S084). 4. Increase the X4 pressure to 80 bar at pressure relief valve (252.2) by loosening the lock nut (Fig. 10-4, Pos. 4) and then turning in set screw (Fig. 10-4, Pos. 5). 5. Increase the X2 pressure to 75 bar at pressure relief valve (252.1) by loosening the lock nut (Fig. 10-4, Pos. 6) and then turning in set screw (Fig. 10-4, Pos. 7). 6. Check the setting of pressure relief valve (258.3) at test port (M35.1); required: 70 bar. If the gauge does not show the proper pressure, the entire valve has to be replaced by a new, bench tested safety valve! 7. Reset valve (252.2) to 60+3 bar and reset valve (252.1) to 45+3 bar. 8. At last, tighten the lock nuts (Fig. 10-4, Pos. 4 and 6).

Version 2010/1

10-9


10-10


Version 2010/1

CENTRAL REFILLING SYSTEM (SERVICE ARM)

11. CENTRAL REFILLING SYSTEM (SERVICE ARM)

Version 2010/1

11-1

General


11.1

GENERAL

Fig. 11-1

Overall view of the central refilling system

11-2

Version 2010/1


General


Hydraulic cylinder

(2)

Pull switch 55S087

(3)

Service arm

(4)

Proximity switch 55B023

(5)

Enabling switch 20S094 for the hydraulic service arm operation

Basics The hydraulically operated service arm for diesel driven machines is primarily important to refuel the machine easily. Therefore, it is important to have a basic central refilling system directly connected to the service truck. In order to move the service arm, first of all it is necessary to move the service arm enabling switch 20S094 at the cabin dashboard into position "1". After that, the service arm can be lowered/raised by pulling switch 55S087. NOTE: As long as the pull switch 55S087 is activated, the service arm continues to move up/down. If the pull switch is released, the service arm stops. NOTE: When the service arm enabling switch 20S094 at the cabin dashboard is switched to ON position ("1"), pilot control for shovel movements is switched to OFF.

WARNING Before initiating a service arm movement, make sure nobody is in range of the moving arm.

Version 2010/1

11-3

Function


11.2

FUNCTION

Fig. 11-2

Electric circuit diagram of the central refilling system


Main pump

(8.1)

Pilot pump

(33)

Pilot oil filter

(115)

Hydraulic cylinder

(252.1)

Pressure relief valve – X2 pressure (45+3 bar)

(252.2)

Pressure relief valve – X4 pressure (60+3 bar)

(259.3+.4)

Check valves

(259.5)

Orifice

(57Q624a)

Solenoid valve: refilling arm UP

(57Q624b)

Solenoid valve: refilling arm DOWN

(57Q624c)

Solenoid valve: position with nonreturn valve => service arm locked

11-4

Version 2010/1


Function

Pre-condtion: the engine is running. NOTE: In addition to the hydraulic diagram in Fig. 11-2, also see the respective electric circuit diagram. The pump (Fig. 11-2, Pos. 8.1) delivers oil through filter (Fig. 11-2, Pos. 33) to port A of pressure relief valve (Fig. 11-2, Pos. 252.2). The pressure relief valve (Fig. 11-2, Pos. 252.2) maintains the adjusted pressure of 60+3 bar, called X4 pressure. By means of the pressure relief valve (Fig. 11-2, Pos. 252.1), the X4 pressure will be reduced to 45+3 bar (called X2 pressure), that is present at port P of solenoid valve 57Q624a/b. If the solenoid valves 57Q624a and 57Q624c are energized, pressurized oil flows to the piston side of the service arm cylinder, and the service arm will move up. If the solenoid valves 57Q624b and 57Q624c are energized, pressurised oil flows to the rod side of the service arm cylinder, and the service arm will move down. Under working conditions, solenoid valve 57Q624c is permanently energized to hold the service arm in the upper position under pressure. When the solenoid valve is de-energized by key switch 20S001 in OFF position, the service arm position is held by the non-return valve in solenoid valve 57Q624c. All solenoid valves 57Q624a/b and c are MTC controlled. The pull switch 55S087 is also connected to the MTC and acts as a remote control. The service arm can only be moved down or up with activated key switch 20S001 and activated "service arm enabling switch" 20S094 in the operators cab. The proximity switch 55B023 signalizes the MTC that the service arm is in the upper position. If the service arm enabling switch 20S094 is activated, the pilot pressure is cut off. Pilot pressure is also cut off when the service arm is out of range of the proximity switch 55B023 in order to prevent damage to the lowered service arm.

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11-5

Function

11-6


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HINTS FOR READING THE HYDRAULIC DIAGRAM

12. HINTS FOR READING THE HYDRAULIC DIAGRAM

Version 2010/1

12-1

General


12.1

GENERAL

Fig. 12-1

Example of a hydraulic circuit diagram

12-2

Version 2010/1


General

NOTE: The illustration is only used exemplarily. Use the circuit diagram corresponding to your machine for details. Legend for Fig. 12-1:

Item

Number/Code [Example]

Description

Explanation

A

Diagram no. and type of the specified machine

948 552 40 b PC4000-D

Diagram no. is only valid for the specified machine.

B

Defined serial no.

08199

—

C

Sheet no. / total number of sheets

01 / 02

1st of two sheets

D

Diagram title

Hydraulikplan KS

"Hydraulikplan KS" (KS: Klappschaufel) = "Hydraulic Diagram FSA" (FSA: Front Shovel Attachment) / "Hydraulikplan TL" (TL: Tieflöffel) = "Hydraulic Diagram BHA" (BHA: Backhoe Attachment)

E

Coordinates to specify the location of a component

1 C 10

Page 1, coordinate C vertically and coordinate 10 horizontally

F

Component no.

9

No. for main control block III

G

Line no. with cross reference

L20/ 2D4

Line no. 20; coming from / going to sheet 2 coordinates D4

H

Assignment of main control block spools to machine functions, function priorities

—

The rectangles respresent the main control block spools (numbered from bottom up); when devided in two parts, spool "a…" (left) and spool "b…" (right) are used for different components. Rectangles appearing on the lower right stand for additional components for special functions.

J

Block diagram for assignment of pumps to main control blocks

—

Position of main pumps (with no.) on the PTO and the associated main control block (with control spool designations)

K

See Fig. 12-2 on next page: Switching points for functions acc. to PTO and hydraulic oil temperatures and type of oil

—

The machine control determines the switching points according to the applied oil type/viscosity; therefore, the correct type has to be entered via VHMS.

Further remarks: z

All components are shown in neutral and pressureless position.

z

A wide continuous black line shows a main component or assembly (e.g.: valve and filter panel, main pump, hydraulic tank, …).

z

A continuous black line shows a main hydraulic line. This line is temporarily or permanently loaded with high or pilot pressure.

z

A broken line represents a return, drain or control oil line.

z

A black dot shows a connection point. The position of this connection is not explicitly defined.

z

A white dot shows a connection or port of a component with a well-defined position at the component (e.g.: via port marking/number).

Version 2010/1

12-3

Hydraulic symbols

12.2

HYDRAULIC SYMBOLS

Fig. 12-2

Example of a hydraulic circuit diagram

12-4


Version 2010/1


Hydraulic symbols

NOTICE The illustration is only used exemplarily. Use the original circuit diagram for better readability.

z z

There are symbols described on the following pages not marked in Fig. 12-2.

z

The list of hydraulic symbols is not intended to be exhaustive. For more information, refer to standard ISO 1219.

12.2.1 Lines, unions Item

Symbol

Description

1.

Used as / at / on

Oil supply line, hose or pipe

Suction line or pressurized line of main hydraulic circuit, pilot pressure circuit or auxiliary circuits

Return oil line, hose or pipe

Return lines connected to the return oil filter chamber of the main oil tank

Case drain line (leak oil), hose or pipe

Return line connected to the case drain oil filter chamber of the main oil tank

Control oil line, hose or pipe

Pilot control, pump regulation line, parking brake control line

Crossed line

Pipes or hoses not connected with each other

Connection point

Connection of hydraulic lines without a well-defined position

Component connection point

Connection to components like valve blocks, tanks, pumps. Connection with a well-defined position at a component.

2.

3.

4.

5.

6.

7.

Version 2010/1

12-5

Hydraulic symbols


12.2.1 Lines, unions Item

Symbol

Description

Used as / at / on

8. Plugged connection point, plugged with any kind of plug

Shut (currently not used) connection point

Plugged connection point, plugged with any kind of plug

Shut (currently not used) connection point

Compensator, compensates line differences in length due to vibration and change in temperature

Oil reservoir outlet to the suction tank

Quick coupling, special union with integrated check valve

Tank drain couplings and lines to be removed frequently, e.g. at lubrication systems with removable barrels.

Orifice restriction, not adjustable, with stated orifice diameter [mm]

E.g.: oil cooler inlet

Pressure test port, with a special quick coupling

HP filter, fan valve block.... at all important circuits

Distributor block

Connection of lines with the same destination, e.g. return lines to tank

9.

10.

11.

12.

13.

14.

12-6

Version 2010/1


Hydraulic symbols

12.2.2 Components, valves Item

Symbol

15.

Description

Used as / at / on

Accumulator, filled with nitrogen with the specified pressure for the accumulator

Input line to the remote control valves, return oil collecting tube, track tensioning system

Screen filter (min screening size: 1.0 mm)

Installed in suction lines to the pumps, oil tank outlet and return oil collecting tube.

Oil cooler

Hydraulic oil cooler, PTO oil cooler

Breather filter

On top of PTO or hydraulic oil tank

Spray nozzles, inside a case for cooling and lubrication

Gearbox (PTO) cooling and lubrication system

16.

17.

18.

19.

12.2.3 Sensors Item 20.

Symbol

Description

Used as / at / on

Pressure switch / sensor Input = pressure Output = electrical signal (analogue or digital)

E.g.: return/leak oil tank (digital), high pressure filter (analogue)

Pressure switch Input = pressure Output = digital

E.g.: Filter monitoring PTO lubrication

21.

Version 2010/1

12-7

Hydraulic symbols


12.2.3 Sensors Item

Symbol

22.

23.

Description

Used as / at / on

Temperature sensor Input = temperature Output = electrical signal, proportional to the temperature

E.g.: hydraulic tank

Level sensor Input = fluid level Output = electrical signal, analogue or digital

Hydraulic tank

12.2.4 Valves, valve components Item

Symbol

Description

Used as / at / on

24. Manually operated lever

Valve in track tensioning system to hold the cylinders’ position

Electric / magnetic operated unit Solenoid

Solenoid valves

Pilot pressure controlled unit

Pressure relief valves, disc brakes

Spring (fixed force)

Solenoid valves

Spring (adjustable spring force)

Pressure relief valves

25.

26.

27.

28.

12-8

Version 2010/1


Hydraulic symbols

12.2.4 Valves, valve components Item 29.

30.

31.

Symbol

Description

Used as / at / on

Check valve In drawn position: free flow from right to left, blocked flow from left to right

E.g.: main pump outlet, swing brake valve block, anti cavitation valves at main control blocks

Check valve, spring loaded Opens in flow direction only against spring force (if pressure exceeds spring force)

Double check valve In shown position: valve only allows flow from left to bottom or from right to bottom

Slew brake control

Shut-off valve with monitoring switc, The adjustable switch monitors the valve position

Main shut-off valve between oil tank and suction tank

2/2 control valve, manually operated (with lever); check valve

Track tensioning system

3/2 control valve, manually operated; change-over valve

Change-over valve of pump regulation

4/2 directional control valve, electrically controlled (4/2 solenoid valve) Neutral position: P-A and B-T connected

Slew parking brake, travel parking brake, ladder control

Variable throttle valve, hydraulically controlled, pilot control port pressureless = maximum restriction

Travel brake valve located at the car body

32.

33.

34.

35.

36.

Version 2010/1

12-9

Hydraulic symbols



38.

Symbol

Description

Used as / at / on

3/2 directional control solenoid valve, seat design = leak oil free; 3/2 way solenoid valve, neutral = ports P–A connected

4/3 direction control solenoid valve, 4/3 solenoid valve; in neutral position all ports closed

Ladder control, service arm control

External pilot controlled proportional floating valve

PC3000 and PC4000 FSA: at stick and boom

39.

40. Main control valve with standard function Neutral position: open pump flow (P–T), control port flushing (T–a, T–b), closed pressure ports A and B. Position b: closed circulation port (P–T), ports P–B and A–T connected. Position a: closed circulation port (P–T), ports P–A and B–T connected.

41.

Main control valve with pressureless lowering function (lowering function marked with additional symbol " ") Neutral position: open pump flow (P–T), control port flushing (T–a, T–b), closed pressure ports A and B. Position b: closed circulation port (P–T), ports P–B and A–T connected. Position a: open pump flow P–T, closed pressure port A, ports B–T connected.

12-10

Standard control valve for bi-directional motors and double-acting cylinders

Control valve for pressureless lowering. Used to assist the floating function of boom and/or stick.

Version 2010/1


Hydraulic symbols


Symbol

Description

Used as / at / on

Main control valve with floating function (floating function marked with additional symbol " ") Neutral position: open pump flow (P–T), control port flushing (T–a, T–b), closed pressure ports A and B. Position b: closed circulation port (P–T), ports P–B and A–T connected, check valve prevents flow BÖP. Position a: open pump flow P–T and P–A, ports B–A connected with check valve to prevent flow TÖB.

43.

Floating valve for boom and/or stick

Pressure reducing valve assembly Variable inlet pressure at port P and constant lower output pressure at port A, adjustable output pressure (set to 35 bar)

Pressure reducing valve to provide reduced operating pressure for travel parking brakes and slew parking brakes

Pressure relief valve, directly controlled and adjustable

Safety valve in ladder control circuit

Pressure relief valve with anti-cavitation valve (check valve) assembly, external drain at port Y

Secondary relief valve at main control blocks

Throttle check valve with secondary relief valve, throttle and secondary valve mechanically adjustable, external drain at port Y

Distribution manifold normally in the line to the cylinder, piston side

Pressure increasing valve, pressure relief valve with variable setting, pilot pressure controlled via port X, low pilot pressure = low relief pressure

Slew brake valve block, track tensioning system

44.

45.

46.

47.

Version 2010/1

12-11

Hydraulic symbols


12.2.4 Valves, valve components Item

Symbol

Description

Used as / at / on

48. Proportional pressure valve, to reduce the supply pressure P at port A proportional to the solenoid current

Remote control valves, pump regulation

4-port proportional valve, directly operated by a solenoid

Pump regulation

Pressure relief valve, mechanically and hydraulically adjustable via pilot port X, pilot valve drain port Y

Radiator and oil cooler fan drive

49.

50.

12.2.5 Pump, motor, cylinder Item 51.

Symbol

Description

Used as / at / on

Single-acting cylinder, only moving in one direction when pressurized, returning by external forces

Track tensioning system

Double-acting cylinder, operated in both directions by pressurized oil

Attachment

Drive shaft of a motor or pump with one direction

Main pumps

Hydraulic pump, fixed volume per REV, suction port S, pressure outlet P

Pilot pump, engine coolant fan, oil cooler fan, PTO lubrication pump

52.

53.

54.

12-12

Version 2010/1


Hydraulic symbols

12.2.5 Pump, motor, cylinder Item

Symbol

Description

Used as / at / on

55. Hydraulic pump, variable output volume per REV with external case drain

Main pump

Hydraulic pump assembly with pump bearing lubrication, one direction and external case drain

Main pump

Variable hydraulic pump with charge pump and external drive shaft bearing lubrication

Main pump

Hydraulic motor can be used in both directions, with external case drain L

Oil cooler fan motors

Motor with disc brake, disc brake spring loaded: pressureless pilot line = maximum brake torque

Travel motor, slew motor

56.

57.

58.

59.

Version 2010/1

12-13

Hydraulic symbols



Symbol

Description

Used as / at / on

60.

Lubrication pump drive, differential cylinder with integrated control valves

Lubrication pump station for central lubrication system and slew ring lubrication system

61. Slew brake valve assembly Acts as a hydraulically back pressure system parallel to a slew motor with variable pressure setting and independent pressure side. Input port A or B and outlet on the opposite side, relieve port T

Slew service brake system on top of the slew motor

62.

63.

64.

12-14

Rotary joint, upper part with connections to the superstructure hydraulic, and lower part with connections to the car body

Hydraulically connection between superstructure and car body

Travel brake valve block with secondary pressure relief valve 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

Hydraulic oil tank with leak and return oil filter, back pressure valve and sensors


Version 2010/1


Hydraulic symbols


Symbol

Description

Used as / at / on

65.

Main pump with charge pump, variable displacement individual for each pump, controlled via proportional solenoid valve

Version 2010/1

Main pumps

12-15

Hydraulic symbols

12-16


Version 2010/1

HINTS FOR READING THE ELECTRIC WIRING DIAGRAM

13. HINTS FOR READING THE ELECTRIC WIRING DIAGRAM

Version 2010/1

13-1

General

13.1


GENERAL

In this chapter you’ll find information about: z

the (new) designation of electrical components (reference code)

z

the graphical symbols used

z

the layout of the electric wiring diagram

z

hints for a fast look-up of electrical components in the electric wiring diagram.

NOTE: The electric wiring diagram is solely intended for wiring purposes. For information on operating sequences or the process logic, refer to the CoDeSys visualisation software.

13-2

Version 2010/1


13.2

Reference designation of the electrical components

REFERENCE DESIGNATION OF THE ELECTRICAL COMPONENTS

Each electrical component is well-defined by a code containing two single reference designations, see following table. Code "aabcdd–x"

Meaning

Remarks

aabcdd–x

aa : Area code (location reference designation)

See chap. 13.2.1 for details

aabcdd–x

b : Product reference designation, component identifying letter acc. to IEC 61346-2

See chap. 13.2.2 for details

aabcdd–x

c : 2 = Pre-heating / 3 = CAN bus / 5 and 6 = valves

aabcdd–x

dd : Further product reference designation

aabcdd–x

–x : Powertrain (–1 and –2)

Because this reference designation was just introduced at KMG, and differs from the previously used designation, this chapter also contains a table with the new and old component designation are listed side by side, refer to section 13.6 on page 13-21.

13.2.1

AREA CODE

The first two letters of the product code of the electrical components indicate its location, see following table: Area code

CAN*

10

Location Cab base

11

X

ELV board (DC / 0…60 V)

12

X

Low voltage board (AC / 60…400 V)

13

Cab base bottom compartment

14

—

15

Customer board in the cab base

16

Switch board, pre-heating hydraulic oil

17

Air condition at cab base

18

Air condition switch board, HV cabinet

19

Air condition switch board, LV cabinet

20

X

Cab

21

Customer board in the cab

30

Drive

31

Fuel tank

32

High voltage cabinet (400 V and up)

33

Low voltage in the high voltage cabinet

34

Air condition at the high voltage cabinet

40

Version 2010/1

X

Hydraulic oil tank

13-3


Area code

CAN*

Location

41

Oil cooler (hydraulic)

50

Machinery house

51

X

Engine / motor room

52

Engine / motor

54

Counterweight

55

Service arm

56

X


Pump compartment

57

Control panel, PTO

59

Suction tank

60

Superstructure

61

Control blocks, remote control valves

62

Lubrication system

63

Reserve oil tank, engine

65

Engine coolant pre-heating

67

Crane

68

Compressor

70

Stairs, access ladder

71

Battery box

80

Loader attachment

90

Undercarriage

91

X

Cable drum

92

Rotary joint

93

Slip ring

94

Junction box, cable drum

* : "X" = Location with CAN node

13-4

Version 2010/1


13.2.2


COMPONENT IDENTIFYING LETTER

According to IEC 61346-2, it is now the function / purpose of the electrical component within the circuit that determines its identifying letter in the reference designation (refer to section 13.2 on page 13-3). Letter

Component fuction / purpose

Examples

A

Double function (basic functions are equivalent)

VHMS display, multimonitor

B

Converting physical values into processable signals

End switch, binary or analog sensor, transducer, camera

C

Saving/storing of energy, information, or material

Battery, data memory

E

Supplying rays, heat, or coldness

Heater, lamp

F

Protective devices

Fuse, circuit breaker, power circuit breaker, emergency shut-off switch, safety lock switch, insulation monitor, motor overload switch, ground fault circuit interruptor

G

Initiate energy signals, material flow signals, referBattery, generator ence signals

K

Information processing (without F)

Relay, time relay, controller, phase protective relay

M

Supply mechanical energy (linear or rotating)

E-motor, actuation coil

P

Exposition of information

Display, signal transducer, gauge, clock, counter or operating hours, LED, printer, counter, sevensegment display

Q

Switching or modifying material flow or energy flow Contactor, power relay, battery main switch, dis(without F) connecting switch, starter, power switch

R

Limiting, damping, stabilizing, blocking of energy, information, or material

"Z-diode, diode, throttle, resistance, series resistance, capacitor module, cut-in unit

S

Converting manual mechanical signals into processable signals

Switch, buttton, selector switch, setpoint sensor/ transmitter

T

Converting energy or information without modifica- Current transformer, voltage transformer, amplifier, tion of the kind of energy and the information con- aerial, measurement transformer, transformator, tent rectifier, charger, inverter

U

Supporting, retaining, carrying, holding up of objects

Isolator, cable duct, switchboard, wiring rack, cable drum

V

Processing material, energy, information signals

Mains filter, frequency filter

W

Guiding, channeling, transferring energy, material, Conductor, wiring, rail, bus, fiber optic cable, slipinformation ring

X

Connecting objects

Version 2010/1

Terminal, terminal block, terminal strip, connector, socket, cable connector

13-5

Graphical symbols

13.3


GRAPHICAL SYMBOLS

The circuit symbols used in the wiring diagram are based upon IEC (International Electrical Commission) standard IEC 60617, which differ from the symbols in accordance with the standards NEMA ICS 19-2002 (R2007), ANSI Y32.2/IEEE 315/315A, CSA Z99 for the North American market. The symbols shown in the table below only present an excerpt of the standards, not an exhaustive list of all symbols relating to the standards.

Description

Junction of conductors

Symbol acc. to IEC

or

Symbol acc. to NEMA ICS/ANSI/IEEE

or

Connection of conductors (node) Terminal Line of effect, general symbol Line of effect, denoting small interval Line of separation between functional units Shielding Earth, general symbol ’Ground’, general symbol Protective earth / Protective ground Connector with plug and socket

or

Isolating point, lug, closed Passive components Resistor, general symbol

or

or

Variable resistor, general Resistor with sliding contact, potentiometer Winding, inductance, general Capacitor, general symbol

or or

or

Variable capacitor Visual indicator, general symbol

13-6

(* with color indication)

Version 2010/1


Description Indicator light, general symbol

Symbol acc. to IEC

Graphical symbols


or

or

Buzzers Horn, claxon Drives Manual operation, general use Operated by pushing Operated by pulling Operated by turning Operated by key Operated by rollers, sensors Stored energy mechanism, general symbol Operated by motor Emergency switch Operated by electromagnetic overcurrent protection Operated by thermal overcurrent protection Electromagnetic operation Control by fluid level Electromechanical, electromagnetic operating devices Electromechanical operating device, general symbol, relay coil, general symbol Electromechanical operating device with ONdelay Electromechanical device with OFF-delay

or or (× : device code letter)

Electromechanical device with ON- and OFFdelay Electromechanical device of a thermal relay

Version 2010/1

or

13-7

Graphical symbols

Description


Symbol acc. to IEC


Contacts N/O contact

or

N/C contact

or

Changeover contact with interruption

or TC or TDC

Early-make N/O contact of a contact assembly

TO or TDO

Late-break N/C contact of a contact assembly N/O contact, delayed when closing N/C contact, delayed when reclosing

or

or or

Control devices Push-button (not stay-put) Spring-return switches with N/C contact, manually operated by pushing, e.g. push-button Spring-return switches with N/O and N/C contact, manually operated by pushing Spring-return switches with latching position and one N/O contact, manually operated by pushing Spring-return switches with latching position and one N/C contact, manually operated by striking (e.g. mushroom button) Position switches (N/O contacts), limit switches (N/O contacts) Position switches (N/C contacts), limit switches (N/C contacts) Proximity switches (N/C contacts), actuated by the proximity of iron Proximity switches, inductive, N/O contacts Proximity switches, block diagram Under-pressure relays, N/O contacts Pressure switches, N/C contact

or or

Float switches, N/O contact Float switches, N/C contact

13-8

Version 2010/1


Description

Symbol acc. to IEC

Graphical symbols


Switchgear Contactors (N/O contacts)

(× : code letter)

Three-pole switch-disconnector Three-pole circuit-breaker Fuse, general symbol Transformers, current transformers Transformers with two windings

Current transformer

or

or

or

Machines Generator Motor, general symbol

or or

DC motor, general symbol AC motor, general symbol Three-phase asynchronous motor with squirrel-cage rotor

or

Three-phase asynchronous motor with slipring rotor Semiconductor components Semiconductor diode, general symbol Limiting diode Zener diode Light-emitting diode (LED), general symbol Bi-directional diode, diac Thyristor, general symbol

Version 2010/1

13-9

Drawing concept


13.4

DRAWING CONCEPT

Fig. 13-1

Cover page of the KMG electric circuit diagram

13-10

Version 2010/1


Drawing concept

Komatsu circuit diagrams Each page of the circuit diagram has the following information in the bottom right hand corner: z

Diagram number (Fig. 13-1, Pos. 5); – example: 942 123 40 d

z

Machine type (Fig. 13-1, Pos. 6) – example: PC4000-6D

z

Machine number(s), the diagrams are valid for (Fig. 13-1, Pos. 7) – example: 08210 and following

z

Diagram title (Fig. 13-1, Pos. 8) and contents – example: "Elektroplan" [German for "electric circuit diagram"] and "Table of contents"

z

Current page number and total number of pages (Fig. 13-1, Pos. 4) – example: 01/175

Each page 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 (see Fig. 13-1, Pos. 3). This coordinate system allows to indicate the location of components, as well as to locate a component on a given page more easily.

Table of contents In the table of contents on the first pages, the pages (Fig. 13-1, Pos. 1) are listed in ascending order, for each page the title (Fig. 13-1, Pos. 2, with area code relating to the units presented on the page, where applicable) is listed. The english version of the table of contents is to be found following the german version. Example: "103 51 bus connector node 17, 18, 19" => On page 103, the bus connectors for nodes 17, 18, and 19, to be found in the engine room (area code 51), are shown.

Version 2010/1

13-11

Drawing concept


Cross reference list The pages following the table of contents contain the cross reference list.

Fig. 13-2

Cross reference list

In the cross reference list, all electrical parts/components are listed in alphabetical order (Fig. 13-2, Pos. 2 and 3). In front of the components’ designation, the relevant page number (Fig. 13-2, Pos. 1) on which the component is drawn, is given. NOTE: Following the cross reference list, but still in front of the circuit diagram pages, you’ll find: – the FAQ (about how information is represented in the diagrams) – information about the structure of the reference designations. NOTE: The underscore in cross references like "40X_41.5" stands for a connection to a terminal block.

13-12

Version 2010/1


Drawing concept


Version 2010/1

13-13

Drawing concept


Eletrical wiring diagrams – explanations The following illustrations shall show up some basics about the wiring diagrams and how information is presented.

Fig. 13-3

13-14

Wiring diagram (example)

Version 2010/1


Drawing concept


Phase / wire designation

(2)

Cross reference to further connection (e.g. "158.1" : continuation on page 158, column 1)

(3)

Notation of temperature switch (63B204: pre-heating reserve oil tank)

(4)

Notation of circuit breaker (12F206a: heater in cab support)

(5)

Required wire cross-section area in mm² (e.g.: 2.5 mm² = AWG 14)

(6)

Separation line for an electrical module / assembly group

(7)

Cable connector designation and pin number

(8)

Connection to a terminal block (e.g. pin 19 of terminal block 11X_51)

(9)

Contacts of relay 12K201 (Fig. 13-3, Pos. 10). The switching contacts are always drawn at the bottom below the associated relay. For switching contacts in usage, a cross reference is given alongside; for contacts not used, only ":" is shown. In the example, only the switching contacts 43 an 44 are used, the contacts are shown in detail on page 69, section/column 1.

(10)

Relay coil

(11)

Notation of heating resistor (e.g.: 63E212)

(12)

Functional unit’s name for the wiring diagram sector shown above

(13)

Protective earthing (PE)

(14)

Ground wire / machine ground (e.g.: 12GND)

(15)

Designation for optional design (e.g.: TT = low-temperature design)

Version 2010/1

13-15

Drawing concept

Fig. 13-4

13-16


Wiring diagram (example)

Version 2010/1


Drawing concept


Designation of CAN-bus node

(2)

Separating line for functional unit (40K311, ICN-D, CAN-bus node 11)

(3)

Notation of input resistance of CAN-bus node ICN-D (at socket 3, pin 8)

(4)

Identification for logic input signal also used in the flowchart (first line), first letter in second line identifying type of port (SB_… : input / OB_… : output)

(5)

Notation of pressure switch (40B024: filter monitoring of air filter at the hydraulic tank)

(6)

Functional unit’s name for the wiring diagram sector shown above

(7)

Color code of connecting line (e.g.: "BN" = brown), refer to cable color identification table below.

(8)

Connector identification

(9)

Cross reference/location of the complete assembly group, if only a part of the group is shown here. In the example, onyl the relevant resistor between pins 9 and 10 of the resistor array 40R008 is shown in th drawing for the functional unit (hydraulic oil tank monitoring); the complete resitor array is shown on page 143, section/column 2.

(10)

Cross reference/location of the complete assembly group, if only a part of the group is shown here. In the example, onyl the relevant diode between pins 1 and 2 of the diode array 40R014 is shown in th drawing for the functional unit (hydraulic oil tank monitoring); the complete diode array is shown on page 143, section/column 1.

NOTE: All circuits are shown without current, and all relays and switches in neutral position.

Cable color identification Refer to the following table if the identification of cable colors in wiring diagrams may be unclear due to different existing systems of color codes. Color English

Color code Standard IEC 60757*

German (current)

German (previous)

BK

SW

sw

BN

BR

br

Black

German Schwarz

Brown

Braun

Red

Rot

RD

RT

rt

Orange

Orange

OG

OR

or

Yellow

Gelb

YE

GE

ge

Green

Grün

GN

GN

gn

Blue

Blau

BU

BL

bl

Violet

Violett

VT

VI

vi

Grey

Grau

GY

GR

gr

White

Weiß

WH

WS

ws

Pink

Rosa

PK

RS

rs

Turquoise

Türkis

TQ

TK

tk

* IEC: International Electrotechnical Commission

Version 2010/1

13-17

Drawing concept


Wiring diagram sequence The layout of the wiring diagram, especially the order of the contents, is shown in the following chart. Location (in ascending order) Emergency equipment Power supply / ground Circuit breaker Circuit breaker, controller Sensors Bus connectors (CAN-bus) Node / controller Power supply / ground Bus connections (CAN) Diode and resistor arrays (built-in) Input digital and analog Output digital and analog Node / controller Power supply / ground Bus connections (CAN) Diode and resistor arrays (built-in) Input digital and analog Output digital and analog ... Other elements Location Emergency equipment Power supply / ground Circuit breaker Circuit breaker, controller Sensors Bus connectors (CAN-bus) Node / controller Power supply / ground Bus connections (CAN) Diode and resistor arrays (built-in) Input digital and analog Output digital and analog Node / controller ... ... Other elements ... (Location) Accessories Settings Additional information Correlation hand-lever deflection – movements Pump and control block layout Coding of connectors DIP switch setting ...

13-18

Version 2010/1


Drawing concept

Search hints In order to find the required information fast and easily, the following hints may be useful. 1. A component at a certain location is to be looked-up in the wiring diagram, the component designation is missing / unrecognizable: => if needed, look-up the location reference designation (area code) for the relevant place of the machine in the "List of location reference designations" following the FAQ. => Look-up the page number the wiring diagram starts for the desired location in the table of contents. => If the functional unit the component belongs to is identified, look-up the page number for the functional unit in the table of contents for the entries for the relevant location reference code. => Identify the electrical component on the specified page(s). 2. The component’s product reference code is known / identifiable: => Go to the cross reference list following the table of contents. => Look-up the component’s product reference designation and the corresponding page number in the alphabetically sorted list. => Identify the electrical component on the specified page.

Version 2010/1

13-19

Cable marking

13.5


CABLE MARKING

On all blue wires there is a printed code approx. every 10 cm.

Fig. 13-5

Example for cable marking

The code next to the cable end shows where the cable end has to be connected, the code further away from the end gives information about what is connected at the other end of the wire.

13-20

Version 2010/1


13.6

Table of new and old component designations

TABLE OF NEW AND OLD COMPONENT DESIGNATIONS

The following table lists components of all KMG excavator models. Therefore, it possibly contains components not existing at the particular machine. New code

Previous code

10a000

Component Cab support

10B001

6B1

Temperature cab support

10B002

3B2

Temperature switch for heater in LV switch cabinet

10B005

2S5

Door switch in LV switch cabinetLV switch cabinet

10B006a

2B6a

Temperature switch for air condition in LV switch cabinet

10B007a

2B7a

Dampness switch for air condition in LV switch cabinet

10B351

Fire suppression system pressure switch

10B451

9B1

Temperature transmitter for fire suppression system LV switch cabinet

10B452

9B2

Temperature transmitter for fire suppression system LV switch cabinet

10B463

E63

Camera cab support

10E008

7H8

Emergency light cab support (Electric)

10E009

7H9

Emergency light cab support (Electric)

10E025

3R25

Heater in LV switch cabinet

10E026

3R26

Heater in LV switch cabinet

10E046

H46

Lighting cab support (Diesel)

10E055

H55

Lighting at stage for cab

10E144e

H144e

Additional light cab support left

10E144f

H144f

Additional light cab support left

10E144g

H144g

Additional light cab support right

10E144h

H144h

Additional light cab support right

10E231

1H1

Heater for cab support

10G007

M3

Compressor for warning horn

10G010

M10

Excess pressure blower (old cab)

10K032

E32/X14

Load limit regulation

10K300

E46

VHMS controller

10P001

1P1

Battery charging device emergency-lighting, charging-current-display

10P003-1

0P3-1

Cos-Phi-display motor 1

10P003-2

0P3-2

Cos-Phi-display motor 2

12P004-1

0P4-1

KWh_counter_motor_1

12P004-2

0P4-2

KWh_counter_motor_2

10P008

1P8

Battery charging device emergency-lighting, charging-voltage-display

10Q104

*K4M

Power switch for air condition compressor in HV switch cabinet at cab support wall

Version 2010/1

13-21



New code

Previous code

Component

10Q204

+K4M-1

Power switch for air condition compressor in LV switch cabinet at cab support wall

10R100

R100

Terminal resistor at hydraulic tank (in need)

10R101

R101

Terminal resistor at VHMS controller

10S017

S17

Switch for cab support lighting

10T055

E55

Charging device

10T058

E58

Satellite communication ORBCOMM controller (option)

10W322

WLAN-Interface cable between MTC and cab floor (MTC<=>PC)

10X037

Socket connector for satellite communication (option)

10X300

X35d

CAN-Bus-T-Splitter at VHHV controller too QUANTUM for terminal resistor

10X300a

X35d

CAN-Bus-T-Splitter at VHHV controller too MH801 display for terminal resistor

10X300b

X35d

CAN-Bus-Connector in cab support

10X306

CAN-Bus-Connector

10X307

CAN-Bus-Connector

10X309

X35d

CAN-Bus-Connector in cab support

10X322

WLAN-Interface connector in cab floor (MTC<=>PC)

10X335b

CAN-Bus-T-Splitter prepared for Modular-Mining-System-Interface (MMS) hub (Diesel)

10X335c

CAN-Bus-Connector between cab support and cab

11a000

Extra low voltage switch panel (DC)

11B142

E42

Direction of rotation

11B143

E43

Speed of rotation

11B144

Speed of rotation from gyroscop (in preparation!)

11F001

F1

Circuit breaker 15 (+24V DC) (50A)

11F001a

F1a

Circuit breaker 30 (+24V DC) (50A)

11F001b

F1b

Main circuit breaker for pilot control (50 A)

11F001c

F1c

Circuit breaker for working light, lighting superstructure and ladder (50A)

11F001d

F1d

Main circuit breaker cab (50A)

11F001e

F1e

Main circuit breaker TT (50A)

11F001f

F1f

Circuit breaker motor controller QUANTUM (16A)

11F002

F2

Circuit breaker warning light, compressor signal horn (16A)

11F003

F3

Circuit breaker für pilot control (32A)

11F005

F5

Circuit breaker windscreen wiper (16A)

11F005a

F5a

Circuit breaker windscreen wiper wash system (6A)

11F006

F6

Circuit breaker for emergency line and key switch

11F006a

F6a

Circuit breaker service light pump room and engine room (25A) and sockets

11F006b

F6b

Circuit breaker cab indoor light, socket cab support (25A), washbasin pump, cigarette lighter

11F006c

F6c

Circuit breaker sockets in motor- and pump room (16A)

13-22

Version 2010/1


New code

Previous code

11F006d


Component Circuit breaker cab indoor light (16A)

11F007

F7

Circuit breaker light cab roof right (10A)

11F007a

F7a

Circuit breaker light cab roof left (10A)

11F008

F8

Circuit breaker light oil cooler (10A)

11F008a

F8a

Circuit breaker light counterweight (10A)

11F008c

F8c


11F008d

F8d


11F008e

F8e


11F009

F9

Circuit breaker air-condition (50A)

11F009c

F9c

Circuit breaker air-condition control panel

11F011

F11

Circuit breaker motor controller QUANTUM (16A)

11F012

F12

Circuit breaker key switch (6A)

11F013

F13

Circuit breaker for power supply of binary sensors (6A)

11F013a

F13a

Circuit breaker for power supply of analog sensors (6A)

11F014

F14

Circuit breaker for power supply of CAN-node-outputs (20A)

11F015a

F15a

Circuit breaker VHMS controller and VHMS monitor MH801 (10A)

11F016

F17

Circuit breaker PWM-amplifier for cooler fan speed (6A)

11F017

F17

Circuit breaker self-holding (16A)

11F018

F18

Circuit breaker slew park brake (6A)

11F019

F19


11F026

F26

Circuit breaker cab over pressure blower (16A)

11F028

F28

Circuit breaker pilot control supply (10A)

11F028a

F28a


11F029

F29


11F029a

f29a


11F032

F32

Circuit breaker camera system (10A)

11F034

F34

Circuit breaker transfer pump (32A)

11F043

F43

Circuit breaker motor start relay, travel brake, hydr. slew brake, service arm (16A)

11F046

F46

Circuit breaker fan air condition (TT)

11F047

F47

Circuit breaker mixing-valve and fan for cab heater (TT)

11F048

F48

Circuit breaker radio, reading lamp (6A)

11F049

F49

Circuit breaker customer enhancements (16A)

11F059

F59

Main circuit breaker for stabilized battery voltage (50A)

11F061

F61

Circuit breaker load limit regulation (10A)

11F062

F62

Circuit breaker refrigerator, mirror (16A)

11F063

F63

Circuit breaker operator seat heater blower (10A)

11F065

F65

Circuit breaker light superstructure and ladder (16A)

11F066

F66

Circuit breaker engine oil refilling system (16A)

Version 2010/1

13-23



New code

Previous code

Component

11F067

F67

Circuit breaker socket in cab (25A)

11F068

F68

Circuit breaker socket in cab (25A)

11F070

F70

Circuit breaker VHMS supply (10A)

11F071

F71

Circuit breaker independent cab heater Hydronic M (25A)

11F075

F75

Circuit breaker sensor wire for control battery voltage (6A)

11F084

F84

Circuit breaker hydraulic oil level (6A)

11F100

Supply control outputs node 3 (10A)

11F101


11F102


11F103


11F104


11F105


11F106


11F107


11F108


11F109


11F110


11F111


11F112


11F113

Supply control outputs node 19 und 20 (10A)

11F114


11F115


11F116


11F117


11F121

Bus node supply, switched (10A)

11F122

Bus node supply (10A)

11F123

Bus node supply (10A)

11F306

3F6

Supply for cab heater monitoring

11F310c

3F10c

Circuit breaker for blower under operator seat for blower after-running

11G003

A3

Test modul (-10V bis +10V)

11K003-1

K3-1

Engine 1 running (> 300 1/min), generator field current switch on

11K003-2

K3-2

Engine 2 running (> 300 1/min), generator field current switch on

11K032

D32

Safety relay with cut-off delay for zero position signal

11K044a

Safety line (before safety contactors)

11K050

K50

Bucket switch off

11K058

K58

Pilot control boom up (PC4000)

11K064-1

K64-1

Engine enable

11K064-2

K64-2

Engine enable

13-24

Version 2010/1



New code

Previous code

Component

11K065-1

K65

Enable engine-controller 1

11K065-2

K65

Enable engine-controller 2

11K071

K71

Pilot control bucket fill

11K074

K74

Pilot control stick out

11K075

K75

Boom down (PC5500)

11K076

K76

Pilot control left crawler (PC4000)

11K076a

K76a

Stick out (PC5500)

11K077

K77

Pilot control crawler: left crawler (PC5500)

11K077a

Pilot control crawler: right crawler (PC5500)

11K078

K78

Pilot control right crawler (PC4000)

11K079

K79

Boom up (PC5500)

11K080

K80

Control block 1 switch on

11K111a

K111a

Supply pilot control

11K111b

K111b

Supply pilot control redundant

11K126

K126

Supply relay monitoring for pilot control

11K160

K160

Boom floating position OFF

11K170

K170

Stick floating position OFF

11K176

K76

Stick in (PC5500)

11K177

K177

Travel cut off forward

11K177a

Travel cut off forward (Parallel to 11K177)

11K178

K78

Bucket dump (PC5500)

11K178

K178

Travel cut-off backward

11K178a

Travel cut-off backward (Parallel too 11K178)

11K179

K179

Travel cut-off backward left crawler

11K180

K180

Travel cut-off backward right crawler

11K301

MTC (Master Turbo Controller) (central controller in cab support)

11K302

CAN-Node 2 (ICND)

11K303

CAN-Node 3 (ICNV)

11K304

CAN-Node 4 (ICNV)

11K305

CAN-Node 5 (ICNV)

11P001

H1-1

Operating hour meter motors

11P029

H29

Operating hour meter crawler

11P063

H63

LED load limit regulation activ

11P094-1

H94-1

Quantum fluid signal lamp motor 1 (white)

11P094-2

H94-2

Quantum fluid signal lamp motor 2 (white)

11P095-1

H95-1

Quantum warning signal lamp motor 1 (yellow)

11P095-2

H95-2

Quantum warning signal lamp motor 2 (yellow)

11P096-1

H96-1

Quantum stop signal lamp motor 1 (rot)

Version 2010/1

13-25



New code

Previous code

Component

11P096-2

H96-2

Quantum stop signal lamp motor 2 (red)

11P138

H138

LED error load limit regulation

11P143-1

H143-1

Signal lamp motor oil pump 1

11P143-2

H143-2

Signal lamp motor oil pump 2

11Q010

Self holding of MTC; MTC output for travel alarm control by relay and diode

11Q020

K20

Horn

11Q023

K23 / 4K23

Superstructure lighting contactor

11Q023a

K23a / 4K23a

Additional superstructure lighting contactor (option)

11Q044

K44

Control voltage on by key switch-contactor for diesel shovels

11Q044a

K44a

Control voltage on by key switch-contactor for diesel shovels (parallel to 11Q044)

11Q044c

Q44c

Emergency stop circuit

11Q044d

Q44d

Emergency stop circuit

11Q045a

Main supply for pilot control

11Q045b


11Q045c


11Q045d


11Q045e


11Q090

K90

Emergency lighting ladder

11Q100

K100

Self holding control contactor

11Q111

K111c

Supply pilot control power contactor (10A)

11Q122

K122

Connect control voltage battery with battery for starter

11Q190

K190

Select slew brake signal source beetween lever and pedal

11R005

A5a

Pull-up/-down resistors

11R013

Diode array (3A)

11R016

Diode array (3A)

11R017

Diode array (3A)

11S041-1

S41-1

Test speed engine 1 : 1800 1/min

11S041-2

S41-2

Test speed engine 2 : 1800 1/min

11S097

S97

Programming mode switch VHMS

11S145

Windscreen wiper arm (QUIT-button)

11C004

A4

Pilot control capacitor modul bucket

11C004a

A4a

Pilot control capacitor modul boom

11C005

A5a

Pilot control capacitor modul slew gear / stick

11C006

A6

Pilot control capacitor modul crawler / clam

11T007

A7

Pilot control amplifier slew gear

11T007a

A7a

Pilot control amplifier slew gear

11T008

A8

Pilot control amplifier stick

11T008a

A8a


13-26

Version 2010/1



New code

Previous code

Component

11T008b

A8b


11T009

A9

Pilot control amplifier bucket

11T009a

A9a


11T009b

A9b


11T010

A10

Pilot control amplifier boom

11T010a

A10a


11T010b

A10b


11T010c

A10c


11T011

A11

Pilot control amplifier clam

11T012

A12

Pilot control amplifier crawler left

11T013

A13

Pilot control amplifier crawler right

11T016

A16

Pilot control amplifier slew brake

11T017

E17

Electronic bucket limitation (EBL)

11T048

E48

Ramp modul stick

11T049

E49

Ramp modul boom

11T049a

E49a

Ramp modul boom

11T049b

E49b

Ramp modul boom

11T049c

E49c

Ramp modul boom

11T050

E50

Ramp modul slew gear

11T050a

E50a

Ramp modul slew gear

11T050b

E50b

Ramp modul slew brake

11T051

E51

Ramp modul crawlers

11T052

E52

Ramp modul clam

11T059

E59

Ramp modul bucket

11T080

R80

Measuring transducer for battery voltage

11X027a

VHMS: Download- and programming connector in cab

11X027b

X27b

VHMS: Download- and programming connector in cab support

11X030

X30

Socket cab support

11X093

Terminal strip in cab support too slip ring

11X193

Connector at cab support too slip ring

11X301

CAN-Bus-T-Splitter MTC

11X302

CAN-Bus-T-Splitter Node 2

11X303


11X304


11X305


12a000

Low voltage switch panel (Also low voltage for pre-heating for Diesel TT)

12B403a-1

Winding temperature measuring transducer Pt100 motor 1

12B403b-1


Version 2010/1

13-27


New code

Previous code


Component

12B403c-1


12B403d-1

Bearing temperature measuring transducer Pt100 motor 1

12B403e-1


12B404a-2


12B404b-2


12B404c-2


12B404d-2


12B404e-2


12F076

1F76

Circuit breaker charging current (125A)

12F201

1F1

Circuit breaker charging device (16A)

12F202

1F2

Circuit breaker pre-heating motor oil (6A)

12F203

1F3

Circuit breaker pre-heating power take off (PTO) (6A)

12F204

1F4

Circuit breaker pre-heating battery (6A)

12F205

1F5

Circuit breaker pre-heating suction oil tank (6A)

12F206

1F6a

Circuit breaker heater RESERVE - oil tank (6A)

12F206a

1F6a

Circuit breaker heater in cab support (20A)

12F209-1

1F9-1

Circuit breaker pre-heating coolant (25A)

12F209-2

1F9-2

Circuit breaker pre-heating coolant (25A)

12F267

1F8

Circuit breaker pre-heating hydraulic oil (25A)

12F401

2F1

Circuit breaker air condition control for HV and LV switch cabinet

12F401a

1Q1a

Power protection switch for secondary protection for transformer 1

12F401b

1Q1b

Power protection switch for secondary protection for transformer 2

12F402

2F2

Circuit breaker air condition HV switch cabinet

12F403

2F3

Circuit breaker air condition LV switch cabinet

12F404-1

0F4-1

Motor protection relay motor 1

12F404-2

0F4-2

Motor protection relay motor 2

12F405

1F5

Triphasic lightning- and over voltage protection for system voltage

12F405a

1F5a

Triphasic lightning- and over voltage protection for system voltage

12F406a

Power supply vacuum contactor motor 1

12F406b

Power supply vacuum contactor motor 2

12F407

5Q7

Motor protection switch drive cable drum

12F409

0F9

Protection switch for voltage signal too KWh-counter

12F410

1F10

Threefold circuit breaker for lightning protection and over voltage protection 1

12F410a

1F10a

Threefold circuit breaker for lightning protection and over voltage protection 2

12F411

4F11

Circuit breaker socket cab

12F412

4F12

Circuit breaker socket in machinery room

12F412a

4F12a


12F412b

4F12b


13-28

Version 2010/1



New code

Previous code

Component

12F412c

4F12c


12F414

4F10

Circuit breaker socket cab

12F416

4F16

Circuit breaker welding socket machinery room

12F417

F17

Circuit breaker radio, ladder, fire suppressin system (25A)

12F420-1

3F20-1

Circuit breaker motor standstill heater 0.47 KW

12F420-2

3F20-2

Circuit breaker motor standstill heater 0.47 KW

12F421

3F21

Circuit breaker heater and lighting for slip-ring-box

12F422

3F22

Circuit breaker terminal box heater

12F424

3F24

Circuit breaker for heater at HV switch cabinet

12F424a

3F24a

Circuit breaker for heater at HV switch cabinet

12F425

3F25

Circuit breaker for heater in LV switch cabinet

12F426

3F26

Circuit breaker for heater air condition motors

12F427

3F27

Circuit breaker heaters control

12F431

1F2

Isolation monitoring

12F432

7F1

Battery charging device emergency lighting secondary double circuit breaker

12F433

7F2

Circuit breaker emergency lighting HV switch cabinet

12F434

2Q2

Power protection switch for air condition compressor LV switch cabinet

12F435

1Q2

Motor protection relay

12F436

2Q1

Power protection switch for air condition compressor HV switch cabinet

12F437

2Q3a

Power protection switch for air condition compressor cab

12F438

0F6

Threefold circuit breaker between voltage converters

12F439

4F17

Circuit breaker welding socket ladder

12F440-1

Circuit breaker blower control cab heater

12F440-2

Circuit breaker blower control cab heater

12F441

1F4

12F442

Phase sequence relay Power supply cab heater

12F451

4Q1

(RCD) Residual current device for cab sockets, machinery room and options

12F452

4Q2

(RCD) Residual current device for welding sockets machinery room and ladder (Option)

12F453

5Q3

Motor protection switch crane on machinery room

12F454

5Q4

Motor protection switch air compressor

12F456

1F6

Circuit breaker phase sequence relay

12F462

1F12

Circuit breaker charging device supply

12F462a

1F10a


12F462b

1F10b


12F463

4Q2

Power protection switch for working lighting with sodium discharge lamp

12F464

4Q3


12F465

4Q4


12F466

4Q5


Version 2010/1

13-29



New code

Previous code

Component

12F467

4Q6


12F468

4Q7


12F469

4Q8


12F470

4Q9


12F476a

1F76a

Secondary double circuit breaker charging device 1

12F476b

1F76b

Secondary double circuit breaker charging device 2

12F476c

Secondary circuit breaker charging device 1

12F476d

Secondary circuit breaker charging device 2

12F476e

Secondary circuit breaker charging device emergency lighting

12F515

5F15

Circuit breaker heater at cable drum switch cabinet

12K010

1K10

SF6-monitoring

12K201

1K1

Independent heater on

12K209

1K9

Hydraulic oil level

12K306

CAN-Node 6 (ICND)

12K307

CAN-Node 7 (ICND)

12K308

CAN-Node 8 (ICNV)

12K403a

9K3

Fire warning system maschinery room, suppression system switch cabinets ANSUL

12K403b

9K3

Fire warning system maschinery room, suppression system switch cabinets ANSUL

12K408-1

1K8-1a

Auxiliary contactor vacuum contactor motor 1

12K408-2

1K8-2a

Auxiliary contactor vacuum contactor motor 2

12K408a-1

1K8a-1

Auxiliary relay 1 for vacuum contactor 1

12K408a-2

1K8a-2

Auxiliary relay 1 for vacuum contactor 2

12K408b-1

1K8b-1

Auxiliary relay 2 for vacuum contactor 1 redundant

12K408b-2

1K8b-2

Auxiliary relay 2 for vacuum contactor 2 redundant

12K452

K152

Safety relay for switch off heating cartridge under refrigerator for TT 60°

12K453

K152a

Safety relay for switch off heating cartridge under refrigerator for TT 100°

12K481a

K181

Safety relay for switch off heating cartridge under operator seat for TT 60°

12K481b


12K481c


12K481d


12K482a

K182


12K482b


12K482c


12K482d


12K482-re

Reset electric cab heater

12Q201

Pre-heating, manual power switch for power supply

12Q209-1

Pre-heating, level motor oil

13-30

Version 2010/1



New code

Previous code

Component

12Q401

3K1

Relay heater HV switch cabinet

12Q402

3K2

Relay heater LV switch cabinet

12Q403

5K3

Motor contactor air compressor

12Q404

2K4

Powers switch for air condition compressor cab

12Q405

3K5

Contactor for heating cartridge b under operator seat (4 KW)

12Q406

3K6

Contactor for heating cartridge c under operator seat (6 KW)

12Q407

3K7

Contactor for heating cartridge a under operator seat (2 KW)

12Q411

2K1

Relay air condition HV switch cabinet

12Q411a

2K1a

Relay air condition LV switch cabinet

12Q421-1

1K21-1

Standstill heater motor 1

12Q421-2

1K21-2

Standstill heater motor 2

12Q444

1K44

Key switch on for electric shovels

12Q452e

Blower after-running for heater under operator seat

12Q481e

Blower after-running for heater under refrigerator

12Q490a

4K1a

Contactor working lighting sodium discharge lamp

12Q490b

4K1b


12Q490c

4K1c


12Q490d

4K1d


12R402

1R2

Battery charging device emergency lighting shunt

12R403

4L1

Power supply unit working lighting sodium discharge lamp

12R404

4L2


12R405

4L3


12R406

4L4


12R407

4L5


12R408

4L6


12R409

4L7


12R410

4L8


12R420

Resistor array

12R421

Diode array

12S561

1S161

Test key for isolation monitoring

12T082

R82

Measuring transducer for battery voltage (emergency voltage supply)

12T401

1A1

Measuring transducer temperature transformator 1

12T402

1A2

Measuring transducer temperature transformator 1

12T407

0T7

Voltage transformer for load limit regulation and X2-box-controller

12T408-1

0T8-1

Current- / Voltage converter for load limit regulation motor 1 5A AC / 10V AC

12T408-2

0T8-2

Current- / Voltage converter for load limit regulation motor 2 5A AC / 10V AC

12T410-1

0T10-1

Current transformer KWh-counter L1 motor 1

12T410-2

0T10-2


Version 2010/1

13-31



New code

Previous code

Component

12T411-1

0T11-1


12T411-2

0T11-2


12T412-1

0T12-1


12T412-2

0T12-2


12T431

Signal rectifier for voltage, current 1 and current 2

12T431-1

Signal rectifier point of connection for current 1

12T431-2

Signal rectifier point of connection for current 2

12T431-3

Signal rectifier point of connection for voltage

12X001

1X1

Terminal strip on LV-switch panel

12X306


12X307


12X308


13a000

Under-floor from cab support

13B090

B90

Ambient air temperature

13E003

2M3a

Air condition compressor cab

13E101

2R1

Heater air condition compressor HV switch cabinet

13E208

1R8

Pre-heating for battery control voltage

13E209

1R9

Pre-heating for battery control voltage

13G008

G8

Battery control voltage

13G009

G9

Battery control voltage

13M001

**M1V

Air condition compressor motor cab

13Q003

Battery main switch control voltage

13T002

1U2

Battery charging device 75A

13T003

1U3


13T004

1U4


14a000 15a000

Board for customer extensions in cab support

16a000

Switch box pre-heating hydraulic oil

16F260

Circuit breaker pre-heating hydraulic oil heating element 4E60 (3x10A)

16F261


16F262


16F263


16F264


16F265

Circuit breaker pre-heating hydraulic oil on

16K267

Switch off pre-heating hydraulic oil for low hydraulic oil level

16P267

Hydraulic oil pre-heating ready

16P268

Hydraulic oil pre-heating on

16Q260

Pre-heating hydraulic oil heating element 4E60 on

13-32

Version 2010/1


New code

Previous code


Component

16Q261


16Q262


16Q263


16Q264


16Q265

Pre-heating hydraulic oil on

16S267

Pre-heating hydraulic oil on

17a000

Air condition at cab support

17B001a

*B1Ta

Thermostat evaporator LV switch cabinet

17B001b

*B1Tb

Thermostat evaporator LV switch cabinet

17B001f

*B1F

Pressure switch condenser LV switch cabinet (Lower pressure limit)

17B011f

*B11F

Pressure switch condenser LV switch cabinet (Upper pressure limit)

17E001

2M2

Air condition compressor LV switch cabinet

17E101

*2R1

Heater air condition compressor LV switch cabinet

17F001

*A1P

Motor protection relay for compressor motor for LV switch cabinet

17G001

*M1G

Blower evaporator LV switch cabinet

17G021

*M21M

Blower liquefier LV switch cabinet

17G022

*M22M

Blower liquefier LV switch cabinet

17K004

2E4

Air condition LV switch cabinet

17M001

*M1V

Compressor motor LV switch cabinet

18a000

Board for air condition HV switch cabinet

18F001

*F1M

Circuit breaker blower evaporator HV switch cabinet

18F002

*F2M

Circuit breaker blower liquefier HV switch cabinet

18F003

*F3M

Circuit breaker blower liquefier HV switch cabinet

18F004

*F1A

Circuit breaker for blower HV switch cabinet

18K401

2E1-1

Board air condition HV switch cabinet at wall in cab support

18Q001

*K1M

Power relay blower evaporator HV switch cabinet

18Q002

*K2M

Power relay blower liquefier HV switch cabinet

18Q003

*K3M

Power relay blower liquefier HV switch cabinet

19a000

Control panel for air condition LV switch cabinet

19F001

*F1M

Circuit breaker blower evaporator LV switch cabinet

19F002

*F2M

Circuit breaker blower liquefier LV switch cabinet

19F003

*F3M

Circuit breaker blower liquefier LV switch cabinet

19F004

*F1A

Circuit breaker for blower LV switch cabinet

19K404

2E4-1

Board air condition LV switch cabinet at wall in cab support

19Q001

*K1M

Power relay blower evaporator LV switch cabinet

19Q002

*K2M

Power relay blower liquefier LV switch cabinet

19Q003

*K3M

Power relay blower liquefier LV switch cabinet

20a000

Version 2010/1

Cab

13-33



New code

Previous code

Component

20B001

B1N

Thermostat air condition

20B003

3B3

Temperature switch overheat control for heating element under operator seat 60°

20B003a

3B3a

Temperature switch overheat control for heating element under operator seat 100°

20B004

3B4

Temperature switch overheat control for heating element under refrigerator 60° for TT

20B004a

3B4a

Temperature switch overheat control for heating element under refrigerator 100° for TT

20E001

Heater under operator seat

20E001a

3H1a

Heating element a under operator seat (2 KW)

20E001b

3H1b

Heating element b under operator seat (2 KW)

20E001c

3H1c

Heating element c under operator seat (2 KW)

20E002

Heating device under refrigerator

20E002a

3H2a

Heating element a under refrigerator for TT (2 KW)

20E002b

3H2b

Heating element b under refrigerator for TT (2 KW)

20E002c

3H2c

Heating element c under refrigerator for TT (2 KW)

20E013

E13

Cigarette lighter

20E026

E26

Air condition cab

20E034

9R4

Igniter fire suppression system

20E035

9R5

Resistor fire suppression system

20E036

9R6

Resistor fire suppression system

20E044

E44

Refrigerator

20E044a

E44a

Cab indoor lighting

20E044b

E44b

Cab indoor lighting

20E044c

E44c

Cab indoor lighting

20E044d

E44d

Cab indoor lighting

20E045

H45

Lighting pantry

20E047a

H47a

Lighting ladder at cab

20E048

H48

Working light cab roof left

20E048a

E48a

Working light cab roof left

20E048b

H48b

Working light cab roof right

20E048c

H48c

Working light cab roof right

20E090

R90

Operator seat heater

20E160

H160

Reading lamp

20G009

M9

Blower air condition

20G010

M10

Excess pressure blower (new cab)

20G027

M27

Water pump washbasin

20G501

Y3a

Pump windscreen wash system

13-34

Version 2010/1


New code

Previous code


Component For activ independent heater mixing-valve-control switch over from air condition too pre-heating

20K048 20K056

E56

Control panel independent heater Hydronic M

20K057

E57

Timer independent heater Hydronic M

20K166

K166

Switch over blower control between air condition and pre-heating

20K167

K167

Pre-heating on (TT)

20K309

CAN-Node 9 (ICND)

20K310

CAN-Node 10 (ICNV)

20K351

9E1

Fire warning system ANSUL for electric machinery room or fire suppression system ANSUL for diesel machinery room

20K352

9E2

Fire suppression system ANSUL for LV- and HV switch cabinetHV switch cabinet

20K464

E64

Control unit camera cab support

20K467

E67

Control unit camera counterweight left

20K470

E70

Control unit camera counterweight right

20K473

Control unit camera cable delivery

20M004

M4

Windscreen wiper motor upper

20M004a

3M4a

Blower motor under operator seat for TT

20M004b

3M4b

Blower motor under refrigerator for TT

20M007

M7

Windscreen wiper motor lower

20M025

M25

Operator seat adjust

20P022

H22

Acoustic signal for messages

20P025

E25

Radio

20P026

M26

Mirror right

20P026a

M26a

Mirror left

20P047

E47

VHMS monitor MH801

20P056

H56

Acoustic shutdown pre-warning

20P072

H72

Speaker

20P073

H73

Speaker

20P093a

H93a

Rotaflare light left

20P093b

H93b

Rotaflare light right

20P145-1

H145-1

VHMS-diagnostic lamp red 1

20P145-2

H145-2

VHMS-diagnostic lamp red 2

20P146-1

H146-1

VHMS-diagnostic lamp yellow 1

20P146-2

H146-2

VHMS-diagnostic lamp yellow 2

20P465

E65

Monitor camera cab support

20P468

E68

Monitor camera counterweight left

20P471

E71

Monitor camera counterweight rechts

20P474

E74

Monitor camera cable delivery

Version 2010/1

13-35


New code

Previous code


Component

20Q048a

Mixing valve control by pre-heating

20Q048b

Mixing valve control by air condition

20Q067

K67

Excess pressure blower cab

20Q097

Y97

Mixing valve for heater

20Q166

K166

Blower on by independent heater (TT)

20Q166a

Use constant blower speed signal from independent heater (10 V)

20Q166b

Use analog blower speed signal from air condition

20Q166c

Use blower supply from independent heater

20Q166d

Use blower supply from air condition

20Q167a

Swtich on independent heater if pre-heating system is switched on

20Q167b

Switch on independent heater by timer signal of independent heater

20Q193

K193

Windscreen wiper lower stop

20Q194

K194

Windscreen wiper upper stop

20Q195

K195

Windscreen wiper lower slow

20Q196

K196

Windscreen wiper lower fast

20Q197

K197

Windscreen wiper upper slow

20Q198

K198

Windscreen wiper upper fast

20R009

Resistor array

20R019

Diode array

20R101

Terminal resistor CAN-Bus

20R353

9R3

Terminal resistor fire sensor 10 V constant voltage generation for heater-blower-motor speed-signal in case of activ independent heater

20R560 20S001

S1

Key switch

20S004-1

S4-1

Motor / Engine start button 1

20S004-2

S4-2

Motor / Engine start button 2

20S005-1

S5-1

Motor / Engine stop button 1

20S005-2

S5-2

Motor / Engine stop button 2

20S006

S6

Horn contact

20S010

S10

Windscreen wiper wash system switch

20S011

S11

Windscreen wiper mode switch

20S016

S16

Switch cab indoor light

20S018a

S18a

Switch lighting ladder

20S019

E19

Lever right

20S020

E20

Lever left

20S021a

E21a

Pedal move, left crawler

20S021b

E21b

Pedal move, right crawler

20S022

E22

Pedal slew brake

20S023

E23

Pedal left (BC), clam close

13-36

Version 2010/1



New code

Previous code

Component

20S024

E24

Pedal right (BC), clam open

20S026a

E26a

Control panel air condition

20S029

S29

Switch slew parking brake

20S030

S30

Engine speed switch

20S034

S34

EBL-bypass

20S036

S36/0S36

Emergency shutdown cab

20S038

S38

Switch cab light

20S040

S40

Switch excess pressure blower cab

20S042

S42

Truck counter 2

20S053

S53

Service enable motor control QUANTUM for both engines

20S055

S55

Rotaflare light on

20S082

S82

Truck counter 1

20S086

S86

Operator seat adjust

20S088

S88

Mirror adjustment

20S089

S89

Operator seat heater on

20S094

S94

Enable service arm

20S095

S95

Floating position switch

20S096

S96

Mirror heater on

20S098

S98

Floating position switch

20S099

S99

CLS 2, central lubrication system attachment, manual lubrication

20S105

S105

Lock lever at operator seat

20S120

4S20/S20

Switch superstructure lighting

20S120a

S20a

Switch superstructure lighting (option)

20S124

S24

CLS 1, central lubrication system 1, button for manual lubrication cycles

20S126

S26

SLS, slew lubrication system, manual lubrication

20S154

S154

Slew speed mode

20W323

WLAN-Interface cable between cab floor and dashboard (MTC<=>PC)

20X015-1

QUANTUM 1, RS232-Interface in cab

20X015-2

QUANTUM 2, RS232-Interface in cab

20X027a

X27a

VHMS: Download or programming in cab

20X031

X31

Socket cab outside

20X032

X32

Socket cab inside

20X033

X33

Socket cab inside

20X034

X34

Socket cab inside

20X035

X35

Socket cab inside

20X052-1

Diagnose connector in cab, QUANTUM 1, J1587

20X052-2

Diagnose connector in cab, QUANTUM 2, J1587

20X093a

Version 2010/1

X11a

Connector rotaflare light left

13-37



New code

Previous code

Component

20X093b

X11b

Connector rotaflare light right

20X110

X13

Service connector in der cab, load limit regulation

20X309


20X323

WLAN-Interface connector in cab (MTC<=>PC)

20X335b

CAN-Bus-T-Splitter to dispatch monitor HUB in cab support

20X335d

CAN-Bus-T-Splitter to dispatch monitor display in cab

20X335e

CAN-Bus-T-Splitter to service connector MH801

20X336

Service connector MH801 in cab

20X399


20X401

4X1

Socket cab

20X402

4X2

Socket cab

30a000

Drive

30B701

6B1

Temperature sensor in HV switch cabinet

30B703A

0B3-1

Temperature sensor transformer A

30B703B

0B3-2

Temperature sensor transformer B

30B704A

0B3-1


30B704B

0B3-2


30B705A

0B3-1


30B705B

0B3-2


30B706

2B6

Temperature switch air condition in HV switch cabinet

30B707

2B7

Dampness switch air condition in HV switch cabinet

30B753

9B3

Temperature sensor HV switch cabinet fire suppression system

30B754

9B4


30B755

9B5


30B810

0S10

Limit switch at HV switch cabinet

30B811

0S11

Limit switch at transformer room

30E721

3R21

Heater for HV switch cabinet

30E722

3R22

Heater for HV switch cabinet

30E722a

3R22a

Heater am HV switch cabinet

30E723

Heater transformer room

30E802

7H2

Lighting in HV switch cabinet

30T706A

0T6-1

Transformer system voltage A

30T706B

0T6-2

Transformer system voltage B

31a000

Diesel tank

31B063

B63

Level fuel tank

31G140

Y140

Fuel pump Hydronic M

31Q599-1

Y99-1

Fuel valve motor 1

31Q599-2

Y99-2

Fuel valve motor 2

13-38

Version 2010/1


New code

Previous code

32a000


Component HV - switch cabinet

32B802

6B2

Temperature switch at HV switch cabinet

32F701-1

0F1-1

Circuit breaker for motor 1

32F701-2

0F1-2

Circuit breaker for motor 2

32F702

0F2

HV primary circuit breaker for system transformer 1 and 2

32F703-1

0F3-1

Over voltage protection at motor 1 (discharger)

32F703-2

0F3-2

Over voltage protection at motor 2 (discharger)

32F707

0F7

Over voltage protection in high voltage (VDR-resistor)

32Q700

0Q1

Main switch

32Q701-1

0K1-1

Vacuum contactor motor 1

32Q701-2

0K1-2

Vacuum contactor motor 2

32T701-1

0T1-1

Current transformer phase 1 motor 1

32T701-2

0T1-2


32T702-1

0T2-1


32T702-2

0T2-2


32T703-1

0T3-1


32T703-2

0T3-2


32T704

0T4

Voltage transformer between high voltage and low voltage

32T705

0T5

Voltage transformer between high voltage and low voltage

33a000 33X003

Low voltage in HV switch cabinet 0X3

34a000

Terminal strip in HV switch cabinet Air condition at HV switch cabinet

34B001

3B1

Temperature switch heater at HV switch cabinet

34B001a

*B1Ta

Thermostat evaporator HV switch cabinet

34B001b

*B1Tb

Thermostat evaporator HV switch cabinet

34B001f

*B1F

Pressure switch capacitor HV switch cabinet (lower pressure limit)

34B006

2B6

Temperature switch air condition at HV switch cabinet

34B007

2B7

Dampness switch air condition at HV switch cabinet

34B011f

*B11F

Pressure switch capacitor HV switch cabinet (upper pressure limit)

34E801

2M1

Air condition compressor HV switch cabinet

34E802

*2R1

Heater air condition compressor HV switch cabinet

34F001

*A1P

Motor protection relay compressor drive HV switch cabinet

34G001

*M1G

Blower evaporator HV switch cabinet

34G021

*M21M

Blower liquefier HV switch cabinet

34G022

*M22M

Blower liquefier HV switch cabinet

34K801

2E1

Air condition HV switch cabinet

34M801

*M1V

Compressor motor HV switch cabinet

40a000

Version 2010/1

hydraulic oil tank

13-39



New code

Previous code

Component

40B004

B4

Very low hydraulic oil level

40B024

B24

Hydraulic oil tank air filter monitoring

40B031

S31

Shut-off valve oil tank open

40B050

B50

Oil level too low (Refill indicator)

40B068

B68

Level return oil chamber (Nur PC8000)

40B105

B105

Level hydraulic oil

40B111

B111

Temperature sensor transfer pump

40B163

B163

Pressure return oil chamber

40B164

B164

Pressure leak oil chamber

40B165

B165

Pressure oil cooler

40B166

B166

Pressure preload valve return oil

40B260

1B60

Pre-heating temperature switch heating element 4E60

40B261

1B61


40B262

1B62


40B263

1B63


40B264

1B64


40B265

1B65


40B267

1B67

Pre-heating temperature switch hydraulic oiltank

40E260

Pre-heating hydraulic oil heating element

40E261


40E262


40E263


40E264


40E265


40G018

M8

Transfer pump hydraulic oil

40K311

CAN-Node 11 (ICND)

40K312

CAN-Node 12 (ICND)

40K313

CAN-Node 13 (ICNV)

40K601

Y101

Reducing preload pressure oil cooler

40Q062

K62 / 5K62

Electronic relay 35 A for transfer pump 30 A

40R008

Pull-up/-down-resistors (resistor array)

40R014

Diode array

40R101

Terminal resistor CAN-Bus

40S035

S35

Transfer pump on

40X310

CAN-Bus-Connector

40X311


40X312


40X313


13-40

Version 2010/1


New code

Previous code

Component

40X314

CAN-Bus-Connector

41a000

Oil cooler

41E050

H50

Light oil cooler

41E050a

H50a

Light oil cooler

41E050b

H50b

Light oil cooler

41E050c

H50c

Light oil cooler

41E050d

H50d

Light oil cooler

50a000 50B353


Machinery room 9S3

50Q352

Fire sensor Set free extinguishing medium (igniter)

50R352

9R2

Terminal resistor fire sensor

50S058

S58/1S58

Service safty switch

50X020

X20

External start socket

50X201

Main supply connector for pre-heating

51a000

Motor room

51B110

B110

Intake air temperature

51E041

H43

Lighting pump room

51E041a

H43a

Lighting pump room

51E041e

H43c

Lighting motor room

51E041f

H43d

Lighting motor room

51E219-1

Pre-heating coolant

51E219-2

Pre-heating coolant

51K001a-1

K1a-1

Engine start relay motor 1

51K001a-2

K1a-2


51K001b-1

K1b-1

Engine start relay motor 1 redundant

51K001b-2

K1b-2

Engine start relay motor 2 redundant

51K003b-1

K3b-1

Engine running 1

51K003b-2

K3b-2

Engine running 2

51K003c-1

K3c-1

Engine running 1

51K003c-2

K3c-2

Engine running 2

51K045-1

K45-1

Engine speed control 1

51K045-2

K45-2

Engine speed control 2

51K164-1

K164-1

Relay for RESERVE - system motor oil tank not empty for motor 1

51K164-2

K164-2

Relay for RESERVE - system motor oil tank not empty for motor 2

51K317

CAN-Node 17 (ICND)

51K318

CAN-Node 18 (ICNV)

51K319

CAN-Node 19 (ICNV)

51R008


Version 2010/1

13-41


New code

Previous code


Component

51R009


51R013

Diode array (3 A)

51R017

Diode array (3 A)

51S015a

S15a

Lighting pump room / motor room

51S033d

S33d

Emergency stop button engine room (only PC5500 and PC8000)

51T017

E7

Measuring transducer charging-/discharging current

51T018-1

E8-1

Measuring transducer engine speed engine 1

51T018-2

E8-2

Measuring transducer engine speed engine 2

51X008

X8

Socket engine room

51X316

CAN-Bus-Connector

51X317


51X318


51X319


51X320

CAN-Bus-Connector

51X403

4X3

Socket machinery room

51X404

4X4

Socket machinery room

51X405

4X5

Socket machinery room optional

51X405a

4X5a

Socket machinery room optional

51X406

4X6

Welding socket machinery room

52a000

Motor

52B002-1

0B2-1

Motor winding temperature sensor motor 1

52B002-2

0B2-2


52B002a-1

0B2a-1


52B002a-2

0B2a-2


52B002b-1

0B2b-1


52B002b-2

0B2b-2


52B006-1

0B6-1

Motor bearing temperature sensor motor 1 power take-off side

52B006-2

0B6-2

Motor bearing temperature sensor motor 2 power take-off side

52B007-1

0B7-1

Motor bearing temperature sensor motor 1 not power take-off side

52B007-2

0B7-2

Motor bearing temperature sensor motor 2 not power take-off side

52B018-1

B18-1

Monitoring engine intake air filter engine 1

52B018-2

B18-2


52B019-1

B19-1


52B019-2

B19-2


52B064-1

3B64-1

Speed sensor, magnetic pickup 1

52B064-2

3B64-2

Speed sensor, magnetic pickup 2

52B093-1

3B93-1

Engine pre lub pressure reached

52B093-2

3B93-2

Engine pre lub pressure reached

13-42

Version 2010/1



New code

Previous code

Component

52B101-1

0S1-1

Capacitor pressure switch at motor 1

52B101-2

0S1-2


52B102-1

0S2-1


52B102-2

0S2-2


52B201-1

1B1

Pre-heating temperature switch motor oil

52B201-2

1B1

Pre-heating temperature switch motor oil

52C001-1

0C1-1


52C001-2

0C1-2


52E017-1

3R17-1

Motor standstill heater 0.,47 KW

52E017-2

3R17-2

Motor standstill heater 0.47 KW

52E201-1

1R1

Pre-heating motor oil 1

52E201-2

1R1

Pre-heating motor oil 2

52F0039-1

Circuit breaker pre lub pump 1 (300 A)

52F0039-2

Circuit breaker pre lub pump 2 (300 A)

52G005-1

3G5-1

Generator

52G005-2

3G5-2

Generator

52G006-1

3M6-1

Pre lub pump

52G006-2

3M6-2

Pre lub pump

52G045-1

3E45-1

Motor oil refilling system

52G045-2

3E45-2

Motor oil refilling system

52K014-1

3E14-1

Engine controller QUANTUM 1

52K014-2

3E14-2

Engine controller QUANTUM 2

52K030-1

3D30-1

Timer engine pre lub 1

52K030-2

3D30-2

Timer engine pre lub 2

52M001-1

3M1-1

Starter 1 (engine 1)

52M001-2

3M1-2


52M002-1

3M2-1


52M002-2

3M2-2


52M101-1

0M1-1

E-Motor 1

52M101-2

0M1-2

E-Motor 2

52Q002a-1

3K2a-1

Starter 1 for engine 1 on

52Q002a-2

3K2a-2

Starter 1 for engine 2 on

52Q002b-1

3K2b-1

Starter 2 for engine 1 on redundant

52Q002b-2

3K2b-2

Starter 2 for engine 2 on redundant

52Q004-1

Y4

Magnetic clutch air condition

52Q030a-1

3K30a-1

Pre lub pump 1 on

52Q030a-2

3K30a-2

Pre lub pump 2 on

52Q502a-1

Y2-1

Cold start engine 1 valve a

Version 2010/1

13-43



New code

Previous code

Component

52Q502a-2

Y2-2

Cold start engine 2 valve a

52Q502b-1

Y2a-1

Cold start engine 1 valve b

52Q502b-2

Y2a-2

Cold start engine 2 valve b

54a000

Counterweight

54B466

E66

Camera counterweight left

54B469

E69

Camera counterweight right

54E144

H144

Light counterweight

54E144a

H144a

Light counterweight

54E144b

H144b

Light counterweight to cable drum

54S007

S7

Operator warning system, pull key

54S008

S8

Operator warning system, pull key

54S051

S54

Ground shutdown, pull switch

54S052

S54a

Ground shutdown, pull switch

54X008b

X8c

Socket counterweight

55a000

Service arm

55B023

S23

Service arm near upper position

55P052

H52

Hydraulic tank full

55P076

H76

CLS 1 Central lubrication system full

55P078

H78

SLS Slew lubrication system full

55P080

H80

CLS 2 Central lubrication system attachment full

55P139

H139

Signal lamp fuel tank full

55P142-1

H142-1

Signal lamp motor oil tank 1 full

55P142-2

H142-1

Signal lamp motor oil tank 2 full

55S043

S43

Lamp test service arm

55S087

S87

Pull switch service arm

56a000

Pump room

56E041b

H41

Lighting pump room

56E041c

H41a

Lighting pump room

56E041d

H41b

Lighting pump room

56K053-1

E53-1

Blower speed PWM-Converter for coolant 1

56K053-2

E53-2

Blower speed PWM-Converter for coolant 2

56K250a

K250a

Slew gear parking brake

56K250b

K250b


56K251a

K251a

Travel parking brake

56K251b

k251b


56K252a

K252a

Hydraulic slew gear parking brake

56K252b

k252b

Hydraulic slew gear parking brake

56K253a

13-44

Ladder up

Version 2010/1


New code

Previous code


Component

56K253b

Ladder up redundant

56K254a

Ladder down

56K254b

Ladder down redundant

56K255a

Service arm up

56K255b

Service arm up redundant

56K256a

Service arm down

56K256b

Service arm down redundant

56K314

CAN-Node 14 (ICND)

56K315

CAN-Node 15 (ICNV)

56K316

CAN-Node 16 (ICNV)

56R008

Resistor array

56R013

Diode array

56R014

Diode array

56S015

S15

Lighting pump room / motor room

56X008a

X8a

Socket pump room

56X313

CAN-Bus-Connector at switch cabinet pump room

56X314


56X315


56X316


56X317

CAN-Bus-Connector at switch cabinet pump room

57a000

Control plate, pump

57B016

B16

Pressure brake slew gear

57B017-1

B17-1

Pressure gear lubrication

57B017-2

B17-2

Pressure gear lubrication

57B021-1

B21-1

Filter fan drive cooler

57B021-2

B21-2

Filter fan drive cooler

57B022-1

B22-1

Filter pump regulation

57B022-2

B22-2

Filter pump regulation

57B027-1

B27-1

Filter gear oil

57B027-2

B27-2

Filter gear oil

57B028-1

B28-1

Filter fan drive oil cooler

57B028-2

B28-2

Filter fan drive oil cooler

57B048

B48

Pressure travel parking brake

57B049-1

B49-1

Gear oil temperature

57B049-2

B49-2


57B085-1

B85-1

X1-Pressure, motor / engine 1

57B085-2

B85-2

X1-Pressure, motor / engine 2

57B086

B86

X2-Pressure

Version 2010/1

13-45



New code

Previous code

Component

57B097-1

B97-1

Pump support pressure X4-1

57B097-2

B97-2

Pump support pressure X4-2

57B175-1

B175-1

Total loss gear oil

57B175-2

B175-2

Total loss gear oil

57B202-1

1B2

Pre-heating temperature switch PTO 1

57B202-2

1B2

Pre-heating temperature switch PTO 1

57E202-1

1R2, 3R23-1

Pre-heating heater PTO 1

57E202-2

1R2, 3R23-2


57E203-1

1R3, 3R24-1


57E203-2

1R3, 3R24-2


57K506a-1

Y6a-1

Fan drive oil cooler minimum

57K506a-2

Y6a-2

Fan drive oil cooler minimum

57K506b-1

Y6b-1

Fan drive oil cooler medium

57K506b-2

Y6b-2

Fan drive oil cooler medium

57K517

Y17

Pump control, Qmin-off

57K517a

Y17a

Pump control, Half-Qmax-off

57K548

Y48

Slew motor pivoting angle (only PC5500)

57K553-1

Y53-1

Gear oil cooler preload pressure

57K553-2

Y53-2

Gear oil cooler preload pressure

57K561-1

Y61-1

Load limit regulation valve

57K561-2

Y61-2

Load limit regulation valve

57K602-1

Y102-1

Switch off pump support pressure

57K602-2

Y102-2

Switch off pump support pressure

57K620

Y120

Hydraulic brake

57K626

Y126

Pump control, 57K517 at pump 1

57K630

Y130

Pump control, fixed pump 1 for slew gear

57K631

Y131

Pump control, fixed pump 3 for slew gear

57K636-1

Y136-1

Proportional valve fan coolant

57K636-2

Y136-2

Proportional valve fan coolant

57K646

Y146

Loss reduction pump 2+4

57K647

Y147

Loss reduction pump 3

57K648

Y148

Loss reduction pump 1

57K658f

Control pump 1 F

57K658r

Control pump 1 R

57K659f

Control pump 2 F

57K659r

Control pump 2 R

57K660f

Control pump 3 F

57K660r

Control pump 3 R

13-46

Version 2010/1


New code

Previous code


Component

57K661f

Control pump 4 F

57K661r

Control pump 4 R

57K662f

Control pump 5 F

57K662r

Control pump 5 R

57K663f

Control pump 6 F

57K663r

Control pump 6 R

57K664f

Control pump 7 F

57K664r

Control pump 7 R

57K665f

Control pump 8 F

57K665r

Control pump 8 R

57Q505

Y5


57Q516

Y16


57Q623a

Y123a

Valve ladder up

57Q623b

Y123b

Valve ladder down

57Q624a

Y124a

Valve service arm up

57Q624b

Y124b

Valve service arm down

57Q624c

Y124c

Valve service arm enable

57Q625

Y125

Valve ladder fast

57Q627

Y127

Proportional valve brake

57S033c

S33c

Emergency stop button control- and filter panel

59a000

Suction oil tank

59B015

B15

Temperature hydraulic oil

59B162

B162

Pressure suction oil tank

59B203

1B3

Pre-heating temperature switch suction oil tank

59E210

1R10

Pre-heating suction oil tank

59E211

1R11

Pre-heating suction oil tank

60a000

Superstructure

60B059

S59

Angle limit beetween supertructure and undercarriage

60B098

B98

Inductive proximity at sprocket

60B099

B99

Inductive proximity at sprocket

60B472

E72

Camera counterweight cable delivery

60E030

3R30

Pipe heater for fire suppression system

60E049

H49

Outside lighting superstructure atrium center

60E049a

H49a


60E049b

H49b


60E049c

H49c


60E144c

H144c

Light superstructure left

60E144d

H144d

Light superstructure right

Version 2010/1

13-47



New code

Previous code

Component

60E148

4H48

Working lighting sodium discharge lamp 400W

60E149

4H49


60E150

4H50


60E150a

4H50a


60E244

4H144


60E244a

4H144a


60E244b

4H144b


60E244c

4H144c


60P140

H140

Travel alarm

60P351

9H1

Horn for fire ralarm

60S152

S152

Switch lighting superstructure

61a000

Control blocks, Remote control panels

61B087a

B87a

Input pressure control block 1

61B087b

B87b


61B087c

B87c


61B087d

B87d


61B158a

pressure pump 1

61B158b

pressure pump 2

61B158c

pressure pump 3

61B158d

pressure pump 4

61B158e

pressure pump 5

61B158f

pressure pump 6

61B158g

pressure pump 7

61B158h

pressure pump 8

61K071

Y71

Speed bucket BH

61K520

Y20

Directional spool valve boom up (PC4000-6)

61K521

Y21

Directional spool valve boom down (PC4000-6)

61K522

Y22

Directional spool valve bucket fill BC (PC4000-6)

61K523

Y23

Directional spool valve bucket dump BC (PC4000-6)

61K524

Y24

Directional spool valve slew gear left (PC4000-6)

61K525

Y25

Directional spool valve slew gear right (PC4000-6)

61K526

Y26


61K527

Y27


61K528

Y28

Proportional valve crawler right forward (PC4000-6)

61K529

Y29

Proportional valve crawler right backward (PC4000-6)

61K530

Y30

Directional spool valve stick in BH (PC4000-6)

61K531

Y31

Directional spool valve stick out BH (PC4000-6)

61K532

Y32


13-48

Version 2010/1



New code

Previous code

Component

61K533

Y33


61K534

Y34

Directional spool valve crawler left forward (PC4000-6)

61K535

Y35

Directional spool valve crawler left backward (PC4000-6)

61K536

Y36

Directional spool valve bucket fill BH (PC4000-6)

61K537

Y37

Directional spool valve bucket dump BH (PC4000-6)

61K538

Y38


61K539

Y39


61K540

Y40


61K541

Y41


61K542

Y42

Stick in (PC4000-6)

61K543

Y43

Stick out (PC4000-6)

61K544

Y44

Bucket fill (PC4000-6)

61K545

Y45

Bucket dump (PC4000-6)

61K546

Y46

Boom up (PC4000-6)

61K547

Y47

Boom down (PC4000-6)

61K563

Y63

Speed boom (PC4000-6)

61K564

Y64

Speed bucket BC (PC4000-6)

61K565

Y65

Speed slew gear (PC4000-6)

61K566

Y66

Proportional valve speed slew gear (PC4000-6)

61K567

Y67

Proportional valve speed crawler right (PC4000-6)

61K568

Y68

Proportional valve speed stick BH (PC4000-6)

61K569

Y69

Proportional valve speed boom (PC4000-6)

61K570

Y70

Proportional valve speed crawler left (PC4000-6)

61K572

Y72


61K573

Y73


61K574

Y74

Proportional valve speed stick (PC4000-6)

61K575

Y75

Proportional valve speed bucket (PC4000-6)

61K576

Y76


61K620

Y20

Proportional valve speed crawler left (PC5500-6)

61K620a

Y20a

Directional spool valve crawler left forward (PC5500-6)

61K620b

Y20b

Directional spool valve crawler left backward (PC5500-6)

61K621

Y21


61K621a

Y21a

Directional spool valve stick out (PC5500-6)

61K621b

Y21b

Directional spool valve stick in (PC5500-6)

61K622

Y22


61K622a

Y22a

Directional spool valve bucket fill (PC5500-6)

61K622b

Y22b

Directional spool valve bucket dump (PC5500-6)

61K623

Y23


Version 2010/1

13-49



New code

Previous code

Component

61K623a

Y23a


61K623b

Y23b


61K624

Y24

Proportional valve speed clam BC (PC5500-6)

61K624

Y24

Proportional valve speed bucket BH (PC5500-6)

61K624a

Y24a

Directional spool valve bucket fill BH (PC5500-6)

61K624a

Y24a

Directional spool valve clam close BC (PC5500-6)

61K624b

Y24b

Directional spool valve bucket dump BH (PC5500-6)

61K624b

Y24b

Directional spool valve clam open BC (PC5500-6)

61K625

Y25


61K625

Y25

Proportional valve speed bucket BC (PC5500-6)

61K625a

Y25a

Directional spool valve bucket fill BC (PC5500-6)

61K625a

Y25a

Directional spool valve boom up BH (PC5500-6)

61K625b

Y25b

Directional spool valve bucket dump BC (PC5500-6)

61K625b

Y25b

Directional spool valve boom down BH (PC5500-6)

61K626

Y26

Proportional valve speed boom BC (PC5500-6)

61K626a

Y26a

Directional spool valve boom up BC (PC5500-6)

61K626b

Y26b

Directional spool valve boom down BC (PC5500-6)

61K627

Y27

Directional spool valve speed stick (PC5500-6)

61K627a

Y27a

Directional spool valve stick in (PC5500-6)

61K627b

Y27b

Directional spool valve stick out (PC5500-6)

61K628

Y28

Proportional valve speed crawler right (PC5500-6)

61K628a

Y28a

Directional spool valve crawler right backward (PC5500-6)

61K628b

Y28b

Directional spool valve crawler right forward (PC5500-6)

61K629

Y29


61K629a

Y29a


61K629b

Y29b


61K630

Y30


61K630a

Y30a

Directional spool valve bucket fill (PC5500-6)

61K630b

Y30b

Directional spool valve bucket dump (PC5500-6)

61K631

Y31


61K631a

Y31a


61K631a

Y31a

Directional spool valve stick out BC (PC5500-6)

61K631b

Y31b


61K631b

Y31b

Directional spool valve stick in BC (PC5500-6)

61K632

Y32

Proportional valve speed slew gear (PC5500-6)

61K632a

Y32a


61K632b

Y32b


61Q632a

Y132a

Floating position stick (PC4000)

13-50

Version 2010/1


New code

Previous code

Component

61Q633a

Y133a

Floating position stick (PC4000)

61Q635a

Y135a

Floating position boom (PC4000)

61S033b

S33b

Emergency stop button valve block

62a000


Lubrication systems

80B043

B43

CLS 1 Central lubrcation system 1 end line pressure switch for lubrication line (for CLS 1 if CLS 2 installed !)

62B046

B46

SLS Slew lubrication system end line pressure switch for lubrication line

62B108-H

B108

CLS 1 Central lubrcation system container level monitoring

62B108-M

B108

CLS 1 Central lubrcation system container level monitoring

62B108b-H

B108b

CLS 1 Central lubrcation system changing barrel pre-warning

62B108b-M

B108b

CLS 1 Central lubrcation system changing barrel pre-warning

62B108c-H

B108c

CLS 1 Central lubrcation system changing barrel empty

62B108c-M

B108c

CLS 1 Central lubrcation system changing barrel empty

62B109-H

B109

SLS Slew lubrcation system container level monitoring

62B109-K

B109


62B109-M

B109


62B109b-H

B109b

SLS Slew lubrcation system changing barrel pre-warning

62B109b-K

B109b


62B109b-M

B109b


62B109c-H

B109c

SLS Slew lubrcation system changing barrel empty

62B109c-K

B109c


62B109c-M

B109c


62B112b

B112b

CLS 2 lubrication system attachment changing barrel pre-warning

62B112c

B112c

CLS 2 lubrication system attachment changing barrel empty

62B173

B173

CLS 2 lubrication system attachment container level monitoring

62B208

B108

CLS 1 Central lubrcation system container level monitoring binary

62B209

B109

SLS Slew lubrcation system container level monitoring binary

62B273

B173

CLS 2 lubrication system attachment container level monitoring binary

62Q507-H

Y7

CLS 1 Central lubrcation system lubrication pump on

62Q507-M

Y7

CLS 1 Central lubrcation system lubrication pump on

62Q507a-H

Y7a

CLS 1 Central lubrcation system release lubrication line

62Q507a-M

Y7a

CLS 1 Central lubrcation system release lubrication line

62Q509-H

Y9

SLS Slew lubrcation system lubrication pump on

62Q509-K

Y9


62Q509-M

Y9


62Q509a-H

Y9a

SLS Slew lubrcation system release lubrication line

62Q509a-K

Y9a


62Q509a-M

Y9a


62Q642-M

Y142

CLS 2 lubrication system attachment lubrication pump on

Version 2010/1

13-51



New code

Previous code

Component

62Q642a-M

Y142a

CLS 2 lubrication system attachment release lubrication line

63a000

Reserve motor oil tank

63B103-1

B103-1

Engine oil tank empty 1

63B103-2

B103-2

Engine oil tank empty 2

63B106-1

B106-1

Level motor oil tank

63B106-2

B106-2

Level motor oil tank

63B204-1

1B4

Pre-heating temperature switch reserve oil tank

63B204-2

1B4

Pre-heating temperature switch reserve oil tank

63E212-1

1R12

Pre-heating reserve oil tank

63E212-2

1R12

Pre-heating reserve oil tank

65a000

Coolant pre-heater

65B210-1

Temperature switch coolant

65B210-2

Temperature switch coolant

65F210

Circuit breaker coolant pre-heating transformer secondary side (10A)

65F211

Circuit breaker coolant pre-heating transformer secondary side (10A)

65F212

Circuit breaker coolant pre-heating pump motor (3A)

65F213

Circuit breaker coolant pre-heating control transformer primary side (3A)

65G211-1

Pump coolant pre-heating

65G211-2

Pump coolant pre-heating

65K202-1

Pre-heating control coolant

65K202-2

Pre-heating control coolant

65Q210-1

Coolant pre-heating heater on

65Q210-2

Coolant pre-heating heater on

65Q211-1

Pump coolant pre-heating on

65Q211-2

Pump coolant pre-heating on

65T202-1

Control voltage transformer coolant pre-heating

65T202-2

Control voltage transformer coolant pre-heating

67a000

Crane

67M012

5M12

68a000

Motor crane machinery room (option) Compressor

68M013

5M13

Motor air compressor (option)

68S010a

5S10a/5S16

Switch air compressor

70a000

Ladder

70B091

S91

Ladder down

70B122

S22

Ladder up

70E047

H47

Lighting ladder

70E047a

H47a

Lighting ladder

70S018

S18

Switch lighting ladder

13-52

Version 2010/1


New code

Previous code

Component

70S033a

S33a/0S33a

Emergency stop button ladder

70S084

S84

Ladder turn switch up / down

70S084a

S84a

Pull switch ladder down

70X406a

4X6a

Welding socket ladder

71a000


Battery box

71B050

1B50

Temperature transmitter batteries

71B051

1B51

Temperature transmitter batteries

71B052

1B52

Temperature transmitter Batteries emergency lighting

71B250

1B50

Battery temperature transmitter

71E204

Pre-heating start battery

71E205


71E206


71E207


71G001

G1

Battery 1

71G002

G2

Battery 2

71G003

7G1

Battery 3 (E: Emergency lighting)

71G004

7G2

Battery 4 (E: Emergency lighting)

71Q002

S2

Battery main switch control battery

71Q003

S3

Battery main switch for starter 2 and functional earth

71Q004

S2

Battery main switch for starter 1

71Q007

7S1

Battery main switch battery emergency light

71T003

R3

Shunt for measurement of charging- and discharging current

80a000

Attachment

80B020

B20

Pendulum bucket

80B043

B43

CLS 1 Central lubrcation system 1 end line pressure switch lubrication line for CLS 1 without CLS 2

80B174

B174

CLS 2 Central lubrcation system 2 (attachment lubrication system) end line pressure switch lubrication line

90a000

Undercarriage

91a000

Cable drum

91B006a

8S6a

Tight cable

91B006b

8S6b

Slacking cable

91B904a

8S4a

Full cable drum

91B904b

8S4b

Empty cable drum

91B908a

8S8a

Diagonally pulling

91B908b

8S8b

Diagonally pulling

91B909a

8S9a

Diagonally pulling

91B909b

8S9b

Diagonally pulling

91B911

8S11

Antenna style switch

Version 2010/1

13-53



New code

Previous code

Component

91B912

8S12

Ground collision detection

91B913

8S13

Ground collision detection

91B914

8S14


91B915

8S15


91B917

0S17

Limit switch at cable drum (body)

91B918

0S18

Limit switch at cable drum (body)

91B919

8S10


91B979

8F79

Temperature monitoring cable drum motor

91B980

8B79

Transducer for Pt100 at cable drum motor

91E929

3R20

Heating cable drum

91E927

Heater in switch cabinet cable drum

91E929

3R27

Heater in cable drum switch cabinet

91F911

8F13

Circuit breaker rotor circuit

91K320

CAN-Node 20 (ICND)

91K321

CAN-Node 21 (ICNV)

91M906

8M6

Drive motor cable drum

91Q907

8K8

Contactor for cable drum wound up

91Q908

8K11

Contactor for cable drum unwound

91Q911

8K7

Contactor for cable drum high torque

91R901

8R1

3 phasic series resistor for torque reduction

91R973

CAN-BUS-Terminal-Resistor at cable drum

91R974

Resistor array

91R975

Diode array (3A)

91R976

Resistor array

91S901

8S1

Mode selection switch cable drum

91S933e

S33e/0S33e

Emergency stop button cable drum

91U007

Terminal box for controller at cable drum

91U008

X8

Switch cabinet at cable drum

91W901

0E1

Slip-ring-box in cable drum

91X007 91X008

Terminal strip in switch cabinet at cable drum (controller switch cabinet) X8

Terminal strip in switch cabinet at cable drum

91X191

Connector for internal wiring at cable drum

91X194

Connector from controller 91U007 terminal box to HV terminal box

91X291

Connector for internal wiring at cable drum

91X319

CAN-Bus-Connector

91X320


91X321


91X391

Connector for internal wiring at cable drum (from terminal box controller to terminal box contactors, low voltage)

13-54

Version 2010/1


New code

Previous code


Component

92a000

Rotary transmission (hydr.)

93a000

Slip-ring-box (elec.)

93B004

0S4

Limit switch at slip-ring-box

93B004a

0S4a

Limit switch at slip-ring-box

93E918

3R18

Heater slip-ring-box HV room

93E918b

3R18b

Heater slip-ring-box LV room

93E993

3H3

Lighting slip-ring-box

93T909

0T9

Transformer slip-ring-box for lighting

93W901

0E2

Slip-ring-box in cable drum

93W902

0E2

Slip-ring-box between undercarriage and superstructure

93X011

3X2

Terminal strip in Slip-ring-box to cab support

94a000

Terminal box cable drum

94B919

0S19

Limit switch flap-terminal box

94E919

3R19

Heater terminal box cable drum

94F901

0F01

Over voltage protection phase 1

94F902

0F02


94F903

0F03


94F904

0F04

Over voltage protection pilot wire

94F905

Over voltage protection pilot wire

94X091

0X4

Terminal strip in terminal box

94X902

0X2

HV socket

Version 2010/1

13-55


13-56


Version 2010/1

VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM

14. VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM

Version 2010/1

14-1

General


14.1

GENERAL

Fig. 14-1

Data flow and control of the Vehicle Health Monitoring System

14-2

Version 2010/1


General

The Vehicle Health Monitoring System (VHMS) is an electronic on-board monitoring system which includes the functions REAL TIME MONITOR, basic adjustments, and history reporting. Details are as follows: z

System and component monitoring based on fault code detection and storage of faults and other events, incl. trend snapshot data etc.

z

Selected subsystems and components, generation of trending, histogram, and cumulative data to be used as a predictive maintenance aid.

z

PC-based downloads via VHMS Technical Analysis Tool Box.

z

Single serial data connection to the MTC controller, and CAN bus transfer between VHMS controller and VHMS monitor MH801.

z

MTC evaluation ON/OFF function for testing and troubleshooting.

Operating Principle The VHMS system with a keyboard below the monitor allows comfortable operation and quick access to all information about the machine status and maintenance calls. The Diesel engine, a Komatsu SDA16V160 (QSK 60), is equipped with ECMs (Electronic Control Modules). This control system is called QUANTUM. For communication with the shovel control system the Quantum system is connected to the CAN bus #1. Condition monitoring on the shovel systems is established by the MTC (Master Turbo Controller), also called X2Controller, in serial connection with the VHMS controller. The MTC is equipped with a read & write memory and a real time monitoring system. The access to the VHMS controller is established via laptop and a serial interface, using the respective software. The control system components VHMS & monitor, MTC-Controller & nodes, and Quantum are connected as follows: VHMS <=> Quantum

CAN bus #1

MTC-Controller <=> Nodes

internal CAN bus

MTC-Controller <=> VHMS-Controller

RS232 (serial connection)

VHMS-Controller => VHMS monitor MH801

CAN bus #2

As optional equipment the ORBCOMM and the MODULAR MINING SYSTEM are available. View onto the VHMS monitor with key pad in the dashboard

Version 2010/1

14-3

Specifications for Operators


14.2

SPECIFICATIONS FOR OPERATORS

Fig. 14-2

Sequence of displays and opening screen

14-4

Version 2010/1




The monitor displays the condition of the machine, the maintenance status, and messages for the operator & the maintenance staff

(2)

Buttons for changing the screens and for settings on the operator level

(3)

Key pad for entering data and the Personal Identification Number (PIN)

(4)

Main key switch on the dashboard

(5)

Opening message

(6)

Acknowledgement button for the opening message

14.2.1

SEQUENCE OF DISPLAYS

Fig. 14-3

Initialization screen

When the main key switch (Fig. 14-2, Pos. 4) is turned ON, the initialization screen (KOMATSU logo) (Fig. 14-3) is displayed for approx. 3 seconds. NOTE: The standard system offers three languages, ENGLISH - GERMAN - SPANISH, or according to customer’s request. Changing of the present language can be carried out in the main menu settings, refer to section 14.2.8 on page 14-18, Fig. 14-11.

14.2.2

OPENING SCREEN

The second display (Fig. 14-2, Pos. 5) is a general information for the operator. NOTE: Press button F6 (Fig. 14-2, Pos. 6) to acknowledge this message. The monitor will display the Main Gauge Screen 1, refer to Fig. 14-4.

Version 2010/1

14-5



14.2.3

MAIN GAUGE SCREENS 1 TO 3

Fig. 14-4

Main gauge screens 1 to 3

14-6

Version 2010/1



Symbol explanation for Fig. 14-4: Main Gauge Screen 1 of 3 °C 1/min

Celsius, ambient temperature Engine speed

Time

Truck counter 1

Truck counter 2

Engine oil pressure

Engine coolant temperature

Hydraulic oil temperature

Fuel level

Version 2010/1

14-7


Fig. 14-5 14-8


Main gauge screens 1 to 3 Version 2010/1



Symbol explanation for Fig. 14-5: Main Gauge Screen 2 of 3

Battery, board power supply

Voltage


Engine oil temperature

Main Gauge Screen 3 of 3


Slew Lubrication System (SLS)

Engine oil level

Hydraulic oil level

Definition of the gauge range colours Green Red

Normal operating range Serious trouble, act immediately. Engine derate or shutdown may happen.

NOTE: If the pointer of any gauge moves into a red range (upper or lower) the corresponding symbol will also have a red background. If this happens, in most cases an automatic message display will inform the operator in plain text about the failure and the necessary action to be taken. For a typical display refer to section 14.2.9 on page 14-26.

Version 2010/1

14-9



Symbols and functions of the buttons F1 - F6

14-10

F1

This button is used to scroll through the Main Gauge Screens 1, 2, and 3. If other screens are selected, the function of this button changes accordingly.

F2

This button switches to the Fuel Consumption Screen, for details refer to section 14.2.4 on page 14-11.

F3

This button switches to the Failure Message Screen for the operator. The colour of the icon above this button changes to yellow if a current message is pending in the Failure History. The icon remains yellow as long as the cause for the message exists, even if the message was cancelled.

F4

This button switches to the Main Gauge Screen for changing the display from Time to Service Meter Reading (SMR) or to Date and vice versa, refer to section 14.2.6 on page 14-15.

F5

This button switches to the Maintenance Monitor. The colour of the icon above this button changes to yellow or red if maintenance is due, for details refer to section 14.2.7 on page 14-16.

F6

This button switches to the main screen Settings for Operator, for details refer to section 14.2.8 on page 14-18.

Version 2010/1


14.2.4

FUEL CONSUMPTION SCREEN

Fig. 14-6

Fuel consumption screen

Version 2010/1


14-11



Measuring the Fuel Consumption Starting from one of the three Main Gauge Screens press button F2, the screen changes to Fuel Consumption Screen (Fig. 14-6, Pos. 1). The fields in the screen (Fig. 14-6, Pos. 1) can be either blank or filled with the data of the last measurement. If you want to start a new fuel consumption measurement, push the START button F1. The date and the local time will be inserted into the Start Time frame and the START command above button F1 changes to STOP, refer to screen (Fig. 14-6, Pos. 2). Push the RETURN button F5 to go back to the Main Gauge Screen 1. When the time period for fuel consumption measurement is over, for example after 10 hours, select the Fuel Consumption Screen from any of the three Main Gauge Screens by pushing button F2. The displayed Fuel Consumption Screen shows the starting date and time of the fuel consumption measurement. Push the STOP button F1. The current date and time is inserted into the Stop Time field and the split fuel consumption calculated during the previous time period is inserted into the Fuel Consumption Frame. The STOP button F1 changes to START again, refer to screen (Fig. 14-6, Pos. 3). Push the return button F5 to return to the Main Gauge Screen 1.

14-12

Version 2010/1



14.2.5

FAILURE MESSAGE SCREEN FOR THE OPERATOR

Fig. 14-7

Main Gauge Screen 1/3 and Failure Message History

Version 2010/1

14-13



Failure Messages for the Operator The Failure Message Screen (Fig. 14-7) can be selected from the Main Gauge Screens 1, 2, or 3 by pressing button F3. The colour of the icon above the button F3 changes to yellow if a current message is pending in the Failure Message History for the operator.

Fig. 14-8

Failure Message

Legend for Fig. 14-8: F3

Scroll down - shifts down to the next message, if several messages are present

F4

Scroll up - shifts up to the previous message, if several messages are present

F5

Return - switches back to the Main Gauge Screen

If the cause for any failure message, which is shown on the Failure Message Screen for operators does not exist any longer, the message will be removed from the operator’s failure history. The time and the date of the removed failure message are added to the already stored failure information in the failure memory for the service level.

14-14

Version 2010/1



14.2.6

MAIN GAUGE SCREENS - CHANGING OF TIME / SMR / DATE

Fig. 14-9

Changing Time, SMR, Date

If button F4 of the Main Gauge Screen is pressed, the center information in the headline changes in the sequence: Time => Service Meter Reading (SMR) => Date => Time ... The selected information (Time, SMR, or Date) will be shown in the headline of all three Main Gauge Screens. Version 2010/1

14-15



14.2.7

MAINTENANCE MONITOR

Fig. 14-10

Maintenance Monitor

14-16

Version 2010/1



The Maintenance Monitor can be selected from the Main Gauge Screens 1, 2, or 3 by pressing the maintenance button F5. The colour of the icon background above the button changes to yellow if maintenance is due. The colour will change to red if maintenance is overdue. Fig. 14-10 shows a Maintenance Monitor of a new machine which has been operated for 10 hours. There are 240 hours left before the 250 hour maintenance is due and 2990 hours before the 3000 hours maintenance is due. For returning to the Main Gauge Screen press button F5. Specifics to be observed Higher maintenance also includes lower maintenance. (Lower maintenance must also be carried out!) Maintenance Interval Overview Maintenance interval

Remark

250 h

Includes maintenance: 50 h • 10 h

500 h

Includes maintenance: 250 h • 50 h • 10 h

(750 h)

Is a follow-up maintenance of 250 h

1000 h

Includes maintenance: (750 h) • 500 h • 250 h • 50 h • 10 h

... 2000 h

Includes: PM-CLINIC

... 3000 h

Includes maintenance: 1000 h • 750 h • 500 h • 250 h • 50 h • 10 h

Exception: For the 3000 h maintenance it is not necessary to carry out the 2000 h maintenance also. The maintenance cycles are rigidly linked to the running time meter. Only running time hours are taken into consideration (no minutes or seconds). The routine visual checks and inspections after every 10 and 50 operating hours are not called up on the Maintenance Monitor. Carry out these checks and inspections according to the OPERATION & MAINTENANCE MANUEL section 4. The engine maintenance has to be carried out according to the separate ENGINE OPERATION & MAINTENANCE MANUEL filed in the volume 2 binder. REMARK For detailed maintenance cycle information refer to the OPERATION & MAINTENANCE MANUAL, section MAINTENANCE. NOTE: On new machines an INITIAL SERVICING after the first 250 and 1000 operating hours is required in addition to the periodic maintenance intervals displayed on the monitor. Carry out all maintenance items according to the OPERATION AND MAINTENANCE MANUEL, section 4. Maintenance Confirmation by Service Personnel Maintenance indicated with yellow or red background behind the icon above the maintenance button F5 should be confirmed by service personnel in the Service Menu subsequent to the execution of the maintenance. With each confirmation the actual maintenance number is increased by 1. The message in the Service Menu for Maintenance Confirmation then turns to white instead of yellow. For more information about the Maintenance Confirmation screen refer to section 14.4.8 on page 14-84.

Version 2010/1

14-17



14.2.8

SETTINGS FOR OPERATORS

Fig. 14-11

Maintenance Monitor

14-18

Version 2010/1



The user menu Settings for Operators can be selected from the Main Gauge Screens 1, 2, or 3 by pressing the button F6. Selection of the Setting Screens The settings selection menu offers seven different setting screens, starting with USER ID and ending with the Language selection. Use the buttons F3 and F4 to scroll through all the seven selection items. Select the designated setting item and push button F6 in order to open the selected setting screen. Button F5 switches back to the Main Gauge Screen 1. The setting screens on the following pages appear in the same sequence as shown in the Main Setting Screen. Settings for Operators USER ID Screen Entering the USER ID (Operator Identification Number)

Fig. 14-12

Entering User ID

In order to personalize different operators, it is possible to enter any up to 10-digits USER ID (Operator Identification Number) via the key pad, refer to (Fig. 14-12). In order to acknowledge the USER ID press button F6. The display then changes to the Main Setting Screen for operators. NOTE: - If 10 digits are entered, each further entry will be ignored. - If any USER ID has been entered, the ID is saved together with the continuous machine operation records in the VHMS memory.

Version 2010/1

14-19



Reset Truck Counter 1 & 2

Fig. 14-13

Resetting Truck Counter 1

When the upper screen (Fig. 14-13, Pos. 1) is displayed, press button F6 to reset Truck Counter 1 to zero. The screen then changes to the Main Setting Screen. If you don’t want to reset the truck counter, press button F5 to return to the Main Setting Screen for operators again. The reset of Truck Counter 2 is performed analogously.

14-20

Version 2010/1



Screen Adjustment

Fig. 14-14

Screen Adjustment


Day screen

(2)

Night screen

Version 2010/1

14-21



Screen Adjustment Day and Night The Day Screen (Fig. 14-14, Pos. 1) will be displayed during the day when the main working lights are switched off. The screen changes automatically to the Night mode when the main working lights are switched on, refer to Pos. 2 in the previous illustration (Fig. 14-14). The adjustment of both screens is done in the same way. The function of the buttons for Screen Adjustment (Fig. 14-14) is as follows: F2

Select the DEFAULT setting (factory setting) of Brightness, Contrast, and Back Light

F3

Decrease Brightness, Contrast, and Back Light

F4

Increase Brightness, Contrast, and Back Light

F5

Leave the adjustment screen and return to the Main Setting Screen for operators

F6

Save the current adjustment and jump to the next adjustment mode (Brightness >> Contrast >> Back Light)

Screen Adjustment z

Brightness adjustment In the first display of the screen the brightness field is highlighted yellow. For increasing the brightness press button F4 until the desired condition is obtained. For decreasing the brightness press button F3 until the desired condition is obtained. Press button F6 in order to save the selected brightness adjustment and to change over to the contrast adjustment.

z

Contrast adjustment The contrast field is now highlighted yellow. For increasing the contrast press button F4 until the desired condition is obtained. For decreasing the contrast press button F3 until the desired condition is obtained. Press button F6 in order to save the selected contrast adjustment and to change over to the back light adjustment.

z

Back Light adjustment The back light field is now highlighted yellow. For increasing the back light press button F4 until the desired condition is obtained. For decreasing the back light press button F3 until the desired condition is obtained. Press button F6 in order to save the selected back light adjustment and to return to the Main Setting Screen for operators.

If you want to leave the above adjustment screens without saving any adjustment, press button F5 and return to the Main Setting Screen for operators.

14-22

Version 2010/1



Date Adjustment Screen

Fig. 14-15 z

Date adjustment

Date adjustment In the first display of this adjustment screen ’Date’ is highlighted yellow and the year is highlighted orange, refer to Fig. 14-15. Press button F3 (down) or F4 (up) in order to adjust the correct year. If button F1 is pressed one time, the month is highlighted and can be adjusted, using the buttons F3 and F4 again. Press button F1 again in order to change to the adjustment mode of the day. Press button F6 in order to save the adjustment(s) of year, month, or day and to return to the Main Setting Screen for operators. Press button F5 if you want

Screen for Clock Adjustment and Daylight Saving Time ON/OFF

Fig. 14-16

Adjustment for Clock and Daylight Saving Time

NOTE: Via the screen for Clock Adjustment (Fig. 14-16) the clock time can be adjusted, and the Daylight Saving Time can be switched ON/OFF. REMARK If the Daylight Saving Time is switched ON, the Day Screen will be displayed during the day when the main working lights are switched off. The display changes automatically to the Night Screen when the main working lights are switched on.

Version 2010/1

14-23



z

Clock adjustment In the first display of this adjustment screen ’Time’ is highlighted yellow and the hours are highlighted orange, refer to Fig. 14-16. Press button F3 (down) or F4 (up) in order to adjust the correct hours. If button F1 is pressed one time, the minutes are highlighted and can be adjusted, using the buttons F3 and F4 again. Press button F6 in order to save the adjustment(s) of the clock time and to return to the Main Setting Screen for operators.

z

Switching the Daylight Saving Time ON/OFF If you are in the clock adjustment mode for minutes (the minutes are highlighted) press button F1. ’Daylight Saving Time’ will be highlighted yellow. Press the button F3 or F4 in order to select the ON or OFF condition. The selected condition is highlighted green. Press button F6 if you want to save the adjustment(s) of the clock time and to return to the Main Setting Screen for operators.

If you want to leave the above adjustment screens without saving any adjustment, press button F5 and return to the Main Setting Screen for operators. Language Selection Screen

Fig. 14-17 z

Language selection

Language selection Select the desired language using button F3 or F4. Press button F6 in order to save the language selection and to return to the Main Setting Screen for operators. If you want to leave the above selection screen without saving any selection, press button F5 and return to the Main Setting Screen for operators.

14-24

Version 2010/1




Version 2010/1

14-25



14.2.9

AUTOMATIC MESSAGES

Fig. 14-18

View onto the Main Gauge Screen indicating any pending message(s)

Fig. 14-19

Example of a message with red background

Fig. 14-20

Example of a message with yellow background

14-26

Version 2010/1



Legend for Fig. 14-19 and 14-20: (1)

Top Message: Short failure description

(2)

Instruction Message: Follow the displayed instruction(s)

(3)

Error Code: G = Shovel message C = Engine message (Cummins)

(4)

Number of the currently displayed message

(5)

Total number of existing messages

F1

CANCEL button When this button is pressed, the currently displayed message disappears and is listed in the failure history for operators. The message will be displayed again if any different USER ID (operator identification number) is entered.

F3

PAUSE button (green) When this button is pressed, automatic rolling up of messages is stopped and the displayed message will be frozen on the screen for two minutes. After that the button changes to RESET (red) and automatic roll up of current messages starts again. A new message will overwrite a frozen message.

F4

JUMP button This button switches to the previous displayed menu, normally to the Main Gauge Screen 1. After two minutes the display jumps automatically back to the last displayed Automatic Message, and rolling up of messages starts again. If any menu select button was pressed during the two minutes standard period, the display will also jump back to Automatic Message when the two minutes are over. A new message will overwrite any menu display and rolling up of messages starts again.

If any failure or information condition occurs during operation, the background of the exclamation mark (!) over button F3 is coloured yellow. Then the present display is automatically replaced by an Automatic Message. If there are several messages at the same time, the system displays these messages one after the other. Each message is displayed for a few seconds. The message text informs the operator about the type of failure and the action to be taken. Carry out the action which is recommended on the screen. NOTE: The Top Messages have background colours which indicate the trouble condition as follows: z

RED

Shut-down - act immediately Refer to Fig. 14-19 for a typical message with red background.

z

YELLOW

Caution - inform service Refer to Fig. 14-20 for a typical message with yellow background.

z

GREEN

Information Refer to Fig. 14-21 for a typical message with green background.

Version 2010/1

14-27


Fig. 14-21


Example of a message with green background


Top message: Information description

(2)

Help text

(3)

Message (error) Code: G = Shovel message C = Engine message (Cummins)

(4)

Number of the currently displayed message

(5)

Total number of existing messages

NOTE: For all available Top Messages in the system refer to section 14.2.10 on page 14-29.

14-28

Version 2010/1



14.2.10 TABLES OF ALL MESSAGES PROVIDED BY THE SYSTEM The following charts of Top Messages (Error Codes) cover all shovels with X2-Controller. G-Codes

For the excavators PC3000 - PC4000 - PC5500 - PC8000 (Diesel & Electric), including optional equipment, refer to section 14.2.10.1

C-Codes TIER 2

for the Diesel engines QSK38 & QSK60 - Emission Standard TIER 2 refer to section 14.2.10.2 on page 14-39

C-Codes TIER 1

for the Diesel engines KTA38 & QSK60 - Emission Standard TIER 1 refer to section 14.2.10.3 on page 14-46

Instruction Messages

for the G-Codes & C-Codes, refer to section 14.2.10.4 on page 14-52

That means, that not all listed Error Codes and Instruction Messages may be applied to each shovel.

NOTE: Messages w/o color code are not displayed. These messages are stored in the history memory only.

Explanation of the columns in the following Error Code charts Error Code

Error Codes: G = Shovel message, C = Engine message (Cummins)

Colour Code of Top Message

0 = Red, 1 = Yellow, 2 = Green

Instruction Message No.

Number of the Instruction Message, which is displayed together with the Error Code (numbers 1 - 58)

Display

1 = displayed once, 2 = displayed at each occurrence, N = NOT displayed

Acoustic Signal

Y = an acoustic signal sounds if the relating error occurs

Memory

The error/message is saved in a History Memory: 1 = Service & Operator History, 2 = Service History, 3 = Operator History, 5 = VHMS History

G-Code/C-Code

Text of the Error Code or Message

Version 2010/1

14-29



G = Shovel C = Engine

0 = RED 1 = YELLOW 2 = GREEN

Display



Error Code

Acoustic Signal

14.2.10.1 TABLE OF G-CODES

G00001

0

1

2

1

Trouble Shut-Off (gate) valve

G00002

2

37

2

3

Test speed 1800 1/min engine 1

G00003

1

38

1

1

Trouble pump controller

G00005

1

39

1

3

Low hydraulic oil level

G00007

0

2

2

1

Trouble hydraulic oil level

G00012

1

17

1

3

Central lubrication system grease level too low

G00013

1

17

1

3

Slew ring gear lubr. system grease level too low

G00020

0

4

2

1

Trouble Shut-Off (gate) valve (Start blocked)

G00031

2

-

2

3

Set engine to low idle

G00032

1

2

1

1

Trouble starter

G00033

1

2

1

1

Trouble VHMS-Controller

G00034

1

2

1

1

Trouble VHMS-Display

G00035

0

34

2

1

Trouble totally loss gear oil (PTO 1)

G00039

2

-

2

3

Actuate engine speed selector switch

G00040

0

10

2

1

Emergency shut-down pump compartment

G00042

1

2

1

1

Trouble monitoring screen at hydr. cooler entry

G00043

1

2

2

Y

1

Trouble output short-circuit

G00048

0

2

2

Y

1

Trouble emergency safety circuit

G00053

1

56

2

Y

1

Reset emergency safety circuit

G00060

0

6

2

1

Fire in the power house

G00061

0

2

2

1

Trouble monitoring, engine 1 speed too low

G00062

0

2

2

1

Trouble monitoring, engine 1 speed too high

G00063

0

2

1

1

Trouble monitoring hydraulic oil temp

14-30

Y

Y

G-Code Memory

(Message Code)

Version 2010/1



Display



Error Code

Acoustic Signal


G00064

0

2

1

1

Trouble monitoring hydraulic oil level

G00065

1

2

1

1


G00066

0

2

2

1

Trouble hydraulic oil temperature

G00067

1

2

1

1

Trouble battery voltage too high

G00069

1

2

1

1

Trouble monitoring oil temperature gear (PTO 1)

G00070

1

2

2

Y

1

Trouble oil temperature gear (PTO 1)

G00071

1

2

2

Y

1

Trouble gear lubrication (PTO 1)

N

2


G00073

N

2

Trouble monitoring remote engine oil level 1

G00074

N

2

Trouble monitoring grease pressure (central)

G00075

N

2

Trouble monitoring grease pressure (slew ring gear)

G00076

N

2

Trouble monitoring pressure suction tank

G00077

N

2

Trouble monitoring grease level (central)

G00078

N

2

Trouble monitoring grease level (slew ring gear)

G00079

N

2

Trouble monitoring pressure oil cooler 1

G00080

N

2

Trouble monitoring pressure preload valve

1

Trouble lubrication system

G00072

G-Code Memory

(Message Code)

G00081

0

2

2

G00086

2

12

2

Y

3

SHUTDOWN

G00087

2

2

Y

3

Stop all movements for low idle

G00089

1

2

2

3

EBL bypassed

G00090

0

8

2

1

Trouble power supply

G00091

0

9

2

3

Pilot control cut out

Version 2010/1

Y


14-31



Display



Error Code


Acoustic Signal


G00092

0

10

2

3

Emergency shut-down at access ladder

G00093

0

10

2

3

Emergency shut-down at valve block

G00094

0

10

2

3

Emergency shut-down at hydraulic control panel

G00095

0

10

2

3

Emergency shut-down in cabin

G00096

0

14

2

3


G00099

0

48

2

1


G00100

0

11

2

3

Maintenance safety switch

G00102

1

2

2

Y

3

Switch off wiper

G00103

1

47

2

Y

1

Faulty switch 20M004

G00104

1

15

2

Y

1

Trouble battery current

G00105

1

16

2

Y

1

Trouble battery charging current too low

G00106

1

49

2

Y

1


G00107

1

2

1

Y

1

Trouble slew parking brake control 56K250a

G00108

1

2

1

Y

1

Trouble slew parking brake control Output to 56K250a

G00109

1

2

1

Y

1

Trouble slew parking brake control 56K250b

G00110

1

2

1

Y

1

Trouble slew parking brake control Output to 56K250b

G00111

1

2

1

Y

1

Trouble travel parking brake control 56K251a

G00112

1

2

1

Y

1

Trouble travel parking brake control Output to 56K251a

G00113

1

2

1

Y

1

Trouble travel parking brake control 56K251b

G00114

1

2

1

Y

1

Trouble travel parking brake control Output to 56K251b

G00115

1

2

1

Y

1

Trouble slew hydraulic brake control 56K252a

G00116

1

2

1

Y

1

Trouble slew hydraulic brake control Output to 56K252a

14-32

Y

G-Code Memory

(Message Code)

Version 2010/1




Display

Acoustic Signal

Memory



Error Code

G00117

1

2

1

Y

1

Trouble slew hydraulic brake control 56K252b

G00118

1

2

1

Y

1

Trouble slew hydraulic brake control Output to 56K252b

G00140

1

17

1

1

Trouble monitoring X1-1 Pressure

G00141

1

17

1

1

Trouble monitoring X2-Pressure

G00143

1

2

N

2

Trouble monitoring 61B087a

G00144

1

2

N

2

Trouble monitoring 61B087b

G00145

1

2

N

2

Trouble monitoring 61B087c

G00146

1

2

N

2

Trouble monitoring 61B087d

G00147

1

17

1

1

Trouble monitoring gear lubrication (PTO 1)

G00148

1

17

1

1

Trouble monitoring fuel level

G00149

0

2

N

2

Trouble monitoring ambient temperature

G00151

1

17

1

1

Trouble monitoring gear (PTO) oil filter 1

G00152

1

17

1

1

Trouble monitoring oil filter pump lubrication

G00154

1

17

1

1

Trouble monitoring return oil filter

G00155

1

17

1

1

Trouble monitoring leak oil filter

G00159

1

17

1

1

Trouble monitoring breather filter

G00160

1

17

1

1

Trouble monitoring engine air cleaner 1

G00161

1

17

1

1

Trouble monitoring battery voltage

G00162

1

17

1

1

Trouble monitoring charging-/discharging current

G00163

1

17

1

1

Trouble monitoring pilot control

G00164

1

17

1

1

Trouble air cleaner 1

(Message Code)

Version 2010/1


G-Code

14-33



Display



Error Code


Acoustic Signal


G00165

1

17

1

1

Trouble breather filter hydraulic oil tank

G00166

1

17

1

1

Trouble oil filter gear (PTO 1)

G00169

1

17

1

1

Trouble return oil filter hydraulic oil tank

G00170

1

17

1

1

Trouble leak oil filter hydraulic oil tank

G00176

1

17

1

1

Trouble battery voltage too low

G00177

1

17

1

1

Trouble battery charging circuit

G00178

1

17

1

1

Trouble battery charging current too high

G00179

1

17

1

1

Trouble control pressure X1-1

G00180

1

17

1

1

Trouble pilot pressure X2 too low

G00181

1

17

1

1

Trouble pilot pressure X2 too high

G00184

1

20

1

Y

1

Central lubrication system empty

G00185

1

20

1

Y

1

Trouble central lubrication system

G00186

1

20

1

Y

1

Trouble central lubrication system

G00187

1

20

1

Y

1

Slew ring gear lubrication system empty

G00188

1

20

1

Y

1

Trouble slew ring gear lubrication system

G00189

1

20

1

Y

1

Trouble slew ring gear lubrication system

G00207

1

2

1

Y

1

Engine remote oil tank 1 empty

G00216

1

2

2

Y

1

Trouble software not compatible

G00220

1

2

2

Y

1

Trouble transfer pump motor overheated

14-34

G-Code Memory

(Message Code)

Version 2010/1




Display

Acoustic Signal

Memory



Error Code

G00222

1

2

2

Y

1

Load limiting clam defective

G00223

1

2

2

Y

1

Trouble starter control 51K001a-1

G00224

1

2

2

Y

1

Trouble starter control Output to 51K001a-1

G00225

1

2

2

Y

1

Trouble starter control 51K001b-1

G00226

1

2

2

Y

1

Trouble starter control Output to 51K001b-1

G00231

1

2

2

Y

1

Trouble pilot control lever 20S019

G00232

1

2

2

Y

1

Trouble pilot control lever 20S020

G00233

1

2

2

Y

1

Trouble pilot control 11Q045

G00234

1

2

2

Y

1

Trouble pilot control 11K111a

G00235

1

2

2

Y

1

Trouble pilot control Output to 11K111a

G00236

1

2

2

Y

1

Trouble pilot control 11K111b

G00237

1

2

2

Y

1

Trouble pilot control Output to 11K111b

G00238

1

2

2

Y

1

Trouble supply by key switch 11Q044

G00239

1

2

2

Y

1

Trouble electrical matter

G00240

2

21

1

1


G00242

2

22

2

3

Engine 1 already running

G00243

2

23

1

3

Fill up fuel tank

G00245

0

24

2

1

Engine shutdown from ground

G00246

2

25

2

3


G00247

2

26

2

3

Slew ring gear house brake

G00249

1

27

2

3


(Message Code)

Version 2010/1

Y


G-Code

14-35



Display



Error Code


Acoustic Signal


G00252

0

10

2

1

Emergency shut-down at access ladder

G00253

0

10

2

1

Emergency shut-down at valve block

G00254

0

10

2

1

Emergency shut-down at hydraulic control panel

G00255

0

10

2

1

Emergency shut-down in cabin

G00257

2

30

2

3


G00261

1

11

2

1

Maintenance Safety Switch

G00262

1

20

1

Y

1

Trouble screen at hydr. cooler entry clogged

G00308

0

3

2

Y

1

Trouble CAN-Bus or CAN-Hardware

G00309

1

2

1

Y

1

Trouble ladder up 56K253a

G00310

1

2

1

Y

1

Trouble ladder up Output to 56K253a

G00311

1

2

1

Y

1

Trouble ladder up redundant 56K253b

G00312

1

2

1

Y

1

Trouble ladder up redundant Output to 56K253b

G00313

1

2

1

Y

1

Trouble ladder down 56K254a

G00314

1

2

1

Y

1

Trouble ladder down Output to 56K254a

G00315

1

2

1

Y

1

Trouble ladder down redundant 56K254b

G00316

1

2

1

Y

1

Trouble ladder down redundant Output to 56K254b

G00317

1

2

1

Y

1

Trouble service arm up 56K255a

G00318

1

2

1

Y

1

Trouble service arm up Output to 56K255a

G00319

1

2

1

Y

1

Trouble service arm up redundant 56K255b

G00320

1

2

1

Y

1

Trouble service arm up redundant Output to 56K255b

14-36

G-Code Memory

(Message Code)

Version 2010/1




Display

Acoustic Signal

Memory



Error Code

G00321

1

2

1

Y

1

Trouble service arm down 56K256a

G00322

1

2

1

Y

1

Trouble service arm down Output to 56K256a

G00323

1

2

1

Y

1

Trouble service arm down redundant 56K256b

G00324

1

2

1

Y

1

Trouble service arm down redundant Output to 56K256b

G00325

1

2

1

Y

1

Trouble service arm input

G00326

1

2

1

Y

1

Trouble ladder input

G00327

1

2

1

Y

1

Trouble parking brake input

G00328

1

2

1

Y

1

Trouble start input

G00329

1

38

2

Y

1

Protection switch tripped

G00330

1

2

2

Y

1

Trouble pilot control 11Q111

(Message Code)


G-Code

G00401

N

5

Shutdown: Engine / Motor shutdown at bottom - off

G00402

N

5

Shutdown: Engine / Motor shutdown at bottom - on

1

Communication failure PLC <==> VHMS-Controller

2

Manual Trigger

G00417

1

2

MFA0

2

Y

N

G00419

1

2

2

Y

1

Source voltage error

G00420

1

2

2

Y

1

Connector sel error

G00421

1

2

2

Y

G00422

1

2

2

Y

1

Can-net sys (J1939)

G00423

1

2

2

Y

1

Application sys error

G00425

1

2

2

1

Settings impossible to take over into the PLC

G00426

N

5

250 h Maintenance performed

G00427

N

5


G00428

N

5


G00429

N

5


Version 2010/1

Farm sys error

14-37


G-Code Memory


Acoustic Signal

(Message Code)


Display

Error Code




G00430

N

5


G00431

N

5

Messages switched off

G00432

N

5

Messages switched on

G00433

N

5

PLC-Evaluation switched off

G00434

N

5

PLC-Evaluation switched on

G00451

N

5

Shutdown: Shut-Off (gate) valve (Start bl.) - off

G00452

N

5

Shutdown: Shut-Off (gate) valve (Start bl.) - on

G00453

N

5

Shutdown: Shut-Off (gate) valve - off

G00454

N

5

Shutdown: Shut-Off (gate) valve - on

G00455

N

5

Shutdown: Hydraulic oil level - off

G00456

N

5

Shutdown: Hydraulic oil level - on

G00457

N

5

Shutdown: Hydr. oil temp. too high - off

G00458

N

5

Shutdown: Hydr. oil temp. too high - on

G00459

N

5

Shutdown: Trouble Lubrication system - off

G00460

N

5

Shutdown: Trouble Lubrication system - on

G00461

N

5

Shutdown: Monitoring engine speed too low - off

G00462

N

5

Shutdown: Monitoring engine speed too low - on

G00463

N

5

Shutdown: Monitoring engine speed too high - off

G00464

N

5

Shutdown: Monitoring engine speed too high - on

G00465

N

5

Shutdown: Fire suppression system - off

G00466

N

5

Shutdown: Fire suppression system - on

1

Communication failure MH800 <==> VHMS-Controller

G00491

1

2

2

Y

G00501

N

5

Shutdown: Total loss gear oil 1 - off

G00502

N

5

Shutdown: Total loss gear oil 1 - on

G00533

14-38

2

13

2

Engine state is "Warm-up".

Version 2010/1




C115

0

34

1

(Message Code)

Menory


Display



Error Code

Acoustic Signal

14.2.10.2 TABLE OF C-CODES - DIESEL ENGINES WITH EMISSION STANDARD TIER 2

Y

1

Engine Speed Signal Lost

C-Code TIER 2

C135

N

2

Oil Press Ckt Failed High

C141

N

2

Oil Press Ckt Failed Low

C143

0

33

1

Y

1

Low Oil Press

C144

1

20

2

Y

1

Coolant Temp Ckt Failed High

C145

1

20

2

Y

1

Coolant Temp Ckt Failed Low

C146

1

40

1

Y

1

Coolant Temp Above Normal

C151

0

33

2

Y

1

High Coolant Temp

C153

N

2

Int Man Temp 1 Ckt Failed High

C154

N

2

Int Man Temp 1 Ckt Failed Low

1

High Int Man Temp 1

C155

0

32

2

Y

C156

N

2


C157

N

2


1

High Int Man Temp 2

C158

0

32

2

Y

C159

N

2


C161

N

2


1

High Int Man Temp 3

C162

0

32

2

Y

C163

N

2


C164

N

2


1

High Int Man Temp 4

C165

0

32

2

Y

C187

N

2

Sensor Supply 2 Ckt Failed Low

C195

N

2

Coolant Level Ckt Failed High

C196

N

2

Coolant Level Ckt Failed Low

C197

N

2

Coolant Level Below Normal

C212

N

2

Oil Temp Ckt Failed High

C213

N

2

Oil Temp Ckt Failed Low

1

Engine Oil Temp to High

C214

0

32

2

Y

C221

N

2

Ambient Air Press Failed High

C222

N

2

Ambient Air Press Failed Low

C223

N

2

Centinel Burn Valve Below Normal

Version 2010/1

14-39


C-Code TIER 2 Menory


Acoustic Signal

(Message Code)


Display

Error Code




C224

N

2

Centinel Burn Valve Above Normal

C227

N

2

Sensor Supply 2 Ckt Failed High

1

Very Low Coolant Pressure

C228

0

32

2

Y

C231

N

2

Coolant Press Ckt Failed High

C232

N

2

Coolant Press Ckt Failed Low

C234

0

32

2

Y

1

Engine overspeed

C235

0

31

2

Y

1

Low Coolant Level

C238

N

2


C245

N

2

Fan Control Circuit Failed Low

1

High Fuel Temp

C261

0

31

1

Y

C263

N

2

Fuel Temp Ckt Failed High

C265

N

2

Fuel Temp Ckt Failed Low

1

Very High Fuel Temp

C266

0

33

2

C271

1

40

1

1

Fuel Pump Press 1 Ckt Failed Low

C272

1

40

1

11

Fuel Pump Press 1 Ckt Failed High

C322

1

40

1

1

Injector Sol Driver Cyl 1 Below Normal

C323

1

40

1

1


C324

1

40

1

1


C325

1

40

1

1


C331

1

40

1

1


C332

1

40

1

1


N

2

ECM Hardware Issue Non Mission\n\ Disabling

1

1

Injector Power Supply Failed

C352

N

2


C386

N

2

Sensor Supply 1 Ckt Failed High

1

Very Low Oil Pressure

1

WIF Indicator Warning

1

Engine Oil Temp Above Normal

2

J1939 Datalink Can Not Transmit

C343 C351

0

34

C415

0

32

2

C418

1

31

1

C421

1

40

1

C426

Y

Y

Y

N

C441

1

31

1

Y

1

Low Battery Voltage

C442

1

31

1

Y

1

High Battery Voltage

14-40

Version 2010/1


C449

0

31

2

(Message Code)

Menory


Display



Error Code

Acoustic Signal


Y

2

High Rail Pressure

C-Code TIER 2

C451

N

2

Rail Press Ckt Failed High

C452

N

2

Rail Press Ckt Failed Low

1

1

High Intake Manifold Temp

C527

N

2

Dual Output A Failed High

C529

N

2

Dual Output B Failed High

C546

N

2

Fuel Del Pressure Ckt Failed High

C547

N

2

Fuel Del Pressure Ckt Failed Low

1

High Crankcase Pressure

C488

1

31

C556

0

32

2

C559

1

40

1

1

Rail Pressure 1 Below Normal

C621

N

2

Low Power Cylinder 1

C622

N

2


C623

N

2


C624

N

2


C625

N

2


C626

N

2


C627

N

2


C628

N

2


C631

N

2


C632

N

2


C633

N

2


C634

N

2


C635

N

2


C636

N

2


C637

N

2


C638

N

2


C671

N

2

Exh Temp Ckt Failed Low Cylinder 1

C672

N

2


C673

N

2


C674

N

2


C675

N

2


Version 2010/1

Y


14-41




Acoustic Signal

(Message Code)


Display

Error Code




C676

N

2


C677

N

2


C678

N

2


1

1

Engine Crankshaft Speed Erratic

C721

N

2


C722

N

2


C723

N

2


C724

N

2


C725

N

2


C726

N

2


C727

N

2


C728

N

2


C731

N

1

Engine Speed Cam/Crank Misalignment

1

Rapid rise int man temp 1

N

2

Power Lost with Ignition On

C689

C783

1

0

40

32

C1117

2

Y

C1357

1

31

1

1

Remote Oil Level Below Normal

C1362

1

31

1

1

High Lube Oil Filter Restriction

C1363

1

40

1

1

Int Man Press 1 Below Normal

C1367

N

2

Pre Filter Oil Press Ckt Failed High

C1368

N

2

Pre Filter Oil Press Ckt Failed Low

C1373

N

2

Ether Injection Ckt Failed

C1377

N

2

Post Filter Oil Press Ckt Failed High

C1378

N

2

Post Filter Oil Press Ckt Failed Low

C1383

N

2

Int Man Press 1 Failed High

C1384

N

2

Int Man Press 1 Failed Low

C1385

N

2

Int Man Press 2 Failed High

C1386

N

2

Int Man Press 2 Failed Low

1

J1939 Engine Commanded Shutdown

C1387

0

34

2

Y

C1411

N

2

Gen Output Freq Ckt Failed High

C1412

N

2

Droop Adj Ckt Failed High

C1418

N

2

Gain Adj Ckt Failed High

14-42

Version 2010/1


Display

Acoustic Signal

Menory



Error Code


C1427

2

2

Y

2

Overspeed Shutdown Relay Driver Error

C1428

2

2

Y

2

Low Oil Press Shutdown Relay Driver Err

C1429

2

2

Y

2

High Eng Temp Shutdown Relay Driver Err

(Message Code) G = Shovel C = Engine


C-Code TIER 2

C1431

N

2

Oil Pressure Relay Driver Error

C1432

N

2

High Engine Temp Relay Driver Error

C1517

1

31

1

1

ECM Detects Most Severe Fault

C1518

1

31

1

1

ECM Detects Moderately Severe Fault

C1519

1

31

1

1

ECM Detects Least Severe Fault

C1521

N

2

Exh Temp Ckt Failed High Cylinder 3

C1522

N

2


C1523

N

2


C1524

N

2


C1525

N

2


C1526

N

2


C1527

N

2


C1529

N

2


C1531

N

2


C1532

N

2


C1533

N

2


C1534

N

2


C1535

N

2


C1536

N

2


C1542

N

2

Engine oil level sensor Ckt Failed High

C1543

N

2

Engine oil level sensor Ckt Failed Low

C1548

40

N

2

Injector Sol Driver 7 Below Normal

C1549

40

N

2


C1551

40

N

2


C1552

40

N

2


C1553

40

N

2


C1554

40

N

2


C1555

40

N

2


Version 2010/1

14-43

Display



Error Code


Acoustic Signal


C1556

40

N

2


C1557

40

N

2


31

1

1

ECM Critical Internal Failure

C1618

N

2


C1619

N

2


C1622

N

2


1

1

Int Man Press 2 Below Normal

C1843

N

2

Crankcase Press Ckt Failed High

C1844

N

2

Crankcase Press Ckt Failed Low

C1845

N

2

WIF Indicator Ckt Failed High

C1846

N

2

WIF Indicator Ckt Failed Low

C1847

N

2

Engine Coolant Temp Exception

1

1

WIF Indicator Above Normal

N

2

Engine Oil Change Interval Exceeded


C1597

C1638

C1852


1

1

1

40

31

C1891


(Message Code)

C1911

1

31

1

1

Inj Rail Pressure Above Normal

C1984

1

31

1

1

Int Man Temp 2 Above Normal

C1985

1

31

1

1


C1986

1

31

1

1


N

2

Engine Speed Above Normal

C1992 C2121

0

32

2

Y

1

High Exhaust Temp Cyl 1

C2122

0

32

2

Y

1


C2123

0

32

2

Y

1


C2124

0

32

2

Y

1


C2125

0

32

2

Y

1


C2126

0

32

2

Y

1


C2127

0

32

2

Y

1


C2128

0

32

2

Y

1


C2131

0

32

2

Y

1


C2132

0

32

2

Y

1


C2133

0

32

2

Y

1


14-44

Version 2010/1




Display

Acoustic Signal

Menory



Error Code

C2134

0

32

2

Y

1


C2135

0

32

2

Y

1


C2136

0

32

2

Y

1


C2137

0

32

2

Y

1


C2157

0

32

2

Y

1

Rapid Rise Int Man Temp 2

C2158

0

32

2

Y

1


C2159

0

32

2

Y

1


(Message Code)


C-Code TIER 2

C2185

N

2

Sensor Supply 4 Ckt Above Normal

C2186

N

2

Sensor Supply 4 Ckt Below Normal

C2215

1

40

1

1

Fuel Pump Pressure Below Normal

C2261

1

31

1

1

Fuel Pump Del Pressure Above Normal

C2262

1

40

1

1

Fuel Pump Del Pressure Below Normal

C2265

N

2

Lift Pump Supply Ckt Failed High

C2266

N

2

Lift Pump Supply Ckt Failed Low

C2311

N

2

Fuel Injection Valve Ckt Error

C2321

N

2

Engine Crankshaft Speed - Data Erratic

C2322

N

2

Engine Camshaft Speed - Data Erratic

C2377

N

2

Fan Control Ckt Failed High

C2474

N

2

Turbocharger 1 Speed - Data Erratic

Version 2010/1

14-45





C112

1

35

C113

Acoustic Signal

(Message Code)


Display

Error Code


14.2.10.3 TABLE OF C-CODES - DIESEL ENGINES WITH EMISSION STANDARD TIER 1

Y N

C-Code TIER 1

Timing Fueling Mismatch Timing Act Shorted High

C115

0

34

Y

Speed Signal Lost

C116

1

35

Timing Rail Press Ckt Failed High

C117

1

35

Timing Rail Press Ckt Failed Low

C118

N

Timing Rail Press Ckt Failed Low

C119

N

Fuel Pump Press Ckt Failed Low

C121

N

1 Eng Speed Signal Lost

C122

N

LB Boost Ckt Failed High

C123

N

LB Boost Ckt Failed Low

C124

1

31

1

High Boost LB

C125

N

Low Boost LB

C126

N

High Boost RB

C127

N

Low Boost RB

C128

N

RB Boost Ckt Failed High

C129

N

RB Boost Ckt Failed Low

C131

N

Throttle Ckt Failed High

C132

N

Throttle Ckt Failed Low

C133

N

PTO Circuit Shorted High

C134

N

PTO Circuit Shorted Low

C135

N

Oil Press Ckt Failed High

C136

N

Pre Filter Oil Press Ckt Failed High

C137

N

Pre Filter Oil Press Ckt Failed Low

C141

N

Oil Press Ckt Failed Low

C143

0

33

Low Oil Press

C144

N

Coolant Temp Ckt Failed High

C145

N

Coolant Temp Ckt Failed Low

C147

N

Freq Throttle OOR High

C151

14-46

0

33

Y

High Coolant Temp

Version 2010/1



Acoustic Signal

(Message Code)


Display

Error Code



C-Code TIER 1

C153

N

LBF IMT Ckt Failed High

C154

N

LBF IMT Ckt Failed Low

C155

0

33

Y

High IMT LBF

C156

N

LBR IMT Ckt Failed High

C157

N

LBR IMT Ckt Failed Low

C158

0

32

Y

High IMT LBR

C159

N

RBF IMT Ckt Failed High

C161

N

RBF IMT Ckt Failed High

C162

0

32

Y

High IMT RBF

C163

N

RBR IMT Ckt Failed High

C164

N

RBR IMT Ckt Failed Low

C165

0

32

Y

High IMT RBR

C212

N

Oil Temp Ckt Failed High

C213

N

Oil Temp Ckt Failed Low

C214

1

31

Y

High Oil Temp

C219

N

Remote Oil Level Low

C221

N

Ambient Air Press Failed High

C222

N

Ambient Air Press Failed Low

C223

N

CORS Burn Valve Open Circuit

C225

N

CORS Makeup Valve Open Circuit

C231

N

Coolant Press Ckt Failed High

C232

N

Coolant Press Ckt Failed Low

C233

0

33

Y

Low Coolant Press

C234

0

32

Y

Engine Overspeed

C235

1

31

Y

Low Coolant Level

C237

N

Multi Unit Sync Error

C252

N

Oil Level Signal Invalid

C253

0

33

C254

0

34

FSOV Open Cicuit

C259

1

31

FSOV Mech Stuck Open

Version 2010/1

Y


Oil Level Low

14-47



C261

0

33

Acoustic Signal

(Message Code)


Display

Error Code




Y

C-Code TIER 1

High Fuel Temp

C263

N

Fuel Temp Ckt Failed High

C265

N

Fuel Temp Ckt Failed Low

C299

N

Hot Shutdown

C316

N

Fuel Pump Open Circuit

C318

N

Fuel Pump Mech Stuck

C343

N

ECM Hardware Issue Non Mission Disabling

C346

N

ECM Software / Hardware Failure

C349

N

Output Shaft Speed above normal

C384

N

Ether Solenoid Ckt Failed

C422

N

Coolant Level Signal Invalid

C423

1

35

Timing Press Incorrect

C426

N


C427

N


C431

N

Idle Validation Invalid

C432

N

Idle Validation Invalid

C441

1

31

Y

Low Battery Voltage

C442

1

31

Y

High Battery Voltage

C451

N

Rail Press Ckt Failed High

C452

N

Rail Press Ckt Failed Low

C455

1

31

Rail Actuator Open Ckt

C467

1

35

Desired Timing Not Achieved

C468

1

40

Desired Rail Press not Achieved

C473

N

Remote Oil Level Signal Invalid

C487

N

Ether Bottle Empty

C489

N

AXG Speed Low Error

C514

1

40

Rail Actuator Mech Stuck

C524

N

Alt Droop SW Val Fault

C527

N

Dual Output A Shorted High or Open Ckt

C528

N

Alt Torque SW Val Fault

14-48

Version 2010/1



C529

Acoustic Signal

(Message Code)


Display

Error Code



N

C-Code TIER 1

Dual Output B Shorted High or Open Ckt

C551

0

32

Throttle Validation Switch High Error

C553

1

31

Rail Press OOR High

C554

1

40

Rail Press Incorrect

C555

0

33

C611 C612

Y N

1

31

High Blowby Press Engine Hot Shutdown High Oil Filter Rest

C616

N

High Turbo Comp Inlet Temp LBR

C621

N

Low Power #1 LB

C622

N

Low Power #2 LB

C623

N

Low Power #3 LB

C624

N

Low Power #4 LB

C625

N

Low Power #5 LB

C626

N

Low Power #6 LB

C627

N

Low Power #7 LB

C628

N

Low Power #8 LB

C631

N

Low Power #1 RB

C632

N

Low Power #2 RB

C633

N

Low Power #3 RB

C634

N

Low Power #4 RB

C635

N

Low Power #5 RB

C636

N

Low Power #6 RB

C637

N

Low Power #7 RB

C638

N

Low Power #8 RB

C641

0

32

High Exh Temp #1 LB

C642

0

32

High Exh Temp #2 LB

C643

0

32

High Exh Temp #3 LB

C644

0

32

High Exh Temp #4 LB

C645

0

32

High Exh Temp #5 LB

C646

0

32

High Exh Temp #6 LB

Version 2010/1


14-49

Acoustic Signal

(Message Code)


Display

Error Code




C-Code TIER 1



C647

0

32

High Exh Temp #7 LB

C648

0

32

High Exh Temp #8 LB

C649

N

Change Lubricating Oil and Filter

C651

0

32

High Exh Temp #1 RB

C652

0

32

High Exh Temp #2 RB

C653

0

32

High Exh Temp #3 RB

C654

0

32

High Exh Temp #4 RB

C655

0

32

High Exh Temp #5 RB

C656

0

32

High Exh Temp #6 RB

C657

0

32

High Exh Temp #7 RB

C658

0

32

High Exh Temp #8 RB

C661

N

High Power #1 LB

C662

N

High Power #2 LB

C663

N

High Power #3 LB

C664

N

High Power #4 LB

C665

N

High Power #5 LB

C666

N

High Power #6 LB

C667

N

High Power #7 LB

C668

N

High Power #8 LB

C671

N

Exh Temp Ckt Failed Low #1 LB

C672

N


C673

N


C674

N


C675

N


C676

N


C677

N


C678

N


C694

N

LBR Turbo Comp Inlet Temp Sesnor Ckt Failed High

C695

N

LBR Turbo Comp Inlet Temp Sesnor Ckt Failed Low

C711

N

High Power #1 RB

14-50

Version 2010/1



Acoustic Signal

(Message Code)


Display

Error Code



C-Code TIER 1

C712

N

High Power #2 RB

C713

N

High Power #3 RB

C714

N

High Power #4 RB

C715

N

High Power #5 RB

C716

N

High Power #6 RB

C717

N

High Power #7 RB

C718

N

High Power #8 RB

C719

N

Blowby Press Ckt Failed High

C721

N

Exh Temp Ckt Failed Low #1 RB

C722

N


C723

N


C724

N


C725

N


C726

N


C727

N


C728

N


C729

N

Blowby Press Ckt Failed Low

C753

N

Cam Sync Error

C777

N

Ambient Derate Error

C783

0

32

C2154

Y N


Rapid rise in left bank front intake temp. Post Oil Filter Press Ckt Failed High

C2155

Post Oil Filter Press Ckt Failed Low

C2157

0

32

Y

Rapid rise in left bank rear intake temp.

C2158

0

32

Y

Rapid rise in right bank front intake temp.

C2159

0

32

Y

Rapid rise in right bank rear intake temp.

Version 2010/1

14-51



14.2.10.4 TABLE OF AVAILABLE INSTRUCTION MESSAGES Message No.

14-52

Instruction Message

1

Engine stopped because of main Shut-Off (gate) valve. - Open the Shut-Off (gate) valve. - If failure exist further, inform service.

2

Inform service.

3

Stop the engine. - Inform service.

4

Start blocked because of main Shut-Off (gate) valve. - Open the Shut-Off (gate) valve. - If failure exist further, inform service.

5

Start blocked - Inform service.

6

The fire suppression system has been actuated. - Inform the fire brigade. - Evacuate endangered persons. - Fight the fire. - Inform service.

7

Bucket motion switched off. - Inform service.

8

No 24V at circuit breaker 11F013 - If failure exist further, inform service.

9

Ladder end switch or lock lever contact open or service arm down or unlock. - If failure exist further, inform service.

10

Emergency shut-down switch was actuated. - Unlock before restarting. - If failure exist further, inform service.

11

Engine switched off by Maintenance Safety Switch in the engine room.

12

Operate the machine into the parking position.

13

Please wait! No high idle !

14

Enable switch for refilling arm active - If failure exist further, inform service.

15

Load of the batteries too high. - Inform service.

16

Batteries are not being charged. - Inform service.

17

Inform service till end of shift and then press cancel button.

Version 2010/1


Message No.

Instruction Message

18

Slew ring gear house brake OFF - Inform service till end of shift and then press cancel button.

19

Travel gear house brake OFF - Inform service till end of shift and then press cancel button.

20

Inform service and then press cancel button.

21

Hydraulic oil far below operating temperature ! - Pre-heat hydraulic oil or warm up at low idle speed and reduced power.

22

Engine runs (starter motor inactive).

23

A fuel reserve only is still in the tank - Order tanker.

24

Engine shutdown has been actuated from ground man.

25

Hydraulic oil below operating temperature. - Operate with reduced power !

26

Slew ring gear house brake ON

27

Hydraulic oil overheat - engine power derated

28

The VHMS is by-passed. - Reset by-pass switch.

29

Engine shutdown by keyswitch before proper engine cool down. - Before you switch off the engine, cool down the engine in the low idle for 2-3 minutes.

30

Hydraulic oil far below operating temperature ! - Pre-heat hydraulic oil or warm up at low idle speed and reduced power.

31

Continue shift but advise service.

32

Stop engine call service.

33

Derate active, continue to work. Later shutdown possible. Inform service.

34

Call service because of shutdown.

35

Interrupt work and inform service about Speed Derate .

36

Continue work until next PM (Schedule work for next PM)

37

Switch Testspeed in cab base forces the engine to run constantly 1800 1/min.

Version 2010/1


14-53



Message No.

14-54

Instruction Message

38

If failure exist further, inform service.

39

Inform service if attachment in defined position.

40

Continue to work and inform service about Power Derate.

41

Cable Drum at limit. - Move the shovel in an other direction.

42

Motor overheated. Wait until cooldown. - If failure exists further, inform service.

43

Switch off and restart motor - If failure exists further, inform service.

44

Switch off and restart motor (It may be necessary to wait for cool down) - If failure exists further, inform service.

46

Switch off windscreen wiper and call service.

47

Only upper windscreen wiper! Inform service.

48

No 24V at circuit breaker 11F013a - If failure exist further, inform service.

49

Only lower windscreen wiper! Inform service.

50

Reverse travel cut out by cable drum.

51

Cable drum-motor temperature too high. Allow motor to cool down.

52

Permanently switch off by device overheating. Inform service.

53

Temporary switch off by heating-air overheating. Inform service.

54

Wait during one minute after last start of motor.

55

Risk of collision with the cable drum!

56

Key switch off and back on !

57

Cool down period !

58

Travel gear house brake ON

Version 2010/1


Flow Charts (1-4) VHMS Main Screens

14.3

FLOW CHARTS (1-4) VHMS MAIN SCREENS

Fig. 14-22

Main screen flow chart for the Operater Level (1 of 1)

Version 2010/1

14-55


Fig. 14-23 14-56


Main screen flow chart for the Service Level (1 of 3) Version 2010/1


Fig. 14-24


Main screen flow chart for the Service Level (2 of 3)

Version 2010/1

14-57


Fig. 14-25 14-58


Main screen flow chart for the Service Level (3 of 3) Version 2010/1


14.4

VHMS SERVICE LEVEL

Fig. 14-26

Entering the Service Level

VHMS Service Level


Keep key 4 pressed

(2)

Enter digits 123 and release key 4

Version 2010/1

14-59

VHMS Service Level


The Service Level can be activated from all of the three Main Gauge Screens in the operator mode only. If one of the Main Gauge Screens is open, keep key 4 of the key pad pressed and simultaneously enter the digits 1, 2, 3. Then release key 4. Refer to illustration (Fig. 14-26). The following screen will appear:

Fig. 14-27

Input Service ID -1-

Enter the Service ID number and press F6 to confirm.

Fig. 14-29


14.4.1

EXPLANATION OF THE BUTTON SYMBOLS (SERVICE LEVEL)

NOTE: The function of the buttons depends on the menu context.

NOTE: The Service ID number 0400008152 is programmed ex factory.

Functions of the buttons F1 to F6 Go to the next screen. F1 Go to the previous screen. F2

Fig. 14-28

Move the cursor down or left in a menu.

F4

Move the cursor up or right in a menu.


If the entered Service ID was not correct, the display changes to the following screen. Enter the correct Service ID and press F6 to confirm. The number of attempts to enter the Service ID is not limited. NOTE: If you are unsure about the correct Service ID number, please contact your supervisor or your dealer if necessary.

14-60

F3

F5

F6

Leave the sub-menu and go back to the previous main menu. Confirm any setting, or switch any function ON or OFF (1 or 0).

Version 2010/1


14.4.2

SERVICE MENU SELECT SCREEN

After the log-in with the Service ID, the following 8 options of the SERVICE MENU SELECT screen are available:

Fig. 14-30

Fig. 14-31

Legend for Fig. 14-30 and 14-31:

01

z Real Time Monitor Shifts to the menu which allows to display real-time controller data, refer to section 14.4.3 on page 14-62.

02

z PM-Clinic Shifts to the menu which displays PM-Clinic data, refer to section 14.4.4 on page 14-78.

03

z Serial/GCC No. Setting Registers the serial numbers of the excavator model, the engine, and the VHMS monitor, refer to section 14.4.5 on page 14-80.

04

z Memory Clear Shifts to the menu which allows to clear the records in the VHMS memory, refer to section 14.4.6 on page 14-81.

05

z Failure History Shifts to the screen which displays the event and error history for service, refer to section 14.4.7 on page 14-83.

06

z Maintenance Shifts to the menu which allows to manage the data of the Maintenance Monitor, refer to section 14.4.8 on page 14-84.

07

z Snapshot Shifts to the menu which allows to manage the saving options of machine data in manual snapshots, refer to section 14.4.9 on page 14-85.

08

z Setting Shifts to the menu which allows to manage specific settings of machine data, refer to section 14.4.10 on page 14-86.

Service Menu - items 01 - 06

Service Menu - items 03 - 08

Version 2010/1

VHMS Service Level

14-61

VHMS Service Level

14.4.3


REAL TIME MENU SELECT SCREEN

NOTE: For entering the Service Menu refer to section 14.4 on page 14-59.

14.4.3.1

REAL TIME MENU, OPTION: 01 ENGINE 1

Press F3 or F4 to move up or down in the menu.

Use the three REAL TIME MENU SELECT screens to open sub-screens for all 15 options. The sub-screens are called REAL TIME MONITOR. i

Fig. 14-33

Real Time Menu, selection 01

Select menu option 01 Engine 1 and press button F6.i

Fig. 14-34

Real Time Monitor - Engine 1, 1 of 6

Press F1 or F2 to toggle the screens.i

Fig. 14-32

REAL TIME MENU - options 1 -15

The following REAL TIME MONITOR screens display all relevant controller data in real-time. Use the realtime data for testing & adjustment work and for troubleshooting.

14-62

Fig. 14-35


Version 2010/1


Fig. 14-36


VHMS Service Level

Fig. 14-39


14.4.3.2

REAL TIME MENU, OPTION: 02 PTO 1


Fig. 14-37


Fig. 14-40


Select menu option 02 PTO 1 and press button F6.

Fig. 14-38


Fig. 14-41

Version 2010/1

Real Time Monitor - PTO 1, 1 of 1

14-63

VHMS Service Level

14.4.3.3


REAL TIME MENU, OPTION: 03 HYDRAULIC


Fig. 14-42

Fig. 14-45

Real Time Monitor - Hydr. Press. 3 of 4

Fig. 14-46



Select menu option 03 Hydraulic and press F6.

Fig. 14-43


Press F1 or F2 to toggle the screens.

Fig. 14-44

14-64


Version 2010/1


VHMS Service Level

14.4.3.4

REAL TIME MENU, OPTION: 04 SLEW

Select option 05 Electrical Equipm. and press F6

Fig. 14-47


Fig. 14-50

Real Time Monitor - Electr. Equipm. 1 of 2

Select menu option 04 Slew and press F6.


Fig. 14-48

Fig. 14-51

Real Time Monitor - Electr. Equipm. 2 of 2

14.4.3.6

REAL TIME MENU, OPTION: 06 EMERGENCY STOP

Real Time Monitor - Slew 1 of 1

REMARK The entries SLEW SPEED ANALOG 11B144 and SLEW POSITION 60B059 only apply to PC5500 (automatic slew speed system).


14.4.3.5

REAL TIME MENU, OPTION: 05 ELECTRICAL EQUIPMENT


Fig. 14-52

Fig. 14-49



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14-65

VHMS Service Level


Select option 06 Emergency Stop and press F6.

Select option 07 Manual Switch and press F6.

Fig. 14-53

Fig. 14-56

Real Time Monitor - Emerg. Stop 1 of 2

Real Time Monitor - Manual Switch 1 of 4



Fig. 14-54

Real Time Monitor - Emerg. Stop 2 of 2

Fig. 14-57


14.4.3.7

REAL TIME MENU, OPTION: 07 MANUAL SWITCH

Fig. 14-58



Fig. 14-55

14-66


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VHMS Service Level


Fig. 14-59


Fig. 14-62

Real Time Monitor - Centr. Lube 2 of 2

14.4.3.8

REAL TIME MENU, OPTION: 08 CENTRAL LUBE SYSTEM 1

14.4.3.9

REAL TIME MENU, OPTION: 09 SLEW RING GEAR LUBE SYSTEM



Fig. 14-60


Select option 08 Central Lube System 1 and press F6.

Fig. 14-63


Select 09 Slew ring gear Lube System and press F6.

Fig. 14-61

Real Time Monitor - Centr. Lube 1 of 2 Fig. 14-64

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Real Time Monitor - Slew ring lube 1 of 2

14-67

VHMS Service Level




Fig. 14-65

Fig. 14-68

Real Time Monitor - Slew ring lube 2 of 2

Real Time Monitor - Windscr. Wiper 2 of 2

14.4.3.10 REAL TIME MENU, OPTION: 10 WINDSCREEN WIPER

14.4.3.11 REAL TIME MENU, OPTION: 11 LADDER



Fig. 14-66

Fig. 14-69



Select option 10 Windscreen Wiper and press F6.

Select option 11 Ladder and press F6.

Fig. 14-67

Fig. 14-70

14-68

Real Time Monitor - Windscr. Wiper 1 of 2

Real Time Monitor - Ladder 1 of 5

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VHMS Service Level


Fig. 14-71


Fig. 14-74


14.4.3.12 REAL TIME MENU, OPTION: 12 SERVICE ARM Press F3 or F4 to move up or down in the menu.

Fig. 14-72


Fig. 14-75


Select option 12 Service arm and press F6.

Fig. 14-73


Fig. 14-76

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Real Time Monitor - Service arm 1 of 5

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VHMS Service Level



Fig. 14-77


Fig. 14-80


14.4.3.13 REAL TIME MENU, OPTION: 13 PILOT CONTROL Press F3 or F4 to move up or down in the menu.

Fig. 14-78


Fig. 14-81


Select option 13 Pilot control and press F6.

Fig. 14-79


Fig. 14-82

14-70

Real Time Monitor - Pilot control 1 of 6

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VHMS Service Level


Fig. 14-83


Fig. 14-86


Fig. 14-84


Fig. 14-87


14.4.3.14 REAL TIME MENU, OPTION: 14 OTHER ITEMS Press F3 or F4 to move up or down in the menu.

Fig. 14-85


Fig. 14-88


Select option 14 Other items and press F6

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14-71

VHMS Service Level

Fig. 14-89


Real Time Monitor - Other items 1 of 4

Fig. 14-92



14.4.3.15 REAL TIME MENU, OPTION: 15 OUTPUT SIGNALS Press F3 or F4 to move up or down in the menu.

Fig. 14-90


Fig. 14-93


For testing and troubleshooting the Output Signals can be switched on (1) and off (0). For the appropriate procedure refer to Output Signals with deactivated MTC-Evaluation on page 77. Select option 15 Output Signals and press F6.

Fig. 14-91


Fig. 14-94

Real Time Monitor - Output Signals 1/24

Press F1 or F2 to toggle the screens. 14-72

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VHMS Service Level

Fig. 14-95


Fig. 14-98


Fig. 14-96


Fig. 14-99


Fig. 14-97


Fig. 14-100 Real Time Monitor - Output Signals 7/24

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14-74

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VHMS Service Level







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VHMS Service Level







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14.4.3.16 OUTPUT SIGNALS WITH DEACTIVATED MTCEVALUATION

z

VHMS Service Level

Press button F6 (ON /OFF) to switch the solenoid valve 57K506b-1 ON (= 1) manually.f

As an on-board assistance for troubleshooting, the output signals of the REAL TIME MONITOR selection "15 Output Signals" can manually be switched on (1) and off (0), if the MTC-evaluation is deactivated. NOTE: For the procedure how to activate and deactivate the MTC-evaluation, refer to section 14.4.10.5 on page 14-90, PLC-evaluation ON/ OFF. Terminology (MTC & PLC) MTC is a synonym for PLC. Both acronyms indicate the same main control module. MTC is the acronym of Master Turbo Controller PLC is the acronym of Programmable Logic Controller WARNING If you need to deactivate the MTC-evaluation for testing, strictly observe the operating instructions for deactivation & activation of the MTC-evaluation. Refer to section "PLC-evaluation ON/OFF on page 91".

SAMPLE: Assumption It is necessary to check if voltage is present in the wiring of 57K506b-1 and at the solenoid valve itself.

Fig. 14-118 Output signal manually switched ON z

Now check the voltage in the circuit of solenoid valve 57K506b-1 and repair if necessary.

z

After check and repair are finished:

1. Switch the solenoid valve OFF (= 0) again in this case. 2. Activate the MTC-evaluation again, refer to "PLC-evaluation ON/OFF on page 91". 3. Switch off the main key switch (20S001) for more than 5 seconds, in order to cause a reset. After such a reset the MTC-evaluation is activated again and the electrical component is switched to its primary condition again by the system.

Procedure z

Stop the engine.

z

Turn the main key switch 20S001 to ON position.

z

Enter the service level on the VHMS monitor.

z

Deactivate the MTC-evaluation, refer to "PLCevaluation ON/OFF on page 91".

z

On the SERVICE MENU SELECT screen, select and open the entry 01 Real Time Monitor. Refer to Fig. no. 14-30.

z

Select and open the last option 15 Output signals. Refer to Fig. no. 14-93.

z

Move to the screen 16/ 24 REAL TIME MONITOR (Output Signals Control panel).

z

Use buttons F3 or F4 and select the second entry VALVE FAN DRIVE 1 MED.

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VHMS Service Level

14.4.4


PM-CLINIC

NOTE: For entering the Service Menu refer to section 14.4 on page 14-59. The PM-Clinic Menu provides the following features: 1. General data of the machine and operating conditions are displayed, refer to Fig. 14-120 & 14-121. 2. Power Check relevant data can be frozen and also displayed by actuating: z

Button F4 in Fig. 14-123.

z

Push button 20S082 (R.H. control lever), which is normally used as truck counter.

3. The frozen data can be stored 3 times.

14.4.4.1

GENERAL


Fig. 14-121 PM-CLINIC - screen GENERAL 2 of 2 Press F6 to get into the second PM-CLINIC menu POWER CHECK Menu. In case data are already stored in the Menu POWER CHECK (Fig. 14-123) the following screen (Fig. 14122) appears before screen POWER CHECK (Fig. 14123) opens.

Fig. 14-119 Service Menu - 02 PM-CLINIC selected Select 02 PM-CLINIC and press F6.

Fig. 14-122 Delete PM-Clinic data - Yes/No If you want to save the current PM-Clinic data, delete the previously saved data by pressing button F6. If you don’t want to delete all PM-Clinic data, press button F5 in order to open the following screens of PM-Clinic POWER CHECK.

Fig. 14-120 PM-CLINIC - screen GENERAL 1 of 2 Press F1 or F2 to toggle the screen.

14-78

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14.4.4.2

POWER CHECK

VHMS Service Level

After pressing button F6 in screen POWER CHECK 3/3 (Fig. 14-124) the following screen appears:

The POWER CHECK screens should assist you if you want to check or identify: (a) engine performance/engine output power (b) pressure adjustment/hydraulic system problems There are 3 screens POWER CHECK for freezing data under different conditions. NOTE: In order to obtain a complete POWER CHECK, the F6 button should only be pressed after the 3rd screen (Fig. 14-124) "POWER CHECK 3/3" has been frozen. Fig. 14-125 Record PM-Clinic data - Yes/No Press button F6 if you want to record the data. Press button F5 for exit if you don’t want to record the data. The system returns to the POWER CHECK screen

Fig. 14-123 PM-CLINIC - POWER CHECK 1/3 It is possible to store the values of 3 different POWER CHECKS in the screens 1/3, 2/3, and 3/3. Press button F1 or F2 to monitor the POWER CHECK data of all 3 screens. If you want to freeze the data, press button F4 to move the yellow mark to Hold at the bottom of the display (Fig. 14-124). If Hold is highlighted yellow, press button F4 to freeze the current PM-CLINIC data. To show the current data again, press button F3. The yellow mark moves to Monitoring again (Fig. 14-123).

Fig. 14-124 PM-CLINIC - POWER CHECK 3/3

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14-79

VHMS Service Level

14.4.5


SERIAL/GCC NO. SETTING

NOTE: For entering the Service Menu refer to section 14.4 on page 14-59. Use this option to display the serial number of: (a) the excavator (b) the Diesel engine (c) the VHMS monitor MH801 Press F3 or F4 to move up or down in the menu.

Fig. 14-126 Service Menu - item 03 selected Select 03 Serial/GCC No. Setting and press F6.

Fig. 14-127 Screen SERIAL NO SETTING

14-80

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14.4.6

VHMS Service Level

MEMORY CLEAR

NOTE: For entering the Service Menu refer to section 14.4 on page 14-59.

14.4.6.1

INPUT MEMORY CLEAR ID

Use this option to enter the Memory Clear ID, which enables the user to delete memory data. With this function it is made sure that only authorized service personnel may delete saved data. Press F3 or F4 to move up or down in the menu. Fig. 14-129 Input Memory Clear ID Enter the Identification Number (ID) for clearing the memory and press F6 to confirm.

Fig. 14-128 Service Menu - item 04 selected Select 04 Memory Clear and press F6. Entry of the Identification Number Fig. 14-130 Memory Clear ID is typed in If 04 Memory Clear is selected in the Service Menu Selection screen, the display changes to the Input Memory Clear ID screen.

If the entered ID is not correct, the display changes to the following screen. Enter the ID number again.

The ID number entry is done via the key pad. The ID number is a number with up to 10 digits (same as the Service ID number). The enterd number is compared with the number which is registered in the VHMS controller. If the check result is correct, the display changes to the MEMORY CLEAR screen (Fig. 14-132), refer to section 14.4.6.2 on page 14-82.

Fig. 14-131 Enter Memory Clear ID again

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VHMS Service Level

14.4.6.2


MEMORY CLEAR SCREEN

NOTE: For entering the Memory Clear ID refer to section 14.4.6.1 on page 14-81. After the correct Memory Clear ID is entered, the following MEMORY CLEAR menu will open. Press button F3 or F4 to move up or down in the menu and select the requested data set (01 - 06) which should be cleared in the memory.

Fig. 14-132 Memory Clear Menu - item 01 selected Confirm your selection by pressing button F6.

Fig. 14-133 Memory Clear - confirmation for deletion Press button F6 to confirm the deletion of the selected data or press F5 to exit. The deletion procedure is the same for all 6 entries in the above MEMORY CLEAR menu (Fig. 14-132).

14-82

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14.4.7

VHMS Service Level

FAILURE HISTORY

NOTE: For entering the Service Menu refer to section 14.4 on page 14-59. Press F3 or F4 to move up or down in the menu.

The chart FAILURE HISTORY(for Service) is displayed in the reverse order of the failure occurrence. The failure message which was saved lastly, is shown at the top of the displayed chart. As long as any listed failure is not rectified, the failure detection end time is not displayed. If you want to delete any failure record from the displayed chart: (a) Press button F3 or F4 to select any failure record. (b) Press F6 to delete the selected failure record. If you want to delete more failure records from the chart, proceed analogously.

Fig. 14-134 Service Menu - item 05 selected Select 05 Failure History and press button F6.

Fig. 14-135 Screen FAILURE HISTORY Legend for Fig. 14-135: (1)

Frame which indicates the selected failure message (using buttons F3 or F4)

(2)

Failure detection start time

(3)

- Number in the failure history chart (2) - failure code (G00253) - failure text message (Emergency ...)

(4)

Failure detection end time

(5)

Total number of saved failure messages in this failure history

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VHMS Service Level

14.4.8


MAINTENANCE MONITOR

Press F6 to reset the selected service meter.


Fig. 14-138 Maintenance Monitor - reset function

Fig. 14-136 Service Menu - item 06 selected

NOTE: In this section only the selection of the 250h Maintenance is described as a sample. The procedure is the same for all remaining Maintenance entries on the MAINTENANCE MONITOR (Fig. 14-137).

Select 06 Maintenance and press F6.

Fig. 14-137 Maintenance Monitor - overview Maintenance Confirmation by the Service Personnel Maintenance indicated with yellow or red background colour should be confirmed by service personnel in the Service Menu subsequent to the execution of the respective maintenance. After that the selection in the Service Menu, used for maintenance confirmation, is without any function. The confirmation of the maintenance is stored in the VHMS controller. Example: 250h maintenance is required (red marked), service meter reading is -2 hours.

14-84

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14.4.9

VHMS Service Level

SNAPSHOT


Fig. 14-142 Snapshot running 5:34 minutes When data capturing is completed, the following screen appears for 2 seconds. Fig. 14-139 Service Menu - item 07 selected Select 07 Snapshot and press F6.

Fig. 14-143 Snapshot finished

Fig. 14-140 Snapshot - Start Monitor Press the START button F1 in the upper screen (Fig. 14-140) in order to save the (manual) SNAPSHOT data in the VHMS controller.

After that the screen changes back to the SNAPSHOT start monitor (Fig. 14-140). For any analysis of the manual SNAPSHOT data it is necessary to download these data onto a laptop. REMARK For download and analysis the VHMS-Setting Tool and the VHMS-Analizing Tool are required.

NOTE: If certain troubles occur, machine data at the time of the failure occurrence are saved automatically (automatic Snapshot). For details refer to the respective TROUBLESHOOTING MANUAL.

Fig. 14-141 Snapshot started and running 1 minute

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14-85

VHMS Service Level


14.4.10 SETTINGS NOTE: For entering the Service Menu refer to section 14.4 on page 14-59.

Enter the requested number of minutes via the key pad, for example 30.

This option allows you to determine the basic operating and system conditions (settings) via the VHMS system. Press F3 or F4 to move up or down in the menu.

Fig. 14-146 Enter CLS 1 PAUSE TIME Press button F6 to confirm the entered value.

Fig. 14-144 Service Menu - item 08 selected Select 08 Setting and press button F6.

14.4.10.1 CENTRAL LUBRICATION SYSTEM (CLS 1), SCREEN 1/8

Lubrication Cycle Counter Setting Use buttons F3 or F4 to select the Lubrication Cycle Counter (Fig. 14-145) and then press F6 to enter the Lubrication Cycle Counter setting screen. REMARK It is recommended to keep the counter reading over the live time of the machine. If necessary enter the number of the last download.

Fig. 14-145 SETTINGS 1/8 - CLS 1 SETTINGS Options on screen CLS 1 SETTINGS (Fig. 14-145): Pause Time Setting Use buttons F3 or F4 to select the CLS 1 Pause time and then press button F6 to open the Pause time setting screen (Fig. 14-146). Only values between 10 and 60 minutes can be selected.

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14.4.10.2 SWING LUBRICATION SYSTEM (SLS), SCREEN 2/8

VHMS Service Level

Lubrication Cycle Counter Setting Use buttons F3 or F4 to select the Lubrication Cycle Counter and then press button F6 to enter Lubrication Cycle Counter Setting screen. REMARK It is recommendable to keep the counter reading over the live time of the machine. If necessary enter the number of the last download.

Fig. 14-147 SETTINGS 2/8 - SLS SETTINGS Press F1 or F2 to move up or down in the menu. Options on screen SLS SETTINGS 2/8 (Fig. 14-147): Pause Time Setting Use buttons F3 or F4 to select the Pause time and then press button F6 to enter the Pause time setting screen (Fig. 14-148). Only values between 10 and 20 minutes can be selected. Enter the requested number of minutes via the key pad, for example 13.

Fig. 14-148 Enter SLS SETTINGS Press button F6 to confirm the entered value.

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VHMS Service Level


14.4.10.3 QMIN - QMAX - SETTING, SCREEN 3/8

14.4.10.4 OTHER SETTINGS 1/2, SCREEN 4/8

The settings Qmin and Qmax are provided for testing and adjustment procedures on the pump regulation system. Refer to the relevant descriptions in section 7 of this Service Manual.

Fig. 14-150 SETTINGS 4/8-OTHER SETTINGS (1/2) Press F3 or F4 to move up or down in the menu.

Fig. 14-149 SETTINGS 3/8 - Qmin-Qmax-SETTING Press button F1 or F2 to move up or down in the menu and then press button F6 to confirm your selection. Qmin This setting is e.g. used for the adjustment of the secondary relief valves.

NOTE: This screen only displays current information without any option for settings. REMARK For changing the settings of e.g. Language, Date, Time, and Daylight saving time refer to section 14.2.8 on page 14-18 "Settings for Operators". Hydraulic Oil & PTO Gear Oil Definition Table

Qmax This setting is e.g. used for the adjustment of the backpressure valve. AUTOMATIC This is the standard setting for machine operation (pump regulation). NOTE: If the setting Qmax is activated engine start is not possible. Always remember to activate the setting AUTOMATIC (pump regulation) again for normal machine operation, after any testing or adjustment under the condition of Qmin or Qmax is finished.

14-88

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VHMS Service Level

Fig. 14-151 Hydraulic Oil & PTO Gear Oil Definition Table

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14-89

VHMS Service Level


14.4.10.5 OTHER SETTINGS 2/2, SCREEN 5/8

PTO Gear Oil Viscosity Use this option to save the specification of the used PTO gear oil in the system. This saved information takes effect on the monitoring and controlling characteristics during machine operation. Select Oil viscosity gear and press button F6.

Fig. 14-152 SETTINGS 5/8-OTHER SETTINGS (2/2) Press button F3 or F4 to move up or down in the menu, and press button F6 to open the selected submenu. Fig. 14-154 PTO gear oil selection chart Hydraulic Oil Viscosity Use this option to save the specification of the used hydraulic oil in the system. This saved information takes effect on the monitoring and controlling characteristics during machine operation. Select Oil viscosity hydraulic and press button F6.

Fig. 14-155 PTO gear oil selection chart Refer to the Hydraulic Oil & PTO Gear Oil Definition Table (Fig. 14-151) and choose the required PTO gear oil specification according to the specific temperature conditions.

Fig. 14-153 Hydraulic oil selection chart

Press button F3 or F4 to select the required PTO gear oil specification on the above screen (Fig. 14-155) and press button F6 for confirmation.

Press button F1 or F2 to toggle the 5 screens. Refer to the Hydraulic Oil & PTO Gear Oil Definition Table (Fig. 14-151) and choose the required hydraulic oil specification according to the specific temperature conditions. Press button F3 or F4 to select the required hydraulic oil specification on the above screen (Fig. 14-153) and press button F6 for confirmation.

14-90

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Messages ON/OFF Use this option to avoid and eliminate unnecessary failure messages during certain service activities. In the OFF-state, setting works are not interrupted by accidentally generated messages and the memory will not be filled with messages caused by testing operations. Control and monitoring functions remain active. Every setting modification of the function Messages ON/OFF is saved in the service memory. Press button F3 or F4 to move up or down in the menu.

VHMS Service Level

If the MTC-evaluation is switched OFF, it is possible to manipulate the switch status (0/1) of the electrical components which are displayed on the Real Time Monitor, option 15 Output Signals, refer to section 14.4.3.15 on page 14-72. But always remember that all monitoring and control functions of the MTC controller are deactivated in this OFF-state. The MTC does no longer evaluate input signals and it does not transmit any control output signals. Every setting modification of the option PLC-evaluation ON/OFF is saved in the service memory. CAUTION As long as the PLC-evaluation is switched OFF, all monitoring and control functions of the MTC controller are inoperative.

Pre-conditions for the deactivation of the PLCevaluation z The engine must stand still. z

Fig. 14-156 Message OFF selected

The main key switch (20S001) must be in ON position.

If the option Messages ON/OFF is selected, press button F6 to deactivate messages (= OFF). After testing or service work is finished, activate the messages again by switching Messages ON/OFF to ON again. Optionally switch off the main key switch (20S001) for more than 5 seconds, in order to cause a reset. After such a reset the function Messages ON/OFF is set to ON again by the system. Fig. 14-157 PLC-evaluation OFF selected PLC-evaluation ON/OFF Use this option to deactivate the MTC-evaluation, if testing or troubleshooting procedures must be performed without any intervention of the MTC controller. Terminology (MTC & PLC) MTC is a synonym for PLC. Both acronyms indicate the same main control module. MTC is the acronym of Master Turbo Controller PLC is the acronym of Programmable Logic Controller

Version 2010/1

Use buttons F3 or F4 to select PLC-evaluation ON/ OFF. Then press button F6 to deactivate the PLC (= OFF). After testing or service work is finished, activate the MTC again by switching PLC-evaluation ON/OFF to ON again. Optionally switch off the main key switch (20S001) for more than 5 seconds, in order to cause a reset. After such a reset the function PLC-evaluation ON/OFF is set to ON again by the system.

14-91

VHMS Service Level


14.4.10.6 SHUTDOWN BYPASS ON/OFF For purposes of initial start-up and during troubleshooting it is possible to bypass trouble conditions which may cause a shutdown. Refer to the following 3 screenshots.

Even if the automatic shutdown is deactivated, a corresponding message is generated at the moment when the trouble condition for a shutdown is met. Every setting modification of the function SHUTDOWN BYPASS ON/OFF is saved in the service memory.

WARNING Only activate the Shutdown Bypass in case of emergency. Fatal injury and serious damage of the machine may occur.

Press button F1 or F2 to toggle the 3 screens.

CAUTION If you consciously deactivate the automatic Shutdown for troubleshooting, always make sure that there is no risk for personal injury and damage of the machine.

REMARK If you feel unsure about the function SHUTDOWN BYPASS ON/OFF contact your supervisor.

Fig. 14-158 Shutdown Bypass ON/OFF (1/3)

Explanation of the Function Logic (1) SHUTDOWN BYPASS OFF - Standard setting The BYPASS of any trouble condition is switched OFF (Bypass = deactivated). In this case the trouble condition is not bypassed and it does trigger a shutdown, if the trouble condition is met (Shutdown = activated)

Fig. 14-159 Shutdown Bypass ON/OFF (2/3)

(2) SHUTDOWN BYPASS ON - Exceptional setting The BYPASS of any trouble condition is switched ON (Bypass = activated). In this case the trouble condition is bypassed and it does not trigger a shutdown, even if the trouble condition is met (Shutdown = deactivated) An activated SHUTDOWN BYPASS remains active until the setting of of the SHUTDOWN BYPASS is switched to OFF again. z

If the SHUTDOWN BYPASS is not switched to OFF again, this condition is only stored in the Failure History (Service Level) after next start, invisible for the operator.

14-92

Fig. 14-160 Shutdown Bypass ON/OFF (3/3) Use buttons F3 and F4 to select the desired shutdown option. Then press button F6 (ON/OFF) to confirm your selection.

Version 2010/1


VHMS Service Level

Automatic Shutdown Functions (Standard Setting = OFF) There are 3 different kinds of system intervention which are combined in the term SHUTDOWN. Refer to the below samples:

Fig. 14-161 Different kinds of SHUTDOWN Legend for Fig. 14-161

(1)

z Engine shutdown In case the hydraulic oil level is definitely too low, the engine is shutdown

(2)

z Bucket cut off In case the lubrication is disturbed, the bucket movement is cut off after a specified time period

(3)

z Start blocked In case the main gate valve is not open, engine start is blocked

(4)

Spare option

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14-93

Interface-Connection VHMS-Controller

14.5


INTERFACE-CONNECTION VHMS-CONTROLLER

Fig. 14-162 Interface-connection VHMS-controller

14-94

Version 2010/1


Legend for Fig. 14-162 (1)

VHMS monitor (MH801)

(2)

MTC-controller (11K301)

(3)

Interface panel on the rear of the operator’s console

(4)

(5)

(6)

(7)

11X027a - VHMS Setting Tool - VHMS Analysis Tool 20X323 (LAN connector) - CoDeSys Software - Visualization 20X336 - Service Connector for the VHMS Monitor (MH801) 20X052-1 QUANTUM Service Connector

14.5.1

Interface-Connection VHMS-Controller

VHMS-CONTROLLER

The VHMS-Controller (10K300) provides interfaces and options for the user as follows: - Data link to the VHMS monitor - Data link to the MTC-controller - Data link to Quantum (engine control) - VHMS programming - Input of operator settings - Input of machine settings - Reading out machine troble codes - Download of snapshot data - Download of VHMS memory data - Trouble shooting features & assistance - Service link to Quantum (engine control)

REMARK Data cables, hardware devices, and software tools for data exchange via the VHMS interface connections are optional equipment. For detailed information about the VHMS software refer to the Troubleshooting Manual of your machine.

Version 2010/1

14-95

Wiring of the VHMS-Controller

14.6


WIRING OF THE VHMS-CONTROLLER

Fig. 14-163 VHMS-Controller connectors 14-96

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z VHMS-Controller (10K300) Mounted in the cab base

(2)

LED indicator During standard operation the controller is continuously counting up a loop of digits. In case of any malfunction the counting loop is stopped.

(3)

Type label

(4)

Connector panel

(5)

Supply voltage indicator

(6)

z LED green ON = supply voltage (24V) OK

(7)

LED yellow ON = supply voltage error

z

z

CN2-B (green) Remark: not used

CN3-A (white) Remark: Pin 1 = tacho check (to Quantum unit 52K014) Pin 9 = connection check Pin 4, 12, 13 = RS232 interface to MTC Pin

Function

1

D_IN8

4

RS232 TX2

9

GND

12

RS232 RX2

13

RS232 GND

Pin layout of the sockets at the VHMS-Controller:

CN1 (white) Remark: Supply voltage & ground Pin

Function

6

VBB_IN

7

VBB_IN

Pin

Function

8

VB_IN

12

GND

9

VB_IN

11

GND

12

GND

18

Flash_write

19

GND

20

GND

CN3-B (white)

CN2-A (green) Remark: for optional equipment ORBComm Pin

Function

17

(low active input)

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14-97



CN4-A (white) Remark: Pin 4, 12, 13 = CAN bus to Quantum Pin 5, 6, 14 = CAN bus to VHMS monitor and service connector 20X336 PIN 9, 10, 11 = RS232 interface to 20X027a and 11X027b CAN 0 = interface to VHMS monitor CAN 1 = interface to Quantum 20X027a = download or programming in cab 20X027b = download or programming in cab base Pin

Function

4

CAN 1 +

5

CAN 0 Shield

6

CAN 0 +

9

RS232 GND

10

RS232 RX0

11

RS232 TX0

12

CAN 1 -

13

CAN 1 Shield

14

CAN 0 -

CN4-B (white) Remark: for optional equipment ORBComm RS232 interface to ORBComm controller Pin

Function

3

RS232 GND

4

RS232 TX1

9

GND (shield)

10

RS232 RX1

CN5 (black) Remark: not used

14-98

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14-99

Global Layout of the MTC Control System VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM

14.7

GLOBAL LAYOUT OF THE MTC CONTROL SYSTEM

Fig. 14-164 Global layout of the MTC control system 14-100

Version 2010/1

VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM Global Layout of the MTC Control System


VHMS monitor (MH801) including key pad - located in the operator’s cab

(2)

VHMS controller - located in the cab support

(3)

Engine control modules (3 pcs) "Quantum system" - fitted at the engine

(4)

CAN bus - between VHMS controller and VHMS monitor

(5)

CAN bus - between VHMS controller and Quantum

(6)

Serial interface (RS 323) - between MTC and VHMS controller

(7)

MTC [MTC = Master Turbo Controller]

(8)

CAN bus - internal CAN bus between MTC and nodes

(9)

Node, type ICN-V and type ICN-D, [ICN = Intelligent CAN Node] - interface between internal CAN bus and electr. machine components

(10)

CAN node type ICN-V (9 pcs)

(11)

CAN node type ICN-D (6 pcs)

(12)

INPUT (status signal from component) - binary and analog inputs, e.g. signal from any switch

(13)

OUTPUT (control signal to component) - digital outputs, e.g. signal to any solenoid valve

NOTE: Optional equipment as ORBCOMM or MODULAR MINING SYSTEM can be connected to the system. Refer to the specific documents and Wiring Diagrams.

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14-101


14.7.1

MTC (MASTER TURBO CONTROLLER)

14.7.1.1

MTC-FLOWCHART

Fig. 14-165 MTC-Flowchart

14.7.1.2

MTC FEATURES

The MTC is a shock & vibration resistant (4G) controller for mobile configuration. It is dust & water resistant and works within a temperature range of -40°C to +85°C without any separate heating or cooling equipment. It is equipped with a motherboard with 32-Bit / 396 MHz and Floating Point Unit (parallel working process). The task time is < 1 µs.

The second part of the Microcontroller is the “Watch Dog” function. It includes system check, LED´s, and Input / Output sensing. Data storing features are: Compact Flash Card for data storing, real-time watching, and FRAM for safe data storing. There are also 2 DIGITAL main inputs & 2 DIGITAL main outputs (max. 400mA short cut resistant) including detection of wiring connection.

It runs with the software system CoDeSys V2.3.9.10 It is equipped with the following connections: 4x Main CAN open – connections, 2x RS 232 Serial ports, Ethernet port 10/100Mbit – Download / Upload / TCP/IP / UDP / USB connection for Firmware Upload.

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14.7.1.3

MTC-FIRMWARE AND SOFTWARE

The MTC is programmed with Firmware and Software. FIRMWARE The Firmware internally operates and manages the MTC unit, independent of the kind of the machine. SOFTWARE The Software is a machine-specific application which manages the excavator’s control system. Therefore it is essential that the Software version and the machine model properly fit together. It is possible to replace the programs (Firmware and Software) of the MTC. For such a procedure a specific version of the CoDeSys software must be installed on the used laptop. Via LAN connection such a software upload can be done comfortably. The CoDeSys software can also be used as a Visualization, which is an important tool for troubleshooting. For more details of the CoDeSys Visualization refer to the Visualization User Manual and to the Troubleshooting Manual of your machine.

For the details of the: z

MTC Firmware & Software

z

CoDeSys software

z

Visualization

z

Appropriate equipment

z

Communication procedures with the MTC

refer to the Troubleshooting Manual of your machine. CAUTION Before trying to change any software of the MTC, always make sure that: - the complete required equipment is present - the correct software packages are present - a qualified service technican will perform the procedure Otherwise a complete shutdown of the machine may result.

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14.7.1.4

VIEW ONTO THE MTC UNIT AND ITS CONNECTORS

Fig. 14-166 View onto the MTC unit and its connectors

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MTC unit [Master Turbo Controller]

(2)

Left hand side MTC connectors

(3)

LED panel1 of the MTC unit

(4)

Right hand side MTC connectors

(5)

MTC ground connection (housing)

(6)

LAN connection to cab / laptop

(7)

Digital output

(8)

Supply voltage (24V) connection

(9)

CAN bus connection

(10)

Serial port COM 2 (RS 232) to VHMS controller

1The

LEDs are showing operation conditions and they also blink out those trouble codes which cause a shutdown.

For the description of the LED panel and the operating mode of the LEDs refer to the OPERATION & MAINTENANCE MANUAL or to the TROUBLESHOOTING MANUAL of your machine.

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Global Layout of the Internal CAN bus


14.8

GLOBAL LAYOUT OF THE INTERNAL CAN BUS

14.8.1

GENERAL INFORMATION ABOUT A CAN BUS SYSTEM

Fig. 14-167 Control system - conventional layout [A] and CAN bus layout [B] The acronym CAN means: Controller Area Network Legend for Fig. 14-167: [A]

Wiring in a conventional control circuit

[B]

Wiring in control circuit with CAN bus

(1)

Low voltage switch board (11a000) and controller (A = PLC / B = MTC) in the cab base

(2)

Long wiring between low voltage switch board and each electrical component (including intermediate connectors for cable sections)

(3)

Electrical component (e.g. switch or solenoid valve)

(4)

Short wiring between nodes and electrical component

(5)

Internal CAN bus, leading from the MTC to each node

(6)

Node, type ICN-V and type ICN-D, [ICN = Intelligent CAN Node] - interface between internal CAN bus and electrical machine components

(7)

End resistor (120 Ω) of the CAN bus

(8)

INPUT - Status signals from the machine components

(9)

OUTPUT - Control signals from the MTC-controller

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14.8.1.1

GENERAL CAN BUS DESCRIPTION

The comparison of the wiring in a conventional control circuit and in a control circuit with CAN bus shows that the total length of the wiring between the controller and the electrical components in the CAN bus system is visibly shorter. Also the number of connectors is reduced, as several cable sections in the wiring between the controller and the machine components are no longer needed. In a CAN bus system all system components (input & output) are connected to a common data line via short branch lines. Therefore the system wiring is reduced and additional components may be connected easily.

14.8.1.2


CAN BUS TROUBLESHOOTING

The CAN bus system is equipped with effective selfdiagnosis tools. CAN troubles are displayed via the VHMS monitor and/or blinked out at the MTC-controller. With the help of a visualization software the location of any trouble can easily be determined. For troubleshooting in the CAN bus system a special CAN-Test Box is available. For details refer to the Tools and Accessories Catalogue. For the appropriate and qualified troubleshooting procedures refer to the TROUBLESHOOTING MANUAL of your machine.

The interfaces between the CAN bus and the electrical machine components are called Nodes. It is a fundamental idea of the CAN bus layout that the nodes are as close to the machine components as possible. However, the data flow must be controlled by an access method (protocol) in order to manage the well organized data transfer in one common data line. The MTC unit (refer to section 14.7 on page 14-100) and the Nodes (refer to section 14.9 on page 14-112) are essential components for the control and mangement of the CAN bus system. The status information from the electrical components as well as the control signals from the MTC are not continuously present in the CAN bus cable. Status information and control signals of each component are packed in data packages which are called Data Frames. These Data Frames are sent through the CAN bus periodically in small fractions of a second. The control components MTC & Nodes send and receive the Data Frames. Also they organize and manage a safety system, to make sure that defined and complete information packages are received by the designated components. Each Data Frame contains a protocol for its identification. A CAN bus cable consists of only 3 wires, which are: z

CAN high (H)

z

CAN low (L)

z

Shield

In a CAN bus system 2 voltages are present. Depending on the kind of system the CAN high voltage is in a range of up to approx. 6V. The CAN low voltage is up to approx. 3.5V.

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14.8.1.3


CAN BUS WIRING

Fig. 14-168 Detail of the CAN bus wiring1 1

For the entire overview refer to the complete Wiring Diagrams of the respective machine.

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CAN bus wire CAN high (H)

(2)

CAN bus wire CAN low (L)

(3)

CAN bus wire shield

(4)

CAN bus branch connector

(5)

Node, type ICN-D, [ICN = Intelligent CAN Node] interface between internal CAN bus and electrical machine components

(6)

Node pin - connection CAN high to node

(7)

Node pin - connection CAN low to node

(8)

Node pin - connection shield to node

(9)

CAN bus End Resistor

(10)

Annotation in the Wiring Diagram: Length of branch cable max. 1m

(11)

View onto a standard CAN bus connector (male & female)

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14.8.1.4


CAN BUS END RESISTOR

A CAN bus does not build a closed wiring circuit as a conventional electrical circuit system in general does. As a result there is an "open" end. At this end the wires CAN high and CAN low must be connected by an End Resistor. The resistance of these End Resistors is 120 Ω each. A CAN bus can be split, and in this case an End Resistor needs to be connected to each end of the CAN bus. The following chart gives an overview over the fitted End Resistors on your machine. End Resistors - Overview Component Code2

No.

Location Code1

CAN bus

1

10

1

Cab base, CAN bus VHMS-controller to Quantum

10R100

2

10

2

Cab base, CAN bus VHMS-controller to VHMS monitor

10R101

3

20

internal

Operator’s cab, node 9

20R101

4

40

internal

Hydraulic oil tank, node 13

40R101

Description

1, 2

For a detailed explanation of the Location Code & Component Code definition refer to section 13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM in this Service Manual. View onto End Resistors

Fig. 14-169 View onto 2 different types of End Resistor

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The Nodes in the CAN bus System


14.9

THE NODES IN THE CAN BUS SYSTEM

14.9.1

GLOBAL LAYOUT

Fig. 14-170 Exemplary Drawing of a CAN bus and its Nodes

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Internal CAN bus, leading from the MTC to each node

(2)

MTC-controller and low voltage switch board (11a000) in the cab base

(3)

Node (type ICN-V or type ICN-D)

(4)

Wiring between node and electrical machine component

(5)

Electrical machine component (e.g. switch or solenoid valve)

(6)

INPUT - Status signals from the machine components

(7)

OUTPUT - Control signals from the MTC-controller

(8)

End resistor (120 Ω) of the CAN bus

14.9.2

INTRODUCTION

The Nodes are the interfaces between the CAN bus and the electrical machine components. They are located as close as possible to the machine components to permit a short wiring of the machine components. The Nodes organize: (a) the INPUTS from the machine components into the CAN bus (b) the CONTROL OUTPUTS from the MTC-controller to the actuating elements via CAN bus There are 2 different types of Nodes in the CAN bus system, ICN-V and ICN-D.

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14.9.2.1


ICN-V FEATURES

The acronym ICN-V means: Intelligent Can Node-Variable (application sample: Valves) The features of the ICN-V node are: - Designed for mobile use - Compact design - Solid housing - Equipped with one 55-pin central plug - Optional dual node design (in that case the housing is equipped with two 55-pin central plugs) - DIP-switches for individual adaption - Especially for the control of hydraulic components - 4 digital inputs, each to be configured as 0...10V or 0...20mA analog inputs - 8 digital Inputs & Outputs max. 4A, variable programmable - 2 separate power outputs (operating voltage) max. 0.1A - The outputs are short cut safe - CAN bus interface with CAN open protocol - Load dump safety 8...32V - Temperature range -40°C...+ 85°C

View onto ICN-V Nodes (dual & single)

Fig. 14-171 View onto ICN-V Nodes (dual & single) Legend for Fig. 14-171: (1)

Dual ICN-V Node

(2)

Single ICN-V Node

(3)

55-pin central plug for dual node function LH (shown sample: 11K303)

(4)

55-pin central plug for dual node design RH (shown sample: 11K304)

(5)

55-pin central plug for single node function (shown sample: 40K313)

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14.9.2.2


ICN-D FEATURES

The acronym ICN-D means: Intelligent Can Node-Digital (application sample: Dashboard) The features of the ICN-D node are: - Designed for mobile use - e.g. for installation in the dashboard - max. 64 configurable inputs / outputs - 28 digital inputs - 6 analog inputs 0...10V - 2 analog inputs 0...20mA - 4 separate input slots - 16 digital outputs - 4 digital inputs / outputs - 2 separate power sources 5, 7.5 / 8.2, 10V - 2 separate power output sources 10mA / 300Ω - Load dump safety 8...32V - Temperature range -40°C...+85°C - CAN bus interface with CAN open protocol - DIP-switches for individual adaption

View onto a ICN-D Node

Fig. 14-172 View onto a ICN-D Node

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14-115


14.9.3


NODE DIP-SWITCHES

All nodes of both node types are equipped with DIP-switches at the circuit board. These DIP-switches must be adjusted according to the requirement of each mounting location in the system. Ex factory the design of all used ICN-V nodes is identical and the design of all used ICN-D nodes is identical as well. If any node needs replacement its DIP-switches must be adjusted as defined in the Wiring Diagram of the respective machine. In the Wiring Diagram the adjustment of the DIP-switches is shown as in the below sample. Exemplary iew onto the DIP-switch setting specification

Fig. 14-173 Exemplary View onto the DIP switch setting specification

NOTE: When replacing any Node unit always check and adjust the DIP-switch setting according to the relevant Wiring Diagram to avoid malfunction or shutdown of the machine.

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14.9.4

NODE BOX


.

The node units which need to be installed at the outside of the machine are mounted in Node Boxes on the roof of the machine. Inside these boxes the electrical components are installed on 3 levels. 1st level: Wiring connections, resistors, and diodes 2nd level: CAN bus connections 3rd level: Nodes (ICN-V and ICN-D) Refer to the following figure which shows a typical node box and the arrangement of the 3 levels inside.

Fig. 14-174 View onto the 3 levels inside a Node Box

Fig. 14-175 View onto an open Node Box

To reach the 3 levels inside the Node Box open the door of the Node Box. Now there is access to the 1st level switch board (3).

Legend for Fig. 14-175

Fold the 1st level switch board forward and down. Now there is access to the 2nd level switch board (4) on the backside of the folded frame. The 3rd level switch board (5) is mounted at the inside of the Node Box backwall. Refer to the following photographs (Fig. 14-175).

Version 2010/1

(1)

Node Box

(2)

1st level switch board - Wiring connections, resistors, and diodes

(3)

Door of the Node Box

(4)

2nd level switch board - CAN bus connections

(5)

3rd level switch board - ICN-V node(s) and ICN-D node(s) 14-117


14.9.5


NODE LOCATIONS ON THE MACHINE

Fig. 14-176 Node location overview Legend for Fig. 14-176: (11)

Location: Low voltage switch board in the cab base

(20)

Location: Operator’s cab

[40]

Location: Hydraulic oil tank (node box on top of the roof)

[51]

Location: Engine room (node box on top of the roof)

[56]

Location: Pump compartment (node box on top of the roof)

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14.9.5.1


NODE & LOCATION CHART

The following chart lists all Nodes and the relating Locations of the MTC control circuit on a PC4000-6D with MTCcontroller. For further details refer to the Wiring Diagrams of the respective machine. Node No.

Node Type

Component Code1

2

ICN-D

11K302

3

ICN-V

11K303

4

ICN-V

11K304

5

ICN-V

11K305

9

ICN-D

20K309

10

ICN-V

20K310

11

ICN-D

40K311

12

ICN-D

40K312

13

ICN-V

40K313

14

ICN-D

56K314

15

ICN-V

56K315

16

ICN-V

56K316

17

ICN-D

51K317

Location Code2

Description

11

Extra low voltage switch board in the cab base

20

Operator’s cab

40

Hydraulic oil tank (node box on top of the roof)

56

Pump compartment (node box on top of the roof)

51

Engine room (node box on top of the roof)

1, 2

For a detailed explanation of the Location Code & Component Code definition refer to section 13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM in this Service Manual.

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14.9.5.2


EXEMPLARY VIEW ONTO LOCATION 11 (CAB BASE)

The following exemplary views show the arrangement of the CAN bus control components in a cab base.

Fig. 14-177 Exemplary view onto the CAN bus control components in the cab base Legend for Fig. 14-177: (1)

Low voltage switch board (11a000) in the cab base

(2)

ICN-D node (11K302)

(3)

Dual ICN-V node, LH side (11K303)

(4)

Dual ICN-V node, RH side (11K304)

(5)


(6)

CAN bus connector plate

(7)

Single ICN-V node (11K305) behind the CAN bus connector plate

For further troubleshooting information regarding the MTC control system refer to the Troubleshooting Manual of your machine.

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14-121


14-122


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AUTOMATIC LUBRICATION SYSTEMS

15. AUTOMATIC LUBRICATION SYSTEMS

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15-1

General Overview CLS & SLS


15.1

GENERAL OVERVIEW CLS & SLS

Fig. 15-1

General overview CLS & SLS

Legend for Fig. 15-1: CLS SLS

Central Lubrication System Pin & bearing lubrication

z

Swing ring Lubrication System z Open swing ring gear lubrication

(1)

Superstructure

(2)

Attachment (FSA & BHA)

(3)

Swing ring

(4)

Swing gearbox

(5)

Undercarriage

(6)

CLS station (barrel)

(7)

SLS station (barrel)

15-2

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15.1.1

General Overview CLS & SLS

GENERAL DESCRIPTION

For maximum machine reliability and maximum lifetime the principal bearing points must be frequently lubricated with a sufficient amount of specified lubricant. For best lubricating reliability with minimum maintenance there are automatic lubrication systems which are controlled by the MTC. They lubricate all connected lubrication points within adjustable time intervals and with the required amount of lubricant. The automatic lubrication starts as soon as the machine runs at high idle. The excavator is equipped with 2 independent lubrication systems: CLS The CLS (Central Lubricating System) supplies the attachment bearings and the swing ring bearing with grease. SLS The SLS (Swing ring gear Lubrication System) supplies the open gear of the swing ring teeth and the lower bearings of the swing gearboxes with grease. These two independent lubrication systems are necessary because the attachment bearings and the open gear teeth require different types of lubricant.

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15-3

Basic Function of the Lubrication Systems


15.2

BASIC FUNCTION OF THE LUBRICATION SYSTEMS

Fig. 15-2

Basic function of the lubrication systems

15-4

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Basic Function of the Lubrication Systems


Drive of lubrication pump (hydraulically)

(2)

Flow control valve (19-21 double strokes/min)

(3)

Pressure relief valve (max. 45 bar)

(4)

Grease pump control solenoid valve (62Q507 / 62Q509) - (pump on / off)

(5)

Hydraulic oil return line

(6)

Hydraulic oil supply line (60+3 bar X4-pressure)

(7)

Lubricant pressure gauge

(8)

Lubricant in-line filter

(9)

Lubricant pressure release solenoid valve (62Q507a / 62Q509a)

(10)

Lubricant supply line from pump to injector

(11)

Lubricant release line

(12)

End-line-pressure switch (80B043 / 62B046)

(13)

Lubricant injector

(14)

Lubricant feed line from injector to the lubrication point (bearings or open gear of the swing ring teeth)

(15)

Lubricant pump

(16a)

Bearing

(16b)

Dummy wheel

(17)

Lubricant

(18)

Lubricant container

(19)

Breather filter for lubricant container

(20)

Sonar sensor for lubricant level indication (62B108 / 62B109)

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15-5



15.3

CENTRAL LUBRICATION SYSTEM (CLS)

Fig. 15-3

Lubrication pump station CLS

15-6

Version 2010/1




Lubrication pump drive (hydraulic cylinder)

(2)

Solenoid valve (oil pressure supply)

(3)

Flow control valve

(4)


(5)

Hydraulic oil supply line (pilot pressure)

(6)


(7)

Vent valve (solenoid valve, de-energized open to the barrel)

(8)

Grease supply line to injectors

(9)

Grease level sensor (sonar sensor)

(10)

Grease barrel

(11)

Pump suction pipe

(12)

Lubricant filter

(13)

Hydraulic pressure test plug (operating pressure)

(14)

Lubricant pressure gauge (operating pressure)

(15)

Vent line to barrel

(16)

Breather

(17)

Electrical terminal box

(18)

Lubricant injector

(19)

Lubricant supply line to lubrication points (bearings or open gear of the swing ring teeth)

(20)

End-line switch

Description The lubrication pump station includes the grease barrel (Fig. 15-3, Pos. 10) and the barrel cover with the pump system. The barrel is fix-mounted. With the refilling arm the barrel is rechargeable via a filter. The main grease pump system is mounted onto the barrel cover. It includes the pump (Fig. 15-3, Pos. 1 & 11), valves (Fig. 15-3, Pos. 2, 3, 4, 7), a grease filter (Fig. 15-3, Pos. 12), a grease level sensor (Fig. 15-3, Pos. 9), and an end-line switch (Fig. 15-3, Pos. 20).

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15-7


15.3.1


GENERAL INFORMATION ON CLS

A hydraulic driven lubricant pump (Fig. 15-3, Pos. 1 & 11) pumps grease from a barrel (Fig. 15-3, Pos. 10) through pipes (Fig. 15-3, Pos. 8) or hoses to the injectors (Fig. 15-3, Pos. 18). These injectors pump a defined quantity of grease to the lubrication points. After all injectors delivered their grease quantity to the lube points, the grease pump stops and the next lubrication cycle will start after an adjusted time period (pause time). The central lubrication system is only active if the engine is running at high idle. z

After the pilot pressure has been reduced it passes to the hydraulic cylinder (Fig. 15-3, Pos. 1) which operates the grease pump (Fig. 15-3, Pos. 11).

z

The hydraulic cylinder (Fig. 15-3, Pos. 1) operates the grease cylinder with 19 – 21 double strokes per minute. In that way 612 - 680 cm3 (approx. 550 - 612 g) of lubricant are delivered per minute.

z

With the vent valve (Fig. 15-3, Pos. 7) closed, the pump continues to cycle until the maximum pressure is achieved and the injectors (Fig. 15-3, Pos. 18) have metered grease to the lubrication points. The pressure in the lubrication system is 180 bar.

z

When the maximum system pressure is reached, the end-line switch (Fig. 15-3, Pos. 20) will open.

z

The open end-line switch (Fig. 15-3, Pos. 20) signals the controller that the pumping cycle has to be stopped.

z

The solenoid valve (Fig. 15-3, Pos. 2) is de-energized and the hydraulic oil stops flowing to the pump (Fig. 15-3, Pos. 1).

z

The MTC starts to count down a fixed time (pressure holding time) and an adjustable pause time (rest time between the automatic lubrication cycles).

z

The vent valve (Fig. 15-3, Pos. 7) is still closed (solenoid active) and the lubricant pressure will be kept on the pressure (a slow pressure decrease is normal).

z

If the countdown for the pressure holding time (5 min) is finished the controller terminates the signal to the solenoid valve (Fig. 15-3, Pos. 7).

z

If the vent valve (Fig. 15-3, Pos. 7) is de-energized, it opens and allows the grease pressure to drop to zero.

z

All injectors move into their initial position by spring force and recharge themselves for the next lubricant cycle.

z

The system is at rest now and ready for another lube cycle.

Manual lube activation A manual activation of the lubrication systems is possible by operating switch 20S124 (CLS) or 20S126 (SLS) at the dashboard. The MTC counts the number of switch activations and operates the lube system successively, as often as the switch was activated. The system rests between the lube cycles according to an adjustable pause time (pressure relief time). After the previous loop is completely finished and after the pause time is experied the next lubrication cycle can start if the engine is running at high idle (CLS/SLS) and if a slew movement was activated (SLS). Component Code Table (according to Wiring Diagram) System

Solenoid Valve (2)

Vent Valve (7)

End-Line Switch (20)

CLS

62Q507

62Q507a

80B043

SLS

62Q509

62Q509a

62B046

15-8

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15-9

Lubrication Pump Station (SLS)


15.4

LUBRICATION PUMP STATION (SLS)

Fig. 15-4

Lubrication pump station SLS

15-10

Version 2010/1




Lubricant pump drive (hydraulic cylinder)

(2)

Solenoid valve (oil pressure supply)

(3)

Flow control valve

(4)


(5)

Hydraulic oil supply line (pilot pressure)

(6)


(7)

Vent valve (solenoid valve, de-energized open to barrel)

(8)


(9)


(10)

Grease barrel

(11)

Pump suction pipe

(12)

Lubricant filter

(13)

Hydraulic pressure test plug (operating pressure)

(14)

Lubricant pressure gauge (operating pressure)

(15)

Vent line to barrel

(16)

Breather

(17)


(18)

Lubricant injector

(19)

Lubricant supply line to dummy wheel

(20)

End-line switch

(R)

Dummy wheel

(A)

Swing circle gear

(B)

Center bore

(C)

Stator radial bore

(D)

Grease outlet

Description The lubrication pump station includes the grease barrel (Fig. 15-4, Pos. 10) and the barrel cover with the pump system. The barrel is fix-mounted. With the refilling arm the barrel is rechargeable via a filter. The main grease pump system is mounted onto the barrel cover. It includes the pump (Fig. 15-4, Pos. 1, 11), valves (Fig. 15-4, Pos. 2, 3, 4, 7), a grease filter (Fig. 15-4, Pos. 12), a grease level sensor (Fig. 15-4, Pos. 9), and an end-line switch (Fig. 15-4, Pos. 20).

Version 2010/1

15-11


15.4.1


GENERAL INFORMATION ON SLS

The swing circle gear lubrication system (SLS) uses a special dummy wheel to apply the gear grease onto the swing circle gear. All other components between the grease barrel and the injectors are comparable to the central lubrication system (CLS). With each lube cycle the dummy wheel receives grease from two or more parallel connected injectors. After the injectors delivered their gear grease quantity through the dummy wheel to the swing ring gear, the grease pump stops and the next lubrication cycle will start after an adjusted time period (pause time). The swing circle gear lubrication system is only active if the engine is running at high idle and if the slew function is activated. z

After the pilot pressure has been reduced it passes to the hydraulic cylinder (Fig. 15-4, Pos. 11) which operates the grease pump.

z

The hydraulic cylinder (Fig. 15-4, Pos. 1) operates the grease cylinder with 19 - 21 double strokes per minute. In that way 612 - 680 cm3 (approx. 550 - 612 g) of lubricant are delivered per minute.

z

With the vent valve (Fig. 15-4, Pos. 7) closed, the pump continues to cycle until maximum pressure is achieved and the injectors (Fig. 15-4, Pos. 18) have metered grease to the dummy wheel. The pressure in the lubrication system is 180 bar.

z

When the maximum system pressure is reached, the end-line switch (Fig. 15-4, Pos. 20) will open.

z

The open end-line switch (Fig. 15-4, Pos. 20) signals the controller that the pumping cycle has to be stopped.

z

The solenoid valve (Fig. 15-4, Pos. 2) is de-energized and the hydraulic oil stops flowing to the pump (Fig. 15-4, Pos. 1).

z

The MTC starts to count down a fixed time (pressure holding time) and an adjustable pause time (rest time between the automatic lubrication cycles).

z

The vent valve (Fig. 15-4, Pos. 7) is still closed (solenoid active) and the lubricant pressure will be kept on the pressure (a slow pressure decrease is normal).

z

If the countdown for the pressure holding time (5 min) is finished the controller terminates the signal to the solenoid valve (Fig. 15-4, Pos. 7).

z

If the vent valve (Fig. 15-4, Pos. 7) is de-energized, it opens and allows the grease pressure to drop to zero.

z

All injectors move into their initial position by spring force and recharge themselves for the next lubricant cycle.

z

The system is at rest now and ready for another lube cycle.

Manual lube activation A manual activation of the lubrication systems is possible by operating switch 20S124 (CLS) or 20S126 (SLS) at the dashboard. The MTC counts the number of switch activations and operates the lube system successively during swing movement, as often as the switch was activated. The system rests between the lube cycles according to an adjustable pause time (pressure relief time). Component Code Table (according to Wiring Diagram) System

Solenoid Valve (2)

Vent Valve (7)

End-Line Switch (20)

CLS

62Q507

62Q507a

80B043

SLS

62Q509

62Q509a

62B046

CLS = Central Lubrication System SLS = Swing circle Lubrication System

15-12

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15.5

LUBRICATION CYCLE

15.5.1

OPERATION AND CONTROL

Lubrication Cycle

General The lubrication systems (CLS & SLS) are completely controlled and monitored by the MTC. The MTC activates the outputs dependent on the inputs and dependent on the system timelines. For the electrical interrelations refer to the respective Wiring Diagram. NOTE: The exemplary explanations in this section are based on the Wiring Diagram 94856340 and on the Flow Chart 9485640. Beside the MTC the following electrical components are involved in lubrication control and operation: Inputs Description

CLS

SLS

End-line switch

80B043

62B046

Grease level sensor

62B108

62B109

Switch for manual lubrication cycle

20S124

20S126

Pre-condition: Swing circle (lever) moved

20S020

Pre-condition: Engine running at high idle

Engine ECM

Outputs Description

CLS

SLS

Lubrication pump solenoid valve

62Q507

62Q509

Vent valve (solenoid)

62Q507a

62Q509a

Version 2010/1

15-13

Lubrication Cycle

15.5.2

LUBRICATION CYCLE - COMPONENTS

Fig. 15-5

Lubrication cycle components

15-14


Version 2010/1


Lubrication Cycle



(2)

Flow control valve (19 - 21 double strokes / min)

(3)


(4)

Main pump control solenoid valve (pump on / off)

(5)


(6)

Hydraulic oil supply line (60 bar, X4 pressure)

(7)


(8)


(9)

Lubricant pressure release solenoid valve

(10)


(11)


(12)

End-line switch

(13)

Lubricant injector

(14)

Lubricant feed line to swing ring gear

(15)

Lubricant pump

(16)

Lubricant points (bearings) CLS only

(17)

Lubricant container

(18)


(19)


(20)

Test port lubricant pump drive pressure

(21)


(22)

Dummy wheel, SLS only

(23)

Dipstick grease level

Version 2010/1

15-15

Lubrication Cycle


15.5.3

LUBRICATION CYCLE - PROCESSING

Fig. 15-6

Process of a lubrication cycle

Legend for Fig. 15-6 X axis

Task time

Y axis

Pressure timeline in the lubricant supply line

PINCREASE E-L SWOPENING PHOLD E-L SWCLOSING PRELEASE TPAUSE

15-16

Pressure increasing time End-line switch opening point Pressure holding time (5 minutes) End-line switch closing point Pressure release time Pause time

Version 2010/1


15.5.4

Lubrication Cycle

TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE

Terms

PINCREASE

E-L SWOPENING

PHOLD

E-L SWCLOSING

PRELEASE

TPAUSE

Time segment

Explanation

a-b

If the engine is running at high idle a lubrication cycle starts after the pause time is expired or if the switch for manual lubrication 20S124 (CLS) or 20S126 (SLS) was activated. For SLS there is also the precondition that the control lever for "Swing" is moved out of its zero position. The MTC activates the solenoid valve and the pilot pressure (X4 pressure) starts to move the oscillating cylinder. At the same time the vent valve is closed and the lubrication pressure starts to increase. This time segment for building-up the pressure in the lubricant line is fix-programmed in the MTC and it is not adjustable.

b

After all lubrication points have been lubricated there is a pressure rise which opens the end-line switch when the max. pressure is reached. At this time the MTC de-energizes the solenoid valve and stops the oscillating cylinder of the lubrication pump. Now the pressure increasing phase is finished and the pressure holding time starts. The switch point of the end-line switch is 180 +5 bar.

b-c

At this time the MTC starts to count the pressure holding time (5 min) which is fix-programmed in the controller. This time segment is not adjustable. During the pressure holding time the vent valve is kept closed and the pressure is kept at its max. level of 180 bar.

c

After the pressure holding time (5 min) is expired, the end-line switch closes and the vent valve opens. Now the pressure holding phase is finished and the grease pressure is released back to the barrel.

c-d

The pressure release time is fix-programmed in the MTC. This time segment is not adjustable. It is necessary to drop the lubricant pressure completely to zero so the injectors can be recharged for the next lubrication cycle.

b - a’

The pause time prevents that the next lubrication cycle would start too early in case the switch for manual lubrication 20S124 (CLS) or 20S126 (SLS) was actived several times. The counting of the pause time starts at "b" when the end-line switch opens at max. line pressure. The next lubrication cycle starts after the pause time is expired. Preconditions: SLS/CLS: Engine running at high idle SLS only: Slew movement was activated Via the VHMS monitor the pause time is adjustable: CLS 10 - 60 minutes SLS 10 - 20 minutes

Lubrication pump solenoid valve

Vent valve (solenoid)

End-line switch

CLS

62Q507

62Q507a

80B043

SLS

62Q509

62Q509a

62B046

Version 2010/1

15-17

Lubrication Cycle


15.5.5

LUBRICATION MODES

15.5.5.2

15.5.5.1

AUTOMATIC LUBRICATION MODE

A manual lubrication cycle can be activated via the switches 20S124 (CLS) or 20S126 (SLS) at the dashboard.

The lubrication systems are controlled and monitored complete by the program of the MTC. The MTC activates the outputs dependent on inputs and time-lines according to the programmed software. The Pause Time can be adjust in a specified range via the VHMS Real Time Monitor. Monitoring time and pressure relief time are fix-programmed. After a restart of the engine the SLS / CLS system first continues the residual time of the current pause time period before a new start of the grease system is possible. The lube system only starts if the engine is running at high idle.

MANUAL LUBRICATION MODE

In the Operator Mode a manual lube cycle can be started after a waiting period of 10 minutes. This timeline is independent of the Pause Time setting for the automatic mode, which is input via the VHMS monitor.

15.5.5.3

VHMS SERVICE MODE

As long as the VHMS Service Mode is activated the Pause Time is automatically reduced to 30 seconds. Test and adjustment works can be performed more comfortable if the Pause Time is shortened in the VHMS Service Mode. After return to the Operator Mode the Pause Time will be reset to the automatic period which has been adjusted on the VHMS monitor before.

VHMS Pause Time Settings CLS Pause time range: 10 - 60 minutes Standard setting: 15 minutes SLS Pause time range: 10 - 20 minutes Standard setting: 20 minutes

NOTE: For more details of the Pause Time setting refer to the VHMS information in section 14.

15-18

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Lubrication Cycle


Version 2010/1

15-19

Hydraulically Driven Lube Pump


15.6

HYDRAULICALLY DRIVEN LUBE PUMP

Fig. 15-7

Hydraulically driven lubrication pump

15-20

Version 2010/1




Pump drive hydraulic cylinder

(2)

Flow control valve

(3)


(4)

Lubricant pump intake

(5)

Hydraulic oil supply port

(6)

Hydraulic oil return port

(7)

Pump drive control block

(8)

Breather port

(9)

Pump tube

(10)

Lubricant outlet port

(11)

Outlet check valve (ball type)

(12)

Piston rod

(13)

Pump rod shaft seal

(14)

Check valve (ball type)

(15)

Main piston and plunger

(16)

Piston rod set

(17)

Inlet valve

(18)

Scoop piston

(19)

Lubricant inlet

The lubrication pump is a hydraulically driven seal free differential piston pump. The pump pumps lubricant at the up and down stroke but sucks lubricant only during the up stroke. The scoop piston at the pump bottom supports the main pump especially with high viscosity lubricants. There are only one dynamic seal at the piston rod on top of the pump pipe therefor less on wear and long service time. The lubrication pump is divided in two main components, the pump drive 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 inside and reaches into the lubricant. The maximum possible lubricant pressure depend on the adjusted supply pressure. The pressure multiplication factor between supply pressure and maximum lubricant pressure is 6.55. The pressure reduction valve has to be adjusted to 45 bar. Example: 45 bar supply pressure x 6.55 = 295 bar lubricant pressure. During normal operation the end-line switch stops the pump before reaching this high pressure. For a sufficient lube pump operation 19 - 21 double strokes / min for the pump drive cylinder are required. Therefore the flow reducing valve has to be adjusted, refer to section 15.6.1 on page 15-22. Technical pump data Pump stroke

Pump delivery per stroke

Pump speed

Total pump delivery

152 mm

30 cm3 / double stroke

19 - 21 double strokes / min

540 - 600 cm3 / min

Version 2010/1

15-21



15.6.1

ADJUSTMENT OF LUBE PUMP SPEED & WORKING PRESSURE

Fig. 15-8

Adjustment of pump speed and working pressure

15-22

Version 2010/1


15.6.1.1

STROKE SPEED ADJUSTMENT


15.6.1.2

WORKING PRESSURE ADJUSTMENT

For a sufficient lubricating pump operation 19 - 21 double strokes / min of the pump drive cylinder are required. Therefore the flow reducing valve (Fig. 15-8, Pos. 3) has to be adjusted accordingly.

The pressure reducing valve (Fig. 15-8, Pos. 2) is mounted on the oscillation control block. It reduces the supply pressure to 45 ± bar.

Adjustment procedure

Adjustment procedure

1. Remove the connector from the vent valve (Fig. 15-8, Pos. 7), in order to avoid any pressure rise during the following test.

1. If not yet mounted install a test fitting in port M at the oscillation block, and connect a pressure gauge (0 - 60 bar)

2. Start the engine and run it at high idle.

2. Disconnect the quick-coupling (Fig. 15-8, Pos. 8) from the lubricant supply line in order to block the pump when it is started.

3. Manually switch ON the lube system by using switch 20S124 (CLS) or 20S26 (SLS) at the dasboard and count the double strokes per minute. Therefore remove the plug (Fig. 15-9, Pos. 1) from the pump cover (Fig. 15-9, Pos. 2) and watch the piston going up and down.

3. Start the engine and run it at high idle. 4. Manually switch ON the lube system. The gauge should indicate a max. pressure of 45 ± bar. If adjustment is required 5. Loosen the lock nut (Fig. 15-8, Pos. 2.1). 6. Turn the adjustment screw (Fig. 15-8, Pos. 2) until a pressure of 45 ± bar is achieved. 7. Tighten the lock nut (Fig. 15-8, Pos. 2.1). 8. Reconnect the quick-coupling (Fig. 15-8, Pos. 8). NOTE: If it is not possible to adjust the pressure to 45 ± bar, check the adjustment of the pilot pressure valve (X4 pressure) at the valve cartridge block in the machinery house. The pilot pressure should be 60 bar.

Fig. 15-9

Pump cover with plug

If adjustment is required 4. Loosen the lock nut (Fig. 15-8, Pos. 3.1). 5. Turn the adjustment screw (Fig. 15-8, Pos. 3) until the correct number of double strokes is achieved. 6. Tighten the lock nut (Fig. 15-8, Pos. 3.1). 7. Stop the engine. 8. Connect the connector to the vent valve (Fig. 15-8, Pos. 7).

Version 2010/1

15-23

Lubricant Injectors

15.7

LUBRICANT INJECTORS

Fig. 15-10

Lubricant Injectors type SL-1 and type SL-11

15-24


Version 2010/1


Lubricant Injectors

15.7.2

Legend for Fig. 15-10 SL-1

Injector type SL-1

SL-11

Injector type SL-11

(1)

Adjustment screw

(2)

Indicator stem

(3)

Lock nut

(4)

Injector piston

(5)

Spring

(6)

Slide valve

(7)

Stud fitting (NPT)

(7a)

Cap nut

(8)

Discharge chamber

(9)

Passage

(10)

Lubricant supply inlet

(11)

Lubricant outlet

(12)

Mounting manifold

DESCRIPTION

Series SL-1 Injector The lubricant output volume is adjustable from 0.13 ... 1.3 cm3 per cycle. An hydraulic type fitting with a screw type cover cap is provided for initial filling of the feeder line. It may also be used for visual checks of the injector operation. Series SL-11 Injector The lubricant output volume is adjustable from 0.82 ... 8.2 cm3 per cycle. It is designed for systems where a large amount of lubricant is required. The operation principle is similar to the series SL-1.

15.7.3

ADJUSTMENT OF THE LUBRICANT OUTPUT

1. Loosen the lock nut (Fig. 15-10, Pos. 3).

15.7.1

TIGHTENING TORQUE FOR FITTINGS AT THE GREASE INCETORS

The exact tightening torque of 14 Nm has to be observed when installing a fitting to a grease injector. CAUTION

2. Turn the adjustment screw (Fig. 15-10, Pos. 1) counterclockwise (OUT) for more lubrication outlet. Turn the adjustment screw clockwise (IN) for less lubricant outlet. 3. Tighten the lock nut (Fig. 15-10, Pos. 3).

NOTE: The max. lubricant outlet is adjusted if the indicator stem (Fig. 15-10, Pos. 2) can no further be screwed out.

When installing a grease nipple fitting or a stud fitting (NPT) to an injector, always observe the maximum tightening torque of 14 Nm. Otherwise the fitting will be screwed too far into the injector and the injector piston movement will be blocked. As a result the grease supply will fail.

For the tightening procedure also refer to the PARTS & SERVICE NEWS AH10532 (latest edition). NOTE: In case of leakage use thread tape (Teflon®) or Loctite® when installing a fitting to any injector.

Version 2010/1

15-25

Lubricant Injectors


15.7.4

OPERATION PRINCIPLE OF LUBRICANT INJECTORS

Fig. 15-11

Operation principle of lubricant injectors

15-26

Version 2010/1


Lubricant Injectors

Legend for Fig. 15-11 A

Normal position (rest position) pressure-free

B

Inlet pressure increasing and lubricant application

C

Maximum inlet pressure application completed

D

Inlet pressure relieved and internally reloading

(1)

Set screw

(2)

Indicator stem

(3)

Lock nut

(4)

Injector piston

(5)

Spring

(6)

Slide valve

(7)

Service port

(8)

Discharge chamber

(9)

Passage

(10)

Lubricant supply inlet

(11)

Lubricant outlet

(12)

Measuring chamber

Version 2010/1

15-27

Lubricant Injectors

15.7.4.1


FUNCTION DESCRIPTION

Stage A

Stage D

Inlet pressure 0 bar Outlet pressure 0 bar

Inlet pressure relieved

The injector piston is in its normal, or rest position. Visible by the extracted indicator stem (2) which is blocked in final position by the set screw (1). The discharge chamber (8) is filled with lubricant from the previous cycle.

Stage B

After lubricant supply pressure (10) is relieved, the compressed spring (5) moves the slide valve (6) to the closed position. This opens the port from the measuring chamber (12) and permits the lubricant to be transferred from the top of the piston to the discharge chamber (8). The indicator stem (2) extract to its initial final stop of the adjustment screw (1). Now the injector is prepared for the next lubricant application.

Inlet pressure increasing from 0 to 180 bar Outlet: lubricant injection 0 - 180 bar Output volume: adjusted amount of lubricant Under the pressure of incoming lubricant via port (10), slide valve (6) is about to open the passage (9) leading to the piston (4). When the slide valve (6) uncovers the passage (9), lubricant is admitted to the measuring chamber (12) at the top of the piston (4), forcing the piston down. The piston (4) forces lubricant from the discharge chamber (8) through the outlet port (11) to the bearing. The indicator stem (2) retracts.

Stage C Inlet pressure at maximum 180 bar Output injection is finished As the piston (4) completes its stroke, it pushes the slide valve (6) past the passage (9), cutting off further admission of lubricant to the passage (9). Piston (4) and slide valve (6) remain in this position until lubricant pressure in the supply line (10) is vented (relieved) at the pump station. The indicator stem (2) is fully retracted and the adjusted amount of lubricant is injected to the bearing.

15-28

Version 2010/1


Lubricant Injectors

15.7.5

CONNECTION OF ONE OR MORE INJECTORS

Fig. 15-12

Connection of lubricant injectors

Description To increase the lubricant output volume, the injectors (1) are designed to be combined (2 or more injectors). A connector pipe (2) is used to connect two injectors (1). Lubricant from the first injector, outlet (b), is directed through the connector pipe (2) to the inlet (c) of the second injector. Both injectors are now connected, in order to lubricate one lubrication point via pipe (3). This connection is possible for both injector types (SL-1 and SL-11).

CAUTION When installing a fitting to an injector, always observe the maximum tightening torque of 14 Nm. Otherwise the fitting will be screwed too far into the injector and the injector piston movement will be blocked. As a result the grease supply will fail.

For the tightening procedure also refer to the PARTS & SERVICE NEWS AH10532 (latest edition). NOTE: In case of leakage use thread tape (Teflon®) or Loctite® when installing a fitting to any injector.

Version 2010/1

15-29

Vent Valve


15.8

VENT VALVE

Fig. 15-13

Vent valve

15-30

Version 2010/1


Vent Valve


Solenoid

(2)

Valve assembly

(3)

Solenoid stem

(4)

Lever

(5)

Main valve piston

(6)

Auxiliary valve piston

(7)

Reset spring

15.8.1

DESCRIPTION

Task By the function of the vent valve the pressure in the lubricant supply line is relieved, after a lubrication cycle is finished. The injector pistons move back into their initial positions. The valve is open if the solenoid is de-energized. Then port A is connected with port B. Function The solenoid isenergized when a lubrication cycle starts. The connection from A to B gets closed, thus a pressure build-up in the grease supply line is possible. The solenoid gets de-energized, as soon as a lubrication cycle is finished. This causes an opening of the connection A to B, thus the supply line to the lubricant barrel is open. The lubricant flows from A to B or vice versa along the main valve piston (Fig. 15-13, Pos. 5).

Version 2010/1

15-31

End-Line Switch

15.9

END-LINE SWITCH

Fig. 15-14

End-line switch

15-32


Version 2010/1


End-Line Switch


Piston

(2)

Disk

(3)

Switch contact

(4)

Spring

(5)

Pressure switch

(6)

Adjustment sleeve

(7)

Connection to pressure circuit

(8)

Electrical connection

15.9.1

DESCRIPTION

Task The end-line pressure switch is the main part to monitor and to control the lubrication system. It stops the lubrication pump when the lubricant pressure reaches the max. adjusted pressure. Function One pressure control unit is installed in each lubrication system (CLS & SLS). The grease pressure, produced by the hydraulic barrel pump, acts also at the piston (Fig. 15-14, Pos. 1) If the force of the grease pressure exceeds the spring forces (Fig. 15-14, Pos. 4), the piston (Fig. 15-14, Pos. 1) is forced against the disk (Fig. 15-14, Pos. 2). Thus the contacts of the switch (Fig. 15-14, Pos. 5) are operated and an electric contact is given to the MTC. Any adjustment has to be done with the sleeve (Fig. 15-14, Pos. 6): Turning it clockwise - higher switch point Turning it counterclockwise - lower switch point

Version 2010/1

15-33

End-Line Switch

15.9.2

CLS END-LINE SWITCH ADJUSTMENT

Fig. 15-15

End-line switch adjustment (CLS)

15-34


Version 2010/1


End-Line Switch

Legend for Fig. 15-15: 80B043

End-line switch (CLS)

(1)

Pressure gauge

(2)

Grease container

(3)

Location of CLS pump station

(4)

Bolt

(5)

Cover

(6)

Allen key

(7)

Allen screw

Procedure 1. For adjustment use the pressure gauge (Fig. 15-15, Pos. 1) which is mounted on top of the grease container (Fig. 15-15, Pos. 2). NOTE: For the following adjustment procedure 2 service technicians are required. 2. Start the engine and run it at high idle. 3. Start a manual CLS lube cycle using the dashboard switch 20S124. 4. Watch the pressure gauge (Fig. 15-15, Pos. 1). At a pressure of 180 ± 5 bar the end-line switch (80B043) must open and the lubrication pump must be stopped. NOTE: 180 ± 5 bar is the standard setting. Under particular circumstances it may be necessary to increase the pressure slightly. If re-setting is required 5. Screw out the bolts (Fig. 15-15, Pos. 4) and remove the cover (Fig. 15-15, Pos. 5). 6. Using an allen key (Fig. 15-15, Pos. 6) turn the allen screw (Fig. 15-15, Pos. 7) and alter the spring tension until the switch operates at 180 ± 5 bar. 7. After adjustment is finished install the cover (Fig. 15-15, Pos. 5) and tighten the 4 bolts (Fig. 15-15, Pos. 4).

Version 2010/1

15-35

End-Line Switch

15.9.3

SLS END-LINE SWITCH ADJUSTMENT

Fig. 15-16

End-line switch adjustment (SLS)

15-36


Version 2010/1


End-Line Switch

Legend for Fig. 15-16: 62B046

End-line switch (SLS)

(1)

Pressure gauge

(2)

Grease container

(3)

Location of SLS pump station

(4)

Bolt

(5)

Cover

(6)

Allen key

(7)

Allen screw

Procedure 1. For adjustment use the pressure gauge (Fig. 15-15, Pos. 1) which is mounted on top of the grease container (Fig. 15-15, Pos. 2). NOTE: For the following adjustment procedure 2 service technicians are required. 2. Block the swing function by applying the slew parking brake via switch 20S029. 3. Start the engine and run it at high idle. 4. Start a manual SLS lube cycle using the dashboard switch 20S126. 5. Watch the pressure gauge (Fig. 15-15, Pos. 1). At a pressure of 180 ± 5 bar the end-line switch (62B046) must open and the lubrication pump must be stopped. NOTE: 180 ± 5 bar is the standard setting. Under particular circumstances it may be necessary to increase the pressure slightly. If re-setting is required 6. Screw out the bolts (Fig. 15-15, Pos. 4) and remove the cover (Fig. 15-15, Pos. 5). 7. Using an allen key (Fig. 15-15, Pos. 6) turn the allen screw (Fig. 15-15, Pos. 7) and alter the spring tension until the switch operates at 180 ± 5 bar. 8. After adjustment is finished install the cover (Fig. 15-15, Pos. 5) and tighten the 4 bolts (Fig. 15-15, Pos. 4).

Version 2010/1

15-37

In-Line Filter


15.10 IN-LINE FILTER

Fig. 15-17

15-38

In-line filter

Version 2010/1



Plug screw

(2)

Plug screw gasket

(3)

Filter element

(4)

Filter housing

(5)

Spring guide

(6)

Spring

In-Line Filter

15.10.2 MAINTENANCE PROCEDURE CAUTION Before starting to work on the system, stop the engine and remove the key from the main key switch in order to prevent any engine start.

1. Remove the plug screw (Fig. 15-17, Pos. 1) using a 36 mm wrench. 2. Remove the plug screw gasket (Fig. 15-17, Pos. 2).

15.10.1 DESCRIPTION

3. Take out the spring (Fig. 15-17, Pos. 6), the spring guide (Fig. 15-17, Pos. 5), and the filter element (Fig. 15-17, Pos. 3).

Task 4. Clean all parts and inspect them for damage. The in line-filter between lubricant pump and injectors prevents a system contamination by rough particles. To prevent a too high intake pressure due to a blocked filter, the filter element is equipped with a by-pass function.

NOTE: A clogged filter element will be pressed against the spring force by the lubricant pressure and unfiltered lubricant reaches the system. 5. Replace damaged parts as necessary. 6. Insert the filter element, the spring guide, and the spring. 7. Install the plug screw with gasket and tighten it with a wrench. NOTE: For the service intervals refer to the MAINTENANCE MANUAL.

Version 2010/1

15-39

Lubricant Level Sensor


15.11 LUBRICANT LEVEL SENSOR

Fig. 15-18

15-40

Lubricant level sensor

Version 2010/1



Grease level sensor

(2)

Cover of grease container

(3)

Section of wiring diagram Sensor 62B108 (CLS)

(4)

Section of wiring diagram Sensor 62B109 (SLS)

(a)

Elbow plug

(b)

LED location at the sensor (red & yellow)

(c)

Upper lock nut

(d)

Retainer

(e)

Seal ring

(f)

Lower lock nut

(g)

Top view onto the sensor


Function The sonar sensor sends a proportional current signal according to the distance between the sonar sensor and the grease level to the MTC. The sensor operates in a range of 320 to 950 mm. The min. distance means the lubricant barrel is full. In this case the signal current to the MTC is ~ 20 mA. The max. distance means the lubricant barrel is empty. In this case the sensor signal current to the MTC is ~ 4 mA. NOTE: The sonar sensor gets out of range if it comes in contact with grease. Therefore an overfilling of the grease barrel should be avoided. In case of a sensor malfunction (red LED at the sensor ON), remove the sensor and wipe off any grease from its lower surface. For the LED function in case of a sensor error see the following section.

15.11.1 DESCRIPTION

15.11.1.1 LEDS AT THE SONAR SENSOR

Task

At the upper collar (Fig. 15-18, Pos. b) the sensor is equipped with LEDs (red & yellow). The function of these LEDs is as follows:

The lubricant level sensor is an analog sonar sensor type. Lubricant maximum filling level monitoring is necessary to prevent an overfilling of the grease barrel via the refilling arm. The minimum grease level monitoring allows timely refilling of grease and it prevents the grease pump from running dry. General The analog level signal comes from the sonar sensor which is mounted on the cover of the lubricant pump station. The sensor is connected to the MTC. The MTC activates the "full" light if the grease level reaches the maximum. This indication light is mounted at the refilling arm. If a grease level of 10 - 15 % is reached the MTC generates the message Central lubrication system grease level too low or Slew gear lubrication system grease level too low. This allows grease charging in time, which prevents an unexpected breakdown. If the lubricant level reaches 0 % the MTC deactivates the lubrication pump and generates the message Central lubrication system empty or Slew gear lubrication system empty. Version 2010/1

Sensor condition

LED red

LED yellow

Normal operation

OFF

ON

Error

ON

Previous state

Adjustment The sonar sensor doesn’t need adjustments, except the mounting depth in the lubricant container cover. This adjustment only has to be done if the sensor was removed for cleaning or if it is replaced by another one. Standard sensor length below the lubricant container cover: 20 mm If adjustment is required: 1. Unplug the sensor connector. 2. Loosen the upper lock nut (Fig. 15-18, Pos. c). 3. Loosen the lower lock nut (Fig. 15-18, Pos. f). 4. Adjust the sensor length below the lubricant container cover to 20 mm by turning the upper and lower nuts. 15-41



5. If the correct measurement (20 mm) is achieved tighten the upper and lower lock nut (Fig. 15-18, Pos. c & f). 6. Plug-in the sensor connector. The MIN and MAX points of the grease level don’t need any sensor adaption. The sensors are preadjusted ex factory. NOTE: For the wiring connection of the sonar sensor also refer to the wiring diagram of the distribution box on top of the lubricant container.

15-42

Version 2010/1




Version 2010/1

15-43

Lubrication Pinion (SLS)


15.12 LUBRICATION PINION (SLS)

Fig. 15-19 15-44

Dummy wheel Version 2010/1



Swing circle gear

(B)

Center shaft

(C)

Stator radial bore

(D)

Grease outlet

(1)

Lubrication pump station

(2)

Lubrication container

(3)

Main pump control solenoid valve (pump on/off)

(4)

Lubricant pressure relief solenoid valve

(5)


(6)

End-line pressure switch

(7)

Injectors

(8)

Lubricant feed line from injector to lubrication pinion

(9)

Lubrication pinion

Lubrication Pinion (SLS)

15.12.1 DESCRIPTION The SLS system lubricates the open gear of the swing ring with special open gear lubricant. The lubricant pump station (Fig. 15-19, Pos. 1) is the same as for the CLS system. To apply the lubricant equally to the swing ring gear teeth (Fig. 15-19, Pos. A) a special lubrication pinion (Fig. 15-19, Pos. 9) close to the swing drive pinion is mounted. The lubrication pinion (Fig. 15-19, Pos. 9) distributes the lubricant from the injectors evenly to the teeth. Normally two or more injectors are parallel connected to supply the required amount of lubricant to the lubrication pinion. The pinion center shaft (Fig. 15-19, Pos. B) acts as a rotary joint and distributes the lubricant through radial bores only to those teeth witch are in contact with the swing ring gear teeth. Outlet bores (Fig. 15-19, Pos. B) at different pinion gear levels distribute the lubricant equally to the swing ring gear teeth (Fig. 15-19, Pos. A). To prevent unnecessary lubrication with the swing ring in park position, the SLS pump only starts to operate after "swinging" was activated with the control lever. All other SLS control and monitoring functions are the same as they are used in the CLS system.

Version 2010/1

15-45

Commissioning


15.13 COMMISSIONING 15.13.1 COMMISSIONING OF THE CLS LUBRICATION SYSTEM Commissioning procedures for the automatic Central Lubrication System. These procedures must be performed after the first assembly of the excavator, or after repair and exchange of components.

WARNING z

Some checks and adjustments can only be done with the engine running. For such jobs two persons are necessary.

z

Thereby, the controls must not be left unattended, while the other man carries out checks and adjustments.

z

The service technican on the operator’s seat must be skilled in the operation of the excavator.

z

He must keep constant visual contact with the other service technician and both must agree on suitable communication signals before they start their work.

1. Visual check of all hose and pipe connections from the lubrication pump station to the lubrication points via the injectors. 2. Check the correct mounting of the lubrication system. 3. Check the correct connection of the hydraulic oil supply line and the tank line. 4. Check the correct electrical connection. 5. Check the correct kind and quality of the respective grease according to the OPERATION AND MAINTENANCE MANUAL. In addition refer to the relevant PARTS & SERVICE NEWS. 6. Check the injector adjustment of each injector. It should be on max. volume, if not, adjust to max. volume, refer to section 15.7.3 on page 15-25. 7. Check if the grease supply line (from the pump station to the injectors) is pre-charged with grease. If not, open (unplug) the supply line close to the end-line switch. Start the engine and activate the lubrication station so often until grease comes out of the open end of the supply line. Stop the engine and close the open supply line. 8. Manually pre-lubricate all bearings with a grease gun of the lube track. To do this, unscrew the dust cap at the second port of each injector and connect the grease gun to the grease nipple. Apply sufficient grease into the bearing until a small amount of fresh grease appears at the bearing seals or open bearings. 9. Adjust the end-line switch if necessary, refer to section 15.9 on page 15-32. 10. Check the lubrication pump speed. If required adjust it, refer to section 15.6.1 on page 15-22. 11. Check the time settings of the pause time at the VHMS Real Time Monitor. Adjust the suggested settings which are given in the PM-CLINIC forms. This is the basic setting and also a guaranty for sufficient lubrication. NOTE: A fine adjustment is possible to adapt the lubricant apply to the working and environmental conditions by minimized lubricant consumption. 12. Start the engine and activate several cycles of the CLS lubrication. 13. Set the lubrication cycle counter to zero and note the actual working hours from the hour meter. 14. The excavator is now ready for operation. 15-46

Version 2010/1


Commissioning

15. After ~20 working hours check the lubrication systems. Check the lubrication points for sufficient grease. Check the swing circle lubricating, a small amount of grease must appear at the inner swing circle seal. Watch the cycle counter and compare it with the respective working hours. z

Example: Pause time setting = 30 minutes Working hours since the last check = 10 hours 10 h / 0.5 h = 20 cycles Compare with the indication of the cycle counter. There should be 20 –1 cycles, provided no manual cycle was activated.

16. Check the lubrication systems every day. Compare all lubrication points. There should be a well balanced small amount of fresh grease at each bearing seal or open bearing.

15.13.2 FINE ADJUSTMENT General Under normal circumstances the lubrication system - with the basic adjustment - applies more lubricant as required. 1. Find out the lubrication point with the lowest quantity of fresh grease. This point is the indicator for the following pause time fine adjustment. 2. Reduce the applied quantity by extending the pause time as much until a small amount of wet grease appears at the bearing seal or open bearing of the indicator point. Extend the pause time only in small steps (~2 - 5min). Between each step wait for 40 working hours or more and watch the lubrication points. 3. If there are one or more bearing points with too much grease, adjust the respective injector to a lower volume, refer to section 15.7.3 on page 15-25. Change the setting only in small steps (max. 1 - 2 turns clockwise). Between each step wait for 40 working hours or more and watch the lubrication points. Be careful, don’t turn the set screw too much in, and block the injector against moving. NOTE: Check the CLS every day (Daily Check)! The lubrication points of a correct adjusted Central Lubrication System have a well balanced small amount of wet grease. Never let the excavator operate with a grease shortage. Find out the reason for this shortage and eliminate this problem immediately.

Version 2010/1

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Commissioning


15.13.3 COMMISSIONING OF THE SLS LUBRICATION SYSTEM Commissioning procedures for the automatic Swing circle Lubricating System. These procedures must be performed after the first assembly of the excavator, or after repair and exchange of components.

WARNING z

Some checks and adjustments can only be done with the engine running. For such jobs two persons are necessary.

z


z

The service technican on the operator’s seat must be skilled in the operation of the excavator.

z

He must keep constant visual contact with the other service technician and both must agree on suitable communication signals before they start their work.

1. Visual check of all hose and pipe connections from the lubrication pump station to the dummy wheel via the injectors. 2. Check the correct mounting of the lubrication system. 3. Check the correct connection of the hydraulic oil supply line and the tank line. 4. Check the correct electrical connection. 5. Check the correct kind and quality of the respective grease according to the OPERATION AND MAINTENANCE MANUAL. 6. Check the injector adjustment of each injector. It should be on max. volume, if not, adjust to max. volume, refer to section 15.7.3 on page 15-25. 7. Check if the grease supply line (from the pump station to the injectors) is pre-charged with grease. If not, open (unplug) the supply line close to the end-line switch. Start the engine and activate the lubrication station so often until grease comes out of the open end of the supply line. Stop the engine and close the open supply line. 8. Remove protection fluid, dust or old grease with adequate solvent from the swing circle toothing. 9. Important: First apply open ring gear compound manually at the clean slew ring, before the assembly of the swing circle protection. Use adhesive voler compound spray for the swing circle toothing (KMG ET-No.500 893 98). It is delivered together with the new excavator. 10. Apply the swing circle parking brake. Start the engine and activate the SLS manually (switch 20S126) and move the swing circle lever to one direction, only for a short time. The SLS starts to work due to the swing movement. 11. Adjust the end-line switch if necessary, refer to section 15.9 on page 15-32. 12. Check the lubrication pump speed. If required adjust it, refer to section 15.6.1 on page 15-22. 13. Check the time settings of the pause time at the VHMS Real Time Monitor. Adjust the suggested settings which are given in the PM-CLINIC forms. This is the basic setting and also a guaranty for sufficient lubrication. 14. Start two or three lubrication cycles. 15. Stop the engine and check the lubrication system. Check if a small amount of grease arrived at one or two dummy wheel teeth.

15-48

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Commissioning

16. Set the lubrication cycle counter to zero and note the actual working hours from the hour meter. The excavator is ready for digging. 17. After ~20 working hours check the SLS. Check the dummy wheel and the swing circle toothing. A small amount of fresh grease must be at the swing circle toothing. Check the SLS lubricant cycle counter. Its indication must be higher as the number of CLS cycles during the same time. NOTE: Check the SLS every day (Daily Check)! Never let the excavator work with a grease shortage. If the teeth get a clear metallic look it is immediately necessary to apply fresh open ring gear lubricant. Find out the reason of this shortage and eliminate this problem immediately. The swing circle toothing of a correct adjusted SLS have a thin layer of open ring gear lubricant. There should be a small amount of fresh open ring gear lubricant around the tooth contact area.

Version 2010/1

15-49

Commissioning

15-50


Version 2010/1

LUBRICATION SYSTEMS


A manually activation of the lubrication systems is possible by switching a switch at the dashboard. The controller count the number of switch activated and operate the system this number one by on. The system rest between the cycles for a adjustable time (pressure relief time). Circuit Diagram Code Table Solenoid Valve 2

Vent Valve 7

End-Of-Line Switch

CLS (1)

Y7

Y7a

B43

SLS (2)

Y9

Y9a

B46


Version 2009/1

15-9


15.3

LUBRICATION PUMP STATION (SLS)

Fig. 15-4

Lubrication pump station SLS

15-10

LUBRICATION SYSTEMS

Version 2009/1

LUBRICATION SYSTEMS



Lubricant pump drive (Hydraulic cylinder)

(2)

Solenoid valve (Oil pressure supply)

(3)

Flow control valve

(4)


(5)

Hydraulic oil supply line (Pilot pressure)

(6)


(7)

Vent valve (Solenoid valve, de-energized open to barrel)

(8)


(9)

Lubricant level indication (Sonar sending and receiver principal)

(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)

Breather

(17)


(18)

Injector

(19)

Lubricant supply line to dummy wheel

(20)

Lubricant pressure sensor

(21)

Lubricant pressure test point

(22)

End of line switch

(R)

Dummy wheel

(A)

Swing circle gear

(B)

Center bore

(C)

Stator radial bore

(D)

Grease outlet

The lubrication pump station include the barrel (Fig. 15-4, Pos. 10) and the barrel cover with the pump system. The barrel is fix mounted. From the refilling arm is the barrel via a filter rechargeable. The main grease pump system is mounted on the barrel cover it consist the pump (Fig. 15-4, Pos. 1, 11), valves (Fig. 15-4, Pos. 2, 3, 4, 7), lubricant screen filter (Fig. 15-4, Pos. 12), lubricant level sensor (Fig. 15-4, Pos. 9) and a lubricant pressure sensor (Fig. 15-4, Pos. 20).

Version 2009/1

15-11


Fig. 15-5 15-12

LUBRICATION SYSTEMS

Lubrication Pump Station SLS Version 2009/1

LUBRICATION SYSTEMS


General The swing circle gear lubrication system use a special dummy wheel to apply the gear grease on to the swing circle gear. All other components between grease barrel and injectors are the same as the central lubrication system. The dummy wheel receives by each lub cycle grease from two or more parallel connected injectors. After the injectors have pump its gear grease quantity through the dummy wheel to the swing ring gear the grease pump stops and the next grease cycle starts after a adjusted time (pause time). The swing circle gear lubrication system start only by running engine in high idle and active slew function. z

After the pilot pressure has been reduced it passes to the hydraulic cylinder which operates the grease pump.

z

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.)

z

With the vent valve (Fig. 15-5, Pos. 9) closed the pump continues to cycle until maximum pressure is achieved and the injectors have transmitted lubricant to the dummy wheel. In most lubrication systems this is 185 bar (2630 psi. ).

z

When the maximum system pressure is reached the end-of-line switch opens.

z

The open pressure switch signals the controller to stop the pump cycle.

z

Solenoid valve (Fig. 15-5, Pos.4) are de-energized and the hydraulic oil stops flowing to the pump.

z

The controller starts to count down a fixed time (load holding time) and a adjustable pause time (rest time between the automatic lubrication cycles).

z

The vent valve (Fig. 15-5, Pos. 9) is still closed (solenoid active) and the lubricant pressure will be rest on pressure (slow decrease is normal).

z

If the count down of the load holding time is finished the controller terminate the signal to solenoid valve (Fig.15-5, Pos. 9).

z

Vent valve (Fig. 15-5, Pos. 9) is de-energized, it opens and allows the grease pressure to drop to zero.

z

All injectors move in the initial position by spring force and recharge itself for the next lubricant cycle.

z

The system is now at rest and ready for another lube cycle.

It is possible to activate the slew gear lubrication system manually by using switch S26 on the dashboard. The controller count the number of switch activatings and operate the system this number one by on provided the slew function was activated. The system rest between each cycles for a adjustable time (pressure relief time).

Version 2009/1

15-13


15.3.0.1

SLS LUBRICATION SYSTEM ELECTRIC LAYOUT

Fig. 15-6

Circuit diagram lubrication system

15-14

LUBRICATION SYSTEMS

Version 2009/1

LUBRICATION SYSTEMS


. Circuit Diagram Code Table Solenoid Valve 2

Vent Valve 7

End-Of-Line Switch

CLS (1)

Y7

Y7a

B43

SLS (2)

Y9

Y9a

B46


CAUTION Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area.

NOTE: The content of molybdenum must not exceed 5 %. Only synthetic graphite must be contained in graphite lubricants.

Version 2009/1

15-15


15.3.1

HYDRAULICALLY DRIVEN LUBE PUMP

Fig. 15-7

Hydraulically driven “Power Master III” lube pump

15-16

LUBRICATION SYSTEMS

Version 2009/1

LUBRICATION SYSTEMS


Legend for Fig. 15-7 (more detailed see parts list 991-0266a): (P)

Hydraulic oil supply

(T)

Hydraulic oil return

(Pr)


(Q)

Flow regulator valve

(M)

Measure point

(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

The pump assembly consist three main groups: z

Propulsion cylinder (Fig. 15-7, Pos. 1)

z

Cylinder controlling (Fig. 15-7, Pos. 2)

z

Grease pump (Fig. 15-7, Pos. 3)

The Propulsion cylinder (Fig. 15-7, Pos. 1) is connected to the pump piston (Fig. 15-7, Pos. 10). The lubricant pump pumps per stroke (up or down) lubricant through the pump tube (Fig. 15-7, Pos. 3) to the lubricant outlet port. The piston speed and force is adjustable via two valves mounted on the cylinder controlling block (Fig. 15-7, Pos. 2). The left hand valve is a adjustable flow regulation valve to limit the oil flow to the propulsion cylinder. This flow is responsible for the cylinder speed. The right hand valve is a pressure reducing valve to limit the maximum lubrication supply pressure. The stroke direction change automatically if the cylinder stops moving. Reach the cylinder its own stroke limit the moving direction change also if the cylinder stops by an external force. The maximum possible lubricant pressure depend on the adjusted supply pressure. The pressure multiplication factor between supply pressure and maximum lubricant pressure is 6,55. The pressure reduction valve has to be adjusted to 50 bar. Example: 50 bar supply pressure x 6,55 = 327,5 bar lubricant pressure. During normal operation the end line switch stop the pump before reaching this high pressure. For a sufficient lube pump operation 18 – 20 double strokes / min for the pump drive cylinder are required. Therefore the flow reducing valve has to be adjusted, refer to section 15.5 on page 15-38. Version 2009/1

15-17


15.3.2

VENT VALVE

Fig. 15-8

Vent valve

15-18

LUBRICATION SYSTEMS

Version 2009/1

LUBRICATION SYSTEMS



Solenoid

(2)

Valve assembly

(3)

Solenoid stem

(4)

Lever

(5)

Main valve piston

(6)

Auxiliary valve piston

(7)

Reset spring

Task By the function of the vent valve the lubricant supply line gets pressure relieved, after the lubrication cycle is finished. The injector pistons move back into their initial position. The valve is open if the solenoid is de-energized. It means port A is connected with port B. Function The solenoid gets energized. When the lubrication cycle starts. The connection from A to B gets closed, thus a pressure build-up in the grease supply line 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 or vice versa along the main valve piston (Fig. 15-8, Pos. 5).

Version 2009/1

15-19


15.3.3

END OF LINE SWITCH

Fig. 15-9

End of line switch

15-20

LUBRICATION SYSTEMS

Version 2009/1

LUBRICATION SYSTEMS



Piston

(2)

Disk

(3)

Switch contact

(4)

Spring

(5)

Pressure switch

(6)

Adjustment sleeve

(7)

Connection to pressure circuit

(8)

Electrical connection

Task The pressure control unit (end of line switch) is monitoring and controlling the lube system. Function One pressure control unit is installed in each lubrication system. The grease pressure, produced by the hydraulic barrel pump, acts also at the piston (Fig. 15-9, Pos. 1) If the grease pressure reaches the tension of the spring (Fig. 15-9, Pos. 4), the piston (Fig. 15-9, Pos. 1) is forced against the disk (Fig. 15-9, Pos. 2), thus that the contacts of the switch (Fig. 15-9, Pos. 5) are operated and a electric contact is given to the electronic control unit of the PLC. Adjusting has to be done with the sleeve (Fig. 15-9, Pos. 6). Clockwise - higher switch point, counterclockwise lower switch point. The adjusting have to be done, refer to section 15.5.3 on page 15-44 and on page 15-46.

Version 2009/1

15-21


15.3.4

IN-LINE FILTER

Fig. 15-10

In-line filter

15-22

LUBRICATION SYSTEMS

Version 2009/1

LUBRICATION SYSTEMS



Plug screw

(2)

Plug screw gasket

(3)

Filter element

(4)

Filter housing

(5)

Spring guide

(6)

Spring

Task The in line filter prevent the lubrication injectors against contamination.

CAUTION Before servicing stop the motor and remove ignition key in order to prevent operation of the system!

NOTE: A clogged filter element will be moved against the spring force by the lubricant pressure and unfiltered lubricant reaches the system! For Maintenance proceed as follows: 1. Remove plug screw (Fig. 15-10, Pos. 1) using 36 mm width wrench. 2. Remove plug screw gasket (Fig. 15-10, Pos. 2). 3. Take out spring (Fig. 15-10, Pos. 6), spring guide (Fig. 15-10, Pos. 5) and filter element (Fig. 15-10, Pos. 3). 4. Clean all parts and inspect for damage. Replace as necessary. 5. Insert filter element, spring guide (Fig. 15-10, Pos. 5) and spring. 6. Install plug screw (Fig. 15-10, Pos. 1) with gasket (Fig. 15-10, Pos. 2) and tighten with a wrench. NOTE: For service intervals refer to MAINTENANCE MANUAL

Version 2009/1

15-23


15.3.5

LUBRICANT LEVEL SENSOR

Fig. 15-11


LUBRICATION SYSTEMS

Capacitive analog level sensor for machines with PLC (PC 4000 .... PC8000) Legend for illustration Z 21190 1

Capacitive analog sensor housing

2

Capacitive level sensor pipe

3

Lubricant

4

Lubricant container

5

Electrical connection line

General: The capacitive analog level sensor measure the lubricant level with a capacitive measurement principle which is independend from the lubricant surface condition. The sensor create proportional to the lubricant level a analog output signal which use the PLC to monitor the lubricant level and to control the lubricant level messages. It is only one sensor for one container required. For power supply and signal output only two shield wires connected. The sensor is exact to the lubricant container adjusted there are no adjustments and maintenance required.

15-24

Version 2009/1

LUBRICATION SYSTEMS

15.3.6

LUBRICANT PRESSURE SENSOR

Fig. 15-12



Lubricant Pressure Sensor Function (electrical diagram Z 27402Page 26) The sensor is additional to the mechanical analogue pressure gauge mounted on the lubrication pump station. On display page REAL TIME MONITOR 4.1.21 is the grease pressure shown. The pressure sensor B160 (1) with a range from 0 bar to 500 bar is hydraulically connected parallel to the mechanical analog pressure gauge (2) in the lubricant supply line on top of the lubricant pump station. On electrical side there are three wire. +24 V electrical supply on plug A (br = brown) and ground on plug D (ws = white). The signal with a proportional voltage output to the lubricant pressure is connected on plug C (gn = green). Connecting between plug and main electrical box X2 is used a shielded wire, to protect the signal line against electrical magnetic interferences. this wire is in the X2 box connected with terminal 3-4, 5, 7-8 and ground (GND) on terminal group Z. The PLC is also connected from analog input port EW14.3 to the terminals. The PLC receive a voltage signal on port 6 of input plug 15 (EW14.3) between 0 – 10 Volt proportional to the lubricant pressure. Task The pressure sensor is used only for the VHMS. It check the lubricant pressure only for observe. NOTE: The grease pressure represent the lubrication pump pressure. The pressure on the end of the grease supply line is lower depend on line resistance and lubricant viscosity.

Version 2009/1

15-25

LUBRICATION SYSTEMS

15.3.7

LUBRICANT INJECTOR

Fig. 15-13

Lubricant injector (metering valve)


Legend for Fig. 15-13 (for model SL1 and SL11): (1)

Set screw

(2)

Control pin

(3)

Lock nut

(4)

Injector piston

(5)

Spring

(6)

Slide valve

(7)

Second outlet with greaser (injector couple poind)

(8)

Discharge chamber

(9)

Passage (Connecting bore)

(A)

Lubricant inlet

(B)

Lubricant outlet

Version 2009/1

15-26

LUBRICATION SYSTEMS


General: Each injector can be manually adjusted with set screw (1) to discharge the precise amount of lubricant each bearing needs. Injectors are mounted singly at each bearing, or grouped in a manifold with feed lines supplying lubricant to the bearings. In each case, injectors are supplied with lubricant under pump pressure through a single lubricant inlet port (A). Two injector size are used on KMG machines. Both size can be used in the same circuit, their selection is made on the basis of bearing lubricant requirements.The injectors are externally adjustable so each bearing can receive the correct amount of lubricant. Each injector incorporates an indicator pin that gives visual confirmation the injector is operating correctly. When necessary, troubleshooting is the simple process of checking indicator pins. Via service port (7) it is possible to lubricate the bearing with a manual operated grease gun. Open only cab nut (7a) of service port (7) to get access to the grease nipple. The cup nut (7a) must be replaced after manuel lubrication to plug and protect the nipple.

Injector type

Output volume range

SL1 (A)

0,131 to 1,31 cm³

SL11 (B)

0,82 to 8,2 cm³

Version 2009/1

15-27


15.3.7.1

FUNCTION STEPS:

Fig. 15-14

Function lubricant injectors

15-28

LUBRICATION SYSTEMS

Version 2009/1

LUBRICATION SYSTEMS


Function steps: Stage A: Inlet pressure 0 bar, Outlet pressure 0 bar The injector piston is in its normal, or rest position. Visible by the extracted indicator stem (2) which is blocked in final position by the set screw (1). The discharge chamber (8) is filled with lubricant from the previous cycle.

Stage B: Inlet pressure increasing from 0 to 180 bar, Outlet: lubricant injection 0 - 180 bar, Output volume: adjusted amount of lubricant Under the pressure of incoming lubricant via port (10), slide valve (6) is about to open the passage (9) leading to the piston (4). When the slide valve (6) uncovers the passage (9), lubricant is admitted to the measuring chamber (12) at the top of the piston (4), forcing the piston down. The piston (4) forces lubricant from the discharge chamber (8) through the outlet port (11) to the bearing. The indicator stem (2) retracts. Stage C: Inlet pressure at maximum 180 bar Output injection is finished As the piston (4) completes its stroke, it pushes the slide valve (6) past the passage (9), cutting off further admission of lubricant to the passage (9). Piston (4) and slide valve (6) remain in this position until lubricant pressure in the supply line (10) is vented (relieved) at the pump station. The indicator stem (2) is fully retracted and the adjusted amount of lubricant is injected to the bearing. Stage D: Inlet pressure relieved z

After lubricant supply pressure (10) is relieved, the compressed spring (5) moves the slide valve (6) to the closed position. This opens the port from the measuring chamber (12) and permits the lubricant to be transferred from the top of the piston to the discharge chamber (8). The indicator stem (2) extract to its initial final stop of the adjustment screw (1). Now the injector is prepared for the next lubricant application.

Version 2009/1

15-29


15.3.7.2

INLINE CONNECTION OF INJECTORS

Fig. 15-15

Connection of lubricant injectors

LUBRICATION SYSTEMS

To increase the lubricant output volume the injectors are designed to combined two or more injectors together. The injector body (1) has two outlet ports (a) and (b), both connected to the discharge chamber. A connector pipe (2) is used to couple two injectors together. Lubricant from the first injector is directed through the connector pipe into the discharge chamber of the second injector. Both injectors now parallel connected to one bearing. Lubrication pinion

15-30

Version 2009/1

LUBRICATION SYSTEMS

15.3.8

LUBRICATION PINION

Fig. 15-16

Dummy wheel


Legend for Fig. 15-16: (R)

Lubrication pinion (Dummy whee)l

(A)

Swing circle gear

(B)

Center bore

(C)

Stator radial bore

(D)

Grease outlet

Principle of Operation By mean of a lubricant pump, the lubricant is supplied to the centered bore hole (B) of the lubricating pinion (R). Bore hole (B) must be perfectly aligned to the swing circle gear (A) to be greased, so that lubricant leaves the tooth flank always at matched condition. The grease outlet (D) of the lubricating 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. The pinion propulsion is by the slew gear. The pinion bearings are lubricated himself by the gear grease. The picture shows an example with one pinion only. There are also machines which will have two pinion (dummy wheel).

Version 2009/1

15-31


LUBRICATION SYSTEMS


15-32

Version 2009/1

LUBRICATION SYSTEMS

15.4

Operating and Controlling

OPERATING AND CONTROLLING

General The Lubrication Systems are controlled and monitored complete through the PLC. The PLC activate the outputs dependent on inputs and time. The programmed flow is shown in the flowchart (898 688 40, page 31 to 34) and the electrical connection is shown in the electrical diagram 897 844 40 d. In- and Outputs of the PLC

Inputs

End of line switch Lubricant level Switch manual cycle Lubricant pressure

CLS

SLS

E2.6 / B43

E2.7 / B46

EW14.1 / B108

EW14.2 / B109

E4.4 / S24

E4.5 / S26

EW14.3 / B160

EW14.4 / B161

Swing circle condition

E 3.5 (18.4) Lever E 20

Engine operating condition

Engine controller

Outputs CLS

SLS

Lubrication pump

A3.1 / Y7

A3.2 / Y9

Vent line

A7.1/Y7a

A7.2 / Y9a

A5.2 / H76

A5.3 / H78

Light “full barrel”

Version 2009/1

15-33


15.4.1

OPERATING FLOW, ELECTRICAL FLOW

Fig. 15-17

Operating flow, Electrical flow

15-34

LUBRICATION SYSTEMS

Version 2009/1

LUBRICATION SYSTEMS


Function of a lubrication cycle. (Illustration Z24042d). PT - phase With the pump and controller system in a rest sate a pre-set pause time interval occurs as determined by PLC: Diagram position (a): A 24Vdc signal from the PLC activate solenoid valve (2) that opens and activate the lubrication pump (*). As solenoid valve (2) opens, hydraulic oil flow 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 grase pump. The oil cylinder shuttle the grease cylinder at 18 - 20 double strokes per minute and delivering 212 680cm³ (37.3 - 41.5 in³) of lubricant per minute (approx. 550- 612 / 19....64 - 21.45 oz.) At the same time a 24V signal energize release valve (7), it close now the release line to the lubricantion container. PI - phase With energized release valve (7) (*) and solenoide valve (4) the pumpcontinues to cycle until mayimum pressure is achieved and the injectors have transmitted lubricant to the brearings. S + ponit, diagram position (b) Whenthe maximum system pressure is reached the end of the line switch (*) open it’s contact. In the normal application es the end of line switch adjusted to 180 bar (2610psi.). 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 valve (2). The pilot oil flow to the pump stops 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.) Once cycle With expired pressure holding time vent valve (7) de-energize. Itopens the release line to the lunbricant container. The lubricant line pressure drop to zero so the injectors can recharge for the next lubricant cycle. (PR-phase) PR-phase In the pressure relieve phase, the end of line switch (*) move back to neutral contact, given a singnal to PLC that the lube pressure relieve phase is now active. Pause time The systemis after pressure releasing at rest (pause time), ready for another lube cycle and the sequence repets itself when the adjusted pause time is elapsed.

Version 2009/1

15-35


Fig. 15-18 15-36

LUBRICATION SYSTEMS

Operating flow, electrical flow Version 2009/1

LUBRICATION SYSTEMS


:. Soleniod valve 2

Vent valve 7

End of line switch

Y7, CLS

Y7a, CLS (1)

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

X axis

Time

Y axis

Lubricant supply line pressure

PI

Pressure Increasing

S+

Swittch point ON of the end line pressure switch

PH

Pressure Holding

S-

Switch piont OFF of the end line pressure switch

PR

Pressure Relieve

Version 2009/1

15-37

Adjustments

LUBRICATION SYSTEMS

15.5

ADJUSTMENTS

Fig. 15-19

Adjust pump speed and working pressure

15-38

Version 2009/1

LUBRICATION SYSTEMS

15.5.1

PUMP SPEED AND WORKING PRESSURE

15.5.1.1

ADJUSTMENTS LUBRICATING PUMP SPEED

Adjustments

Stroke speed (Q) For a sufficient lubricating pump operation 18 – 20 double strokes/ min of the pump drive cylinder are required. Therefore the flow reducing valve (2) has to be adjusted accordingly. Procedure: 1. Disconnect electrical plug connection from the lubricant pressure release valve (9), so no pressure built up will take place during the following test. 2. Start engine and run at high idle. 3. Activate the required lube system manually with dash board switch S24 (CLS) or S26 (SLS) and count strokes per minute, visible via the oscillating pipe (24). If adjustment is required: 4. Loosen lock nut (2.1) 5. Turn setscrew (2) cadre to increase or cr. to decrease the stroke speed until the right number of strokes is achieved. 6. Tighten lock nut (3.1). 7. Reconnect electrical plug from lubricant pressure release valve (9).

Version 2009/1

15-39

Adjustments

Fig. 15-20

15-40

LUBRICATION SYSTEMS

Adjust pump speed and working pressure

Version 2009/1

LUBRICATION SYSTEMS

Adjustments

Adjustments lubricating pump pressure Maximum pump operating pressure (P) The pressure reducing valve (3) mounted in the oscillation control block reduce the pump drive cylinder pressure internally. The maximum allowed pressure is 45 bar but there is no direct pressure check required. The pressure ratio is 6,55 to 1, that means 45 bar supply pressure result in 295 bar maximum lubricant pressure. At the end line pressure switch the pressure should be 180 ±5bar. With the lubricant line resistance and different lubricant viscosity the pressure at the lubricant pump must be higher as 180 bar. 220 – 250 bar pump pressure (pressure gauge at lubrication station) is sufficient to achieve the 180 bar end line pressure after line resistance and different lubricant viscosity.

Procedure: 1. Disconnect quick coupling (10), so the pump supply line from the pump to the injectors is blocked. 2. Start engine and run at high idle. 3. Activate the required lube system manually, the gauge (14) should show 220-250 bar. 4. If adjustment is required: 5. Loosen lock nut (3.1) 6. Turn adjustment (3) until the right pressure is shown at the gauge (7) turn set screw ccw to lower pressure and cw to increase the pressure until the required pressure is achieved. 7. Tighten lock nut (3.1). 8. Change engine to low idle or stop engine which stop the lubricant pump and opened relieve valve (9) to relieve the lubricant pressure. 9. Reconnect quick coupling (8).

Version 2009/1

15-41

Adjustments

LUBRICATION SYSTEMS

15.5.2

INJECTORS

Fig. 15-21

Injectors

15-42

Version 2009/1

LUBRICATION SYSTEMS

Adjustments

Legend for illustration Z 21187a

General: Each injector can be manually adjusted with set screw (1) to discharge the precise amount of lubricant each bearing needs. Injectors are mounted singly at each bearing, or grouped in a manifold with feed lines supplying lubricant to the bearings. In each case, injectors are supplied with lubricant under pump pressure through a single supply line (10). Two injector size used. Both size can be used in the same circuit, their selection is made on the basis of bearing lubricant requirements.The injectors are externally adjustable so each bearing can receive the correct amount of lubricant. Each injector incorporates an indicator pin that gives visual confirmation the injector is operating correctly. When necessary, troubleshooting is the simple process of checking indicator pins. Via service port (7) it is possible to lubricate the bearing with a manual operated grease gun. Open only cab nut (7a) of service port (7) to get access to the grease nipple. The cup nut (7a) must be replaced after manuel lubrication to plug and protect the nipple.

Injector type

Output volume range

SL1 (A)

0,131 to 1,31 cm³

SL11 (B)

0,82 to 8,2 cm³

Version 2009/1

15-43

Adjustments

LUBRICATION SYSTEMS

15.5.3

END OF LINE SWITCH SETTING CLS

Fig. 15-22

End of line switch setting CLS

15-44

Version 2009/1

LUBRICATION SYSTEMS

Adjustments

1. Connect pressure gauge (0-400 bar) to check point near by the end line switch. There is only a T-union with one plugged port. Open this port and mount a adapter test union to connect the pressure gauge. NOTE: Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test. 2. Start engine. 3. Start a lube cycle with the dashboard switch S24. 4. Watch pressure gauge. At a pressure of 180+10 bar the end-line switch must react and the lubricants pump must be stopped. *) NOTE: *) 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. NOTE: 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly. If re-setting is required: 1. Screw out screw (Fig. 15-22, Pos. 1) and take off cover (Fig. 15-22, Pos. 2). 2. Alter the spring tension with adjustment screw (Fig. 15-22, Pos. 3) that the switch operates at 180 bar. 3. Install cover (Fig. 15-22, Pos. 2) and screw (Fig. 15-22, Pos. 1).

Version 2009/1

15-45

Adjustments

LUBRICATION SYSTEMS

15.5.4

END OF LINE SWITCH SETTING SLS

Fig. 15-23

End of line switch setting SLS

15-46

Version 2009/1

LUBRICATION SYSTEMS

Adjustments

1. Connect pressure gauge (0-400 bar) to check point near by the end line switch. There is only a T-union with one plugged port. Open this port and mount a adapter test union to connect the pressure gauge. NOTE: Use an other gauge as for checking hydraulic pressures, because the gauge remains filled with grease after the test. 2. Fix the swing functionby using the swing parking brake (Switch S29). 3. Start engine. 4. Start a lube cycle with the dashboard switch S26 and move the lever for the swing function for a short time. 5. Watch pressure gauge. At a pressure of 180+10 bar the end-line switch must react and the lubricant pump must be stopped. *) NOTE: *) 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. NOTE: 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly. If re-setting is required: 1. Screw out screw (Fig. 15-23, Pos. 1) and take off cover (Fig. 15-23, Pos. 2). 2. Alter the spring tension with adjustment screw (Fig. 15-23, Pos. 3) that the switch operates at 180 bar. 3. Install cover (Fig. 15-23, Pos. 2) and screw (Fig. 15-23, Pos. 1).

Version 2009/1

15-47

Troubleshooting

15.6

TROUBLESHOOTING

Fig. 15-24

Troubleshooting

15-48

LUBRICATION SYSTEMS

Version 2009/1

LUBRICATION SYSTEMS

Troubleshooting

If the following procedures do not correct the problem, contact a factory authorized service center. Problems: Lubrication Pump Cylinder does not move 1. Check if the PLC start currently a lubrication cycle. z

Activate the lubrication system manually.

z

Be sure that the pressure holding time and relief time is over.

z

SLS only: move the slewing lever for a short time to switch the zero position contact.

2. Check if there a fault message on display CGC. z

If the level sensor indicate zero level, the PLC stop the lubrication system as long as the barrel is recharged.

3. Check for 24 VDC signal at solenoids (Fig. 15-22, Pos. 2). 4. Check the hydraulic oil supply and tank line coupling (Fig. 15-22, Pos. 5, 6). 5. Check system pressure to lubrication pump (X-4 Pressure). 6. Check pressure reducing valve (Fig. 15-22, Pos. 4) (lubrication pump) setting. 7. Check for faulty valves (Fig. 15-22, Pos. 3, 4) (check for foreign matters). Lubricant Pressure built up very slowly or not at all. 1. Check lubricant supply line to the injectors for leak or broken lines. 2. Check injectors for internal leaks. 3. Pressure reducing valve (Fig. 15-22, Pos. 4) may be set too low. 4. Grease viscosity may be too high for temperature at which pump is operating. 5. Check end line switch for correct setting. 6. Check lubrication pump (Fig. 15-22, Pos. 11). Piston and inlet checks may have foreign matter trapped causing leakage. Remove, inspect and clean if necessary. 7. Check solenoid valve (Fig. 15-22, Pos. 7) (vent line) for correct function and completely closed port. 8. Check lubricant pressure gauge (Fig. 15-22, Pos. 14) for correct function.

Version 2009/1

15-49

Troubleshooting

Fig. 15-25 15-50

LUBRICATION SYSTEMS

Troubleshooting Version 2009/1

LUBRICATION SYSTEMS

Troubleshooting

Insufficient Lubricant Supply to one or more Attachment Bearings 1. Check lubricant supply line to the respective bearing for leak or broken line. 2. Check injector function and adjustment z

Check if the indication pin move smooth during a lubrication cycle.

z

Check if the indication pin move completely back in the initial position.

z

Check the application volume by open line.

3. Check end line switch for correct setting. 4. Check lubricant supply bore for clogged up 5. Check pause time setting. 6. Check bearing condition (extensive wear) Insufficient Lubricant at the Swing Ring Gear 1. Check lubricant supply line to the dummy wheel 2. Check dummy wheel for clogged supply bore. 3. Check dummy wheel mounting position 4. Check electrical controlling system, especially the idle identify circuit. 5. Check kind of lubricant and quality.

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15-51

Commissioning

LUBRICATION SYSTEMS

15.7

COMMISSIONING

15.7.1

COMMISSIONING OF THE CLS

Commissioning procedure for the automatic central lubricating systems. This procedure must be done after the first erection of the excavator or repair and exchange of components.

WARNING z

Some checks and adjustments can only be done with the engine running. For such jobs two person are necessary.

z


z

The Service technica in the operator’s seat must be skilled in the operating of the excavator.

z

He must keep constant visual contact with the other one and they must agree on suitable communication signals before they start their work.

1. Visual check of all hose and pipe connections from the lubrication pump station to the lubrication points via the injectors. 2. Check the correct mounting of the lubrication systems. 3. Check the correct connection of the hydraulic oil supply line and tank line. 4. Check the correct electrical connection. 5. Check the correct kind and quality of the respective grease according to the OPERATION AND MAINTENANCE MANUAL. 6. Check the injector adjustment of each injector, it should be on max. volume, if no adjust to max. volume refer to section 15.5.2 on page 15-42. 7. Check out if the grease supply line (from the pump station to the injectors) is precharged with grease. If no open (unplug) the supply line near by the end of line switch. Start engine and activate the lubrication station so often as grease comes out on the open end of the supply line. Stop engine and close the open supply line. 8. Pre lubricate all bearings manually with a grease gun. To do this, unscrew the dust cap at the second port of each injector and connect the grease gun to the grease nipple. Apply sufficient grease into the bearing until a small amount of fresh grease appears at the bearing seals or open bearings. 9. Adjust the end of line switch refer to section 15.5.3 on page 15-44. 10. Check the lubrication pump speed. If required adjust refer to section 15.5.1 on page 15-39. 11. Check the time settings of pause time, monitoring time and relief time. Set to our suggested settings written in the final test report . It is the base setting and guaranty a sufficient lubrication. NOTE: A fine adjustment is possible to adapt the lubricant apply to working and environmental conditions by minimized lubricant consumption. 12. Start engine and activate the CLS several cycles. 13. Set lubricant cycle counter to zero and note the actual working hours from hour meter. 14. The excavator is now ready for operation.

15-52

Version 2009/1

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Commissioning

15. After ~20 working hours check the lubrication systems. Check the lubrication points for sufficient grease. Check the swing circle lubricating, a small amount of grease must appear at the inner swing circle seal. Watch to the cycle counter and compare it with the respective working hours. z

Example: Pause time setting = 30 min Working hours since the last check = 10 hours 10 h / 0.5 h = 20 cycle Compare with the number of cycle counter it should be 20 –1 cycle, provided no manual cycle was activated.

16. Check the lubrication systems every day. Compare all lubrication points. There should be a well balanced small amount of fresh grease at each bearing seal or open bearing.

15.7.2

FINE ADJUSTMENT

General In normal circumstance the lubrication system apply with the basic adjustment more lubricant as required. 1. Find out the lubrication point with the lowest quantity of fresh grease. This point is the indicator for the following pause time fine adjustment. 2. Minimize the apply quantity by extending of the pause time as much as a small amount of wet grease appears at the bearing seal or open bearing from the indicator point. Extend the pause time only in small steps (~2-5min). Between each step wait 40 working hours or more and watch the lubrication points. 3. If there one or more bearing points with to much grease adjust this respective injector to a lower volume, refer to section 15.5.2 on page 15-42, change setting only in small steps (max. 1-2 turn clock wise) Between each step wait 40 working hours or more and watch the lubrication points. Be carefully, don’t turn the set screw to much in and block the injector moving. NOTE: Check the CLS every day. NOTE: The lubrication points of a correct adjusted central lubrication system have a well balanced small amount of wet grease. Never let the excavator operate with a grease shortage. Find out the reason of this shortage and eliminate this problem.

15.7.3

COMMISSIONING OF THE SLS

Commissioning procedure for the automatic swing circle lubricating systems. This pro-cedure must be done after erection of the excavator or repair and exchange of compo-nents.

WARNING z

Some checks and adjustments can only be done with the engine running. For such jobs two person are necessary.

z

Thereby, the controls must not be left unattended, while the other person carries out checks and adjustments.

z

The Service technica in the operator’s seat must be skilled in the operating of the excavator.

z

He must keep constant visual contact with the other one and they must agree on suitable communication signals before they start their work.

Version 2009/1

15-53

Commissioning

LUBRICATION SYSTEMS

1. Visual check of all hose and pipe connections from the lubrication pump station to the dummy wheel via the injectors. 2. Check the correct mounting of the lubrication systems. 3. Check the correct connection of the hydraulic oil supply line and tank line. 4. Check the correct electrical connection. 5. Check the correct kind and quality of the respective grease according to the OPERATION AND MAINTENANCE MANUAL. 6. Check the injector adjustment of each injector, it should be on max. volume, if no adjust to max. volume refer to section 15.5.1 on page 15-39. 7. Check out if the grease supply line (from the pump station to the injectors) is precharged with grease. If not open (unplug) the supply line near by the end of line switch. Start engine and activate the lubrication station so often as grease comes out on the open end of the supply line. Stop engine and close the open supply line. 8. Clean swing circle toothing from protection fluid with adequate solvent. 9. Apply the first open ring gear lubricant manually before assembly the swing circle protection. 10. Close swing circle parking brake. Start engine and activate the SLS manually (switch S26) and move the swing circle lever to one direction, only for a short time. The SLS start to work. Adjust the end of line switch refer to section 15.5.4 on page 15-46. 11. Check the lubrication pump speed. If required adjust refer to section 15.5.1 on page 15-39. 12. Check the time settings of pause time, monitoring time and relief time. Set to our suggested settings written in the final test report . It is the base setting and guaranty a sufficient lubrication. 13. Start two or three lubrication cycle. 14. Stop engine and check lubrication system. Check if a small amount of grease arrived at one or two dummy wheel tooth. 15. Set lubricant cycle counter to zero and note the actual working hours from hour meter. The excavator is ready for digging. 16. After ~20 working hours check the SLS. Check the dummy wheel and swing cir-cle toothing, a small amount of fresh grease must be at the swing circle toothing.. Check the SLS lubricant cycle counter. This cycle must be higher as the cycles at the CLS during the same time. NOTE: Check the SLS every day. NOTE: Never let the excavator work with a grease shortage. If the teeth get a clear metallic look it is immediately necessary to apply fresh open ring gear lubricant. Find out the reason of this shortage and eliminate this problem. The swing circle toothing of a correct adjusted SLS have a thin layer of open ring gear lubricant. It should be a small amount of fresh open ring gear lubricant around the tooth contact area.

15-54

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Commissioning


Version 2009/1

15-55

Commissioning

15-56

LUBRICATION SYSTEMS

Version 2009/1

TS 08199-upD-GB-0

HYDRAULIC MINING EXCAVATOR PC4000-6 DIESEL Machine model

Serial numbers

PC4000-6

08199 and up

40 Troubleshooting Troubleshooting procedures Release 0

10/2010


PC4000-6 S/N 08199 and up

1

2

PC4000-6 S/N 08199 and up

40 Troubleshooting

Contents of this Troubleshooting Manual Part I

Safety

Part II

Introduction & general information for troubleshooting

Part III Mounting locations, connector types and electrical standard values Part IV Troubleshooting by trouble code Part V

Troubleshooting by symptoms

PC4000-6 S/N 08199 and up

3

40 Troubleshooting

4

PC4000-6 S/N 08199 and up

40 Troubleshooting

Table of Contents SAFETY INFORMATION ............................................................................. 15 OVERVIEW .................................................................................................. 16 NORMAL OPERATIONS ....................................................................................................................... REGULAR MAINTENANCE .................................................................................................................. TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................................... ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR ........................................................................................

16 16 16 16

SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB......................... 17 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR ....................................................................................... 18 UNDERSTANDING THE MACHINE...................................................................................................... PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................................... PREPARATIONS FOR SAFE OPERATION ......................................................................................... FIRE PREVENTION .............................................................................................................................. PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ......................................................... BURN PREVENTION ............................................................................................................................ PRECAUTIONS WHEN CLEANING CAB GLASS ................................................................................ PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................ PRECAUTIONS AT JOBSITE ............................................................................................................... STARTING ENGINE.............................................................................................................................. OPERATION..........................................................................................................................................

18 18 18 20 22 23 24 25 26 31 32

PRECAUTION FOR MAINTENANCE ......................................................... 38 GENERAL PRECAUTIONS................................................................................................................... 38 PRECAUTIONS FOR INSPECTION AND MAINTENANCE ................................................................. 46 PRECAUTIONS WITH HIGH PRESSURE Fluid ................................................................................... 47

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS............................................ 52 INSPECTION OF THE HYDRAULIC SYSTEM ..................................................................................... 52 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS ................. 52 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR ....................................................... 52

SPECIAL SAFETY EQUIPMENT ................................................................ 54 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB .................................. OBJECT HANDLING ............................................................................................................................. LIGHTING.............................................................................................................................................. WARNING BEACON ............................................................................................................................. SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) .............................

PC4000-6D S/N 08199 and up

55 55 55 55 55

5

40 Troubleshooting

Introduction & general information for troubleshooting ........................ 63 Description of this troubleshooting manual ..................................................................................... 63 1. General precautions ................................................................................................................... 63 2. Preparations for work.................................................................................................................. 64 3. Precautions during work ............................................................................................................. 64 Precautions when carrying out any operation........................................................................................ 66 1. Precautions when carrying out removal work ............................................................................. 66 2. Precautions when carrying out installation work......................................................................... 66 3. Precautions when completing the operation............................................................................... 67 Fundamental requirements for troubleshooting............................................................................... 68 Technical documentation ................................................................................................................ 68 Tools ................................................................................................................................................ 68 Reference Guide for Deutsch removal tools ................................................................................... 70 Personnel ........................................................................................................................................ 71 Points to remember when troubleshooting ............................................................................................ 71 Sequence of events in troubleshooting.................................................................................................. 73 Checks before troubleshooting .............................................................................................................. 74 Handling of electric equipment and hydraulic components............................................................ 75 Points to remember when handling electric equipment ................................................................... 75 1. Handling wiring harnesses and connectors ................................................................................ 75 2. Main failures occurring in wiring harness.................................................................................... 75 3. Disconnecting connectors........................................................................................................... 76 Points to remember when handling hydraulic equipment ................................................................ 77 1. Be careful of the operating environment..................................................................................... 77 2. Disassembly and maintenance work in the field......................................................................... 77 3. Sealing openings ........................................................................................................................ 78 4. Do not let any dirt or dust get in during refilling operations......................................................... 78 5. Change hydraulic oil when the temperature is high.................................................................... 78 6. Flushing operations .................................................................................................................... 78 7. Cleaning operations.................................................................................................................... 78 General working procedures .............................................................................................................. 79 1. Air bleeding of various hydraulic parts........................................................................................ 79 2. Cylinder bypass test ................................................................................................................... 80 Information about MTC & Nodes ............................................................................................................ 81 Outline of the MTC and its connector locations ............................................................................... 81 General description of the MTC ...................................................................................................... 82 Information about the LED indications at the MTC .......................................................................... 82 Information about the ICN-D node .................................................................................................. 82 Information about the ICN-V node ................................................................................................... 85 DIP switches at the ICN-D and ICN-V nodes .................................................................................. 87 Sequence of the CAN nodes at the CAN bus ................................................................................. 88 Basics about „How to crimp” .................................................................................................................. 89 Cable colour identification...................................................................................................................... 92

6

PC4000-6D S/N 08199 and up

40 Troubleshooting

Mounting locations, connector types and electrical standard values .. 93 Component location ............................................................................................................................... 93 View onto the superstructure .......................................................................................................... 93 Location of engine electrical parts (1) ............................................................................................. 95 Location of engine electrical parts (2) ............................................................................................. 96 Location of hydraulic components (I) .............................................................................................. 97 Location of hydraulic components (II) ............................................................................................. 99 Location of the remote control valves ........................................................................................... 100 Location of the high pressure sensors .......................................................................................... 102 View onto the SLS and CLS grease barrel and the lubrication cycle components ....................... 103 View onto the cab base with electrical components ...................................................................... 105 Hydraulic oil tank - Location of electrical components .................................................................. 107 Hydraulically operated access ladder ........................................................................................... 109 Overview connector types and connector pin numbers ....................................................................... 111 Standard value table for electrical components ................................................................................... 114 PT100 temperature charts ................................................................................................................... 126

Troubleshooting by trouble code ........................................................... 129 G00001 - Trouble Shut-Off (gate) valve .............................................................................................. 129 View onto the gap of the proximity switch 40B031 ........................................................................ 131 View onto the VHMS settings for the proximity switch 40B031 ..................................................... 132 Wiring diagram related to trouble code G00001 ........................................................................... 133 Wiring diagram related to trouble code G00001 ........................................................................... 134 G00002 - Test speed 1800 1/min engine 1 ......................................................................................... 135 Wiring diagram related to trouble code G00002 ........................................................................... 137 G00003 - Trouble pump controller ....................................................................................................... 138 G00005 - Low hydraulic oil level.......................................................................................................... 142 Wiring diagram (G00005), oil level label, and defined position of the attachment ........................ 144 G00007 - Trouble hydraulic oil level .................................................................................................... 145 Wiring diagram (G00007) and the defined position of the attachment .......................................... 147 G00012 - Central lubrication system grease level too low................................................................... 148 G00013 - Slew ring gear lubr. system grease level too low................................................................. 148 Wiring diagram 1 related to trouble codes G00012 and G00013 .................................................. 152 Wiring diagram 2 related to trouble codes G00012 and G00013 .................................................. 153 G00020 - Trouble Shut-Off (gate) valve (Start blocked) ...................................................................... 154 Wiring diagram related to trouble code G00020 ........................................................................... 156 View onto the VHMS settings for proximity switch 40B031 ........................................................... 157 View onto the gap of the proximity switch 40B031 ........................................................................ 157 G00060 - Fire in the power house ....................................................................................................... 158 Wiring diagram related to trouble code G00060 ........................................................................... 160 G00061 - Trouble monitoring, engine 1 speed too low ........................................................................ 161 Wiring diagram related to trouble code G00061 ........................................................................... 162 G00062 - Trouble monitoring, engine 1 speed too high ...................................................................... 163 Wiring diagram related to trouble code G00062 ........................................................................... 166 G00063 - Trouble monitoring hydraulic oil temp .................................................................................. 167 Wiring diagram related to trouble code G00063 ........................................................................... 168 G00064 - Trouble monitoring hydraulic oil level .................................................................................. 169 Wiring diagram related to trouble code G00064 ........................................................................... 171

PC4000-6D S/N 08199 and up

7

40 Troubleshooting

G00065 - Very low hydraulic oil level................................................................................................... 172 Wiring diagram related to trouble code G00065 ............................................................................ 174 G00066 - Trouble hydraulic oil temperature ........................................................................................ 175 View onto the solenoid valves related to trouble code G00066 .................................................... 177 Hydraulic oil table .......................................................................................................................... 177 G00067 - Trouble battery voltage too high .......................................................................................... 178 Wiring diagram and component location related to trouble code G00067 .................................... 179 G00069 - Trouble monitoring oil temperature gear (PTO 1) ................................................................ 180 Wiring diagram and component location related to trouble code G00069 .................................... 181 G00070 - Trouble oil temperature gear (PTO 1).................................................................................. 182 Location of the PTO gear oil level dipstick and temperature sensor 57B049 ................................ 184 G00071 - Trouble gear lubrication (PTO 1) ......................................................................................... 185 Wiring diagram related to trouble code G00071 ............................................................................ 186 G00081 - Trouble lubrication system ................................................................................................... 187 Operation cycles of the lubrication systems .................................................................................. 188 Wiring diagram 1 related to trouble code G00081 ......................................................................... 189 Wiring diagram 2 related to trouble code G00081 ......................................................................... 190 G00090 - Trouble power supply........................................................................................................... 191 G00099 - Trouble power supply........................................................................................................... 191 Wiring diagram related to trouble codes G00090 and G00099 ..................................................... 192 G00091 - Pilot control cut out .............................................................................................................. 193 View onto the lock lever and the cover of switch 20S105 ............................................................. 194 G00092 - Emergency shut-down at access ladder .............................................................................. 195 G00093 - Emergency shut-down at valve block .................................................................................. 195 G00094 - Emergency shut-down at hydraulic control panel ................................................................ 195 G00095 - Emergency shut-down in cabin............................................................................................ 195 Wiring diagram related to trouble code G00092 - G00095 ............................................................ 196 G00096 - Pilot control cut out .............................................................................................................. 197 Wiring diagram related to trouble code G00096 ............................................................................ 198 G00100 - Maintenance safety switch................................................................................................... 199 Wiring diagram related to trouble code G00100 ............................................................................ 200 G00102 - Switch off wiper.................................................................................................................... 201 G00103 - Faulty switch 20M004 .......................................................................................................... 202 Wiring diagram 1 related to trouble code G00103 ......................................................................... 204 Wiring diagram 2 related to trouble code G00103 ......................................................................... 205 G00104 - Trouble battery current......................................................................................................... 206 Wiring diagram related to trouble code G00104 ............................................................................ 207 G00105 - Trouble battery charging current too low ............................................................................. 208 G00140 - Trouble monitoring X1-1 pressure ....................................................................................... 209 Wiring diagram for the X1-1 pressure sensor 57B085-1 ............................................................... 211 G00141 - Trouble monitoring X2 pressure........................................................................................... 212 Wiring diagram for the X2 pressure sensor 57B086 ..................................................................... 214 G00143 - Trouble monitoring 61B087a................................................................................................ 215 G00144 - Trouble monitoring 61B087b................................................................................................ 215 G00145 - Trouble monitoring 61B087c................................................................................................ 215 G00146 - Trouble monitoring 61B087d................................................................................................ 215 Wiring diagram related to trouble codes G00143 - G00146 .......................................................... 217

8

PC4000-6D S/N 08199 and up

40 Troubleshooting

G00147 - Trouble monitoring gear lubrication (PTO 1) ....................................................................... 218 Wiring diagram related to trouble code G00147 ........................................................................... 220 G00148 - Trouble monitoring fuel level................................................................................................ 221 Wiring diagram and component location (31B063) ....................................................................... 223 G00149 - Trouble monitoring ambient temperature............................................................................. 224 Wiring diagram related to trouble code G00149 ........................................................................... 225 G00151 - Trouble monitoring gear (PTO) oil filter 1 ............................................................................ 226 Wiring diagram related to trouble code G00151 ........................................................................... 228 G00154 - Trouble monitoring return oil filter ........................................................................................ 229 Wiring diagram related to trouble code G00154 ........................................................................... 231 G00155 - Trouble monitoring leak oil filter ........................................................................................... 232 Wiring diagram related to trouble code G00155 ........................................................................... 234 G00159 - Trouble monitoring breather filter......................................................................................... 235 Wiring diagram related to trouble code G00159 ........................................................................... 237 G00160 - Trouble monitoring engine air cleaner 1 .............................................................................. 238 Wiring diagram related to trouble code G00160 ........................................................................... 240 G00161 - Trouble monitoring battery voltage ...................................................................................... 241 Wiring diagram related to trouble code G00161 ........................................................................... 243 G00162 - Trouble monitoring charging-/discharging current ............................................................... 244 Wiring diagram related to trouble code G00162 ........................................................................... 246 G00163 - Trouble monitoring pilot control ........................................................................................... 247 Wiring diagram related to trouble code 00163 .............................................................................. 249 G00164 - Trouble air cleaner 1............................................................................................................ 250 View onto the engine air cleaner ................................................................................................... 251 G00165 - Trouble breather filter hydraulic oil tank............................................................................... 252 Label showing temperature information and defined positions ..................................................... 253 G00166 - Trouble oil filter gear (PTO 1) .............................................................................................. 254 View onto the PTO gear oil filter with pressure sensor 57B027-1 ................................................. 255 G00169 - Trouble return oil filter hydraulic oil tank .............................................................................. 256 G00170 - Trouble leak oil filter hydraulic oil tank ................................................................................. 257 G00176 - Trouble battery voltage too low............................................................................................ 258 Alternator 52G005-1, shunt resistor 11T003, and batteries 71G001-71G004 & 13G008-13G009 ........................................................................................................................... 259 G00177 - Trouble battery charging circuit ........................................................................................... 260 G00178 - Trouble battery charging current too high............................................................................ 261 G00179 - Trouble control pressure X1-1 ............................................................................................. 262 View onto the valve cartridge block 263 G00180 - Trouble pilot pressure X2 too low ........................................................................................ 264 View onto the valve cartridge block with X2 pressure sensor 57B086 & M1.2 ............................. 265 G00181 - Trouble pilot pressure X2 too high ....................................................................................... 266 View onto the valve cartridge block with X2 pressure sensor 57B086 & M1.2 ............................. 267 G00184 - Central lubrication system empty......................................................................................... 268 G00187 - Slew ring gear lubrication system empty ............................................................................. 268 G00185 - Trouble central lubrication system ....................................................................................... 269 G00188 - Trouble slew ring gear lubrication system ........................................................................... 269 Trouble codes G00185 and G00188 - view onto the vent valve ................................................... 271 Allocation of vent valves and end-of-line switches ........................................................................ 272 Wiring diagram related to trouble codes G00185 and G00188 ..................................................... 272 G00186 - Trouble central lubrication system ....................................................................................... 273

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40 Troubleshooting

G00189 - Trouble slew ring gear lubrication system............................................................................ 273 Allocation of the vent valves .......................................................................................................... 273 Time diagram for the operation cycles of the lubrication systems CLS and SLS .......................... 274 Trouble codes G00186 and G00189 - view onto the vent valve ................................................... 275 G00207 - Engine remote oil tank 1 empty ........................................................................................... 276 G00240 - Trouble hydraulic oil temperature ........................................................................................ 277 G00242 - Engine 1 already running ..................................................................................................... 278 G00243 - Fill up fuel tank..................................................................................................................... 279 G00245 - Engine shutdown from ground ............................................................................................. 280 Wiring diagrams related to trouble code G00245 .......................................................................... 281 G00246 - Hydraulic oil temperature ..................................................................................................... 282 G00247 - Slew ring gear house break ................................................................................................. 283 G00252 - Emergency shut-down at access ladder .............................................................................. 284 G00253 - Emergency shut-down at valve block .................................................................................. 284 G00254 - Emergency shut-down at hydraulic control panel ................................................................ 284 G00255 - Emergency shut-down in cabin............................................................................................ 284 Wiring diagram related to trouble codes G00252 - G00255 .......................................................... 285 G00257 - Hydraulic oil temperature ..................................................................................................... 286 G00261 - Maintenance safety switch................................................................................................... 287 Wiring diagram related to trouble code G00261 ............................................................................ 288 G00262 - Trouble screen at hydr. cooler entry clogged....................................................................... 289 Wiring diagram related to trouble code G00262 ............................................................................ 290 G00417 - Communication failure PLC <==> VHMS controller............................................................. 291 Serial harness and ports between MTC and VHMS controller ...................................................... 291 G00420 - Connector sel error .............................................................................................................. 292 G00421 - Farm sys error...................................................................................................................... 293 G00422 - Can-net sys (J1939)............................................................................................................. 294 G00423 - Application sys error ............................................................................................................ 295 G00425 - Settings impossible to take over into the PLC ..................................................................... 296 Overview for G00425: Display (MH801) → VHMS controller → MTC .......................................... 297 G00491 - Communication failure MH800 <==> VHMS-Controller ....................................................... 298 Overview for G00491: Display (MH801) → VHMS controller ........................................................ 299

Troubleshooting by symptoms ............................................................... 301 Symptoms of the engine and related electrical system ................................................................. 301 SEL001 - Engine does not start (engine does not rotate).................................................................... 301 Wiring diagram 1 related to trouble code SEL001 ......................................................................... 303 Wiring diagram 2 related to trouble code SEL001 ......................................................................... 305 SEL002 - Engine stops while in operation ........................................................................................... 306 View onto the fuel system water separator ................................................................................... 308 SEL003 - Engine speed is hunting during boom-up movement........................................................... 309 SEL004 - Engine does not stop ........................................................................................................... 310 SEL005 - Engine lacks output (no power) ........................................................................................... 311 SEL006 - Exhaust smoke is black ....................................................................................................... 313 SEL007 - Oil consumption is excessive............................................................................................... 315 SEL008 - Oil becomes contaminated quickly ...................................................................................... 317 SEL009 - Fuel consumption is excessive ............................................................................................ 319 SEL010 - Oil is in engine coolant......................................................................................................... 321 SEL011 - Oil level rises........................................................................................................................ 323 SEL012 - Coolant temperature becomes too high (overheating)......................................................... 325 10

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40 Troubleshooting

Symptoms of the hydraulic system ................................................................................................. 327 SHY001 - All the work equipment shows lack of power or slow movement (especially the "boom up" function) ..................................................................................................... 327 SHY002 - Engine speed sharply drops or engine stalls too much....................................................... 329 SHY003 - No work equipment, travel or swing movement .................................................................. 331 SHY004 - Work equipment has too much hydraulic drift ..................................................................... 332 SHY005 - Work equipment has big time lag ........................................................................................ 334 SHY006 - Machine deviates during travel movement.......................................................................... 335 SHY007 - Hydraulic system has lack of power (energy efficiency) ..................................................... 336 SHY008 - Machine does not swing...................................................................................................... 338 SHY009 - Swing acceleration is poor .................................................................................................. 339 SHY010 - Excessive overrun when stopping swing ............................................................................ 341 SHY011 - Floating system without function ......................................................................................... 343 SHY012 - Abnormal noise coming from SRV or MRV ......................................................................... 344 SHY013 - Track tensioning system without function ........................................................................... 345 SHY014 - Ladder does not move, or slow movement ......................................................................... 346 SHY015 - Refilling arm does not move, or slow movement ................................................................ 348 SHY016 - The hydraulic driven grease pump does not move ............................................................. 349 SHY017 - Trouble pump bearing lubrication........................................................................................ 350 SHY018 - Abnormal track chain movement during digging ................................................................. 351 SHY019 - Swing parking brake without function.................................................................................. 352 SHY020 - Travel parking brake without function ................................................................................. 353 Symptoms of the mechanical system.............................................................................................. 354 SME001 - Abnormal noise is made ..................................................................................................... 354 SME002 - Abnormal noise around the PTO / hydraulic pumps ........................................................... 356 SME003 - Vibration is excessive (engine mountings) ......................................................................... 358 SME004 - Vibration is excessive (engine torsion) ............................................................................... 360 SME005 - There is a big shock when stopping swing ......................................................................... 361 SME006 - There is a big abnormal noise when moving/stopping swing ............................................. 362 SME007 - Fan hub bearing noise is abnormal .................................................................................... 364 SME008 - Abnormal noise coming from a travel gearbox ................................................................... 365 SME009 - Abnormal noise coming from the work equipment (lack of grease) .................................... 367 SME010 - Abnormal idler movement ................................................................................................... 369 SME011 - Leak at the PTO shaft seal ................................................................................................. 370 Symptoms of additional systems..................................................................................................... 372 SAD001 - Air conditioner does not work .............................................................................................. 372 View onto the A/C unit ................................................................................................................... 373 SAD002 - Air conditioner compressor clutch is burnt .......................................................................... 374 View onto the A/C compressor and its mounting .......................................................................... 375 SAD003 - Air conditioning system defective (pipes and hoses full of moisture) .................................. 376 SAD004 - Travel alarm does not sound............................................................................................... 377 Wiring diagram related to trouble code SAD004 ........................................................................... 378

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40 Troubleshooting

12

PC4000-6D S/N 08199 and up

1 SAFETY

WARNING 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.

13

Safety

CONTENTS

14

1.1

SAFETY INFORMATION .................................................................................................................... 15

1.2

OVERVIEW.......................................................................................................................................... 1.2.1 NORMAL OPERATIONS ........................................................................................................ 1.2.2 REGULAR MAINTENANCE.................................................................................................... 1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ........................................................ 1.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR .................................................................

16 16 16 16 16

1.3

SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB. ............................................................... 17

1.4

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR............................ 1.4.1 UNDERSTANDING THE MACHINE ....................................................................................... 1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ....................... 1.4.3 PREPARATIONS FOR SAFE OPERATION........................................................................... 1.4.4 FIRE PREVENTION................................................................................................................ 1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE .......................................... 1.4.6 BURN PREVENTION.............................................................................................................. 1.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS ................................................................. 1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ............................................. 1.4.9 PRECAUTIONS AT JOBSITE................................................................................................. 1.4.10 STARTING ENGINE ............................................................................................................... 1.4.11 OPERATION ...........................................................................................................................

18 18 18 18 20 22 23 24 25 26 31 32

1.5

PRECAUTION FOR MAINTENANCE ................................................................................................. 1.5.1 GENERAL PRECAUTIONS .................................................................................................... 1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................... 1.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID..................................................................

38 38 46 47

1.6

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS .......... 1.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ...................................................................... 1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS... 1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR.........................................

52 52 52 52

1.7

SPECIAL SAFETY EQUIPMENT........................................................................................................ 1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ................... 1.7.2 OBJECT HANDLING .............................................................................................................. 1.7.3 LIGHTING ............................................................................................................................... 1.7.4 WARNING BEACON............................................................................................................... 1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ..............

54 55 55 55 55 55

SPECIAL SAFETY EQUIPMENT

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Safety

Part II

40 Troubleshooting

Part II

Introduction & general information for troubleshooting Description of this troubleshooting manual In this manual you find troubleshooting information which should assist you when troubleshooting. The content of this manual is divided in 5 parts, which are titled: Part I

Safety

Part II

Introduction and general information for troubleshooting

Part III Mounting locations, connector types, and electrical standard values Part IV Troubleshooting by trouble code Part V

Troubleshooting by symptoms

Part II contains Safety Notes and Precautions which should be followed during troubleshooting work. Furthermore fundamental requirements and points to remember when troubleshooting are given. Also you find recommendations concerning the sequence of working steps, checks which should be done before troubleshooting, how to handle electric and hydraulic equipment, and how to perform basic working procedures. Part III provides you with information about mounting locations of components, different connector types as they are used in your machine, and standard values for electrical components as a quick reference. In Part IV troubleshooting charts are listed in the numerical sequence of trouble codes as they are stored in the control system. The monitoring system follows the logic of defined flow charts. If predetermined conditions occur, the VHMS displays relevant trouble codes and messages. In Part V troubleshooting charts are listed for various engine electrical, mechanical, and hydraulic problems. These charts are showing symptoms of any malfunction which the monitoring system can not detect under the particular conditions. Therefore these malfunctions are not indicated by stored trouble codes or messages via VHMS. Nevertheless the troubleshooting charts in Part IV and Part V can not cover all eventual malfunctions which may possibly occur. In such cases a general inspection of the suspected system is necessary. Furthermore, it is not necessary that you strictly follow the given troubleshooting charts in every case. It is important to find the cause for any trouble in the easiest way and in the shortest time. In most times the relevant flow chart will help you to be successful.

1.

General precautions Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1)

Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.

2)

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, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

3)

When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

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• Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 4)

When carrying out any operation with 2 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 warning signs in the operator's compartment.

5)

Only qualified workers must carry out work and operation which require license or qualification.

6)

Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.

8)

Before starting work, warm up your body thoroughly to start work under good condition.

Safety points

2.

3.

1

Good arrangement

2

Correct work clothes

3

Following work standard

4

Making and checking signs

5

Prohibition of operation and handling by unlicensed workers

6

Safety check before starting work

7

Wearing protective goggles (for cleaning or grinding work)

8

Wearing shielding goggles and protectors (for welding work)

9

Good physical condition and preparation

10

Precautions against work which you are not used to or you are used to too much

Preparations for work 1)

Before adding oil or making any repairs, park the machine on hard and level ground. Isolate the machine according to local regulations.

2)

Before starting work, make sure that the work equipment is lowered to the ground. Also make sure that the maintenance safety switch (S58) is switched OFF and locked with a padlock. In addition hang up warning signs.

3)

When disassembling or assembling, support the respective unit with blocks, jacks, or stands as necessary before starting work.

4)

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 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits.

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40 Troubleshooting

3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused 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 operated. 11) 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. In addition, check that connecting parts are correctly installed. 12) When assembling or installing parts, always tighten them to the specified 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. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) 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. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

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Precautions when carrying out any operation When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation. 1.

Precautions when carrying out removal work

•

If the coolant contains antifreeze, dispose of it correctly.

•

After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.

•

When draining oil, prepare a container of adequate size to catch the oil.

•

Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling.

•

To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.

•

Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.

•

Check the number and thickness of the shims, and keep in a safe place.

•

When raising components, be sure to use lifting equipment of ample strength.

•

When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.

•

Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal.

•

After disconnecting any piping during disassembly operations make sure to use the correct plugs and seals when connecting the piping again.

2.

Precautions when carrying out installation work

•

Tighten all bolts and nuts (sleeve nuts) to the specified torque.

•

Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.

•

Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.

•

Bend the cotter pins and lock plates securely.

•

When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive.

•

When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant.

•

Clean all parts, and correct any damage, dents, burrs, or rust.

•

Coat rotating parts and sliding parts with engine oil.

•

When press fitting parts, coat the surface with anti-friction compound (LM-P).

•

After fitting snap rings, check that the snap ring is fitted securely in the ring groove.

•

When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.

•

When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook.

•

When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure.

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40 Troubleshooting

3.

Precautions when completing the operation 1) Refilling with coolant, oil and grease • If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. • If any engine component has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassembling the parts. For details, see “Bleeding air”. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

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40 Troubleshooting

Part II

Fundamental requirements for troubleshooting Technical documentation The personnel in charge of troubleshooting must have permanent and easy access to the following appropriate and up-to-date documents of the relevant hydraulic excavator: •

Electric Circuit Diagram

•

Hydraulic Circuit Diagram

•

Operation & Maintenance Manual

•

Service Manual

•

Cross-Reference Table (in process)

•

Cummins Troubleshooting and Repair Manual for the QSK60 Engine (SDA 12V 160 Komatsu Engine)

•

Inspection and Maintenance Manual of the equipped Fire Suppression System (optional equipment)

•

Inspection and Maintenance Manual of the equipped Air Conditioning System

Without the above documents troubleshooting is ineffective and unreliable! Tools For proper troubleshooting and subsequent repairs it is essential to have access to complete facilities which include appropriate measuring instruments as well as necessary tools for the repair of a hydraulic excavator. For troubleshooting, testing, and repair the following tools are obligatory. Multi Tester

Electrical Cable Set

The cable set includes: 732 702 40 732 703 40 732 704 40 732 705 40 732 706 40 732 707 40

P/N 232 756 40

68

Measuring cable Measuring cable Probe tip Probe tip Crocodile clip Crocodile clip

P/N 232 496 40

Clamp-On Ammeter

Deutsch T-Box

CAN T-Box

P/N 232 756 40

P/N 232 762 40

P/N 942 136 40

PC4000-6D S/N 08199 and up

Part II

40 Troubleshooting

Magnetic Stick

Insulation Pliers

Deutsch Crimp Pliers

P/N 232 712 40

P/N 232 663 40

P/N 793 729 73

Deutsch Test-Cable

Cable Stripping Knife (4 - 16 mm)

Digital Dial Gauge

In preparation

P/N 232 699 40

P/N 794 537 73

Infrared thermometer

RPM Tester

Digital hydr. test gauge

P/N 232 665 40

P/N 232 551 40

P/N 232 720 40

CoDeSys HMI software

Cables for CoDeSys & VHMS

VHMS techn. analysis tool box

Standard LAN cable

CoDeSys HMI

for CoDeSys (2 m), without P/N

Basis Software Tool (Visualization)

VHMS download cable (serial connection)

P/N 941 825 40

PC4000-6D S/N 08199 and up

P/N 894 580 40

P/N 792 504 73

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40 Troubleshooting

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Deutsch Removal Tools

Standard Deutsch removal tools: 932 634 40 932 632 40 932 633 40 932 631 40

1.00 mm2 1.50 mm2 1.00 - 2.00 mm2 3 - 8 - 16 mm2

Also refer to the next chart

Reference Guide for Deutsch removal tools

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40 Troubleshooting

Personnel Only authorized and trained personnel s hould perform troubleshooting and the resulting repairs. Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of the hydraulic equipment. Work on the Fire Suppression System must be carried out only by certified persons.

Points to remember when troubleshooting Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure.

It will also cause a waste of man hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2.

Points to ask user or operator: 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?

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3.

Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment 3) Other maintenance items can be checked externally, so check any item that is considered to be necessary.

4.

Confirming failure • Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation etc. When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.

5.

Troubleshooting • Use the results of the investigation and inspection in items 2-4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information.

6.

Measures to remove the root cause of any failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

72

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Sequence of events in troubleshooting

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Checks before troubleshooting Item

Lubricating oil, Coolant

Inspection

Hydraulic, mechanical equipment

Electrical compoments

74

Remedy

1.

Check of level and type of fuel

-

Add fuel

2.

Check of fuel for foreign matter

-

Clean and drain

3.

Check of fuel filter

-

Replace

4.

Check of hydraulic oil level

-

Add oil

5.

Check of hydraulic oil strainer

-

Clean and drain

6.

Check of swing machinery oil level

-

Add oil

7.

Check of level and type of engine oil (in oil pan)

-

Add oil

8.

Check of coolant level

-

Add coolant

9.

Check of dust indicator for clogging

-

Clean or replace

-

Replace

10. Check of hydraulic oil filter

Electrical equipment

Criterion

1.

Check of battery terminals and wiring for looseness and corrosion

-

Retighten or replace

2.

Check of alternator terminals and wiring for looseness and corrosion

-


3.

Check of starting motor terminals and wiring for looseness and corrosion

-


1.

Check for abnormal noise and smell

-

Repair

2.

Check for oil leakage

-

Repair

3.

Bleeding air

-

Bleed air

1.

Check of battery voltage (with engine stopped)

22 - 24V

Replace

2.

Check level of battery electrolyte

-

Add or replace

3.

Check of wires for discoloration, burn, and removal of the isolation cover

-

Replace

4.

Check for released wire clamp and dropping wire

-

Repair

5.

Check of wires for wetness (in particular check connectors and terminals for wetness)

-

Disconnect the connectors and dry

6.

Check for broken or corroded fuses

-

Repair

7.

Check alternator voltage (engine running at over half throttle)

8.

Check battery relay for operating sound (when starting switch is turned ON or OFF)

After operating for several minutes: 27.5 - 29.5V

Replace

-

Replace

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Handling of electric equipment and hydraulic components Points to remember when handling electric equipment 1.

Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.

2.

Main failures occurring in wiring harness

1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

2) Defective criming or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

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4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if highpressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air. 3.

Disconnecting connectors 1)

When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. Never pull with one hand.

2) •

76

When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.

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•

When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. If the connector is twisted up and down or to the left or right, the housing may break.

3)

Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1.

Be careful of the operating environment Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.

2.

Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.

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Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.

4.

Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

5.

Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

6.

Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7.

Cleaning operations After repairing the hydraulic equipment (pump, control valve etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 µ) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

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General working procedures 1.

Air bleeding of various hydraulic parts

A)

Air bleeding from the hydraulic pumps The air bleeding procedures for the hydraulic pumps are described in the following manuals. Refer to these manuals as necessary.

•

Operation & Maintenance Manual, section HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER

•

PARTS & SERVICE NEWS AH01513 (latest version) Precautions for air bleeding from the hydraulic pumps Before starting the air bleeding work explained above, run the engine at low idle for 10 minutes.

B)

Air bleeding from hydraulic cylinders 1)

Start the engine and keep it running at low idle for 5 minutes.

2)

Running the engine at high idle raise and lower the respective cylinders 12 to 15 times. Be careful not to apply the relief pressure, stopping the piston rod approx. 100 mm before its stroke end.

3)

Apply the relief pressure smoothly by extending the piston rod to its stroke end and with the engine running at high idle.

4)

For bleeding air from the arm cylinder and bucket cylinder, follow the same steps explained in items 2) and 3) above.

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Cylinder bypass test The cylinder bypass test can be performed in order to check if a hydraulic cylinder has an internal leakage. A cylinder with an internal leakage generates a higher temperature (at operating temperature of the machine) than a hydraulic cylinder which has no internal leakage. For a bypass test at mining machines always use an infrared thermometer, refer to section Fundamental requirements for troubleshooting in this manual. Refer to chapter Safety and observe all safety notes for the following procedure.

Procedure 1. Before starting the bypass test, always make sure that the hydraulic circuit which is to be tested, has reached the operating temperature (T3). 2. Bring the concerning cylinders in their end position → rod end completely moved in or out. 3. Keep up the system pressure in the concerning hydraulic circuit for approx. 10 minutes. 4. During these 10 minutes, measure the cylinder temperature in the piston area of both cylinders, using an infrared thermometer. If any cylinder seal package is leaking, hydraulic oil is now pressed through this leakage, which causes the temperature to increase (90°C and higher) within a few minutes.

Case 1 Seal package is leaking in 1 cylinder only

Seal package is leaking in both cylinders

Defective cylinder: Temperature increase during the test, increased temperature approx. 90°C

Both defective clinders: Temperature increase during the test, increased temperature approx. 90°C

Proper clinder: No temperature increase during the test, normal temperature approx. 70°C

-

Remark: The hydraulic oil will heat up at the MRV, not in the proper cylinder.

80

Case 2

Remark: A strong drift occurs.

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Information about MTC & Nodes 1.

Outline of the MTC and its connector locations During troubleshooting always make sure to use your wiring diagrams which are assigned to your machine. Due to variable requirments in many aspects, the samples of wiring diagrams, MTC & nodes shown in this manual can not meet the actual state of each machine in every case. Inputs and outputs of MTC & nodes are not identical in construction. The shown connector locations in the below illustration are exemplarily. MTC connectorsRH

MTC connectors LH

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Part II

General description of the MTC For a general description of the MTC refer to your SERVICE MANUAL:

3.

Chapter

14. VEHICLE HEALTH MONITORUNG SYSTEM

Section

14.7 GLOBAL LAYOUT OF THE MTC CONTROL SYSTEM

Information about the LED indications at the MTC

*The LEDs are showing operation conditions and they also blink out those trouble codes which cause a shutdown. The LED function is described in the OPERATION & MAINTENANCE MANUAL:

4.

Chapter

3. OPERATION

Section

3.8.3 MASTER TURBO CONTROLLER MTC - LED INDICATIONS

Information about the ICN-D node Intelligent Can Node - Digital (Dashboard) with max. 64 free programmable in- and outputs.

For further information also refer to the SERVICE MANUAL, chapter 14. VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM

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View onto an ICN-D node without wiring

1.

ICN-D node

2.

DIP switches

3.

Status LEDs

4.

Allocation of the Status LEDs

5.

Connector X0 (power supply 24V, ground, CAN bus 3x)

6.

Connector X1 - X8 (in- & outputs)

7.

Ground receptacle

For details about the DIP switches refer to section 6. DIP switches at the ICN-D and ICN-V nodes in this manual.

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View onto the Status LEDs at the ICN-D node

1.

Allocation of the Status LEDs

2.

ICN-D node unit

3.

Status LED (4x)

General information on the LED control The node status (ICN-D) is indicated by the following 4 LEDs. •

PWR LED (red = RESET, green = normal operation)

•

CAN LED (CAN-Run and CAN-Error)

•

ERR LED (red and green)

•

DIAG LED (red and green)

Overview over all possible LED conditions (all LEDs red & green) LED

PWR

State

Meaning

OFF red green

Indication of Logic Power Supply and Operational State. Vcc not ON! System in RESET condition System RUNNING Indication of CAN Communication.

CAN

ECU ERR ECU DIAG

84

green blinking green single flash green ON red OFF red ON

Pre-operational Stopped Operational No error in the CAN bus CAN bus OFF

ERR + DIAG OFF ERR green ON ERR red ON ERR red ON + DIAG red ON ERR green + DIAG red blinking alternately DIAG green blinking

No errors or warnings present Internal warning present Internal error present An internal trouble code is set An internal trouble code is set Internal error or warning present (depending on the state of the ERR LED)

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40 Troubleshooting

Information about the ICN-V node Intelligent Can Node - Variable (Valve) with max. 8 variable free programmable in- and outputs. The ICN-V node box may contain 1 or 2 node units. Each node unit is connected with a 55-pin central connector. View onto an ICN-V node

1.

ICN-V node box (dual unit)

2.

V-node connector, 55 pins (LH)

3.

V-node connector, 55 pins (RH)

4.

V-node socket, 55 pins

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View onto an open ICN-V node and its DIP-switches

86

1.

ICN-V node, taken out of the node box

2.

DIP-switches of an ICN-V node

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40 Troubleshooting

DIP switches at the ICN-D and ICN-V nodes

General information 1.

The DIP switches 1 - 7 define the node number (binary), which is node #17 in the above illustration.

2.

The DIP switches 8 - 10 define the CAN bus transfer speed (kbaud).

3.

The adjustment principle and function of the DIP switches is the same for the ICN-V and ICN-D nodes.

Note •

The DIP switches of a new node unit are pre-adjusted ex factory.

•

If the DIP adjustment needs to be rechecked e.g. for troubleshooting, refer to he CoDeSysy Visualization or to the Wiring Diagram. The individual patterns of the DIP switches are shown there for each node unit.

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Sequence of the CAN nodes at the CAN bus In case of a multiple trouble, the VHMS monitor displays only one faulty node. The faulty node which is closest to the MTC is displayed first. 1

The nodes in this direction are displayed first: MTC → Hydraulic tank

2

The nodes in this direction are displayed thereafter: MTC → operator‘s cab

Refer to the following chart, which lists the nodes in their sequence at the CAN bus. Component code

Component type

Location

20K309

ICN-D

Operator‘s cab

20K310

ICN-V

Operator‘s cab

11K301

MTC

Cab base

11K302

ICN-D

Cab base

11K303

ICN-V

Cab base

11K304

ICN-V

Cab base

11K305

ICN-V

Cab base

51K317

ICN-D

Machinery house - engine room

51K318

ICN-V


51K319

ICN-V


56K314

ICN-D

Machinery house - pump area

56K315

ICN-V


56K316

ICN-V


40K311

ICN-D

Hydraulic tank

40K312

ICN-D

Hydraulic tank

40K313

ICN-V

Hydraulic tank

2

1

Hint for troubleshooting The above system provides an advantage for effective troubleshooting. In case of an eventual CAN bus interruption use the CAN testbox and search for the interruption in the line from the displayed CAN node towards the MTC.

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Basics about „How to crimp” Stripping a wire for use with the HDT 48 crimp tool 1. Choose the correct wire cross section [mm2] respectively AWG for the contact being used. 2. Measure from the end of the wire the recommended strip length according to the contact size. 3. Place the wire into the stripping tool at the recommended strip length. Strip the wire according to stripping tool instructions. 4. After stripping, a small piece of the insulation shouldcome off.

5. Check for any broken strands or for a dent in the wire. If either exist, the wire is damaged and should be cut and stripped again. 6. Measure the exposed strands to be sure the crimp length is correct.

View onto the Deutsch crimp tool HDT 48

Crimp range: 0.35 - 3.0 mm2 / AWG 12 - 22

Basic adjustment of the wire size at the Deutsch crimp tool HDT 48

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Wire cross section units in mm2 and AWG The above scale of the crimping tool uses the units mm2 and AWG (American Wire Gauge). Free conversion charts and/or free calculators to convert between mm2 and AWG are open to the public. Refer to the following sample illustration of an AWG gauge.

Crimping instructions (for Deutsch crimp tool HDT 48) 1. Strip the insulation from the wire. Refer to Stripping a wire for use with the HDT 48 crimp tool 2. Raise the selector knob and rotate it until the arrow is aligned with the wire gauge to be crimped. Refer to illustration Z 28059-2a

3. Loosen the lock nut (1) and turn the adjusting screw (2) in until it stops.

4. Insert a contact into the insertion point (3), turn the adjusting screw clockwise out until the contact is flush or a bit above flush with the indentor cover. Tighten the lock nut.

5. Insert the wire into the contact (4). The contact must be centered between the indicators. Close the handles until the handles stop. 6. Release the handles and remove the crimped contact.

7. After completion, the correct assembly can be checked visually. When stripped, the insulation should expose a conductor length that will pass beyond the inspection hole in the contact. There should be about 0.63 to 2.54 mm of free conductor between the contact and the insulation on the wire.

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After crimping, check for: 1.

Damaged wire strands

2.

Missing wire strands

3.

Wire strands not entering the contact barrel or splayed wires

4.

Wire not inserted to the proper depth in the contact, not visible through the inspection hole

If any of the above conditions exists, please discard the contact, re-cut and strip the wire, and start the crimping process over.

Proper crimp

Crimp is OK if: 1.

Conductor strands must be visible through the inspection hole.

2.

Crimp centered between the inspection hole and the crimp barrel end.

3.

Insulation gap: 0.66 to 2.54 mm

For more detailed crimp specifications refer to the instructions which are delivered with the crimp tool.

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Cable colour identification Colour (English)

Colour (German)

Short Marks Standard IEC 60757*

German (current)

German (previous)

BK

SW

sw

Braun

BN

BR

br

Rot

RD

RT

rt

Orange

Orange

OG

OR

or

Yellow

Gelb

YE

GE

ge

Green

Grün

GN

GN

gn

Blue

Blau

BU

BL

bl

Black

Schwarz

Brown Red

Violet

Violett

VT

VI

vi

Grey

Grau

GY

GR

gr

White

Weiß

WH

WS

ws

Pink

Rosa

PK

RS

rs

Turquoise

Türkis

TQ

TK

tk

* IEC: International Electrotechnical Commission

Refer to the above table if the identification of cable colours in wiring diagrams may be unclear due to different existing systems of colour codes.

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Part III

Mounting locations, connector types and electrical standard values 1.

Component location

1.1 View onto the superstructure

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Legend for illustration Z 27752 - View onto the superstructure (1)

Hydraulically operated access ladder

(2)


(2a)


(3)

Lift cylinder for access ladder

(4)

Batteries, location below the catwalk (batteries G1-G4)

(5)

Control switch for access ladder

(6)

Emergency engine shut down switch

(7)

Fuel tank

(8)

Cab base, contains the electronic components of the VHMS system, the electrical switch boards, and the batteries G8 & G9

(9)

Side window of operator’s cab

(10)

Swing circle guard

(11)

Emergency escape ladder

(12)

Engine air cleaners

(13)

Exhaust mufflers

(14)

Air duct

(15)

Extinguishing agent tank assemblies, only on machines equipped with a fire detection, actuation and suppression system

94

(16)

Counterweight

(17)

Main control valves & remote control valves with high pressure in-line filters

(18)


(19

Return oil filters and leak oil filter

(20)


(21)

Swing machinery

(22)


(23)

Swing circle pinion Lubrication System (SLS)

(24)


(25)


(26)


(27)


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1.2 Location of engine electrical parts (1)

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1.3 Location of engine electrical parts (2)

96

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1.4 Location of hydraulic components (I)

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Legend for illustration Z 21632f Solenoid valves (57Q505)

Slew parking brake operating pressure

(57K506a-1) Cooler fan RPM control, minimum speed (57K506b-1) Cooler fan RPM control, medium speed (57Q516)

Travel parking brake operating pressure

(57K517)

Qmin control (pump control system)

(57K517a)

½ Qmax (reduced oil flow at cold oil [below T2])

(57K553-1)

"Reduction pre-load pressure PTO gear lubrication - oil cooler”

(57K561-1)

X1 pressure, pumps 1 – 4

(57K620)

Hydraulic swing brake, operating pressure

(57Q623a)

Ladder, raise

(57Q623b)

Ladder, lower

(57Q624a)

Refilling arm, raise

(57Q624b)

Refilling arm, lower

(57Q624c)

Refilling arm stop, hold position

(57Q625)

Ladder, fast movement

(57K626)

Flow reduction swing (pump 1)

(57Q627)

Proportional swing brake pressure

(57K630)


(57K631)


(57K636)

Engine radiator fan speed (proportional valve)

(57K646)

Energy Efficiency (pump No. 2 + No. 4)

(57K647)


(57K648)


Filters (33)

Pilot pressure

(34.1)

Hydraulic oil cooler fan drive

(34.2)

Engine radiator fan drive

(36)

PTO gear lubrication

Miscellaneous (29)

Pressure relief valve – PTO gear lubrication

(31.1)

Pressure relief valve – hydraulic oil cooler fan drive, with solenoid valve 57K506a/b-1 for fan RPM control

(31.2)

Pressure relief valve - engine radiator fan drive, with proportional solenoid valve 57K636-1 for fan RPM control

98

(47)


(124)

Pressure relief valve medium speed cooler fan

(152)

Pressure reducing valve – Energy Efficiency (X3 ~ 18 bar, pre-adjustment)

(252.1)


(252.2)


(253.1)

Change-over valve – electronic pump regulation or hydraulic constant regulation

(253.2)

Pressure reducing valve – hydraulic constant regulation

(255.4)

Pressure reducing valve – ½ Qmax

(257.1)

Pressure relief valve – safety valve for travel brake / track tensioning system (55 bar)

(258.3)

Pressure relief valve – safety valve for hydraulic access ladder (70 bar)

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1.5 Location of hydraulic components (II)

Legend for illustration Z28188 (40B015)

Temperature sensor

(57B049-1)

Gear oil temperature sensor

(59B162)

Pressure sensor suction oil tank

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1.6 Location of the remote control valves

100

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Legend for illustration Z 21636e - Location of the remote control valves Remote control unit schematic code

Directional solenoid


61K540

Function BHA

FSA Boom raising

61K573 61K541

Boom lowering

61K538

Stick extending

Clam closing

Stick retracting

Clam opening

Bucket filling

Bucket filling

Bucket dump

Stick extending

61K572 61K539 (15.1) 61K536 61K571 61K537 61K534

L.H. crawler reverse 61K570

61K535

L.H. crawler forward

61K524

L.H. swing 61K565

61K525

R.H. swing

61K522


(14.1) 61K523

Bucket emptying

61K520

Boom raising 61K563

61K521

Boom lowering

61K526

R.H. swing 61K566

61K527

L.H. swing

61K532 (14.2)

Boom lowering

Bucket filling

Boom raising

Boom raising

61K569 61K533 61K530


61K531

Stick retracting

61K546

Boom raising 61K576

61K547

Boom lowering

61K544


61K545

Bucket emptying

(15.2) 61K542


61K543

Stick retracting

61K528

R.H. crawler forward 61K567

61K529

PC4000-6D S/N 08199 and up

R.H. crawler reverse

101

40 Troubleshooting

Part III

1.7 Location of the high pressure sensors

Legend for illustration Z28189

102

(61B087a)

Pressure sensor – Input pressure control block I

(61B087b)

Pressure sensor – Input pressure control block II

(61B087c)

Pressure sensor – Input pressure control block III

(61B087d)

Pressure sensor – Input pressure control block IV

PC4000-6D S/N 08199 and up

Part III

40 Troubleshooting

1.8 View onto the SLS and CLS grease barrel and the lubrication cycle components

PC4000-6D S/N 08199 and up

103

40 Troubleshooting

Part III

Legend for illustration Z 28063-6 View onto the SLS and CLS grease barrel and the lubrication cycle components

(1)


(2)

Flow control valve (19 - 21 double strokes / min)

(3)


(4)

Main pump control solenoid valve (pump on / off)

(5)


(6)

Hydraulic oil supply line (60 bar, X4 pressure)

(7)


(8)


(9)

Lubricant pressure release solenoid valve

(10)


(11)


(12)

End-line switch

(13)

Lubricant injector

(14)

Lubricant feed line to swing ring gear

(15)

Lubricant pump

(16)

Lubricant points (bearings) CLS only

(17)

Lubricant container

(18)


(19)


(20)

Test port lubricant pump drive pressure

(21)


(22)

Dummy wheel, SLS only

104

PC4000-6D S/N 08199 and up

Part III

40 Troubleshooting

1.9 View onto the cab base with electrical components

PC4000-6D S/N 08199 and up

105

40 Troubleshooting

Part III

Legend for illustration Z 27364 - Cab base with electrical components

106

(1)

Resistor and diode array (11R005, 11R013, 11R016 and 11R017)

(2)

Node, type ICN-D (11K302)

(3)


(4)

Node, type ICN-V (11K305)

(5)

Dual node, type ICN-V (11K303/11K304)

(6)

Controller battery (13G008)

(7)

Controller battery (13G009)

(8)

VHMS controller (10K300)

(9)

Battery main switch (71Q002) for controller batteries

(10)

Electronic load limiting control (RC4-4)

PC4000-6D S/N 08199 and up

Part III

40 Troubleshooting

1.10 Hydraulic oil tank - Location of electrical components

PC4000-6D S/N 08199 and up

107

40 Troubleshooting

Part III

Legend for illustration Z26983 - Hydraulic oil tank

108

40B004

Hydraulic oil level sensor (minimum level indication)

59B015

Hydraulic oil temperature sensor

40B050

Hydraulic oil level sensor (refill level indication)

40B105

Hydraulic oil level - pressure transducer

59B162

Hydraulic oil level - pressure transducer

40B163

Pressure return-oil chamber - pressure transducer

40B164

Pressure leak-oil chamber - pressure transducer

40B165

Pressure oil cooler - pessure transducer

40B166

Pressure pre-load (back pressure) valve - pressure transducer

40G018

Hydraulic oil transfer pump

40B031

Proximity switch for shut-off gate valve

40B267

Thermostat (TT only, hydraulic oil pre-heating)

PC4000-6D S/N 08199 and up

Part III

40 Troubleshooting

1.11 Hydraulically operated access ladder

PC4000-6D S/N 08199 and up

109

40 Troubleshooting

Part III

Legend for illustration Z 27964 - Hydraulically operated access ladder

(A)


(B)


(1)

Stop bar

(2)


(3)

Hydraulic cylinder

(70B091)

Monitor and control sensor This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (70B122) fails to function properly, the sensor (70B091) prevents unintended movement of the ladder.

(70B122)

Safety sensor, located on ladder pivot bracket Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position.

(70S084)


(70S084a)

Safety switch for emergency lowering of the access ladder. When the chain is being pulled down with the engine running, the pilot control system is made inoperative preventing further movement of the shovel.

110

PC4000-6D S/N 08199 and up

Part III

2.

40 Troubleshooting

Overview connector types and connector pin numbers The terms male and female refer to the connector pins, while the terms male housing and female housing refer to the mating portion of the connector housing parts. Male (female housing)

Female (male housing)

2 pins DT04-2P (Deutsch)

2 sockets DT06-2S (Deutsch)





PC4000-6D S/N 08199 and up

111

40 Troubleshooting

Part III

31-pole connector with aluminium housing

21-pole connector with plastic housing

Grease barrel connector

CAN bus connector

CAN feed-through into node box

Deutsch connectors HD 34/36-18-8-S…

Picture shows socket rear insert.

112

PC4000-6D S/N 08199 and up

Part III

40 Troubleshooting

Deutsch connectors HD 34/36-18-14-S… Picture shows socket rear insert.




PC4000-6D S/N 08199 and up





113

40 Troubleshooting

3.

Part III

Standard value table for electrical components Used abbreviations

Pre-lube oil pressure switch

Engine cold start aid solenoid valve

51B110

52B093-1

52Q502a-1 52Q502b-1

Inspection method Measure resistance Measure resistance Measure resistance

Air intake temperature sensor

52B064-1

If the condition is within the range shown in the table below, it is normal Between (1) - (2)

8.0 ± 2.0Ω

If the condition is within the range shown in the table below, it is normal.

Between (1) - (2)

850 ± 50Ω

If the condition is within the range shown in the table below, it is normal. Between (1) - (2)

Refer to: PT100 temperature charts



Measure voltage

52B018-1 52B019-1

Between (1) - (2)

Between (1) - (2)

min. 1MΩ

1) 2) 3) 1) 2) 3)

38 ± 3Ω

1) 2) 3) 1) 2)

Between (1) - (2)

20S001 OFF Disconnect connector Insert T-box Pick up adjustment: refer to S/M 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box

6)

7)

Filters: clogged

0V

22 - 24V

20S001 OFF Disconnect connector Insert T-box

20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at the T-box Engine high idle

3) 4) 5)

Between (1) - (2)

114

1) 2) 3) 4)


Engine air filter clogging sensor [N.O. type]

1) 2) 3)

Measure resistance

Engine related parts

Engine speed sensor

31Q599

Measurement conditions

Judgement table

Measure resistance

Fuel tank shut off solenoid valve

Component code

Engine Normally Closed Normally Open Main key switch 20S001 Service Manual Electrical test box for Deutsch connectors Electrical test box for the CAN bus

Component name

System

Eng N.C. N.O. 20S001 S/M Deutsch T-box CAN T-box

PC4000-6D S/N 08199 and up

Inspection method

Component code

40 Troubleshooting

Component name

System

Part III

57B021-1

Measure voltage


Coolant cooler fan filter clogging sensor [N.O. type]

Between (1) - (2)

Between (1) - (2)

Measure voltage

63B103-1

22 - 24V

Between (1) - (3) Between (1) - (2)

22 - 24V 22 - 24V

→ without oil Between (1) - (3) Between (1) - (2)

22 - 24V 0V

If the condition is within the range shown in the table below, it is normal. Engine oil level sensor (pressure sensor)

63B106-1

Measure voltage


0V


Engine remote oil tank level sensor [N.C. type] → with oil

Between A (1) - C (4) Between B (2) - C (4)

22 - 24V 0.8 - 1.0V

Between B (2) - C (4)

1.0 - 6.0V

Measure voltage


31B063

Measure current

Fuel level sensor (pressure sensor)

PC4000-6D S/N 08199 and up


Judgement table

Between B (2) - A (1) Between A (1) - C (3)

22 - 24V 0.8 - 1.0V

Between C (3) - C (3)

4 - 20mA

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Eng OFF 7) Engine high idle 8) When filter clogged differential pressure >5bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine OFF 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine OFF 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine OFF

6)

Engine high idle

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine OFF

7)

Engine high idle

115

Inspection method

Part III

Component code

Component name

System

40 Troubleshooting


Judgement table

Abient temp sensor

Measure voltage Measure resistance

If the condition is within the range shown in the table below, it is normal. Between (C) - (B)

Refilling arm solenoid valve → enable

57K553-1

57Q624a

57Q624b

57Q624c

Measure resistance

0V

Start engine Engine high idle

1) 2)


1) 2) 3) 1) 2) 3) 4) 5)

If the condition is within the range shown in the table below, it is normal. Between (C) - (B)

Refer to PT100 temperature charts






Between (1) - (2)

Between (1) - (2)

Between (1) - (2)

Between (1) - (2)

Between (1) - (2)

min. 1MΩ

1) 2)


1) 2)

1) 2)

1) 2) 3)

20 ± 1.0Ω

35 ± 1.0Ω

3)

3)

20 ± 1.0Ω

20S001 OFF Insert T-box 20S001 ON Open terminals 1 & 2 at T-box Engine OFF Engine high idle When filter clogged, switch point >0.5bar

3)

23 ± 1.0Ω


6) 7) 22 - 24V

Measure resistance

Refilling arm solenoid valve → down

57B027-1



1) 2)

3)

Measure resistance

Refilling arm solenoid valve → up

57B049-1

4.5 ± 0.5Ω

Measure resistance

PTO lube oil temperature sensor

PTO preload pressure solenoid valve

Refilling arm

57B017-1

Between (R) - (L)

Between (1) - (2)

PTO lube oil filter clogging sensor

116

13B090


Measure resistance

PTO & related parts

PTO lube oil pressure switch [N.C. type]

71T003

When the engine is running (high idle) 27.5 - 29.5 V Remark: If the battery is cold, or after starting in cold areas, the voltage may not increase for a time.

Measure resistance

Shunt resistor

52G005-1

Measure voltage

Alternator → between alternator terminal D+ and chassis

Measure resistance



1) 2) 3) 1) 2) 3)

20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box

PC4000-6D S/N 08199 and up

Refilling arm limit switch [N.O. type] → arm in down position

Inspection method

Component code

Component name

40 Troubleshooting

55B023

→ arm in up position

Between (1) - (2) Between (1) - (3)

22 - 24V 0V

Between (1) - (3)

22 - 24V

Ladder

Down: 70B091

Ladder solenoid valve → lower Ladder solenoid valve → fast

Hydraulic system

Ladder solenoid valve → raise

57Q623b

57Q625

57Q623a

Swing parking brake solenoid valve

57Q505

Oil cooler fan drive solenoid valve

57K506a-1 57K506b-1

Travel parking brake solenoid valve

Qmin solenoid valve

57Q516

57K517

PC4000-6D S/N 08199 and up

Measure Measure Measure Measure Measure Measure Measure resistance resistance resistance resistance resistance resistance resistance

Ladder limit switch [N.O. type]

Measure voltage

If the condition is within the range shown in the table below, it is normal. Up: 70B122


Judgement table

If the condition is within the range shown in the table below, it is normal. Measure voltage

Refilling arm

System

Part III

Between (A) - (B) Between (A) - (C)

22 - 24V 0V

Between (A) - (C)

22 - 24V


20 ± 1.0Ω


35 ± 1.0Ω


20 ± 1.0Ω


20 ± 1.0Ω


22 ± 1.0Ω


30 ± 1.0Ω


35 ± 1.0Ω

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6) Engine OFF 7)

Engine high idle

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6) Engine OFF

7)

Engine high idle

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box

117

Inspection method Measure resistance

57K517a

Slew brake proportional solenoid valve

57K626

Between (1) - (2)

35 ± 1.0Ω

1) 2) Between (1) - (3)

22 - 24V

3) 4)

If the condition is within the range shown in the table below, it is normal. Between (1) - (2) at the solenoid

20 ± 1.0Ω

Between (1) - (2) or at the X2 board

670 ± 10mA 11X_56 pin 17

6)



Between (1) - (2)

20 ± 1.0Ω

Between (1) - (2)

Between (1) - (2)

20 ± 1.0Ω

1) 2) 3)

35 ± 1.0Ω

1) 2) 3)

35 ± 1.0Ω

1) 2) 3)

If the condition is within the range shown in the table below, it is normal. Between (1) - (2) 11X_56 pin 18

1) 2) 3)


1) 2) 3) 4) 5)


57Q627

1) 2) 3)

Measure Measure resistance resistance

Slew flow reduction solenoid valve

57K620


Measure resistance

Hydraulic system

Hydraulic brake (emergency)

40K601


Judgement table

Measure resistance

Oil cooler preload pressure solenoid valve

57K561-1

Measure current

Electronic pump control solenoid valve

Measure current/resistance

Measure voltage

Qmax ½ solenoid valve

Part III

Component code

Component name

System

40 Troubleshooting

Output 11T016 - R2 350 - 370mA

1) 2) 3) 4) 5)

Fixed pump flow solenoid valve (Pump 3) Coolant fan solenoid valve

118

57K630

57K631

57K636-1

Measure resistance

Fixed pump flow solenoid valve (Pump 1)


Measure Measure resistance resistance

6) 7)


Between (1) - (2)

Between (1) - (2)

35 ± 1.0Ω

35 ± 1.0Ω

1) 2) 3) 1) 2) 3) 1) 2)

Between (1) - (2)

10 ± 1.0Ω

3)

20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at T-box Engine high idle 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at T-box Engine high idle Press pedal 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box

PC4000-6D S/N 08199 and up

Remote control solenoid valve



61K527 61K528 61K529 61K530 61K531 61K532 61K533 61K534 61K535 61K536 61K537 61K538 61K539 61K540 61K541 61K542 61K543 61K544 61K545 61K546 61K547

PC4000-6D S/N 08199 and up

Inspection method Measure Measure resistance resistance


61K520 61K521 61K522 61K523 61K524 61K525 61K526

Measure resistance

Remote control proportional solenoid valve

61K570 61K571 61K572 61K573 61K574 61K575 61K576

Measure resistance

Remote control proportional solenoid valve

61K563 61K564 61K565 61K566 61K567 61K568 61K569

Measure resistance

57K648


Measure resistance

Energy efficiency solenoid valve (Pump 1)

Measure resistance

57K647

Measure resistance

Hydraulic system

Energy efficiency solenoid valve (Pump 3)

57K646

Judgement table


Measure resistance

Energy efficiency solenoid valve (Pump 2 & 4)

Component code

40 Troubleshooting

Component name

System

Part III

Between (1) - (2)

20 ± 1.0Ω


Between (1) - (2)

20 ± 1.0Ω

20 ± 1.0Ω


24 ± 1.0Ω


24 ± 1.0Ω


20 ± 1.0Ω


20 ± 1.0Ω


20 ± 1.0Ω


20 ± 1.0Ω


1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box






119

Inspection method

Part III

Component code


Judgement table


Hydraulic oil level sensor (level: low) → with oil 40B004

Measure voltage

Component name

System

40 Troubleshooting

Between (A) - (C) Between (A) - (B)

3) 4) 5)

22 - 24V 22 - 24V

1) 2)

→ without oil

3) 4) 5)

22 - 24V 0V


40B050

Measure voltage

Hydraulic system


Hydraulic oil level sensor (level: refill) → with oil

Between (A) - (C) Between (A) - (B)

22 - 24V 22 - 24V



22 - 24V 0V

Measure voltage Measure current

120

59B015

Measure resistance

Hydr. oil temperature sensor (PT100 type)

Between (A) - (C)

22 - 24V

Between (C) - (B)

4 - 20mA

1) 2) 3) 4) 5)

20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box

Depending on the hydraulic oil level

If the condition is within the range shown in the table below, it is normal. Between (B) - (C)

1) 2) 3) 4) 5)


40B105

1) 2) 3) 4) 5)

→ without oil

Hydraulic oil level sensor (analog)

1) 2)


1) 2) 3)


PC4000-6D S/N 08199 and up

Inspection method

Component code

40 Troubleshooting

Component name

System

Part III

Floating switch at 20X810

Hydraulic system

Stick: 20S098

High pressure switch (analog)

61B087-a 61B087-b 61B087-c 61B087-d

Measure voltage

Boom: 20S095

Measure voltage

40B031

Measure voltage

If the condition is within the range shown in the table below, it is normal. Hydr. oil tank shut off gate valve (proximity switch)


22 - 24V 0V

Between (A) - (C)

22 - 24V

If the condition is within the range shown in the table below, it is normal. Between (B) - (L/K) Between (B) - (L/K)

22 - 24V 22 - 24V

Between (B) - (L/K) Between (B) - (L/K)

0V 0V


Between (A) - (C)

22 - 24V

Between (B) - (C)

1.0 - 11.0V

57B022

Measure voltage


Filter pump control clogging sensor [N.O. type]

Between (1) - (2)

57B016

PC4000-6D S/N 08199 and up

Measure voltage

Between (1) - (2)

Slew brake pressure sensor [N.C. type]


Judgement table

0V

22 - 24V


Between (1) - (2)

0V

Between (1) - (2)

22 - 24V

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6) Main gate closed 7)

Main gate open

1) 20S001 OFF 2) Disconnect connector 3) Insert T-cable 4) 20S001 ON 5) Press switch 7)

Switch in neutral position

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6)

Engine high idle

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine high idle 7) When filter clogged differential pressure >5bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) 7)

Engine high idle Switch point 24bar

121

57B048

Inspection method Measure voltage

Travel brake pressure sensor [N.C. type]

Part III

Component code

Component name

System

40 Troubleshooting


Judgement table


Between (1) - (2)

0V

Between (1) - (2)

22 - 24V

3) 4) 5)

57B085-1

Measure voltage

If the condition is within the range shown in the table below, it is normal. X1 pressure sensor (analog)

Between (A) - (C)

22 - 24V

Between (B) - (C)

1.0 - 11.0V

Measure voltage

Hydraulic system

57B086

Between (A) - (C)

22 - 24V

Between (B) - (C)

1.0 - 11.0V

40B166

Measure voltage

Preload valve pressure sensor (analog)

Between (A) - (C)

22 - 24V

Between (B) - (C)

1.0 - 11.0V

Engine high idle Switch point 24bar

1) 2)

20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box

6) 7)

Engine high idle max. 60bar

1) 2)


3) 4) 5)


6) 7)

Engine high idle max. 60bar

1) 2)


3) 4) 5) 6) 7)

Leak oil chamber pressure sensor (analog)

40B164

Measure voltage


Between (A) - (C)

22 - 24V

Between (B) - (C)

1.0 - 11.0V

1) 2) 3) 4) 5) 6) 7)

122

20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at T-box

6) 7)

3) 4) 5)

If the condition is within the range shown in the table below, it is normal. X2 pressure sensor (analog)

1) 2)

Depending on the pressure max. 60bar 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box Depending on the pressure max. 6bar

PC4000-6D S/N 08199 and up

Inspection method

Component code

40 Troubleshooting

Component name

System

Part III

59B162

Measure voltage

Hydraulic system

Suction tank pressure sensor (analog)

40B163

Measure voltage

If the condition is within the range shown in the table below, it is normal. Return oil chamber pressure sensor (analog)

Between (A) - (C)

22 - 24V

Between (B) - (C)

1.0 - 11.0V

Measure voltage

40B165


Between (A) - (C)

22 - 24V

Between (B) - (C)

1.0 - 10.0V

Between (A) - (C)

22 - 24V

Between (B) - (C)

1.0 - 11.0V

Measure voltage

Between (A) - (B)

Grease pump solenoid valve

Grease line solenoid valve (Vent valve)

62Q507 62Q509

62Q507a 62Q509a

PC4000-6D S/N 08199 and up

Measure resistance

Between (A) - (B)

Measure resistance

Grease system

80B043 62B046

Depending on the pressure 7) max. 6bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6) Engine high idle 7) max. +1bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6)


End line switch grease pressure

1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6)

If the condition is within the range shown in the table below, it is normal. Oil cooler pressure sensor


Judgement table

22 - 24V

0V

If the condition is within the range shown in the table below, it is normal. Between (D) - (F/H)

22 ± 1.0Ω

If the condition is within the range shown in the table below, it is normal. Between (D) - (F/H)

22 ± 1.0Ω

Depending on the pressure 7) max. 60bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-cable 4) 20S001 ON 5) Engine high idle 6) Grease pump running 7) Grease pressure 180bar present 1) Engine high idle 2) Grease pump running 3) Grease pressure below 180bar 1) Engine high idle 2) Grease pump running 3) Grease pressure below 180bar

123

Electronic control levers

Actuator pedal → left crawler

Actuator pedal → right crawler

Actuator pedal → slew brake

124

20Q097

20S021a

20S021b

20S022

Inspection method Measure current Measure voltage Measure voltage

52Q004


Measure voltage

Heater mixing valve

62B108 62B109


Judgement table


Measure voltage

Air conditioning

Magnetic clutch compressor

Component code

Component name Grease barrel level sensor

Part III

Measure voltage

Grease system

System

40 Troubleshooting

Between (B) - (B)

Between (1) - (gnd)

1) 2) 3) 4) 5)

4 - 20mA

1) 2) 3) 4) 5)

22 - 24V


1) 2) 3) 4) 5)

Between (1) - (2)

22 - 24V

6)


Between 11X_20 - 87

0 up to +10V

Between 11X_20 - 87

0 up to -10V

3) 4) 5)


Between 11X_20 - 86

0 up to +10V

Between 11X_20 - 86

0 up to -10V

0 up to +10V

20S001 OFF Disconnect connection Insert T-cable 20S001 ON Switch ON A/C 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at T-box Switch ON heater 20S001 OFF Disconnect connection Insert T-cable 20S001 ON Move pedal → forward

6)

Move pedal → backward

1) 2)

20S001 OFF Disconnect connection Insert T-cable 20S001 ON Depress pedal → forward

3) 4) 5)


Between 11X_20 - 62

1) 2)

20S001 OFF Disconnect connection Insert T-cable 20S001 ON Depending on grease level

6)

Depress pedal → backward

1) 2)

20S001 OFF Disconnect connection Insert T-cable 20S001 ON Depress pedal

3) 4) 5)

PC4000-6D S/N 08199 and up

Inspection method

Component code

40 Troubleshooting

Component name

System

Part III

Judgement table

Betw. 11X_00 - 7 L

0 up to -10V

Betw. 11X_00 - 7 R

0 up to +10V

Betw. 11X_00 - 12 F

0 up to +10V

Betw. 11X_00- 12 B

0 up to -10V

Control lever → right hand X & Y axis

20S019

Measure voltage

If the condition is within the range shown in the table below, it is normal. Between 11X_00-9 L

0 up to -10V

Between 11X_00-9 R

0 up to +10V

Between 11X_00-14 F

0 up to +10V

Between 11X_00-14 B 0 up to -10V

Actuator pedal → clam open

Actuator pedal → clam close

CAN

20S020

CAN bus resistor

20S024

20S023

10R100 10R101 40R101

PC4000-6D S/N 08199 and up

Measure Measure voltage Measure voltage resistance

Electronic control levers

Control lever → left hand X & Y axis

Measure voltage



Between 11X_00 - 46

0 up to -10V


Between 11X_00 - 46

0 up to +10V

If the condition is within the range shown in the table below, it is normal. Between (A) - (B)

120Ω


1) 20S001 OFF 2) Disconnect connection 3) Insert T-cable 4) 20S001 ON 5) Move lever to left & right side 6) Move lever to front & backward 1) 20S001 OFF 2) Disconnect connection 3) Insert T-cable 4) 20S001 ON 5) Move lever to left & right side 6) Move lever to front & backward 1) 20S001 OFF 2) Disconnect connection 3) Insert T-cable 4) 20S001 ON 5) Depress pedal 1) 20S001 OFF 2) Disconnect connection 3) Insert T-cable 4) 20S001 ON 5) Depress pedal 1) 20S001 OFF 2) Disconnect CAN connector

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40 Troubleshooting

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Part III

PT100 temperature charts Basic resistance values (Ohm) for measuring the resistance of PT100 sensors in relation to the temperature (degree centigrade) Resistance values according to ISO 4376

126

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40 Troubleshooting


PC4000-6D S/N 08199 and up

127

40 Troubleshooting

128

Part III

PC4000-6D S/N 08199 and up

Part IV

40 Troubleshooting

Part IV

Troubleshooting by trouble code G00001 - Trouble Shut-Off (gate) valve [1/5] Trouble code G00001

Trouble

Trouble Shut-Off (gate) valve

Contents of trouble

• The system assumes that the main gate valve is not completely open while the engine is running.

Related information

• If the voltage at the proximity switch 40B031 is 0 V, the main gate valve should be closed.

Action of controller

• Background colour of the trouble code information: red • If the basic VHMS setting for "PLC-evaluation - ON/OFF" is ON and if the shutdown bypass setting for "Shut-Off (gate) valve - ON/OFF" is OFF, the engine will be shut down (for sample VHMS displays refer to illustration Z 28050-1 at the end of this troubleshooting chart, page 4/5). Remark: For detailed information on the VHMS settings refer to the SERVICE MANUAL, section VEHCLE HEALTH MONITORING SYSTEM.

Problem that appears on machine

• The engine start is blocked.

Instruction message

Possible cause

1

Step

• Engine stopped because of main Shut-Off (gate) valve. - Open the Shut-Off (gate) valve. - If failure exists further, inform service.

Test condition & Inspection

Procedure

Nominal value

► Keep the main key switch 20S001 in ON position.

The engine is stopped, because the main gate valve at the hydraulic oil tank is not fully open

1

Verify if the main gate valve is fully open or not. Is the main gate valve fully open?

Yes

Go to next step.

No

Open the main gate valve completely and verify that trouble code G00001 (or G00020) is not set again. If trouble code G00020 is set, refer to the troubleshooting chart of G00020.


The gap between the proximity switch 40B031 and the open main gate valve is too large

2

PC4000-6 S/N 08199 and up

Check for the proper gap between the proximity switch and the open main gate valve. Does the gap meet the specification?

Yes

Go to next step.

No

Adjust the gap. Make sure that the proximity switch does not touch the gate valve when the gate valve is completely open.

Gap: approx. 3–5mm

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G00001 - Trouble Shut-Off (gate) valve [2/5] Possible cause

Step


Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. 3

Disconnect the cable connector from the proximity switch and measure the supply voltage at the connector terminal A. Is supply voltage present?

Incorrect or no supply voltage at the proximity switch 40B031

Vmin 22V Yes

Go to step 6. Vmax 24V

No

Go to next step.

Yes

Go to next step.

Vmin 22V

4

Vmax 24V

Check if supply voltage is present at the power supply line 11F013. Is supply voltage present? No

Follow the troubleshooting chart for trouble code G00090 "Trouble power supply".

► Keep the main key switch 20S001 in OFF position. Malfunction in the power supply wiring between proximity switch 40B031 and circuit breaker 11F013 (disconnection or defective contact in any connector)

5

Refer to the wiring diagram. Disconnect the connector from the proximity switch. Check the wire segments between the proximity switch and the power supply line for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wire segment (including connectors) between proximity switch and circuit breaker. Locate the problem and repair as necessary.

Rmax 1Ω

► VHMS Service menu ON - Input check at node 11

6 Malfunction in the signal wiring between proximity switch 40B031 and node 11 (40K311) (disconnection or defective contact in any connector)

• Engine OFF • 20S001 ON • PLC-evaluation ON (VHMS) Check the input signal of 40B031 at the VHMS Real Time Monitor. Is the input displayed?

Yes

Go to step 8.

No

Go to next step.

► Keep the main key switch 20S001 in OFF position

7

Refer to the wiring diagram. a) Check resistor 40R008: Disconnect the wires from 40R008 and measure its resistance. b) Check the signal wiring: Check the signal wire segments for continuity. Do all measurement readings meet the specifications?

Yes

Got to next step.

No

Locate the problem and repair as necessary.

R40R008 820Ω Rwire max 1Ω

► Keep the main key switch 20S001 in OFF position Defective ground connection at the proximity switch 40B031 (disconnection or defective contact in any connector)

130

8

Disconnect the cable connector from the proximity switch and check for proper ground connection at connector terminal B. Is the ground connection ok?

Yes

Go to next step.

No

Malfunction in any wire segment (including connectors) between proximity switch and ground line (GND). Locate the problem and repair as necessary.

Rmax 1Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00001 - Trouble Shut-Off (gate) valve [3/5] Possible cause

Step


Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Defective proximity switch 40B031

Final check

9

10

If the switch function is not as specified replace the proximity Using the Deutsch T-box, check the proximity switch for switch and verify that continuity in both switch positions. the repair was successful. Got to final step 10.

Switch closed: Rmax 1Ω Switch open: R ∞Ω

Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.

View onto the gap of the proximity switch 40B031

Legend for figure Z 26985 (1)

Proximity switch (40B031)

(A) Gap: 3-5 mm

PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV

View onto the VHMS settings for the proximity switch 40B031 [4/5] Terminology (MTC & PLC) MTC is a synonym for PLC. Both acronyms indicate the same main control module. MTC is the acronym of Master Turbo Controller PLC is the acronym of Programmable Logic Controller

Legend for figure Z 28050-1

(1) Basic setting for the MTC PLC-evaluation ON/OFF ON = MTC evaluation activated OFF = MTC evaluation not activated

(2) Bypass setting for the Shut-Off (gate) valve SHUTDOWN BYPASS for the ShutOff (gate) valve ON/OFF ON = Bypass ON Shutdown function OFF OFF = Bypass Shutdown function ON

132

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40 Troubleshooting

Wiring diagram related to trouble code G00001 [5/5]

PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV


134

PC4000-6 S/N 08199 and up

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40 Troubleshooting

G00002 - Test speed 1800 1/min engine 1 [1/3] Trouble code G00002

Trouble

Test speed 1800 rpm

Contents of trouble

• Test speed 1800 rpm is activated by switch 11S041-1 in the cab base.

Related information

• If the Quantum engine control module is switched to ground, the engine speed is fixed at 1800 rpm.


• Background colour of the trouble code information: green


• In this condition the engine speed is not changeable.

Instruction message

Possible cause

37

Step

• Switch Testspeed (11S041-1) in cab base forces the engine to run constantly 1800 1/min.


Procedure

Nominal value

► Keep the main key switch 20S001 in ON position The function "test speed 1800 rpm" is activated (switch 11S041-1 is closed)

1

If it is necessary, toggle the switch in order to disable the test speed function. Is the test speed function disabled?

Yes

No further troubleshooting necessary.

No

Go to next step.


Defective switch 11S041-1 (switch does not open)

2

Check the switch for continuity between the terminals 1 and 1a. Toggle the switch and check for continuity again. Turn the main key switch in ON position. Toggle switch 11S041-1 and check if the message on the display disappears. Do the measurements correspond to the specification and does the trouble message disappear?

Yes

Go to next step.

No

Replace switch 11S041-1 and verify that the repair was successful.

Switch closed: Rmax 1Ω Switch open: R ∞Ω

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Vmin 22V 3 Incorrect or no supply voltage in the electrical circuit of switch 11S041-1 4

PC4000-6 S/N 08199 and up

Check if supply voltage is present at the switch terminal 1a. Is supply voltage present?

Check if trouble code G00090 "Trouble power supply" is set. Is trouble code G00090 displayed?

Yes


No

Go to next step.

Yes

No power in the supply line of 11F013. Follow the troubleshooting chart for trouble code G00090.

No

Go to next step.

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40 Troubleshooting

Part IV

G00002 - Test speed 1800 1/min engine 1 [2/3] Possible cause

Step


Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position.

Disconnection in the wiring between switch 11S041-1 and the power supply line of circuit breaker 11F013 (disconnection or defective contact in any connector)

5

Refer to the wiring diagram and check the wire segments between switch 11S041-1 and the power supply line 11F013 for continuity. Also check the resistance of resistor 11R005. Is continuity present and is the resistance as specified?

Yes

Go to next step.

No

Continuity problem Disconnection or short circuit in any wire segment (including connectors) between switch 11S041-1 and the line of the circuit breaker 11F13_2. Locate the problem and repair as necessary. Resistor problem Replace resistor 11R005 if necessary.

11R005 820Ω

► Keep the main key switch 20S001 in OFF position Disconnection in the wiring between switch 11S041-1 terminal 1a and the Quantum engine control module (disconnection or defective contact in any connector)

6

Disconnect connector 51X452, pin Q, from the Quantum engine control module. Refer to the wiring diagram and check the wire segments between switch 11S041-1 and the Quantum engine control module for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wire segment (including connectors) between switch 11S041-1 and the Quantum engine control module. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Defective ground connection at switch 11S041-1

7

Final check

8

136

Check the ground connection at the switch terminal 1.

Locate the problem and repair as necessary. Then verify that the repair was successful. Then go to final step 8.


PC4000-6 S/N 08199 and up

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40 Troubleshooting


PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV

G00003 - Trouble pump controller [1/4] Trouble code G00003

Trouble

Trouble pump controller

Contents of trouble

• The microcontroller RC4-4 (10K032) of the Electronic Load Limiting Control signals a problem.

Related information

• If trouble code G00003 is displayed, the electronic pump regulation system is inoperative.


• Background colour of the trouble code information: yellow • The electronic pump control circuit is disturbed. • The hydraulic performance is too slow (or bad).

Problem that appears on the machine

Remark: If you need to keep the shovel busy and if it is not possible to perform the repair in an appropriate space of time, the pump regulation may be switched into the hydraulic mode temporarily. For more information refer to step 4 in the following troubleshooting chart.

Instruction message Possible cause

38

Step

• If failure exists further, inform service.


Procedure

Nominal value

► Keep the engine running at high idle and keep the control levers in neutral position. On normal regulation condition the green LED 10P063 at the X2 board is permanently switched ON (24V).

The pump controller RC4-4 (10K032) may be defective

Yes

The power supply for the pump controller RC4-4 and the electrical circuit inside the controller is faultless. Go to next step.

No

The system assumes that the power input to the pump controller at connector 11X_10, pins 33, 34, 35 is OK. The electrical circuit inside the pump controller is defective. Replace the pump controller and check the system for proper function.

1

Vmin 22V Vmax 24V

Check if the green LED 10P063 at the X2 board is permanently switched ON. Is the green LED switched ON (24V)?

138

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00003 - Trouble pump controller [2/4] Possible cause

Step

The pump controller RC4-4 (10K032) for electronic pump regulation signals any malfunction in the pump regulation system Blink code


2

Remark: If any trouble is detected in the pump regulation system the red LED 11P138 at the X2 board is flashing blink codes. For the meaning of the blink codes refer to the following chart:

Error message

1

57K561-1, proportional solenoid valve (1)

Output stored

Possible cause

Yes

- Electric circuit of 57K561-1 open or short to ground

Effect

- No signal from engine speed sensor 52B064-1 or circuit short or interrupted

Procedure

Main pumps running with max. power (Qmax)

Check solenoid valve or the electric circuit

Reduced hydraulic power

Check signal and connection to 52B064-1, or trouble code G00061

Check high idle limitation (Cummins Service) or trouble code G00062

- Engine is not running or engine rpm too low. 2

2

Low speed (1)

No

3

2

High speed (1)

Yes

- Engine defective or engine rpm too high.

Malfunction of the load limiting control

-

Low battery voltage

Yes

- Battery voltage below approx. 17 V

Check alternator Engine charging or trouble codes: voltage too low G00104, G00105 G00176, G00177

-

57K561-2, proportional solenoid valve (2)

Yes

4

5

Nominal value

► Keep the engine running at high idle and keep the control levers in neutral position.

Refer to Fig. no.

1

Procedure

For engine 2 (PC5500 & PC8000) only

6

-

Low speed (2)

No

7

-

High speed (2)

Yes

► Keep the engine running at high idle without hydraulic load. Checking the output signals of the pump controller - Open terminal 11 X_56-17. - Install a multi-tester at the terminals of 11X_56-17. Step 2 continued

- Measure the current [mA]. Standard: 670 ± 10 mA - Close the terminal of 11X_56-17 again. Otherwise check 57K561-1 and the wiring.

Blink code 1 Fig. no. 1 Check the resistance of 57K561-1 between pin 1 & 2. - Standard: 20 ± 1Ω

PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV


Step


Procedure

Nominal value

Step 2 continued

Blink code 2 & 3 Fig. no. 2

Checking the rpm sensor 52B064-1 ► Engine OFF - Main key switch 20S001 OFF - Lock out switch 50S058 locked -

Disconnect the engine speed sensor 52B064-1 and visually check for damage. Mount 52B064-1 and adjust the gap as follows: turn the sensor in clockwise until it touches the flywheel, then unscrew the sensor ¾ turns, and fasten the locknut securely.

Checking the input signal to the pump controller ► Keep the engine running at high idle. -

Check the voltage at 11X_51-38. Standard: approx. 2.5V Otherwise check the wiring to the rpm sensor 52B064-1.

Checking the function of the rpm sensor 52B064-1 ► Keep the engine running at high idle. Step 2 continued

-

140

Disconnect the connector of the engine speed sensor 52B064-1. Check the resistance between pin 1 & 2. Standard: 850 ± 50Ω Otherwise replace the sensor 52B064-1 and adjust as described above.

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting


Continued

The proportional valve 57K561-1 has been replaced

Step

2

3

Test condition & Inspection If LED 11P138 (red) is flashing any blink code, follow the according procedure in the above chart. Could you locate and repair the problem?

Procedure Yes

Go to final step 5.

No

Go to next step.

Nominal value

Refer to the SERVICE MANUAL section ELECTRONIC PUMP REGULATION SYSTEM subsection CHECKS AND ADJUSTMENT. Go to final step 5. Check and adjust the system as described in this section. If you need to keep the shovel busy and if it is not possible to perform the repair in an appropriate space of time, the pump regulation may be switched into the hydraulic mode temporarily. Turn the lever (253.1) at the valve cartridge block (1) into the horizontal position (H) in order to work in the hydraulic mode only, and put the machine back into operation.

The electronic pump regulation is inoperative

(1)


(253.1)

Emergency lever for pump control (electronic and hydraulic mode)

4

Information In the hydraulic mode (H) the rated output power is reduced to approx. 75%. Therefore it is necessary to perform the repair as soon as possible. Final check

5

PC4000-6 S/N 08199 and up


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Part IV

G00005 - Low hydraulic oil level [1/3] Trouble code G00005

Trouble

Low hydraulic oil level

Contents of trouble

• Pressure transducer 40B105 detected that the hydraulic oil level is low (below the warning limit) • Conditions for the generation of trouble code G00005: Condition 1: The main key switch 20S001 is in ON position for more than 10 seconds. Condition 2: The engine is shut off for more than 15 seconds and the attachment is in its defined position (refer to illustration Z 26724 on page 3 of this troubleshooting chart, showing the hydraulic oil tank label with the defined positions at the bottom).

Related information

• The pressure transducer 40B105 (analog) sends the hydraulic oil level to the VHMS monitor.


• Background colour of the trouble code information: yellow

Problem that appears on the machine

• Risk, to run out of hydraulic oil.


39

Step

• Inform service if attachment in defined position.


Procedure

Nominal value

► Check with stopped engine and the attachment in its defined position.

Hydraulic oil level low

1

In consideration of the kind of attachment (BHA or FSA) and the hydraulic oil temperature, check the hydraulic oil level sight gauge and verify if the hydraulic oil level corresponds to the displayed trouble message. Refer to illustration Z 26724 on page 3 of this troubleshooting chart, which shows the hydraulic oil tank label with the relevant oil levels on the left and right side of the label. Is the oil level too low?

Yes

Refill specified hydraulic oil and verify that trouble code G00005 is not displayed again.

No

Go to next step.

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. 2 Incorrect or no supply voltage in the circuit of pressure transducer 40B105 3

142

Disconnect the cable connector from the pressure transducer and measure the supply voltage at the connector terminal B. Is supply voltage present?

Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 displayed?

Vmin 22V Yes


No

Go to next step.

Yes

Follow the troubleshooting chart for trouble code G00090.

No

Go to next step.

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00005 - Low hydraulic oil level [2/3] Possible cause

Step


Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between pressure transducer 40B105 and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector)

4

Refer to the wiring diagram and check the wire segments between pressure transducer and the power supply line 11F013a for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wire segment (including connectors) between pressure transducer and the line of the circuit breaker 11F013a. Locate the problem and repair as necessary.

Rmax 1Ω


Disconnection in the signal wiring between pressure transducer 40B105 terminal C and node 11 (disconnection or defective contact in any connector)

5

Disconnect connector 2 from node 11 and measure at the terminal of 40X340-3. Refer to the wiring diagram and check the signal wiring segments between the pressure transducer , terminal C, and the cable connector 40X340, terminal 3, and node 11 for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wire segment (including connectors) between pressure transducer and cable connector 40X340, terminal 3, and node 11. Locate the problem and repair as necessary.

Rmax 1Ω


Defective shield wiring at the pressure transducer 40B105 (disconnection or defective contact in any connector)

6

Disconnect the cable connector from the pressure transducer. Refer to the wiring diagram and check the shield wiring segments for proper ground connection and continuity between connector terminal A and shield line 40X340-1. Are ground connection and continuity ok?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between cable connector terminal A and the shield line 40X340-1. Locate the problem and repair as necessary.

Rmax 1Ω

► Prepare with the main key switch S1 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Defective pressure transducer 40B105 (missing or poor signal current)

Final check

7

8

PC4000-6 S/N 08199 and up

Using the Deutsch T-box measure the signal current at the connector terminal C of the pressure transducer. Does the measurement meet the specification?

Yes

Go to next step.

No

Replace the pressure transducer and verify that the repair was successful.

Imin 4mA Imax 20mA


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40 Troubleshooting

Part IV

Wiring diagram (G00005), oil level label, and defined position of the attachment [3/3]

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PC4000-6 S/N 08199 and up

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40 Troubleshooting

G00007 - Trouble hydraulic oil level [1/3] Trouble code G00007

Trouble

Trouble hydraulic oil level

Contents of trouble

• Sensor 40B004 indicates that the hydraulic oil level is below the minimum refill level.

Related information

• If the sensor 40B004 does not sense oil, its signal voltage turns to 0 V. • If the signal voltage of sensor 40B004 continues to be 0 V for 10 seconds, trouble code G00007 is set. • If the monitoring setting of the hydraulic oil level is set to OFF, the engine is stopped. • If the monitoring setting of the hydraulic oil level is set to ON, the engine is not stopped.


• Background colour of the trouble code information: red




2

Step

• Inform service.


Procedure

Nominal value

► Check with stopped engine and the attachment in its defined position. The hydraulic oil level is below the minimum level

1

Verify if the hydraulic oil level in the main oil reservoir is above or below the oil level sensor 40B004. Is the oil level below the sensor?

Yes

Refill specified hydraulic oil and verify that trouble code G00007 is not displayed again.

No

Go to next step.

► Keep the main key switch 20S001 in ON position. The monitoring loop of the hydraulic oil level is inoperative

2

Check the input signal of 40B004 at the VHMS Real Time Monitor. Is the input signal at node 11 displayed?

Yes

Go to next step.

No

Check the condition of the monitoring loop at node 11, connector 3, pin 8.

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. 3 Incorrect or no supply voltage in the circuit of the oil level sensor 40B004 4

Disconnect the cable connector from the oil level sensor , insert the Deutsch T-box, and measure the supply voltage at the cable connector terminal A. Is supply voltage present?

Check if supply voltage is present at the power supply line 11F013. Is supply voltage present?

Yes

Go to step 6.

No

Go to next step.

Yes

Go to step 5.

No


Vmin 22V Vmax 24V

Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring segments between the oil level sensor 40B004 and the power supply line of circuit breaker 11F013 (disconnection or defective contact in any connector)

5

PC4000-6 S/N 08199 and up

Refer to the wiring diagram and check the wiring segments between oil level sensor and the power supply line for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between the oil level sensor and the line of circuit breaker 11F013. Locate the problem and repair as necessary.

Rmax 1Ω

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G00007 - Trouble hydraulic oil level [2/3] Possible cause

Step


Procedure

Nominal value


Defective ground connection at the oil level sensor 40B004

6

Disconnect the cable connector from the oil level sensor and check for proper ground connection at the connector terminal B. Is the ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor and the ground line. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between the oil level sensor 40B004, terminal C, and node 11. (disconnection or defective contact in any connector)

7

Disconnect the signal line connector 3, terminal 8, from node 11 (40K311). Refer to the wiring diagram and check the signal wiring segments between the oil level sensor, terminal C, and the node connector 3, terminal 8, for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor and node cable connector 3, terminal 8. Locate the problem and repair as necessary.

40R008max 820Ω

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position.

Defective oil level sensor 40B004

Final check

146

8

9

Using the Deutsch T-box measure the signal voltage at the connector terminal C of the oil level sensor when the sensor is dipped into oil (sensor closed), and when it is not touching any oil (sensor open). Do the measurements meet the specifications?

Yes

VSignal open: 0V A sporadic malfunction may exist. Further VSignal inspection is required. closed: 22-24V

No

Replace the oil level sensor and verify that the repair was successful.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram (G00007) and the defined position of the attachment [3/3]

PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV

G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low [1/6] Trouble code G00012 G00013 Contents of trouble

Trouble

G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low

• Monitoring of CLS (Central Lubrication System) grease level - 62B108 • Monitoring of SLS (Slew ring gear Lubrication System) grease level - 62B109 • The reserve level in the CLS grease barrel respectively in the SLS grease barrel is reached. • The sensing range of the grease level sensors is pre-adjusted ex factory. Further adjustment is not possible. • The grease level sensors do not influence the engine control. They can not trigger an engine shut down, they have an indication function only. LED functions (A) Green

Power supply (24V) is present

(B) Orange or red Same function as (C) Related information

(C) Orange

Object detected (normal operational condition)

(C) Red

Inhibited area detected (error condition) (grease may be too close to the ultrasonic sensor)

Overview Lube Syst.

Sensor

Node

CLS

62B108

12

SLS

62B109

3

• Background colour of the trouble code information: yellow Problem that appears on machine

• Risk, to run out of grease.


The concerned grease barrel (CLS or SLS) needs refilling

148

17

Step

1

• Inform service till end of shift and then press cancel button.


Using the dipstick, verify if the grease level in the concerned barrel corresponds to the displayed message. Is the grease level too low?

Procedure

Yes

Press the cancel button and refill the specified grease. Verify that trouble code G00012 or G00013 is not displayed again.

No

Go to next step.

Nominal value

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low [2/6] Possible cause

Step


Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. The ultrasonic sensor may be covered with grease or the concerned grease barrel may be overfilled. (a) Is the lower surface of the ultrasonic sensor covered with grease? and/or (b) Is the grease barrel overfilled? LEDs (B) & (C) of the concerned grease level sensor (62B108 or 62B109) light up red

Yes

(a) Clean the lower sensor surface and/or (b) Reduce the grease level in the barrel. Then verify if the problem is solved [LEDs (B) & (C) = orange and G00012/ G00013 no longer displayed].

No

If LED (A) lights green under these trouble conditions, the sensor may be disturbed. Go to step 8.

Definition of the grease levels 2

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Incorrect or no supply voltage in the circuit of the concerning grease level sensor (62B108 or 62B109) [Green sensor LED (A) does not light up]

3

4

PC4000-6 S/N 08199 and up

Remove the cover of the junction box on top of the concerned grease barrel. Measure the supply voltage at terminal 1 of the terminal block inside the junction box. Is supply voltage present?

Check if supply voltage is present at the power supply line 11F013a. Is supply voltage present?

Yes

Go to step 6.

No

Go to next step.

Yes

Go to step 6.

No

Follow the troubleshooting chart for trouble code G00090 "No power supply".

Vmin 22V Vmax 24V

Vmin 22V Vmax 24V

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40 Troubleshooting

Part IV

G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low [3/6] Possible cause Disconnection in the wiring between the concerned grease level sensor (62B108 or 62B109) and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector or in the junction box on top of the concerned grease barrel)

Step


Procedure

Nominal value


5

Refer to the wiring diagrams and check the wiring segments between the concerned grease level sensor and the power supply line for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between the concerned grease level sensor and the line of the circuit breaker 11F013a. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between the concerned grease level sensor (62B108 or 62B109) and node 12 or 3 (disconnection or defective contact in any connector or in the junction box on top of the concerned grease barrel)

6

Disconnect the signal line of the concerned grease level and the respective node. 62B108: Node 12, connector 2, terminal 3 62B109: Node 3, connector 1, terminal 7 Refer to the wiring diagrams and check the signal wiring segments between the concerned grease level sensor and the relating node connector/terminal for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment of the signal line (including connectors and junction box) between the concerned grease level sensor and the relating node/ connector/terminal. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Defective shield wiring at the cables of the concerned grease level sensor (62B108 or 62B109) (disconnection or defective contact in any connector)

150

7

Refer to the wiring diagrams and check the shield wiring segments for continuity and proper ground connection to the shield line. Are continuity and ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between the cable shield and the ground line. Locate the problem and repair as necessary.

Rmax 1Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low [4/6] Possible cause

Step


Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position.

8 Wrong sensor reaction or defective grease level sensor (62B108 or 62B109) [missing or poor signal current]

Yes

Go to next step.

No

Replace the concerned grease level sensor and verify that the repair was successful.


Final check

Move your hand closer than 7 cm towards the lower sensor surface. LEDs (B) and (C) should turn from orange (OK) to red (ERROR). Do the LEDs turm from orange to red?

Upper sensing range limit: <7cm

10

PC4000-6 S/N 08199 and up

Measure the signal current of the concerned grease level sensor at the relating terminal in the junction box. Refer to the latest version of PARTS & SERVICE NEWS AH10510.

If the signal current is wrong, replace the concerned grease level sensor and verify that the repair was successful.

ISignal 4-20mA


151

40 Troubleshooting

Part IV

Wiring diagram 1 related to trouble codes G00012 and G00013 [5/6]

152

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram 2 related to trouble codes G00012 and G00013 [6/6]

PC4000-6 S/N 08199 and up

153

40 Troubleshooting

Part IV

G00020 - Trouble Shut-Off (gate) valve (Start blocked) [1/4] Trouble code G00020

Trouble

Trouble Shut-Off (gate) valve (Start blocked)

Contents of trouble

• After main key switch 20S001 is switched ON (engine still OFF) the proximity switch 40B031 monitors the gate valve between hydraulic tank and suction tank. • Engine start is disabled if the valve is not completely open.

Related information

• If the voltage at the proximity switch 40B031 is 0 V, the main gate valve should be closed.


• Background colour of the trouble code information: red • If the basic VHMS setting for "MTC-evaluation - ON/OFF" is ON and if the setting for "Shut-Off (gate) valve - ON/OFF" is OFF, the engine will be shut down (for sample displays refer to illustration Z 28050-1 at the end of this troubleshooting chart, page 4/4). Remark: For detailed information on the VHMS settings refer to the SERVICE MANUAL, section VEHCLE HEALTH MONITORING SYSTEM.


• The engine start is blocked.

Instruction message

Possible cause

Engine start is impossible, because the gate valve at the hydraulic oil tank is not fully open

The gap between the proximity switch 40B031 and the open main gate valve is too large

154

4

Step

1

2

• Start blocked because of main Shut-Off (gate) valve. - Open the Shut-Off (gate) valve. - If failure exists further, inform service. Test condition & Inspection

Verify if the gate valve is fully open or not. Is the gate valve fully open?

Check for the proper gap between the proximity switch and the open main gate valve. Does the gap correspond to the specification?

Procedure Yes

Go to next step.

No

Open the gate valve completely and verify that trouble code G00020 is no longer set. If trouble code G00001 is set, refer to troubleshooting chart G00001.

Yes

Go to next step.

No

Adjust the gap. Verify that the proximity switch does not touch the gate valve when the gate valve is completely open.

Nominal value

Gap: approx. 3-5mm

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00020 - Trouble Shut-Off (gate) valve (Start blocked) [2/4] Possible cause

Step


Procedure

Nominal value


Incorrect or no supply voltage at the proximity switch 40B031

4

Disconnect the cable connector from the proximity switch and insert the Deutsch T-box. Measure the supply voltage at the connector terminal A. Is supply voltage present?


Yes

Go to step 6.

No

Go to next step.

Yes

Go to next step.

No


Vmin 22V Vmax 24V

Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Malfunction in the power supply wiring between proximity switch 40B031 and circuit breaker 11F013 (disconnection or defective contact in any connector)

5

Refer to the wiring diagram. Disconnect the connector from the proximity switch. Check the wire segments between proximity switch and power supply line 11F013 for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wire segment (including connectors) between proximity switch and circuit breaker 11F013. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between proximity switch 40B031 and node 11. (disconnection or defective contact in any connector)

6

Disconnect the signal line from node 11 (connector 3, terminal 3). Refer to the wiring diagram and check the wiring segments between proximity switch and node 11 for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between proximity switch and node 11. Locate the problem and repair as necessary.

Rmax 820Ω


Defective ground connection at the proximity switch 40B031

7

PC4000-6 S/N 08199 and up

Disconnect the cable connector from the proximity switch and check for proper ground connection at the connector terminal B. Is the ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between proximity switch and the ground line (GND). Locate the problem and repair as necessary.

Rmax 1Ω

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40 Troubleshooting

Part IV

G00020 - Trouble Shut-Off (gate) valve (Start blocked) [3/4] Possible cause

Step


Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Defective proximity switch 40B031

Final check

8

9

Disconnect the sensor connector and insert the Deutsch T-box. Measure the signal voltage at terminal C with closed and open gate valve.

If the switch function is not as specified replace the proximity switch and verify that the repair was successful. Go to final step 9.

VSignal closed: 0V VSignal open: 22-24V


Wiring diagram related to trouble code G00020

156

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

View onto the VHMS settings for proximity switch 40B031 [4/4] Legend for figure Z 28050-1

(1) Basic setting for the MTC PLC-evaluation ON/OFF ON = MTC evaluation activated OFF = MTC evaluation not activated

(2) Bypass setting for the Shut-Off (gate) valve SHUTDOWN BYPASS for the ShutOff (gate) valve ON/OFF ON = Bypass ON Shutdown function OFF OFF = Bypass OFF Shutdown function ON

View onto the gap of the proximity switch 40B031 Legend for figure Z 26985

(A) Gap: 3-5 mm

(1) Proximity switch (40B031)

PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV

G00060 - Fire in the power house [1/3] Trouble code G00060

Trouble

Fire in the power house

Contents of trouble

• Monitoring of the emergency shut-off and fire suppression system (optional equipment) • If fire alarm is initiated the engine is shutdown.

Related information

• All relevant information about the CHECKFIRE SC-N system, i.e. placing the system in service, daily inspection, functional tests, maintenance, and troubleshooting are contained in the separate manuals of your shovel.


• Displayed message: Fire detected • Background colour of the trouble code information: red


• Case A - Fire activated the fire suppression system. • Case B - False alarm caused the activation of the fire suppression system.


Fire alarm was initiated and the fire suppression system was activated in order to extinguish a fire in the power house

6

Step

• The fire suppression system has been actuated. - Inform the fire brigade. - Evacuate endangered persons. - Fight the fire. - Inform service. Test condition & Inspection

A

Remove the residues of the extinguishing agent and clean the power house as Make sure that no danger or risk of injury exists before necessary. entering the power house. The detection and Identify the cause of the fire in the power house. actuation system and the fire suppression Remark: systems must be checked, recharged, Also refer to the troubleshooting procedures which and approved by are described in the manual of the system authorized service manufacturer. personnel immediately after operation. Rectify the cause for the fire.

B

Remove the residues of the extinguishing agent and clean the power house as necessary. The detection and actuation system and the fire suppression systems must be checked, recharged, and approved by authorized service personnel immediately after operation. Rectify the cause for the false fire alarm.

Identify the cause of the false fire alarm. Fire alarm was initiated due to a false alarm and the fire suppression system was activated

158

Procedure

Remark: Also refer to the troubleshooting procedures which are described in the manual of the system manufacturer.

Nominal value

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00060 - Fire in the power house [2/3] Possible cause False fire alarm was initiated and the operator cancelled the alarm by pushing the reset button at the CHECKFIRE SC-N control module. The fire suppression system was not activated.

Step


Identify the cause of the false fire alarm.

C

PC4000-6 S/N 08199 and up

Remark: Also refer to the troubleshooting procedures which are described in the manual of the system manufacturer.

Procedure

Nominal value

The detection and actuation system and the fire suppression systems must be checked and approved by authorized service personnel only. Rectify the cause for the false fire alarm.

159

40 Troubleshooting

Part IV


160

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00061 - Trouble monitoring, engine 1 speed too low [1/2] Trouble code G00061

Trouble

Trouble monitoring, engine 1 speed too low

Contents of trouble

• A malfunction in the monitoring loop for too low engine speed is detected. • While the engine is standing still the Quantum engine ECM (52K014-1) signals an engine speed higher than 300 rpm.

Related information

• Also refer to the Cummins Troubleshooting & Repair Manual, QSK 60, Fuel System.




-


The Cummins ECMs signal any trouble code

2

Step

1

• Inform service.

Procedure

Nominal value

Yes

Go to final step 3.

Cummins Troubleshooting & Repair Manual, QSK 60, Fuel System or Cummins Service

No

Go to next step.


If any engine trouble code is displayed, refer to the corresponding troubleshooting chart in the Cummins Troubleshooting & Repair Manual, QSK 60, Fuel System. Could you rectify the problem?

► Main key switch 20S001 in ON position & engine standing still.

Wrong supply voltage at terminal 51(rpm>300)-1 / 1.04

Final check

2

3

PC4000-6 S/N 08199 and up

If battery voltage (VBatt 22 - 24V) is present at the terminal 51(rpm>300)-1 / 1.04 while the engine is standing still, refer to the wiring diagram and inspect the complete relating wiring loop. The voltage at terminal 51(rpm>300)-1 / 1.04 should be 0V. Is the voltage at terminal 51(rpm>300)-1 / 1.04 = 0V?

Yes

Check 52K014-1. Contact the Cummins service if necessary.

No

Inspect and repair the wiring connections as necessary. Also check the wires and connectors for their correct allocation. After any repair recheck the system for proper function.

VDefault 0V


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40 Troubleshooting

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162

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00062 - Trouble monitoring, engine 1 speed too high [1/4] Trouble code

Trouble

G00062

Trouble monitoring, engine speed too high

Contents of trouble

• A malfunction in the monitoring loop for too high engine speed is detected. • The system assumes that any cable, the sensor, or the RPM-module 51T018-1 is defective.

Related information

-




• The monitoring for too high engine speed is disabled (overspeed).


Wrong adjustment and/ or contamination of the engine speed sensor (pick up) 52B064-1

2

Step

1

• Inform service.

Test condition & Inspection Refer to the SERVICE MANUAL, section MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM, and find the adjustment procedure for the engine speed sensor (pick up). In the first step remove the engine speed sensor and clean the sensor tip from magnetic chips and dirt as described. Then follow the adjustment procedure and perform the final check. If necessary replace the pick up (52B064-1) or the RPM-module (51T018-1). The terminal numbers of your shovel may differ from the terminal numbers mentioned in the SERVICE MANUAL. Refer to the wiring diagram for the individual terminal numbers. Could you rectify the problem?

Procedure

Yes

Go to final step 9.

No

Go to next step.

Nominal value

approx. 10VAC

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Vmin 22V 2

Measure the supply voltage at terminal +24V of the RPM-module. Is supply voltage present?

Incorrect or no supply voltage at the RPMmodule (51T018-1).

Yes

Go to final step 9. Vmax 24V

No

Go to next step.

Yes

Go to next step.

Vmin 22V

3

Vmax 24V

Check if supply voltage is present at the power supply line 11F013a. Is supply voltage present? No

PC4000-6 S/N 08199 and up


163

40 Troubleshooting

Part IV

G00062 - Trouble monitoring, engine 1 speed too high [2/4] Possible cause

Step


Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between the RPM-module 51T018-1 and the line of the circuit breaker 11F013a (disconnection or defective contact in any connector)

4

Refer to the wiring diagram and check the wiring between terminal +24V of the RPMmodule and the power supply line 11F013a for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in the wiring (including connector) between terminal +24V of the RPM-module and the power supply line 11F013a. Locate the problem and repair as necessary.

Rmax 1Ω


Defective or poor ground connection at terminal 0V of the RPM-module 51T018-1

5

Disconnect the cable connector from the RPMmodule. Check the ground cable for continuity between terminal 0V and the ground line. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in the wiring (including connector) between the RPMmodule, terminal 0V, and the ground line. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between the pick up 52B064-1 and the RPM-module 51T018-1 (disconnection or defective contact in any connector)

6

Refer to the wiring diagram. Disconnect the wiring from the RPM-module (terminals sign and 0VS) and disconnect the pick up connenctor. Also disconnect line 52B064-1 which leads to the pump control module 10K032 (RC4-4). Check the wiring segments between the RPMmodule and the pick up for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment between the RPM-module and the pick up (including connectors). Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between the RPM-module 51T018-1 (terminals 1+ and 1-) to node 17 and to ground (disconnection or defective contact in any connector)

164

7

Refer to the wiring diagram. Disconnect the wiring from the RPM-module (terminals 1+ and 1-) and disconnect the node connector 2 , terminal 3. Check the wiring between the RPM-module and node 17 for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in the wiring between the RPMmodule (terminals 1+ and 1-) and the node connector 2, terminal 3 (including connectors). Locate the problem and repair as necessary.

Rmax 1Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00062 - Trouble monitoring, engine 1 speed too high [3/4] Possible cause

Step


Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Measure the signal current at terminals 1+ and 1- of the RPM-module. Do the measurements meet the specification? Defective RPM-module 51T018-1 (missing or poor signal current) or wrong setting

Final check

8

9

PC4000-6 S/N 08199 and up

Remark: The RPM-module is pre-programmed in the factory. Make sure that the presetting is not modified. If further details for the RPM-module are needed, contact the KMG Service department.

Yes

Go to next step.

No

Replace the RPMmodule if necessary and verify that the repair was successful.

Imin 0mA Imax 20mA


165

40 Troubleshooting

Part IV


166

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00063 - Trouble monitoring hydraulic oil temp [1/2] Trouble code G00063

Trouble

Trouble monitoring hydraulic oil temp

Contents of trouble

• A malfunction in the monitoring loop for the hydraulic oil temperature is detected. • The system assumes that the hydraulic oil temperature sensor 59B015 (PT100 type) or the wiring circuit of the monitoring system is defective. • Pre-condition for the monitoring loop: The bucket function is enabled and not shut-off due to overheated hydraulic oil (optional setting)!

Related information

• Within the temperature range of -50°C up to +150°C the sensor 59B015 generates a voltage signal in the range of 0.5 - 9.5V.


• On condition that the engine is running: the fan speed is set to max. speed • Background colour of the trouble code information: red


• The monitoring of the hydraulic oil temperature is disabled.


Wiring or connector problem

No input signal at node 17

Sensor defective

Final check

2

Step

1

2

3

4

PC4000-6 S/N 08199 and up

• Inform service.

Test condition & Inspection Check the wiring between sensor and connector 51X152: pin 23 to shield pin 24 to A pin 25 to C pin 26 to B Is continuty present? Check the input signal at node 17 (51K317). Measure the input signal of 59B015 at connector 2, pin 6 . Measure the signal voltage and compare the voltage to your Real Time temperature. Does the signal correspond to the Real Time temperature? Check the resistance of temperature sensor 59B015. Disconnect the sensor connector and measure the sensor resistance between pin B and C according to the PT100 temperature chart. Does the resistance correspond to the PT100 chart?

Procedure Yes

Go to next step 2.

No

Repair or replace according to the actual wiring diagram.

Yes

Go to final step.

No

Go to next step.

Yes

Go to next step 2.

No

Replace the PT100 sensor.

Nominal value Rmax 1Ω

VSignal 0.5-9.5V

Refer to the PT100 temp. chart


167

40 Troubleshooting

Part IV


168

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00064 - Trouble monitoring hydraulic oil level [1/3] Trouble code G00064 Contents of trouble

Trouble


• The signals of the hydraulic oil level sensors 40B050 (refilling level indication) and 40B004 (minimum level indication) are contradictory. • If trouble code G00064 is displayed, the hydraulic oil level sensor 40B004 has a malfunction.

Related information

Remark: If the sensor 40B004 does not sense oil, its signal voltage turns to 0 V.





Instruction message Possible cause The signal of the hydraulic oil level sensor 40B004 (minimum level indication) is disturbed

2

Step

• Inform service.


Procedure

Nominal value

► Check with stopped engine and the attachment in its defined position. 1

If the actual hydraulic oil level in the main hydraulic oil reservoir is higher than the level of the hydraulic oil level sensor 40B050, then sensor 40B004 or its wiring can be assumed to be defective.

Go to next step.

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 2 Incorrect or no supply voltage in the circuit of the oil level sensor 40B004 3

Disconnect the cable connector from the oil level sensor 40B004, insert the Deutsch T-box, and measure the supply voltage at the cable connector terminal A. Is supply voltage present?

Check if supply voltage is present at the power supply line 11F013 (TT: 11F084). Is supply voltage present?

Yes

Go to step 5.

No

Go to next step.

Yes

Go to step 5.

No


Vmin 22V Vmax 24V

Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between the oil level sensor 40B004 and the power supply line of circuit breaker 11F013 (TT: 11F084) (disconnection or defective contact in any connector)

4

PC4000-6 S/N 08199 and up

Refer to the wiring diagram and check the wiring segments between oil level sensor 40B004 and the power supply line for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B004 and the line of the circuit breaker. Locate the problem and repair as necessary.

Rmax 1Ω

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40 Troubleshooting

Part IV

G00064 - Trouble monitoring hydraulic oil level [2/3] Possible cause

Step


Procedure

Nominal value



5

Disconnect the cable connector from the oil level sensor 40B004 and check for proper ground connection at the connector terminal B. Is the ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B004 and the ground line (B). Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between the oil level sensor 40B004 terminal A and node 11 (disconnection or defective contact in any connector)

6

Refer to the relating wiring diagram and check the input signal at node 11 (40K311). Disconnect the signal line connector 3, terminal 8 from node 11. Refer to the wiring diagram and check the signal wiring segments between the oil level sensor 40B004, terminal C and node 11 cable connector 3, terminal 8 for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B004 and node 11 cable connector 3, terminal 8. Locate the problem and repair as necessary.

Rmax 1Ω

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. VSignal


7

Using the Deutsch T-box, measure the signal voltage at the connector terminal C o f the oil level sensor 40B004 when the sensor is dipped into oil (sensor closed) and when it is not touching any oil (sensor open). Do the measurements meet the specifications?

Yes

approx. 24V No

Final check

170

8

open: A sporadic malfunction 0V may exist. Further VSignal inspection is required. closed:

Replace the oil level sensor 40B004 and verify that the repair was successful.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting


PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV

G00065 - Very low hydraulic oil level [1/3] Trouble code G00065 Contents of trouble Related information

Trouble


• Message: Refill hydraulic oil! • The hydraulic oil level dropped below the refilling oil level (sensor 40B050). • The hydraulic oil level is still above the minimum oil level (sensor 40B004). Remark: If the sensor 40B050 does not sense oil, its signal voltage turns to 0 V.






2

Step

• Inform service.


Procedure

Nominal value

► Check with stopped engine and the attachment in its defined position.

The hydraulic oil fill level is reached

1

Verify if the hydraulic oil level in the main oil reservoir is below the oil level sensor 40B050. Is the oil level below the sensor 40B050?

Yes

Refill hydraulic oil and verify that trouble code G00065 is not displayed again.

No

If the oil level is above the sensor, go to next step.

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 2 Incorrect or no supply voltage in the circuit of the oil level sensor 40B050 3

Disconnect the cable connector from the oil level sensor 40B050, insert the Deutsch T-box, and measure the supply voltage at the cable connector terminal A. Is supply voltage present?


Yes

Go to step 5.

No

Go to next step.

Yes

Go to step 5.

No


Vmin 22V Vmax 24V

Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between the oil level sensor 40B050 and the power supply line of circuit breaker 11F013 (disconnection or defective contact in any connector)

172

4

Refer to the wiring diagram and check the wiring segments between oil level sensor 40B050 and the power supply line 11F013 for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B050 and the line of the circuit breaker 11F013. Locate the problem and repair as necessary.

Rmax 1Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00065 - Very low hydraulic oil level [2/3] Possible cause

Step


Procedure

Nominal value



5

Disconnect the cable connector from the oil level sensor 40B050 and check for proper ground connection at the connector terminal B. Is the ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B050 and the ground line (B). Locate the problem and repair as necessary.

Rmax 1Ω


Disconnection in the signal wiring between the oil level sensor 40B050 terminal C and node 11 (disconnection or defective contact in any connector)

6

Refer to the relating wiring diagram and check the input signal at node 11. Disconnect the signal line connector 3, terminal 5 from node 11 (40K311). Refer to the wiring diagram and check the signal wiring segments between the oil level sensor 40B050, terminal C and the node cable connector 3, terminal 5 for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B050 and the node cable connector 3, terminal 5. Locate the problem and repair as necessary.

Rmax 1Ω

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position.


Final check

7

8

PC4000-6 S/N 08199 and up

Using the Deutsch T-box, measure the signal voltage at the connector terminal C of the oil level sensor 40B050 when the sensor is dipped into oil (sensor closed) and when it is not touching any oil (sensor open). Do the measurements meet the specifications?

Yes

VSignal open: A sporadic malfunction 0V may exist. Further VSignal inspection is required. closed: approx. 24V

No

Replace the oil level sensor 40B050 and verify that the repair was successful.


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40 Troubleshooting

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174

PC4000-6 S/N 08199 and up

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40 Troubleshooting

G00066 - Trouble hydraulic oil temperature [1/3] Trouble code G00066

Trouble


Contents of trouble

• Overheated hydraulic oil is detected. (And the bucket function is disabled - option). • The system assumes that the hydraulic oil temperature sensor 59B015 (PT100 type) or the wiring circuit of the monitoring system is not defective.

Related information

• The hydraulic oil temperature sensor 59B015 detects an oil temperature >T4 for 20 seconds. • For the definition of the hydraulic oil temperatures T1, T2, T3, T4 refer to the oil temperature table on page 3/3 of this troubleshooting chart.


• On condition that the engine is running: the fan speed is set to max. speed. • Background colour of the trouble code information: red


• The hydraulic oil is overheated (option - bucket function is shut off).


2

Step

• Inform service.


Procedure

Nominal value

► Keep the engine running at high idle, with max. fan speed.

The hydraulic oil is overheated

1

Using a laser temperature meter check the hydraulic oil temperature at the temperature sensor 59B015. For the defined hydraulic oil temperatures refer to the oil temperature table at the end of this flowchart. Does the measured hydraulic oil temperature indicate overheating as well?

Yes

Go to next step.

No

Check for other relating trouble codes and follow the relating troubleshooting chart as necessary.

► Keep the main key switch 20S001 in ON position. Wrong hydraulic oil settings may cause the problem

2

Check the hydraulic oil settings (oil type, viscosity) in the service mode of the VHMS system. Are the oil settings correct?

Yes

Go to next step.

No

Adjust the hydraulic oil settings in the service mode of the VHMS system and recheck for normal range.

Yes

Go to next step.

No

Refer to the Service Manual, section Hydraulic Oil Cooling, and perform the setting of the max. fan speed. If the setting is not as specified follow the adjustment and/or inspection procedures in the Service Manual as necessary.

Yes

Clean the hydraulic oil cooler with a water pressure cleaner as necessary. Continue to work and monitor the hydraulic oil temperature on the VHMS display.

No

Go to next step.

► Keep the engine running at high idle.

The fan is not driven at max. speed

3

Maximum fan speed is achieved if no voltage (0 V) is applied at both solenoid valves 57K506a-1 and 57K506b-1. Therefore disconnect the cable connectors from both solenoid valves 57506a-1 & 57K506b-1. If the fan speed does not increase, check the hydraulic settings for the fan speed (refer to the Service Manual). Connect both cable connectors to the solenoid valves 57K506a-1 and 57K506b-1 again. Is the setting for max. fan speed correct?

RPM max. 1250±50 RPM medium 1000±50

► Shut the engine OFF.

Any clogged hydraulic oil cooler caused the overheating of the hydraulic oil

4

PC4000-6 S/N 08199 and up

This test step must only be performed if the engine is standing still. Perform a visual inspection of the hydraulic oil cooler. Also open the swing out doors of the cooler frame and check for deposits between these door wings. Is intense pollution present?

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40 Troubleshooting

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G00066 - Trouble hydraulic oil temperature [2/3] Possible cause

Step


Procedure

Nominal value

► Keep the engine running at high idle, with max. fan speed. Overheating due to any malfunction in the hydraulic system

5

Final check

6

176

Check the hydraulic system by performing the PM-Clinic.

Continue to work and monitor the hydraulic oil temperature on the VHMS display.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

View onto the solenoid valves related to trouble code G00066 [3/3]

Hydraulic oil table

PC4000-6 S/N 08199 and up

177

40 Troubleshooting

Part IV

G00067 - Trouble battery voltage too high [1/2] Trouble code G00067

Trouble

Trouble battery voltage too high

Contents of trouble

• Via the resistor 11T080 the system detects too high battery voltage.

Related information

• If the battery voltage at 11T080 is >=29 V for 5 V, the trouble code is set. • The system assumes that the resistor 11T080 and its wiring is not defective, otherwise trouble code G00161 should be displayed.




-


2

Step

• Inform service.


Procedure

Nominal value

► Keep the engine running at high idle. The voltage regulator in the alternator may be defective and causes the battery over voltage

1

Resistor 11T080 or its wiring may be the cause for the battery over voltage

2

Final check

3

178

Measure the charging voltage between alternator terminal "B+" and chassis (body ground). Also see the charging voltage value which is shown in the VHMS Real Time Monitor. Does the charging voltage exceed the specification? If trouble code G00161 "Trouble monitoring battery voltage" is displayed at the same time, follow the belonging procedures. Could you rectify the problem?

Vcharge Yes

Go to next step.

No

Replace the alternator.

Yes

Go to final step 3.

No

A sporadic malfunction may exist. Further inspection is required.

min. 27.5V max. 29V


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram and component location related to trouble code G00067 [2/2]

PC4000-6 S/N 08199 and up

179

40 Troubleshooting

Part IV

G00069 - Trouble monitoring oil temperature gear (PTO 1) [1/2] Trouble code G00069

Trouble

Trouble monitoring oil temperature gear (PTO 1)

Contents of trouble

• A malfunction in the monitoring loop for the gear oil temperature (PTO) is detected. • The system assumes that the gear oil temperature sensor 57B049 (PT100 type) or the wiring circuit of the monitoring system is defective.

Related information

• Within the temperature range of -50°C up to +150°C the sensor 57B049 generates a voltage of 0,5-9,5 V.




• The monitoring of the gear oil temperature (PTO 1) is disabled.


Wiring or connector problem

No input signal at node 18.

2

Step

1

2

• Inform service.


Procedure

Check wiring between sensor and connector 51X252 pin 26 to shield, pin 27 to A, pin 28 to C and pin 29 to B.

Yes

Go to step 2.

Is continuty present?

No

Repair or replace according the actual electrical circuit drawing.

Check the input signal at node 18 (51K318). Measure the input signal of the 59B049 between connector 0, pin 4. Measure the signal in Voltage and compare the voltage according your real time temperature.


VSignal Yes

Go to final step.

No

Go to next step

Yes

Go to next step.

No

Change the PT100 sensor.

0.5-9.5V

Is the signal according the real temp?

Sensor defective

Final check

180

3

2

Check the temperature sensor 59B049 of resistance. Disconnect the sensor connenctor and measure the sensor of resistance between pin B and C according the PT100 temperature chart. Is the resistance according to the PT100 chart ok?


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram and component location related to trouble code G00069 [2/2]

PC4000-6 S/N 08199 and up

181

40 Troubleshooting

Part IV

G00070 - Trouble oil temperature gear (PTO 1) [1/3] Trouble code G00070 Contents of trouble

Trouble

Trouble oil temperature gear (PTO 1)

• The PTO gear oil temperature sensor 57B049 (PT100 type) signals overheating. • The system assumes that the gear oil temperature sensor 57B049 (PT100 type) or the wiring circuit of the monitoring system is not defective. • PTO gear oil temperature for 5 seconds > TG2 • For the definition of the PTO gear oil temperatures refer to the following table (Z 26718) (taken from the flowchart).

Related information




• The PTO gear oil is overheated.


2

Step

• Inform service.


Procedure

Nominal value

► Keep the engine running at high idle, with max. fan speed.

PTO gear oil overheated

PTO gear oil level too low

1

2

Using a laser temperature meter, verify that the PTO gear oil temperature at the temperature sensor 57B049 is too high. For the location of 57B049 refer to "no. 2" in illustration Z 26958 at the end of this troubleshooting chart. For the definition of the PTO gear oil temperatures refer to the above table (Z 26718). Check the PTO gear oil level with the dipstick as described in the OPERATION & MAINTENANCE MANUAL, section "Every 50 Operating Hours or Weekly". Is the PTO gear oil level within the specified range?

Go to next step.

Yes

Go to next step.

No

Refill or drain PTO gear oil until the target level is reached. Then monitor the PTO gear oil temperature again.

OPERATION & MAINTENANCE MANUAL

► Keep the main key switch 20S001 in ON position. Wrong PTO gear oil settings may cause the problem

182

3

Check the PTO gear oil settings (oil type and viscosity) in the service mode of the VHMS system. Are the oil settings correct?

Yes

Go to next step.

No

Adjust the PTO gear oil settings in the service mode of the VHMS system and verify that the temperature is in normal range.

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00070 - Trouble oil temperature gear (PTO 1) [2/3] Possible cause

Step


Procedure

Nominal value


The fan is not driven at max. speed

4

Maximum fan speed is achieved if no voltage (0 V) is applied at both solenoid valves 57K506a-1 and 57K506b-1. Therefore disconnect the cable connectors from both solenoid valves 57K506a-1 & 57K506b-1. If the fan speed does not increase, check the hydraulic settings for the fan speed (refer to the Service Manual). Connect both cable connectors to the solenoid valves 57K506a-1 and 57K506b-1 again. Is the setting for max. fan speed correct?

Yes

Go to next step.

No

Refer to the Service Manual, section Hydraulic Oil Cooling, and perform the setting of the max. fan speed. If the setting is not as specified follow the adjustment and/or inspection procedures in the Service Manual as necessary.

Yes

Clean the gear oil/ hydraulic oil cooler with a steam cleaner as necessary. Continue to work and verify that the PTO gear oil temperature is in normal range.

No

Go to next step.

Yes

Go to next step.

No

Carry out adjustments as necessary. After that verify that the PTO gear oil temperature is in normal range. If any other relating trouble code is present, follow the troubleshooting procedures of the corresponding troubleshooting chart.

RPM max. 1250±50 RPM medium 1000±50

► Shut the engine OFF. Any clogged gear oil cooler segment in the hydraulic oil cooler frame caused the overheating of the PTO gear oil

5

This test step must only be performed if the engine is standing still. Perform a visual inspection of the gear oil cooler segments. Also open the swing out doors of the cooler frame and check for deposits between these door wings. Is intense pollution present? ► Keep the engine running at high idle.

Overheating due to any malfunction in the PTO lubrication system

6

Final check

7

PC4000-6 S/N 08199 and up

Refer to the Service Manual, chapter 2, section "PTO LUBRICATION AND COOLING" and follow the given adjustment procedures. Are the pump adjustments as specified?


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40 Troubleshooting

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Location of the PTO gear oil level dipstick and temperature sensor 57B049 [3/3]

Legend for illustration Z26958 (1)

Dipstick for PTO gear oil level

(2)

Location of the PTO gear oil temperature sensor 57B049

184

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00071 - Trouble gear lubrication (PTO 1) [1/2] Trouble code G00071 Contents of trouble

Trouble

Trouble gear lubrication (PTO 1)

• Pressure sensor 57B017-1 (NC*) signals, that there is no pressure in the PTO gear lubrication system, even the engine is running. *NC = Normally Closed • A problem with the pressure sensor 57B017-1 or its wiring (G00147) may also cause the trouble. Basic sensor data (57B017-1)

Related information

No pressure present

0V

Switch closed

Pressure present

24 V

Switch open

Switch point

0.5 bar




• Risk, to operate the machine without PTO gear lubrication (PTO overheating).


2

Step

1

• Inform service.


Refer to the Service Manual, chapter 2, section "PTO LUBRICATION AND COOLING" and follow the given adjustment procedures. Are the pump adjustments as specified?

Procedure Yes

Go to next step.

No

Carry out adjustments as necessary. After that recheck if the PTO gear lubrication pressure is in normal range.

Nominal value

► Keep the engine running at high idle. No PTO gear lubrication pressure present

2

Final check

3

PC4000-6 S/N 08199 and up

Check the PTO gear oil settings (oil type and viscosity) in the service mode of the VHMS system. Are the oil settings correct?

Continue to work and verify that trouble code G00071 "Trouble gear lubrication (PTO)" is not set again. If any other relating trouble code is present, in particular G00147 "Trouble monitoring gear lubrication (PTO)", follow the troubleshooting procedures of the corresponding troubleshooting chart.


185

40 Troubleshooting

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186

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00081 - Trouble lubrication system [1/4] Trouble code G00081

Trouble

Trouble lubrication system

Contents of trouble

• The movement of the bucket will be disabled, if there was no successful lubrication cycle during the last approx. 4 working hours (option).

Related information

• The function Bucket Cut-Off is an option. Via the CoDeSys Visualization software this option can be activated or deactivated. • If this option is deactivated the trouble message G00081 is displayed, but the bucket movement is not cut-off.




• If the optional function Bucket Cut-Off is activated: Bucket movement is disabled (lubrication cycle not complete).


2

Step

•

Inform service.


Procedure

Nominal value

► Engine running at high idle & ladder up & safety lever down

Problem in the lubrication system(s). A problem with the lubrication cycles causes the bucket cutoff (option)

Yes

Follow the troubleshooting chart of the displayed trouble code(s) and rectify the lubrication problem. After the repair manually switch the lubrication system and recheck for proper function. Also verify that the bucket motion is no longer affected. (option)

No

Go to next step.

Check if any trouble code(s) concerning the lubrication systems is present. Is any trouble code present which indicates a problem in the lubrication systems?

1

Remark Remember the PauseTime setting is reduced to 30 s: - if you entered the VHMS Service Mode or - after the first manual lubrication cycle was started. If you leave the Service Mode, the preadjusted Pause Time is resumed.


A malfunction of relay 11K050 causes the bucket cut off

2

PC4000-6 S/N 08199 and up

Check the function of relay 11K050 in the X2 switch board. - 11K050 active (24 V): Bucket movement enabled - 11K050 inactive (0 V): Bucket movement disabled Does the function of relay 11K050 meet the above specification?

Yes

Go to next step.

No

Replace the relay and check for proper system function. If the problem is not yet rectified go to next step.

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40 Troubleshooting

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G00081 - Trouble lubrication system [2/4] Possible cause

Step


Procedure

Yes

Malfunction or damage in the wiring circuit of relay 11K050

Final check

3

4

Refer to the wiring diagram: - Check if B+ voltage is present - Check for proper ground connection - Check the wiring for continuity - Check the diode for proper condition Is any problem diagnosable in the wiring circuit of relay 11K050?

No

Nominal value

Repair the wiring or replace any defective electrical component as necessary. Check if any other trouble code is set which may be in crosscorrelation with the existing problem. If so, follow the according troubleshooting chart and after that recheck for proper system function.


Operation cycles of the lubrication systems

188

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram 1 related to trouble code G00081 [3/4]

PC4000-6 S/N 08199 and up

189

40 Troubleshooting

Part IV


190

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00090 - Trouble power supply G00099 - Trouble power supply [1/2] Trouble code G00090 G00099 Contents of trouble

Trouble


• The power supply circuit (stabilized B+) for sensors and switches is interrupted. • The stabilized supply power is provided by the batteries 13G008 and 13G009 (located in the cab base).

Related information

Remark: If the supply voltage (B+) drops below 17 V, the monitoring function is shut dow (supply voltage below the self holding voltage).




• The engine start is impossible. • The monitoring function is inoperative.


8 / 48

Step

• No 24 V at circuit breaker 11F013 / 11F013a. - If failure exists further, inform service.


Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. V min The batteries 13G008 / 13G009 in the cab support are defective

1

Check the batteries. Are the batteries OK?

Yes

Go to next step.

V max 24V

No

Replace the batteries.

The circuit between the batteries 13G008/13G009 and the circuit breaker 11F013 (G00090) or 11F013a (G00099) is disturbed

2

Repair or replace components as Refer to the wiring diagram. necessary and verify Check the circuit (wires and electrical components) that the repair was between the batteries in the cab support and the circuit successful. breaker in the X2 switchboard. After that go to final step 3.

Final check

3


PC4000-6 S/N 08199 and up

17V

191

40 Troubleshooting

Part IV

Wiring diagram related to trouble codes G00090 and G00099 [2/2]

192

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00091 - Pilot control cut out [1/2] Trouble code G00091

Trouble


Contents of trouble

• Pilot control is locked.

Related information

• Pilot control is also locked if the refilling arm and/or ladder are down, or if the lock lever is pulled up. • Verify the switch setting of the refilling arm enable switch 20S094.




• Hydraulic operation is not possible.


9

Step

• Ladder end switch or lock lever contact open or service arm down or unlocked. - If failure exists further, inform service. Test condition & Inspection

Procedure

Nominal value

► Keep the main key switch 20S001 in ON position. The lock lever is not pushed down or its switch 20S105 is not closed

Lock lever switch 20S105 or its wiring is defective

The refilling arm is not in the upper end position

1

2

3

PC4000-6 S/N 08199 and up

Check the position of the lock lever (down). Is the lock lever pushed down in its operating position?

Refer to the wiring diagram and check the switch function and the belonging wiring. Are the switch and its wiring ok?

Yes

Go to next step.

No

Push the lock lever down in its operating position and continue to work.

Yes

Go to next step.

No

Replace the switch if it is defective. If the wiring has a problem, locate the problem and repair as necessary. After the repair recheck the system for proper function.

Yes

If no refilling process takes place, move the refilling arm back into its upper end position. Verify that the trouble message is no longer displayed.

No

For detailed information concerning the adjustment of the proximity switch 55B023 at the refilling arm (end position), refer to the latest version of PARTS & SERVICE NEWS AH05539 and follow the instructions.

Check the refilling arm position. Is the refilling arm in the upper end position?

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40 Troubleshooting

Part IV

G00091 - Pilot control cut out [2/2] Possible cause

Step


Procedure

Yes The access ladder is down

4

Check if the access ladder is down. Is the access ladder down?

No

Final check

5

Nominal value

Move the access ladder up. After that verify the following: - The trouble message is no longer displayed. - The excavator can be operated normally (hydraulic operation is no longer blocked). For detailed information concerning the access ladder function refer to your SERVICE MANUAL, section ACCESS LADDER.


View onto the lock lever and the cover of switch 20S105 Legend for figure Z 27281 (1) Lock lever (2) Cover of lock lever switch 20S105 at the right side of operator's seat [F] UNLOCKED, lock lever down in operation position [L] LOCKED, lock lever up, pilot control is locked

194

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00092 - Emergency shut-down at access ladder G00093 - Emergency shut-down at valve block G00094 - Emergency shut-down at hydraulic control panel G00095 - Emergency shut-down in cabin [1/2] Trouble code G00092 ~ G00095

Trouble

G00092 - Emergency shut-down at access ladder G00093 - Emergency shut-down at valve block G00094 - Emergency shut-down at hydraulic control panel G00095 - Emergency shut-down in cabin

• Emergency shut-down switch was activated when the engine is standing still. Emergency shut-down switch Contents of trouble

Location

Trouble code

70S033a

Ladder

G00092

61S033b

Valve block

G00093

57S033c

Hydraulic control panel

G00094

20S036

Operator´s cab

G00095

Related information

• The engine start is blocked




• It needs to be checked why the relating emergency shut-down switch was activated.

Instruction message

Possible cause

Any emergency shut-off button was activated

10

Step

1

• Emergency shut-down switch was actuated. - Unlock before restarting. - If failure exist further, inform service. Test condition & Inspection

Check the cause for the emergency activation. Is any cause present?

Procedure

Yes

Rectify the cause or problem. After that, release the concerned emergency shut-down switch(es).

No

Go to next step. Refer to the wiring diagram. Repair or replace the concerned switch or its wiring as necessary. After the repair go to final step 3.

The concerned emergency shut-off button or its wiring may be defective

2

Visually inspect the concerned switch, the switch contacts, and the respective wiring.

Final check

3


PC4000-6 S/N 08199 and up

Nominal value

195

40 Troubleshooting

Part IV

Wiring diagram related to trouble code G00092 - G00095 [2/2]

Only present if not equipped with switches 54S051 and 54S052 (option)

196

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00096 - Pilot control cut out [1/2] Trouble code G00096

Trouble


Contents of trouble

• Pilot control is locked.

Related information

• Pilot control is also locked if the refilling arm is down or if the lock lever is pulled up. • Verify the switch setting of the refilling arm enable switch 20S094.




• Hydraulic operation is not possible.


14

Step

• Enable switch for refilling arm active. - If failure exist further, inform service. Test condition & Inspection

Procedure

Nominal value


The enable switch (20S094 - at the dashboard) for the refilling arm is in ON position [1]

1

Check the switch position of the refilling arm enable switch. Is enable switch in ON position [1]?

Yes

Toggle enable switch in OFF position [0].

No

For detailed information concerning the adjustment of the proximity switch 55B023 at the refilling arm (end position) refer to the latest version of PARTS & SERVICE NEWS AH05539 and follow the instructions.

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position.

The enable switch (20S094 - at the dashboard) for the refilling arm or its wiring (safety monitoring of pilot control) is defective

2

Final check

3

PC4000-6 S/N 08199 and up

(a) Pre-check: Check the supply voltage at terminal A. If supply voltage is not present, locate the problem and repair as necessary. In switch position ON [1] there is continuity between A → C. (b) Verification: If the enable switch is in ON position [1] (switch closed), the message should light up on the VHMS display. Does the message light up when the enable switch is switched into ON position?

Yes

Go to final step 3.

No

Check the electric circuit below 20X_20 (terminal 30 at the X2 board). Locate the problem and repair as necessary. After that verify that the pilot control is no longer cut out.


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40 Troubleshooting

Part IV


198

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00100 - Maintenance safety switch [1/2] Trouble code G00100

Trouble


Contents of trouble

• The maintenance safety switch 50S058 is switched off, the engine is turned off / standing still.

Related information

• Engine start is blocked for safety reasons. • 50S058 is the maintenance safety switch which can be secured with padlocks.




• For safety reasons the engine start is made impossible via the safety switch 50S058.


11

Step

• Engine switched off by Maintenance Safety Switch in the engine room.


Procedure

Nominal value

► Main key switch 20S001 in OFF position The maintenance safety switch 50S058 is locked intentionally

1

Check the condition of the maintenance safety switch. Is the maintenance safety switch switched OFF and locked with a padlock?

Yes

Contact your supervisor and clarify the situation.

No

Go to next step.

Yes

Switch 50S058 Repair or replace as necessary. Wiring of 50S058 Refer to the wiring diagram. Locate the problem and repair as necessary.

No

Verify if other trouble codes are displayed, which may cause the problem. If any suspicious trouble code is displayed, follow the relating troubleshooting chart.

► Main key switch 20S001 in OFF position

Malfunction of the maintenance safety switch 50S058 or its wiring

Final check

2

3

PC4000-6 S/N 08199 and up

Check the function of the maintenance safety switch and its wiring. Could you identify any trouble?


199

40 Troubleshooting

Part IV



[2/2]

200

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00102 - Switch off wiper [1/1] Trouble code G00102

Trouble

Switch off wiper

Contents of trouble

• A malfunction in the wiper system is detected.

Related information

• The monitoring system detected any problem with the mechanics or with the logical control of the wiper system.




• The wiper system is inoperative.


2

• Inform Service

Step


Procedure

Nominal value


Malfunction in the wiper system

1

a) Switch off the wiper switch (20S011) (switch position "0"). b) Pull off the wiper arms from the windscreen. Is the wiper system switched off and could you pull off the lower wiper arm from the windscreen?

Yes

Go to next step.

No

Repair or replace the defective wiper parts as necessary (wiper arms and/or wiper blade). Recheck the wiper system for proper function.

Yes

Go to step 4.

No

Go to next step.

► Main key switch 20S001 in ON position Wiper switched OFF (20S011 in position "0") a) The logical wiper control sequence is disturbed

2

Press the QUIT button (11S145) at the X2 board in the cab base in order to reset the wiper system. b) After that, the wiper arms should move into their end position. c) Switch ON the wiper. If the reset was successful, the wiper function should be proper now. Does the wiper operate without any problem?

► Keep the main key switch 20S001 in OFF position. The basic mechanical adjustment of the wiper linkage is wrong

3

Final check

4

PC4000-6 S/N 08199 and up

Refer to the latest version of PARTS & SERVICE NEWS AH06533 and follow the given adjustment instructions. After that, recheck the wiper system for proper function. Does the wiper operate without any problem?

Yes

Go to step 4.

No

If trouble code G00101 or G00103 is present follow the relating troubleshooting chart.


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40 Troubleshooting

Part IV

G00103 - Faulty switch 20M004 [1/4] Trouble code G00103 Contents of trouble

Trouble


• The monitoring system detected any problem with the limit switch in the wiper motor (20M004). • The limit switch in the wiper motor (20M004) may have an electrical problem.

Related information

Remark: If trouble code G00102 is present, first follow the relating troubleshooting chart.




• The wiper doesn't move in its initial position (end position). Therefore the logical control sequence may be disturbed and the wiper system is inoperative. • The wiper motor (20M004) or its limit switch may be burnt.


47

- Only upper windscreen wiper! - Inform Service.

Step


Procedure

Nominal value

► Main key switch 20S001 in ON position. Wiper switched OFF (20S011 in position "0") a) The logical wiper control sequence is disturbed

1

Press the QUIT button (11S145) at the X2 board in the cab base in order to reset the wiper system. b) After that, both wiper arms should move into their end position. c) Switch ON the wipers. If the reset was successful, the wiper function should be proper now. Do the wipers operate without any problem?

Yes

Go to step 6.

No

Go to next step.

Yes

The system assumes that the upper wiper reached its end position, but the wiper arms don't move. When the VHMS shows "1", the wiring between wiper motor 20M004, pin 2 and node 9, connector 3, pin 2 is ok. Go to step 4.

No

Go to next step.

► Main key switch 20S001 in ON position. Wiper switch 20S011 switched ON. Check the conditions via VHMS

The upper wiper motor (20M004), the limit switch, or its wiring is defective

2

Conditions: Upper wiper arm in end position Upper wiper arm not in end position

VHMS : 1 VHMS : 0

For wiper start, the wiper arm has to be in end position. Do the conditions on VHMS correspond to the upper wiper arm position?

Go to next step.

The limit switch system is disturbed

202

3

Refer to the wiring diagrams. Check the wiring between the wiper motor, pin 2, and node 9, connector 3, pin 2 for continuity. Is continuity present?

Locate the problem and repair as necessary. If any problem was found and repaired, verify that the wiper function is free of problems. If no problem was found, go to next step.

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00103 - Faulty switch 20M004 [2/4] Possible cause

Step

The wiper motor 20M004 is defective

4

Malfunction in the wiring circuit of the wiper system

5

Final check

6

PC4000-6 S/N 08199 and up


Procedure

Nominal value

► Main key switch 20S001 in OFF position. Wiper switched OFF (20S011 in position "0") Replace the wiper motor 20M004. Yes Go to step 6. During the installation of the wiper motor follow Refer to the wiring the adjustment procedures in the PARTS & diagrams. SERVICE NEWS AH06533 (latest version) and Check the relating and make sure, that the basic adjustment of circuits and the No electrical components. the wiper linkage is made properly. After that, recheck the wiper system for proper After that, verify that function. the wiper function is free of problems. Do the wipers operate without any problem? Refer to the wiring diagrams. Check the relating circuits and the electrical components, locate the problem, and repair or replace Go to next step. defective components as necessary. After that, verify that the wiper function is free of problems. Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.

203

40 Troubleshooting

Part IV


204

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting


PC4000-6 S/N 08199 and up

205

40 Troubleshooting

Part IV

G00104 - Trouble battery current [1/2] Trouble code G00104

Trouble

Trouble battery current

Contents of trouble

• The discharging current is too high. • At the shunt resistor 71T003 a discharging current of less than -200 A is present (the engine is standing still).

Related information

• For this test step a clamp-on ammeter is required (Ampere). • The discharge current is abnormally high.




-


15

• Load of the batteries too high. - Inform service.

Step


Procedure

Nominal value

► Main key switch 20S001 ON - engine OFF Remark: Before taking the following measurements check for the correct order of the cable connections at 71T003 "B" and 71T003 "L". In case the cable connections are mixed up, connect them in the correct order. B = battery side L = alternator side The alternator (5200G5-1) is defective (short circuit to ground)

1

Yes

Replace the alternator. After repair recheck the system for proper function.

No

Go to next step.

Using a clamp-on ammeter measure the current in front of and behind the shunt resistor 71T003. Ammeter Batteries

Ammeter Alternator

Did you measure a negative current flow < -200 A between 71T003 & 52G005-1 and between 71T003 & the batteries? ► Main key switch 20S001 ON - engine OFF

The starter motors (52M001-1 & 52M002-1) are defective

2

Final check

3

206

Refer to the wiring diagram and using a clamp-on ammeter: • Measure the current between the terminal block 71X_71-4 and starter motor 52M001-1. • Measure the current between the terminal block 71X_71-5 and starter motor 52M002-1. • Measure the current between the starter motors and ground.

If the current flow at one of both starter motors is too high, both starter motors have to be replaced. After repair recheck the system for proper function. Check if other trouble codes relating to the charging system are pending. Go to final step 3.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting


PC4000-6 S/N 08199 and up

207

40 Troubleshooting

Part IV

G00105 - Trouble battery charging current too low [1/1] Trouble code G00105

Trouble

Trouble battery charging current too low

Contents of trouble

• The charging current from the alternator (52G005-1) is too low. • The monitoring system detected that the battery voltage dropped below 23 V.

Related information

• For this test step a clamp-on ammeter is required (Ampere). • Also see the charging current on the REAL TIME MONITOR (Electr. Equipment) in the service mode of the VHMS system (for detailed instructions refer to the SERVICE MANUAL, section VEHICLE HEALTH MONITORING SYSTEM).




• Further engine starts may be impossible due to discharged batteries.


16

Step

• Batteries are not being charged. - Inform service.


Procedure

Nominal value


1

Remark: Before taking the following measurements check for the correct order of the cable connections at 71T003 "B" and 71T003 "L". In case the cable connections are mixed up, connect them in the correct order. B = battery side L = alternator side Measure the charging voltage between alternator, terminal B+, and ground. Does the measurement reading meet the specification?

The alternator (52G005-1) or its wiring is defective

Yes

Go to next step.

No

Replace the alternator and check its wiring. After repair recheck the system for proper function.

2

Ammeter Batteries

208

Vmax 29.5V

► Keep the engine running at high idle. Using a clamp-on ammeter measure the charging current in front of and behind the shunt resistor 71T003.

Final check

Vmin 27.5V

3

Ammeter Alternator

If the charging current is too low, replace the alternator. After repair recheck the system for proper function. Check if other trouble codes relating to the charging system are pending. Go to final step 3.

Icharge 25-35A


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00140 - Trouble monitoring X1-1 pressure [1/3] Trouble code G00140

Trouble

Trouble monitoring X1-1 (XLR) pressure

Contents of trouble

• A malfunction in the monitoring loop for the pump regulation pressure X1 is detected. • Monitoring the X1 pressure is impossible because of: - Defective wiring or defective pressure sensor 57B085-1 - Poor terminal contact or disconnected connector in the wiring of pressure sensor 57B085-1

Related information

• Within a pressure range of 0 - 60 bar the sensor 57B085-1 generates a signal voltage of 1-11 V.




• Monitoring of the pump regulation pressure X1 pressure is disabled.


17

Step



Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the pressure sensor 57B085-1

2

Disconnect the sensor connector and insert the Deutsch T-box. Measure the voltage between the sensor pins A and C. Is supply voltage present? Check if trouble code G00090 "No power supply" is set: Is trouble code G00090 set?

Yes

Go to step 3.

No

Go to next step.

Yes


No

Go to next step.

Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between circuit breaker 11F013a and X1 pressure sensor 57B085-1 (disconnection or defective contact in any connector)

3

Refer to the wiring diagram and check the wiring segments between circuit breaker 11F013a and connector terminal A at the X1 pressure sensor for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between circuit breaker and connector terminal A at the pressure sensor. Locate the problem and repair as necessary.

Rmax 1Ω


Disconnection in the shield wiring between shield terminal 56X157-26 and GND

4

PC4000-6 S/N 08199 and up

Refer to the wiring diagram and check the wiring segments between shield terminal and GND for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between shield terminal and GND. Locate the problem and repair as necessary.

Rmax 1Ω

209

40 Troubleshooting

Part IV

G00140 - Trouble monitoring X1-1 pressure [2/3] Possible cause

Step


Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pressure sensor 57B085-1 (internal malfunction)

5

Disconnect the sensor connector and insert the Deutsch T-box. Measure the signal voltage at the connector terminal B of the X1 pressure sensor. Does the measurement meet the specification?

Yes

Go to next step.

No

Replace the pressure sensor and verify that the repair was successful.

Vsignal 1-11V


Disconnection in the signal wiring between X1 pressure sensor 57B085-1 and node 14 (disconnection or defective contact in any connector)

6

Final check

7

210

Check the wiring between terminal B at the pressure sensor and terminal 6 at node connector 2 for continuity.

If the continuity is not Rmax 1Ω as specified any malfunction in the wiring (including connectors) between terminal B at the pressure sensor and terminal 6 at node connector 2 is the problem. Locate the problem and repair as necessary. After successful repair go to final step 7.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram for the X1-1 pressure sensor 57B085-1 [3/3]

PC4000-6 S/N 08199 and up

211

40 Troubleshooting

Part IV

G00141 - Trouble monitoring X2 pressure [1/3] Trouble code G00141

Trouble

Trouble monitoring X2 pressure

Contents of trouble

• A malfunction in the monitoring loop for the X2 pressure is detected. • Monitoring the X2 pressure is impossible because of: - Defective wiring or defective sensor 57B086 - Poor terminal contact or any disconnected connector in the wiring of sensor 57B086

Related information

• Within a pressure range of 0 - 60 bar the X2 pressure sensor 57B086 generates a signal voltage of 1-11 V. • If the output voltage to the MTC is out of range the trouble code is set.




• The monitoring circuit for the X2 pressure is inoperative.


17

Step



Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the X2 pressure sensor 57B086 2

Disconnect the sensor connector and insert the Deutsch T-box. Measure the voltage between the sensor terminals A and C. Is supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?

Yes

Go to step 3.

No

Go to next step.

Yes

Follow the troubleshooting table for trouble code G00090.

No

Go to next step.

Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between circuit breaker 11F013a and X2 pressure sensor 57B086 (disconnection or defective contact in any connector)

3

Refer to the wiring diagram and check the wiring between circuit breaker and connector terminal A at the X2 pressure sensor for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in the wiring (including connectors) between circuit breaker and cable connector terminal A at the X2 pressure sensor. Locate the problem and repair as necessary.

Rmax 1Ω


Disconnection in the shield wiring between shield terminal 56X257-1 and GND

212

4

Refer to the wiring diagram and check for continuity between the shield terminal and GND. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in the wiring (including connectors) between shield terminal and GND. Locate the problem and repair as necessary.

Rmax 1Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00141 - Trouble monitoring X2 pressure [2/3] Possible cause

Step


Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective X2 pressure sensor 57B086 (internal malfunction)

5

Disconnect the connector from the X2 pressure sensor and insert the Deutsch T-box. Measure the signal voltage at the sensor terminals B and C. Do the measurements meet the specification?

Yes

Go to next step.

No

Replace the X2 pressure sensor and verify that the repair was successful.

Vsignal 1-11V

► Keep the main key switch 20S001 in OFF position. Check for continuity in the signal wiring between sensor terminal B and node 14.

Disconnection in the signal wiring between X2 pressure sensor and node 14, connector 2, pin 4 (disconnection or defective contact in any connector).

6

Final check

7

PC4000-6 S/N 08199 and up

57B086 terminal

Node 14, connector/terminal

B

2/4

If the resistance is too high, refer to the wiring diagram and locate the problem in the signal wiring of the Rmax 1Ω X2 pressure sensor. Repair as necessary. After successful repair go to final step 7.


213

40 Troubleshooting

Part IV

Wiring diagram for the X2 pressure sensor 57B086 [3/3]

214

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00143 - Trouble monitoring 61B087a G00144 - Trouble monitoring 61B087b G00145 - Trouble monitoring 61B087c G00146 - Trouble monitoring 61B087d [1/3] Trouble code G00143 ~ G00146

Contents of trouble

Trouble

G00143 - Trouble monitoring 61B087a G00144 - Trouble monitoring 61B087b G00145 - Trouble monitoring 61B087c G00146 - Trouble monitoring 61B087d

• A malfunction in the monitoring loop of the relating pump pressure sensor is detected. • Monitoring the pump pressure (pump 1–4) is impossible because of: - Defective wiring or defective pressure sensor (61B087a, b, c, d) - Poor terminal contact or disconnected connector in the wiring of any pressure sensor (61B087a–d) • Within a pressure range of 0–500 bar, the pump pressure sensors generate a signal voltage of 1–11 V. • These high pressure sensors (61B087a–d) are used for pump monitoring only, not for pump control.

Related information

Action of controller Problem that appears on machine

Pump 1

Pump 2

Pump 3

Pump 4

Pump pressure sensor

61B087a

61B087b

61B087c

61B087d

Node 12 connector - terminal "Signal"

2-6

2-9

2-8

2-7

Node 12 connector - terminal "Ground"

40X161-4

40X161-8

40X161-12

40X161-16

• The pump pressure monitoring loop of the relating pump is inoperative.


Pump #

2

Step

• Inform Service


Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the relating pump pressure sensor (61B087a–d) 2

Disconnect the relating sensor connector and insert the Deutsch T-box. Measure the voltage between the sensor pins A and C. Is supply voltage present? Check if trouble code G00090 "No power supply" is set: Is trouble code G00090 set?

Yes

Go to step 3.

No

Go to next step.

Yes


No

Go to next step.

Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between circuit breaker 11F013a and the relating pump pressure sensor (61B087a–d) (disconnection or defective contact in any connector)

3

PC4000-6 S/N 08199 and up

Refer to the wiring diagram and check the wire segments between circuit breaker and connector terminal A of the relating pump pressure sensor for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wire segment (including connectors) between circuit breaker and connector terminal A of the relating pump pressure sensor. Locate the problem and repair as necessary.

Rmax 1Ω

215

40 Troubleshooting

Part IV

G00143 - Trouble monitoring 61B087a G00144 - Trouble monitoring 61B087b G00145 - Trouble monitoring 61B087c G00146 - Trouble monitoring 61B087d [2/3] Possible cause

Step


Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. Disconnection in the shield wiring between GND and the relating pump pressure sensor (61B087a–d) (disconnection or defective contact in any connector)

4

Refer to the wiring diagram and check the wire segments between GND and shield terminal 40X161 of the relating pump pressure sensor for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wire segment (including connectors) between shield terminal 41X161 and the relating pump pressure sensor. Locate the problem and repair as necessary.

Rmax 1Ω

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pump pressure sensor (61B087a–d) (internal malfunction)

5

Disconnect the relating pump pressure sensor connector and insert the Deutsch T-box. Measure the signal voltage at the connector terminal B of the relating pump pressure sensor. Does the measurement meet the specification?

Yes

Go to next step.

No

Replace the relating pump pressure sensor and verify that the repair was successful.

Vsignal 1-11V


Disconnection in the signal wiring between the relating pump pressure sensor (61B087a–d) and node 12 (disconnection or defective contact in any connector)

6

Final check

7

216

Check the wire segments between terminal B at the relating pump pressure sensor and the relating node connector & terminal for continuity.

If the continuity is not as Rmax 1Ω specified, any malfunction in the wiring (including connectors) between terminal B of the relating pump pressure sensor and node 12, connector & terminal is the problem. Locate the problem and repair as necessary. After successful repair go to final step 7.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram related to trouble codes G00143 - G00146 [3/3]

PC4000-6 S/N 08199 and up

217

40 Troubleshooting

Part IV

G00147 - Trouble monitoring gear lubrication (PTO 1) [1/3] Trouble code G00147 Contents of trouble

Related information

Trouble

Trouble monitoring gear lubrication (PTO 1)

• A malfunction in the monitoring loop for the PTO gear oil pressure is detected. • Pressure sensor 57B017-1 monitors the pressure in the PTO gear lubrication system. • Conditions: - The engine is standing still - 20S001 in ON position - Pressure switch 57B017-1 signals gear oil pressure (approx. 24 V), even the engine is standing still Basic sensor data (57B017-1) No pressure present

0V

Switch closed

Pressure present

24 V

Switch open

Switch point

0.5 bar




• Monitoring of the PTO gear oil pressure is inoperative.


17

Step



Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the pressure switch 57B017-1 2

Using the Deutsch T-box, measure the supply voltage for 57B017-1 at the connector terminal 24. Is the correct supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?

Yes

Go to step 4.

No

Go to next step.

Yes


No

Go to next step.

Vmin 22V Vmax 24V


Disconnection in the voltage supply wiring between circuit breaker 11F013 and pressure switch 57B017-1 (disconnection or defective contact in any connector)

218

3

Refer to the wiring diagram. Using the Deutsch T-box, check the voltage supply wiring segments between the pressure switch and circuit breaker for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection, short circuit, or fault in the wiring (including connectors and resistor 56R008) between connector 56X157, terminal 24 and circuit breaker. If necessary, check the segments of the voltage supply wiring separately, locate the problem, and repair as necessary.

Rmax 820Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00147 - Trouble monitoring gear lubrication (PTO 1) [2/3] Possible cause

Step


Procedure

Nominal value


Disconnection in the signal wiring between pressure switch 57B017-1 and node 14 (disconnection or defective contact in any connector)

Defective ground connection at the pressure switch 57B017-1

4

Yes

The signal wiring between pressure switch and node 14 is ok. Go to next step.

No

Disconnection, short circuit, or fault in the wiring (including connectors and pins) between pressure switch and node connector 1, pin 8. If necessary, check the segments of the signal wiring separately, locate the problem, and repair as necessary.

Check the input signal at node connector 1, pin 8. Is the signal present?

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 5

Disconnect the cable connector 56X157 and check for proper ground connection at the connector terminal 25. Is the ground connection ok?

Yes

Go to next step.

No


► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pressure switch 57B017-1 (switch does not close)

Final check

6

7

PC4000-6 S/N 08199 and up

Disconnect connector 56X157. Measure the continuity of the pressure switch between the connector pins 25 and 24. Is continuity present?

Yes

Go to next step.

No

Replace the pressure switch and verify that the repair was successful.

Rmax 1Ω


219

40 Troubleshooting

Part IV


220

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00148 - Trouble monitoring fuel level [1/3] Trouble code G00148

Trouble

Trouble monitoring fuel level

Contents of trouble

• A malfunction in the monitoring loop of the fuel level sensor 31B063 is detected. • Monitoring of the fuel level is impossible because of: - Defective wiring or defective sensor 31B063 - Poor terminal contact or any disconnected connector in the wiring of sensor 31B063 • The signal current may be out of range because the shut-off cock is closed.

Related information

• Within a pressure range of 0-0.4 bar the sensor 31B063 generates a signal current of 4-20 mA.




• Risk to run out of fuel.


The shut-off cock is closed

17

Step

1


Test condition & Inspection Open the shut-off cock between fuel tank and fuel level sensor 31B063 to allow pressure compensation. Is trouble code G00148 still present?

Procedure Yes

Go to next step.

No

End of troubleshooting.

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 2 Incorrect or no supply voltage at the fuel level sensor 31B063

3

Disconnect the cable connector from the fuel level sensor and insert the Deutsch T-box. Measure the supply voltage at the connector terminal B. Is supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?

Yes

Go to step 4.

No

Go to next step.

Yes


No

Go to next step.

Vmin 22V Vmax 24V


Disconnection in the wiring between circuit breaker 11F013a and fuel level sensor 31B063 (disconnection or defective contact in any connector)

4

PC4000-6 S/N 08199 and up

Refer to the wiring diagram and check the wiring segments between circuit breaker and connector terminal B at the fuel level sensor for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between circuit breaker and cable connector terminal B at the fuel level sensor. Locate the problem and repair as necessary.

Rmax 1Ω

221

40 Troubleshooting

Part IV

G00148 - Trouble monitoring fuel level [2/3] Possible cause

Step


Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. Disconnection in the shield wiring between connector 10X140, terminal H and fuel level sensor 31B063 (disconnection or defective contact in any connector)

5

Refer to the wiring diagram and check the wiring segments between connector 10X140, terminal H and fuel level sensor connector, terminal A for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between shield terminal and cable connector, terminal A at the fuel level sensor. Locate the problem and repair as necessary.

Rmax 1Ω

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective fuel level sensor 31B063 (internal malfunction)

6

Disconnect the sensor connector and measure the signal current at the connector terminal C of the fuel level sensor. Does the measurement meet the specification?

Yes

Go to next step.

No

Replace the fuel level sensor and verify that the repair was successful.

Imin 4mA Imax 20mA

► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between fuel level sensor 31B063 and connector 10X140, terminal K (disconnection or defective contact in any connector)

7

Refer to the wiring diagram and check the wiring between terminal C at the fuel level sensor and connector 10X140, terminal K for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in the wiring (including connectors) between terminal C at the fuel level sensor and connector 10X140, terminal K. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring of fuel level sensor 31B063 between connector 10X140, terminal K and node 2 (disconnection or defective contact in any connector)

8

Final check

9

222

Check the wiring between connector 10X140, terminal K and node 2, connector 2, terminal 3 for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in the wiring (including connectors) between connector 10X140, terminal K and node connector 2, terminal 3. Locate the problem and repair as necessary.

Rmax 1Ω


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram and component location (31B063) [3/3]

Legend for figure Z 27352

PC4000-6 S/N 08199 and up

(1)

Fuel tank

(2)

Shut-off cock

(3)

Fuel level sensor (pressure transducer) 31B063

223

40 Troubleshooting

Part IV

G00149 - Trouble monitoring ambient temperature [1/2] Trouble code G00149

Trouble

Trouble monitoring ambient air temperature

Contents of trouble

• A malfunction in the monitoring loop of the ambient air temperature sensor 13B090 is detected. • Monitoring of the ambient air temperature may be impossible because of: - Defective wiring or defective sensor 13B090 - Poor terminal contact or disconnected connector in the wiring of sensor 13B090

Related information

• Within the temperature range of -50°C up to +150°C the sensor 13B090 generates a voltage signal of 0.5-9.5 V.


• The monitoring of the ambient air temperature sensor 13B090 is disabled.


Disconnection in the wiring of ambient air sensor 13B090

-

Step

1

-

Test condition & Inspection Check wiring between sensor and connector 11X_13 from pin 4 to shield, from connector pin 1 to sensor terminal A, from connector pin 2 to sensor terminal C, and from connector pin 3 to sensor terminal B.

Procedure

Yes

Go to next step.

No

Repair or replace as necessary according the actual wiring diagram.

Yes

Go to final step.

No

Go to next step

Yes

Go to next step.

No

Replace ambient air temperature sensor.

Is continuty present?

No input signal present at node 2

2

Check the input signal at node 2 (11K302). Measure the voltage of input signal from sensor 13B090 at node connector 2, pin 9. Compare the voltage reading (the related temperature value) with the real ambient air temperature.


VSignal 0.5-9.5V

Does the signal voltage correspond to the real ambient air temperature?

Defective ambient air sensor 13B090

Final check

224

3

4

Check the resistance of the ambient air sensor. Disconnect the sensor connector and measure the resistance of the sensor between pins B and C according the PT100 temperature chart. Is the resistance according to the PT100 temperature chart ok?


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting


PC4000-6 S/N 08199 and up

225

40 Troubleshooting

Part IV

G00151 - Trouble monitoring gear (PTO) oil filter 1 [1/3] Trouble code G00151 Contents of trouble

Related information

Trouble

Trouble monitoring gear (PTO) oil filter 1

• A malfunction in the monitoring loop for the PTO gear oil filter pressure is detected. • Pressure sensor 57B027-1 monitors the differential pressure in the oil filter for the X4 pressure. • Conditions: - The engine is standing still - 20S001 in ON position - Pressure switch 57B027-1 signals pressure in the PTO gear oil filter (0 V), even the engine is standing still. Basic sensor data (NO switch 57B027-1) No pressure present

24 V

Switch open

Pressure present

0V

Switch closed

Switch point

5 bar




• Monitoring of the PTO gear oil filter pressure is inoperative.


17

Step



Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the pressure switch 57B027-1 2

Measure the supply voltage for the pressure switch at connector 56X157, terminal 22. Is the correct supply voltage present?

Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?

Yes

Go to step 4.

No

Go to next step.

Yes


No

Go to next step.

Vmin 22V Vmax 24V


Disconnection in the voltage supply wiring between circuit breaker 11F013 and pressure switch 57B027-1 (disconnection or defective contact in any connector)

226

3

Refer to the wiring diagram. Check the voltage supply wiring between the pressure switch and the line of circuit breaker for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection, short circuit, or fault in the wiring (including connectors and resistor 56R008) between connector 56X157, terminal 22 and the circuit breaker. If necessary, check the segments of the voltage supply wiring separately, locate the problem, and repair as necessary.

Rmax 820Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00151 - Trouble monitoring gear (PTO) oil filter 1 [2/3] Possible cause

Step


Procedure

Nominal value


Disconnection in the signal wiring between pressure switch 57B027-1 and node 14 (disconnection or defective contact in any connector)

4

Yes

The signal wiring between the pressure switch and node 14 is ok. Go to next step.

No

Disconnection, short circuit, or fault in the wiring (including connectors and pins) between pressure switch and node connector 1, pin 2. If necessary, check the segments of the signal wiring separately, locate the problem, and repair as necessary.

Check the input signal at node 14. Is the signal present?

► Keep the main key switch 20S001 in OFF position. Defective ground connection at the pressure switch 57B027-1

5

Disconnect the sensor connector and check for proper ground connection at connector terminal 2 (via 56X157, terminal 23). Is the ground connection ok?

Yes

Go to next step.

No


► Keep the main key switch 20S001 in OFF position. Defective pressure switch 57B027-1 (switch does not open)

6

Final check

7

PC4000-6 S/N 08199 and up


Yes

Go to next step.

No


Rmax 1Ω


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40 Troubleshooting

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228

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00154 - Trouble monitoring return oil filter [1/3] Trouble code G00154

Trouble

Trouble monitoring return oil filter

Contents of trouble

• A malfunction in the monitoring loop for the return-oil chamber pressure is detected. • The system assumes that the pressure sensor 40B163 or its wiring is defective.

Related information

• If the system senses a signal of <= 0.0 bar or >= 6.0 bar for 5 seconds when the engine is standing still, trouble code G00154 is set.




• The pressure monitoring in the return-oil chamber is disturbed.


17

Step



Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage in the circuit of pressure sensor 40B163 (return-oil chamber pressure) 2

Disconnect the cable connector from the pressure sensor, insert the Deutsch T-box, and measure the supply voltage at the pressure sensor connector, terminal A. Is supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 displayed?

Yes

Go to step 4.

No

Go to next step.

Yes


No

Go to next step.

Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between pressure sensor 40B163 (return-oil chamber pressure) and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector)

3

PC4000-6 S/N 08199 and up

Refer to the wiring diagram and check the wiring segments between pressure sensor, terminal A and the power supply line from the circuit breaker for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between the line of the circuit breaker and connector terminal A at the pressure sensor. Locate the problem and repair as necessary.

Rmax 1Ω

229

40 Troubleshooting

Part IV

G00154 - Trouble monitoring return oil filter [2/3] Possible cause

Step


Procedure

Nominal value


Disconnection in the signal wiring between pressure sensor 40B163 and node 11 connector 2, terminal 8 (disconnection or defective contact in any connector)

4

Disconnect the signal line of pressure sensor from node connector 2, terminal 8. Refer to the wiring diagram and check the signal wiring between pressure sensor, terminal B (via connector 40X340, terminal 13) and node 11 (connector 2, terminal 8) for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment of the signal line (including connectors) between pressure sensor (returnoil chamber pressure) and cable connector 2, terminal 2, at node 11. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Defective ground connection at connector terminal C of pressure sensor 40B163 (return-oil chamber pressure) (disconnection or defective contact in any connector)

5

Refer to the wiring diagram and check the ground wiring between pressure sensor and connector 40X340, terminal 14 for continuity and proper ground connection. Are continuity and ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in any ground wiring segment (including connector 40X340) of the pressure sensor. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Defective shield wiring at the cables of pressure sensor 40B163 (return-oil chamber pressure) (disconnection or defective contact in any connector)

6

Refer to the wiring diagram and check the shield wiring for continuity and proper ground connection at connector 40X340, terminal 11. Are continuity and ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connector 40X340, terminal 11) of the shield line. Locate the problem and repair as necessary.

Rmax 1Ω

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pressure sensor 40B163 (returnoil chamber pressure) (missing or poor signal current)

7

Final check

8

230

Insert the Deutsch T-box at the cable connector of the pressure sensor. Measure the signal voltage of the pressure sensor at the relating terminal of the Deutsch T-box. Does the measurement meet the specification?

Yes

A sporadic malfunction Vmin 1V may exist. Further inspection is required. Vmax 11V

No

Replace the pressure sensor (return-oil chamber pressure) and verify that the repair was successful.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting


PC4000-6 S/N 08199 and up

231

40 Troubleshooting

Part IV

G00155 - Trouble monitoring leak oil filter [1/3] Trouble code G00155

Trouble

Trouble monitoring leak oil filter

Contents of trouble

• A malfunction in the monitoring loop for the leak-oil chamber pressure is detected. • The system assumes that the pressure sensor 40B164 or its wiring is defective.

Related information

• If the system senses a signal of <= 0.0 bar or >= 6.0 bar for 5 seconds when the engine is standing still, trouble code G00155 is set.




• The pressure monitoring in the leak-oil chamber is disturbed.


17

Step



Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Incorrect or no supply voltage in the circuit of pressure sensor 40B164 (leak-oil chamber pressure)

1

2

Disconnect the cable connector from the pressure sensor, insert the T-box, and measure the supply voltage at the connector, terminal A. Is supply voltage present? Check if trouble code G00099 "No power supply" is set. Is trouble code G00099 displayed?

Yes

Go to step 4.

No

Go to next step.

Yes


Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between pressure sensor 40B164 (leak-oil chamber pressure) and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector)

232

3

Refer to the wiring diagram and check the wiring segments between the pressure sensor, terminal A) and the power supply line of the circuit breaker for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors) between the line of the circuit breaker and connector terminal A at the pressure sensor. Locate the problem and repair as necessary.

Rmax 1Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00155 - Trouble monitoring leak oil filter [2/3] Possible cause

Step


Procedure

Nominal value


Disconnection in the signal wiring between pressure sensor 40B164 and node 11 connector 2, terminal 7 (disconnection or defective contact in any connector)

4

Disconnect the signal line of the pressure sensor from node 11 (connector 2, terminal 7). Refer to the wiring diagram and check the signal wiring between pressure sensor, terminal B (via connector 40X340, terminal 17) and node 11 (connector 2, terminal 7) for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment of the signal line (including connectors) between pressure sensor (leakoil chamber pressure) and cable connector 2, terminal 7 at node 11. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Defective ground connection at connector terminal C of pressure sensor 40B164 (leak-oil chamber pressure) (disconnection or defective contact in any connector)

5

Refer to the wiring diagram and check the ground wiring between the pressure sensor and connector 40X340, terminal 18 for continuity and proper ground connection. Are continuity and ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in any ground wiring segment (including connector 40X340) of the pressure sensor. Locate the problem and repair as necessary.

Rmax 1Ω

► Keep the main key switch 20S001 in OFF position. Defective shield wiring at the cables of pressure sensor 40B164 (leak-oil chamber pressure) (disconnection or defective contact in any connector)

6

Refer to the wiring diagram and check the shield wiring for continuity and proper ground connection at 40X340, terminal 15. Are continuity and ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in any wiring segment (including connectors and terminal block 40X340) of the shield line. Locate the problem and repair as necessary.

Rmax 1Ω

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pressure sensor 40B164 (leakoil chamber pressure) (missing or poor signal current)

7

Final check

8

PC4000-6 S/N 08199 and up

Insert the Deutsch T-box at the cable connector of the pressure sensor. Measure the signal voltage of the pressure sensor at the relating terminal of the T-box. Does the measurement meet the specification?

Yes

A sporadic malfunction Vmin 1V may exist. Further inspection is required. Vmax 11V

No

Replace the pressure sensor (leak-oil chamber pressure) and verify that the repair was successful.


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40 Troubleshooting

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234

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00159 - Trouble monitoring breather filter [1/3] Trouble code G00159 Contents of trouble

Trouble

Trouble monitoring breather filter

• A malfunction in the monitoring loop for the hydraulic oil tank breather filter (2 pcs) is detected. • Pressure sensor 40B024 monitors the (vacuum) pressure at the breather filter (2 pcs) on top of the hydraulic oil tank. • Conditions: - The engine is standing still - 20S001 in ON position - Pressure switch 40B024 signals vacuum (0 V) at the breather filter, even the engine is standing still

Related information

Basic sensor data (40B024) NO* No pressure present

24 V

Switch open

Pressure present

0V

Switch closed

Switch point

0.08 bar (vacuum)

* NO= Normally Open




• Monitoring of the breather filter pressure is inoperative.


17

Step



Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the pressure switch 40B024 2

Measure the supply voltage for the pressure switch at connector 40X240, terminal 10. Is the correct supply voltage present?

Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?

Yes

Go to step 4.

No

Go to next step.

Yes


No

Go to next step.

Vmin 22V Vmax 24V


Disconnection in the voltage supply wiring between circuit breaker 11F013 and pressure switch 40B024 (disconnection or defective contact in any connector)

3

PC4000-6 S/N 08199 and up

Refer to the wiring diagram. Check the voltage supply wiring between the pressure switch and the line of the circuit breaker for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection, short circuit, or fault in the wiring (including connectors and resistor 40R008) between connector 40X240, terminal 10 and the circuit breaker. If necessary, check the segments of the voltage supply wiri,ng separately, locate the problem, and repair as necessary.

40R008 820Ω

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40 Troubleshooting

Part IV

G00159 - Trouble monitoring breather filter [2/3] Possible cause

Step


Procedure

Nominal value


Disconnection in the signal wiring between pressure switch 40B024 and node 11 (disconnection or defective contact in any connector)

4

Yes

The signal wiring between pressure switch and node 11 is ok. Go to next step.

No

Disconnection, short circuit, or fault in the wiring (including connectors and pins) between pressure switch and node 11, connector 3, pin 9. If necessary, check the segments of the signal wiring separately, locate the problem, and repair as necessary.

Check the input signal at node 11, connector 3, pin 9. Is the signal present?

► Keep the main key switch 20S001 in OFF position. Defective ground connection at the pressure switch 40B024

5

Disconnect connector 40X240 and check for proper ground connection at the connector terminal 11. Is the ground connection ok?

Yes

Go to next step.

No


► Keep the main key switch 20S001 in OFF position. Defective pressure switch 40B024 (switch does not open)

6

Final check

7

236


Yes

Go to next step.

No


Rmax 1Ω


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting


PC4000-6 S/N 08199 and up

237

40 Troubleshooting

Part IV

G00160 - Trouble monitoring engine air cleaner 1 [1/3] Trouble code G00160 Contents of trouble

Trouble

Trouble monitoring engine air cleaner

• A malfunction in the monitoring loop for the engine air filter pressure sensors is detected. • Sensors 52B018-1 & 52B019-1 monitor the (vacuum) pressure in the inlet manifolds between air filters and engine. ► Conditions: - The engine is standing still - 20S001 in ON position - Pressure switch 52B018-1 and/or 52B019-1 signals vacuum (0 V) in the inlet manifold below the engine air cleaner, even the engine is standing still.

Related information

Basic sensor data (52B018-1/52B019-1) NO* No pressure present

24 V

Switch open

Pressure present

0V

Switch closed

Switch point

>60 mbar (vacuum) * NO= Normally Open




• Monitoring of the engine air cleaners is inoperative.


17

Step



Procedure

Nominal value

► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Incorrect or no supply voltage at the affected pressure switch (52B018-1 or 52B019-1)

1

2

Measure the supply voltage for 52B018-1 at connector 51X252, terminal 1. For 52B019-1 measure at terminal 3 in the same connector. Is the correct supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?

Yes

Go to step 4.

No

Go to next step.

Yes


No

Go to next step.

Vmin 22V Vmax 24V


Disconnection in the voltage supply wiring between circuit breaker 11F013 and pressure switch 52B018-1 or 52B019-1 (disconnection or defective contact in any connector)

238

3

Refer to the wiring diagram. Check the voltage supply wiring between pressure switch 52B018-1 or 52B019-1 and the line of the circuit breaker for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection, short circuit, or fault in the wiring (including connectors and resistor 51R008) between connector 51X252, terminal 1 (52B018-1) or terminal 3 (52B019-1) and the circuit breaker. If necessary, check the segments of the voltage supply wiring separately, locate the problem, and repair as necessary.

51R008 820Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00160 - Trouble monitoring engine air cleaner 1 [2/3] Possible cause

Step


Procedure

Nominal value


Disconnection in the signal wiring between pressure switch 52B018-1/52B019-1 and node 17. (disconnection or defective contact in any connector)

4

Yes

The signal wiring between pressure switch 52B018-1/ 52B019-1 and node 17 is ok. Go to next step.

No

Disconnection, short circuit, or fault in the wiring (including connectors and pins) between pressure switch 52B018-1/ 52B019-1 and node 17. If necessary, check the segments of the signal wiring separately, locate the problem, and repair as necessary.

Check the input signal at node 17, connector 3, pin 8 (for 52B018-1) or connector 3, pin 6 (for 52B019-1). Is the signal present?

► Keep the main key switch 20S001 in OFF position. Defective ground connection at the pressure switch 52B018-1 or 52B019-1

5

Disconnect connector 51X252 and check for proper ground connection at the connector terminal 2 (52B018-1) or terminal 4 (52B019-1). Is the ground connection ok?

Yes

Go to next step.

No


► Keep the main key switch 20S001 in OFF position. Defective pressure switch 52B018-1 or 52B019-1 (switch does not open)

6

Final check

7

PC4000-6 S/N 08199 and up

Disconnect connector 51X252. Measure the continuity of the pressure switches between the connector pins 1 and 2 (52B018-1) or between the connector pins 3 and 4 (52B019-1). Is continuity present?

Yes

Go to next step.

No

Replace the defective pressure switch 52B018-1 or 52B019-1 and verify that the repair was successful.

Rmax 1Ω


239

40 Troubleshooting

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240

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00161 - Trouble monitoring battery voltage [1/3] Trouble code G00161

Trouble

Trouble monitoring battery voltage

Contents of trouble

• A malfunction in the monitoring loop for the battery voltage is detected. • The system assumes that the resistor 11T080 or the wiring circuit of the battery charging system is defective.

Related information

• If the battery voltage signal at 11T080 indicates >=39 V for 5 seconds, the trouble code is set.




• The monitoring of the battery voltage is disabled.


17

Step



Procedure

Nominal value

► Keep the engine running at high idle. 1

Measure the input voltage at the resistor. Is correct input voltage present?

Incorrect or no input voltage (24 V) at resistor 11T080 2

Check if supply voltage is present at the power supply line 11F013a. Is voltage present?

Yes

Go to step 4.

No

Go to next step.

Yes

Go to next step.

No


Vmin 22V Vmax 24V

Vmin 22V Vmax 24V

► Keep the main key switch 20S001 in OFF position. Disconnection in the (+) wire between resistor 11T080 and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector)

3

Refer to the wiring diagram and check the (+) wire between the resistor 11T080 and the power supply line of the circuit breaker for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in the (+) wire (including connections) between the resistor and the power supply line of the circuit breaker. Locate the problem and repair as necessary.

Rmax 1Ω


Defective ground connection at resistor 11T080

4

PC4000-6 S/N 08199 and up

Check for proper ground connection at the (-) terminal of the resistor. Is the ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in the (-) wire (including connections) between the resistor and ground (GND). Locate the problem and repair as necessary.

Rmax 1Ω

241

40 Troubleshooting

Part IV

G00161 - Trouble monitoring battery voltage [2/3] Possible cause

Step


Procedure

Nominal value

► Keep the main key switch 20S001 in ON position. The signal voltage of resistor 11T080 to node 2, connector 2, terminal 8 is not correct or not present

VSignal 5

Disconnect the node connector 2 and measure the signal voltage at terminal 8. Does the signal voltage meet the specification?

Yes

Go to step 7.

max. 10V

VSignal min. 0V

No

Go to next step.


Resistor 11T080 is defective

6

Measure the resistance of both internal resistors in 11T080. Does the resistance correspond to the nominal value

Yes

Go to next step.

No

Replace the defective resisitor(s) and recheck the system for proper function.

11T080 30.1kΩ+ 10.0kΩ


Disconnection in the signal wire between resistor 11T080 and node 2, connector 2, terminal 8 (disconnection or defective contact)

7

Check the signal wire between resistor 11T080 and node 2, connector 2, terminal 8 for continuity. Is continuity present?

Yes

Go to next step.

No

Disconnection or short circuit in the signal wire (including connections) between resistor 11T080 and node 2, connector 2, terminal 8. Locate the problem and repair as necessary.

Rmax 1Ω


Defective ground connection between 11T080 and ground (disconnection or defective contact)

8

Final check

9

242

Refer to the wiring diagram and check for proper ground connection from module 11T080 to ground. Is the ground connection ok?

Yes

Go to next step.

No

Disconnection or short circuit in the ground wire (including connections) between 11T080 and ground. Locate the problem and repair as necessary.

Rmax 1Ω


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting


PC4000-6 S/N 08199 and up

243

40 Troubleshooting

Part IV

G00162 - Trouble monitoring charging-/discharging current [1/3] Trouble code G00162 Contents of trouble

Trouble

Trouble monitoring charging-/discharging current

• The system detected that the shunt resistor 71T003, or the module 51T017, or the belonging wiring is defective. • The purpose of the module 51T017 is to monitor the charging and discharging current of the batteries. Battery information Battery

Location

Function

Cat walk

Battery charging

Cab base

Stabilized voltage for MTC

71G001

Related information

71G002 71G003 71G004 13G008 13G009




• The monitoring circuit of the charging and discharging current for the batteries is inoperative. • The batteries will be discharged if the charging current is too low.


17

Step



Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. Switch OFF the battery main switches 71Q003 & 71Q004.

The shunt resistor 71T003 may be defective

1

Disconnect the main battery cables and the signal lines (terminals B & L) from the shunt resistor. Then measure the resistance of the shunt resistor. Does the measurement reading meet the specification?

Yes

Go to next step.

No

Replace the shunt resistor. Connect all cables and recheck the monitoring circuit for proper function. If the repair was successful, go to final step 5.

71T003 4.5±0.5Ω

► Keep the main key switch 20S001 in OFF position. Switch OFF the battery main switches 71Q003 & 71Q004.

The wiring of the shunt resistor 71T003 may cause the problem

244

2

Refer to the wiring diagrams. Check the following cables for continuity: - Between alternator 52G005 and the shunt resistor (input) - Between shunt resistor (output) and all batteries - Between shunt resistor (terrminals B & L) and module 51T017, including the wire shielding Is the continuity as specified?

Yes

Go to next step.

No

Locate the problem and repair as necessary. After repair recheck the system for proper function.

Rmax 1Ω

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00162 - Trouble monitoring charging-/discharging current [2/3] Possible cause

Step


Procedure

Nominal value


The power supply wiring (+/-) at the module 51T017 may cause the problem

3

Refer to the wiring diagrams. Check at the following terminals of the module: - terminal 7 for supply voltage (B+) - terminal 8 for proper ground connection. Is the power supply wiring (+/-) of the module ok?

Yes

Go to next step.

No


Vmin 22V Vmax 24V


The signal lines between shunt 71T003 module 51T017 and node 17 are disturbed

Final check

4

5

PC4000-6 S/N 08199 and up

Refer to the wiring diagrams. Check the following cables for continuity: - between module pin 5, and node connector 2, pin 7 - between module pin 4/2, and shunt connection B/L Is the continuity as specified in both cables?

Yes

Replace module 51T017 and recheck for proper function.

No


Rmax 1Ω


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40 Troubleshooting

Part IV


246

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00163 - Trouble monitoring pilot control [1/3] Trouble code G00163 Contents of trouble

Trouble

Trouble monitoring pilot control

• The message is displayed if any malfunction in the monitoring circuit for the time relay 11K032 (electrical pilot control) is detected. • The power supply of the electrical pilot control may be disturbed. • A contact inside time relay 11K032 may be stuck. • The time relay 11K032 is a redundant relay and it is energized when one (or more) of the control levers or pedals is moved away from the resting (zero) position. • If one of the power supply circuits (11F013 & 11F043) fails, the trouble message (G00163) is displayed. • The fixed time relay setting is 1 second. • If any control is activated the time relay is energized at terminal A1


Time delay relay 11K032

(2)

Green LED (power supply ok)

Related information




• Monitoring is no longer redundant. Only one circuit of the delay control is present.

Instruction message

17

PC4000-6 S/N 08199 and up


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40 Troubleshooting

Part IV

G00163 - Trouble monitoring pilot control [2/3] Possible cause

Step


Procedure

Nominal value


1 Incorrect or no supply voltage at the time delay relay 11K032

2

Measure the supply voltage between 11K032, terminal 28 and ground. Also measure the supply voltage between relay terminal 16, and ground. Is supply voltage present at terminals 28 and 16?

Check if trouble code G00090 "No power supply" is set: Is trouble code G00090 set?

Yes

Go to next step.

No

Refer to the wiring diagram. Check the insufficient supply circuit including the involved relays for malfunction. Locate the problem and replace or repair as necessary. After repair verify that the system function is orderly.

Yes


No

Go to next step.

Vmin 22V Vmax 24V


Malfunction in the contact wiring between 11K032 and ground / node input

3

Refer to the wiring diagram. At the time relay, measure for continuity between: • terminal 15 (11F013 circuit) → node 3, terminal 39 • terminal 27 (11F043 circuit) → 11Q111, terminal A1 • 11Q111, terminal A2 → ground Is continuity present at all of the three tested terminals of the time relay?

Yes

Go to next step.

No

Disconnection or short circuit in the concerned wiring between time relay and ground/ node. Locate the problem and repair as necessary.

Rmax 1Ω

► Main key switch 20S001 ON - control lever in neutral position

Relay test: 11K126

Final check

248

4

5

Check if on-board voltage is present at both relay terminals 13 and 14 (the contact should be closed). Is the relay contact closed?

Yes

Go to next step.

No

Check the time relay and its wiring. Repair the wiring, if necessary, or replace the time relay. After repair recheck for proper function.

Vmin 22V Vmax 24V


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram related to trouble code 00163 [3/3]

PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV

G00164 - Trouble air cleaner 1 [1/2] Trouble code G00164

Trouble

Trouble air cleaner 1

Contents of trouble

• The message is displayed if the sensors 52B018-1 & 52B019-1 of the engine air filters detect clogged air filters. • The system assumes that the monitoring circuits of the engine air filter sensors are not disturbed.

Related information

• The sensors 52B018-1 & 52B019-1 watch the vacuum pressure in the inlet manifolds between air filters and engine.




• With clogged air filter(s) the following problems occur: - Loss in rated engine power - Poor exhaust emission quality - Increased fuel consumption - Increased exhaust gas temperature - Reduced engine lifetime Remark: If machines are operated at locations higher than 3600 m, they sooner will be affected by the above mentioned effects, even though the system does not yet display any trouble message.


17

Step



Procedure

Nominal value

► Main key switch 20S001 OFF – Engine OFF – Maintenance safety switch 50S058 OFF & locked Replace the outer filter elements (4 pieces) and check the inner filter elements at the service indicators. If necessary or if the indicators are switched to red, replace the inner filter elements.

Service advice

The engine air filters (inner and outer elements) are clogged

1

• How to identify a clogged outer engine air filter element The only correct method to identify the clogged condition of an outer engine air filter element is to compare the weights of a new and a clogged outer air filter element. Sample: Weight unit

Weight of a new air filter element

Weight of a clogged air filter element

[kg]

approx. 9

approx 20

• The replacement interval depends on the respective environmental conditions. Always monitor the engine air filter elements according to your local operations conditions. • After every 2nd replacement of the outer engine air filter elements the inner air filter elements must be replaced too. • The air filter box must be cleaned thoroughly after the period of every 1000 operating hours. Go to final step 2. Final check

250

2


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

View onto the engine air cleaner [2/2]


Wing nut

(4)

Outer air filter element

(2)

Lock washer

(5)

Indicator

(3)

Washer

(6)

Inner air filter element

PC4000-6 S/N 08199 and up

251

40 Troubleshooting

Part IV

G00165 - Trouble breather filter hydraulic oil tank [1/2] Trouble code G00165

Trouble

Trouble breather filter hydraulic oil tank

Contents of trouble

• The message is displayed if sensor 40B024 (on top of the hydraulic oil tank) detects a clogged breather filter. • The system assumes that the monitoring circuit of the breather filter sensor 40B024 is not disturbed.

Related information

• Sensor 40B024 (2 pcs) watches the vacuum pressure of the breather and ventilation of the hydraulic oil tank.




• A clogged breather adversely affects the circulation of the hydraulic oil in the tank.


17

Step



Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. Replace the breather filter(s) as necessary. For details refer to the OPERATION & MAINTENANCE MANUAL, section HYDRAULIC SYSTEM - FILTER SERVICE.

A breather filter is clogged

1

Final check

2

252

Remark: Only use steel made filter elements. If this trouble message appears frequently in-between the replacement intervals, make sure that: (a) the hydraulic oil tank is not overfilled when the machine is in its defined position, and (b) consider the dependency on the temperature range.

Go to final check 2.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Label showing temperature information and defined positions [2/2]


Hydraulic oil tank

(2)

Temperature information

(3)

Defined positions

PC4000-6 S/N 08199 and up

253

40 Troubleshooting

Part IV

G00166 - Trouble oil filter gear (PTO 1) [1/2] Trouble code G00166 Contents of trouble

Trouble

Trouble oil filter gear (PTO 1)

• Pressure sensor 57B027-1 (NO*) signals, that the filter for the PTO gear lubrication system is clogged. *NO = Normally Open

• A problem with the pressure sensor 57B027-1 or its wiring (G00151) may also cause the trouble. • The trouble code is not set until the hydraulic oil temperature reached T2 + 18°C Sample Hydraulic oil: T2:

VG100 39°C

In this case the trouble code is not set until the hydraulic oil temperature reached: 39 + 18 = 57°C

Related information

Basic sensor data (57B027-1) No pressure present

24 V

Switch open

Pressure present

0V

Switch closed

Switch point

5 bar




• Unfiltered PTO gear oil flows through the bypass of the filter.


17

Step



Procedure

Nominal value

► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked

The PTO gear oil filter is clogged

1

Screw off the filter case and check for clogging. Is the filter element clogged?

Yes

Replace the filter element if necessary. If the filter element was clogged check the PTO lubrication pump for wear.

No

Go to next step.

► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked The pressure sensor 57B027-1 is defective

2

Final check

3

254

The pressure sensor has an internal stuck in closed position. Remove the sensor and replace it by a new Go to final step 3. one. After that recheck the system for proper function. Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

View onto the PTO gear oil filter with pressure sensor 57B027-1 [2/2]

PC4000-6 S/N 08199 and up

255

40 Troubleshooting

Part IV

G00169 - Trouble return oil filter hydraulic oil tank [1/1] Trouble code G00169 Contents of trouble

Trouble

Trouble return oil filter hydraulic oil tank

• Pressure sensor 40B163 signals, that the back pressure in the return oil filter exceeds 2 bar. • The system assumes that sensor 40B163 and the respective wiring are not defective. • The Qmin / Qmax setting via VHMS must be in ’Automatic’ position. • The trouble code is not set until the hydraulic oil temperature reached T2 + 18°C Sample Hydraulic oil: T2:

Related information

VG100 39°C

In this case the trouble code is not set until the hydraulic oil temperature reached: 39 + 18 = 57°C Action of controller



• Unfiltered return oil flows through the bypass of the filter into the hydraulic oil tank.


17

Step



Procedure

Nominal value


The return oil filter is clogged

1

Remove both filter cover retainers (two-armed & three-armed) on top of the hydraulic oil tank. For details refer to the OPERATION & MAINTENANCE MANUAL, section HYDRAULIC SYSTEM - FILTER SERVICE. Are one or more filters clogged?

Yes

Replace return oil filters as described in the OPERATION & MAINTENANCE MANUAL. Locate the cause of the contamination and rectify the problem.

No

Go to next step.

► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked The pressure sensor 40B163 is defective

2

Final check

3

256

The pressure sensor has an internal stuck. Remove the sensor and replace it by a new one. After that recheck the system for proper function.

Go to final step 3.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00170 - Trouble leak oil filter hydraulic oil tank [1/1] Trouble code G00170 Contents of trouble

Trouble

Trouble leak oil filter hydraulic oil tank

• Pressure sensor 40B164 signals, that the leak oil filter in the hydraulic tank is clogged. • The trouble code is set if the pressure in the leak oil chamber exceeds 0.5 bar. • The trouble code is not set until the hydraulic oil temperature reached T2 + 18°C Sample Hydraulic oil: T2:

Related information

VG100 39°C

In this case the trouble code is not set until the hydraulic oil temperature reached: 39 + 18 = 57°C Action of controller



• Unfiltered leak oil flows through the bypass of the filter into the hydraulic oil tank.


17

Step



Procedure

Nominal value


The leak oil filter is clogged

1

Remove the two-armed filter cover retainer on top of the hydraulic oil tank. For details refer to the OPERATION & MAINTENANCE MANUAL, section HYDRAULIC SYSTEM - FILTER SERVICE. Is the leak oil filter clogged?

Yes

Replace the leak oil filter as described in the OPERATION & MAINTENANCE MANUAL. Locate the cause of the contamination and rectify the problem.

No

Go to next step.

► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked The pressure sensor 40B164 is defective

2

Final check

3

PC4000-6 S/N 08199 and up

The pressure sensor has an internal stuck. Remove the sensor and replace it by a new one. After that recheck the system for proper function.

Go to final step 3.


257

40 Troubleshooting

Part IV

G00176 - Trouble battery voltage too low [1/2] Trouble code G00176

Trouble

Trouble battery voltage too low

Contents of trouble

• Via the resistor 11T080 the system detects too low battery voltage.

Related information

• If the battery voltage at 11T080 is <=18 V for 5 seconds, the trouble code is set. • The system assumes that the resistor 11T080 and its wiring is not defective, otherwise trouble code G00161 should be displayed. • If any other trouble code is displayed which indicates a problem with the alternator or the batteries, consider the influence of this malfunction before starting troubleshooting.




• Another engine start may be impossible.


17


Step


Procedure

Nominal value


The alternator is defective

1

Using a multimeter measure the charging voltage at terminal B of the shunt resistor 71T003. Does the charging voltage meet the specification?

Vcharge Yes

Go to next step.

No

Replace the alternator and recheck for proper charging voltage.

min. 27.5V max. 29.5V


The shunt resistor 71T003 is defective

2

Using a multimeter measure the charging voltage between alternator terminal B+ and chassis (body ground). Also see the charging voltage value which is shown in the VHMS Real Time Monitor. Does the charging voltage meet the specification?

Vcharge Yes

Go to next step.

No

Replace the shunt resistor and recheck for proper charging voltage.

min. 27.5V max. 29.5V

► Keep the main key switch 20S001 in OFF position. Battery information

Any battery is defective (or batteries)

Battery

Location

Function

Cat walk

Battery charging

Cab base

Stabilized voltage for MTC

71G001 71G002 Remark: If the machine is equipped with nonmaintenance-free batteries first check the battery acid level and correct if necessary.

258

71G003 3

71G004 13G008 13G009

Disconnect each battery and measure the battery voltage. Does the voltage of each battery meet the specification?

Check the clamps at the battery poles for proper contact and secure fixation. In case of any poor condition, rework the affected battery pole and reconnect clamps which are not fixed correctly.

VBATTERY min. 10V max. 12V

Replace any defective battery/batteries according to your local regulation.

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Alternator 52G005-1, shunt resistor 11T003, and batteries 71G001-71G004 & 13G008-13G009 [2/2]

PC4000-6 S/N 08199 and up

259

40 Troubleshooting

Part IV

G00177 - Trouble battery charging circuit [1/1] Trouble code G00177

Trouble

Trouble battery charging circuit

Contents of trouble

• The system detected that the batteries are charged even the engine is standing still. • At the shunt resistor 71T003 a charging current of more than 4 A is detected while the engine is standing still.

Related information





-

Instruction message Possible cause The shunt resistor 71T003 is defective or the battery cables are mixed up

17

Step



Procedure

Nominal value

► Main key switch 20S001 ON - engine OFF 1

Using a clamp-on ammeter measure the current at the shown measuring points 1-4 in below illustration Z27996.

If the measurement reading is over 4 A, go to next step.

► Main key switch 20S001 OFF Battery cables disconnected from the shunt resistor 71T003 The shunt resistor 71T003 is defective or the battery cables are mixed up or damaged

2

Final check

3

260

Measure the resistance of the shunt resistor. RShunt If the measurement does not meet the specification, replace the shunt resistor. 4.5±0.5Ω Refer to the wiring diagram. Disconnect all battery connections between the particular batteries, between the starter motors, and between the alternator and the shunt resistor. Locate the problem in the main battery wiring and repair as necessary. Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00178 - Trouble battery charging current too high [1/1] Trouble code G00178

Trouble

Trouble battery charging current too high

Contents of trouble

• The charging current from the alternator via the shunt resistor 71T003 is too high (higher than 200 A).

Related information





• Batteries may be destroyed if they are overcharged for a longer period.


17

Step



Procedure

Nominal value

► Keep the engine running at high idle. Using a clamp-on ammeter measure the charging current in front of the shunt resistor 71T003 (between alternator and shunt resistor).

Icharge max. 200A

Ammeter The charging current of the alternator is too high

1

Batteries

Alternator

If the measurement exceeds the specification (<200 A), replace the alternator. Verify that none of the batteries has an internal short-circuit. Final check

2

PC4000-6 S/N 08199 and up


261

40 Troubleshooting

Part IV

G00179 - Trouble control pressure X1-1 [1/2] Trouble code G00179

Trouble

Trouble control pressure X1-1 (XLR)

Contents of trouble

• The message is displayed if the pump regulation pressure X1 is too high. • The system assumes that the monitoring circuit for the X1 pressure is not disturbed.

Related information

• The pressure sensor 57B085-1 detected a pressure of more than 40 bar during 2 seconds.




• A too high X1 pressure affects the pump regulation adversely (high stall speed).


17

Step



Procedure

Nominal value Temp

► Keep the engine running at high idle and operation temperature.

hydr.oil

>=60°C Connect a pressure gauge (0-60 bar) to the test port M18 at the valve cartridge block The X1 pressure is too high

1

Remark: Make sure that the level for emergency operation at the valve cartridge block is in vertical position (electric/hydraulic regulation), refer to the illustration at the end of this troubleshooting chart.

Yes

Go to next step.

No

Replace the pressure sensor 57B085-1. Verify that trouble code G00179 is not set again. If the repair was successful, go to final step 3.

Measure the pump regulation pressure X1. Is the X1 pressure too high (more than 40 bar)? Wrong X1 pressure adjustment

2

Refer to the SERVICE MANUAL, section ELECTRONIC PUMP REGULATION SYSTEM and follow the adjustment procedures for the X1 pressure.

Final check

3


262

After successful adjustment go to final step 3.

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

View onto the valve cartridge block [2/2]



[M18]

X1 pressure test port

[57B085-1] Pressure sensor - X1 pressure [253.1]

Emergency lever in normal operating position "electronic pump regulation".

PC4000-6 S/N 08199 and up

263

40 Troubleshooting

Part IV

G00180 - Trouble pilot pressure X2 too low [1/2] Trouble code G00180

Trouble

Trouble pilot pressure X2 too low

Contents of trouble

• The message is displayed if the pilot pressure X2 is too low. • The system assumes that the monitoring circuit for the X2 pressure is not disturbed.

Related information

• The pressure sensor 57B086 detected a pressure of more than 30 bar during 2 seconds. • As long as the ladder is down or the refilling is extended, the X2 pressure is disabled.




• A too low X2 pressure affects the hydraulic system adversely.


17

Step



Procedure

Nominal value Temp


hydr.oil

>=60°C

The X2 pressure is too low

1

Connect a pressure gauge (0-60 bar) to the pressure test port M1.2 at the valve cartridge block. Measure the pilot pressure X2. Is the X2 pressure too low (less than 30 bar)?

Yes

Go to next step.

No

Replace the pressure sensor 57B086. Verify that trouble code G00180 is not set again. If the repair was successful, go to final step 3.

Wrong X2 pressure adjustment

2

After successful Refer to the SERVICE MANUAL, section CHECKS AND ADJUSTMENT OF PILOT PRESSURE and follow adjustment go to final the adjustment procedures for the X2 pressure. step 3.

Final check

3


264

X2 pressure 45±2bar

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

View onto the valve cartridge block with X2 pressure sensor 57B086 & M1.2 [2/2]

PC4000-6 S/N 08199 and up

265

40 Troubleshooting

Part IV

G00181 - Trouble pilot pressure X2 too high [1/2] Trouble code G00181

Trouble

Trouble pilot pressure X2 too high

Contents of trouble

• The message is displayed if the pilot pressure X2 is too high. • The system assumes that the monitoring circuit for the X2 pressure is not disturbed.

Related information

• The pressure sensor 57B086 detected a pressure of more than 52 bar during 2 seconds.




• A too high X2 pressure affects the hydraulic system adversely.


17

Step



Procedure

Nominal value Temp


hydr.oil

>=60°C

The X2 pressure is too high

1

Connect a pressure gauge (0-60 bar) to the pressure test port M1.2 at the valve cartridge block. Measure the pilot pressure X2. Is the X2 pressure too high (more than 52 bar)?

Yes

Go to next step.

No

Replace the pressure sensor 57B086. Verify that trouble code G00181 is not set again. If the repair was successful, go to final step 3.

Wrong X2 pressure adjustment

2

Refer to the SERVICE MANUAL, section CHECKS After successful AND ADJUSTMENT OF PILOT PRESSURE and follow adjustment go to final the adjustment procedures for the X2 pressure. step 3.

Final check

3


266

X2 pressure 45±2bar

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

View onto the valve cartridge block with X2 pressure sensor 57B086 & M1.2 [2/2]

PC4000-6 S/N 08199 and up

267

40 Troubleshooting

Part IV

G00184 - Central lubrication system empty G00187 - Slew ring gear lubrication system empty [1/1] Trouble code G00184 G00187

Trouble

G00184 - Central lubrication system empty G00187 - Slew ring gear lubrication system empty

Contents of trouble

• The message is displayed if the corresponding grease barrel needs refilling.

Related information

• The sensing range of the ultrasonic grease level sensors 62B108 & 62B109 is pre-adjusted ex factory. Further settings are not possible. • For more information about the ultrasonic grease level sensors 62B108 & 62B109 also refer to the PARTS & SERVICE NEWS AH10510, latest version.


• Background colour of the trouble code information: yellow • Risk, to operate the machine without grease. • Bucket cut-off after approx. 4 hours (option).


20

Step

• Inform service and then press cancel button.

Test condition & Inspection Using the dipstick, verify if the relating grease barrel needs refilling. Is the grease barrel empty?

Procedure

Yes

Press the cancel button and refill the specified grease. Verify that trouble code G00184 or G00187 is not displayed again.

No

Go to next step.

Yes

Go to final step 3.

No

Verify if other relevant trouble codes are displayed. If so, follow the troubleshooting procedures of the corresponding troubleshooting chart.

Definition of the grease levels

The concerned grease barrel (CLS or SLS) needs refilling

The trouble message is wrong. The concerned grease barrel (CLS or SLS) doesn’t need refilling

1

2

Refer to trouble code G00012/G00013 for: → Information about the LEDs at the ultrasonic sensor → Testing the sensor reaction → Troubleshooting procedures Could you rectify the problem?

Final check

268

Nominal value

3


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00185 - Trouble central lubrication system G00188 - Trouble slew ring gear lubrication system [1/4] Trouble code G00185 G00188

Trouble

G00185 - Trouble central lubrication system G00188 - Trouble slew ring gear lubrication system

Contents of trouble

• The grease pressure increase time (CLS or SLS) is too long.

Related information

• It is not possible to build up the grease pressure (CLS or SLS) in the pre-set time frame. • For further details concerning the lubrication system refer to the SERVICE MANUAL, section LUBRICATION SYSTEMS.




• Risk, to run the machine without CLS/SLS lubrication. • Optional function: If the function Bucket Cut-Off is activated via the CoDeSys Visualization software, and if the machine is operated further on, after trouble code G00185 or G00188 is set, the bucket function will be disabled after approx. 4 hours.


20

Step



Procedure

Nominal value


Grease pump: malfunction, worn or defective

The electrical function of the vent valve is disturbed

The grease may be soiled

The mechanical function of the vent valve is disturbed

The mechanical part of the vent valve is defective

1

Check the performance of the relating grease pump (CLS or SLS) and arrange preparations for testing the grease pressure. For detailed test & adjustment procedures refer to the SERVICE MANUAL, section LUBRICATION SYSTEMS. Make sure that the vent valve is closed. Does the relating grease pump build up grease pressure as specified?

Qvolume 19-21 doublestrokes/min Ppump drive Yes

Go to next step.

Grease pressure max. 180+5bar No

Grease pump defective, replace the grease pump.

Check the electrical function of the respective vent valve solenoid. Is the electrical function ok?

Yes

Go to next step.

No

Replace the vent valve solenoid.

3

Refill the grease barrel through a filter. Is grease pressure built up with clean grease?

Yes

The problem is solved, perform the final check in step 7.

No

Go to next step.

Yes

Go to next step.

4

Remove the mechanical part from the electrical part of the respective vent valve. Disassemble and check the lower part and clean as necessary. Is the mechanical part of the vent valve blocked?

No

Replace the vent valve.

2

5

PC4000-6 S/N 08199 and up

hydr.pressure

45±2bar

Repair or replace the mechanical part of the respective vent valve as necessary. Go to next step. Clean the respective contaminated grease system. Replace the grease filter and the screen.

269

40 Troubleshooting

Part IV

G00185 - Trouble central lubrication system G00188 - Trouble slew ring gear lubrication system [2/4] Possible cause End-of-line switch (grease main line): wrong adjustment or defective

Final check

270

Step


Procedure

6

Refer to the SERVICE MANUAL, section LUBRICATION SYSTEMS, and follow the adjustment procedure. Did you need to correct any wrong adjustment?

7

Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again. Verify that the operation cycles of the lubrication systems correspond to the following time diagram Z 28055-1 (taken from the flowchart).

Yes

Go to next step.

No

Replace the respective end-of-line switch.

Nominal value

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Trouble codes G00185 and G00188 - view onto the vent valve [3/4]


Solenoid

(5)

Reset spring

(2)

Valve assembly

(6)

Auxiliary valve cone

(3)

Solenoid stem

(7)

Main valve cone

(4)

Lever

PC4000-6 S/N 08199 and up

271

40 Troubleshooting

Part IV

Allocation of vent valves and end-of-line switches [4/4] Lubrication system

Vent valve

End-of-line switch

CLS

62Q507a

80B043

SLS

62Q509a

62B046

Wiring diagram related to trouble codes G00185 and G00188

272

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00186 - Trouble central lubrication system G00189 - Trouble slew ring gear lubrication system [1/3] Trouble code Trouble

G00186 G00189

G00186 - Trouble central lubrication system G00189 - Trouble slew ring gear lubrication system

Contents of trouble

• The grease pressure decrease time (CLS or SLS) is too long.

Related information

• It is not possible to release the grease pressure (CLS or SLS) in the pre-set time frame. • For further details concerning the lubrication system refer to the SERVICE MANUAL, section LUBRICATION SYSTEMS.




• Risk, to run the machine without CLS/SLS lubrication. • Optional function: If the function Bucket Cut-Off is activated via the CoDeSys Visualization software, and if the machine is operated further on, after trouble code G00186 or G00189 is set, the bucket function will be disabled after approx. 4 hours.


The electrical function of the respective vent valve is disturbed

The mechanical part of the vent valve is blocked or defective

Final check

20


Step


Procedure Yes

Go to next step.

No

Locate the problem and repair or replace the faulty component of the wiring as necessary. Replace the faulty vent valve solenoid if necessary.

1

Check the electrical function of the respective vent valve solenoid and its wiring. Is the electrical function ok?

2

Remove the mechanical part from the electrical part of the respective vent valve. Disassemble and check the lower part and clean as necessary. If it is necessary repair or replace the mechanical part. Clean the respective contaminated grease system.

3

Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again. Verify that the operation cycles of the lubrication systems correspond to the following time diagram Z 28055-1 (taken from the flowchart).

Nominal value

Go to next step.

Allocation of the vent valves Lubrication system

Vent valve

CLS

62Q507a

SLS

62Q509a

PC4000-6 S/N 08199 and up

273

40 Troubleshooting

Part IV

Time diagram for the operation cycles of the lubrication systems CLS and SLS [2/3]

274

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Trouble codes G00186 and G00189 - view onto the vent valve [3/3]

Legend for figure Z 26959 (1) Solenoid (2) Valve assembly (3) Solenoid stem (4) Lever (5) Reset spring (6) Auxiliary valve cone (7) Main valve cone

PC4000-6 S/N 08199 and up

275

40 Troubleshooting

Part IV

G00207 - Engine remote oil tank 1 empty [1/1] Trouble code G00207 Contents of trouble

Trouble

Engine remote oil tank 1 empty

• Sensor 63B103 in the remote engine oil tank signals that the tank is nearly empty. • The system assumes that the level sensor 63B103 in the remote engine oil tank or the wiring of this monitoring circuit system is not defective. • The remote engine oil tank is part of the engine oil management system.

Related information

Remark: The remote engine oil tank is also equipped with an oil level sight gauge.




• Risk, to run out of remote engine oil.


2

• Inform service.


Procedure

Nominal value

Keep the main key switch 20S001 in ON position. Check the remote engine oil level at the sight gauge of the tank and refill specified engine oil as necessary. Do not overfill.

Information - Engine oil management For the engine oil management system an engine oil consumption (for internal lubrication) of max.1% of the fuel flow-rate is determined. The engine remote oil tank is empty

If the engine oil consumption considerably exceeds the specification, contact the Cummins service.

Information - Engine oil specifications For the engine oil specifications refer to the Cummins Operation and Maintenance Manual QSK45 and QSK60 Series Engines, section Cummins Engine recommended fluids and lubricants. The minimum oil quality requirement is CF-4 and higher.

276

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00240 - Trouble hydraulic oil temperature [1/1] Trouble code

Trouble

G00240


Contents of trouble

• Sensor 59B015 in the hydraulic oil tank signals that the hydraulic oil temperature (< T1) is far below the operating temperature (T2). • Below the hydraulic oil operating temperature T2 the pump regulation is automatically set to ½Qmax. • The system assumes that the hydraulic oil temperature sensor 59B015 and its wiring circuit are not defective.

Related information

• The sensor 59B015 detects an hydraulic oil temperature

• Background colour of the trouble code information: green • On condition that the engine is running: the fan speed is set to min. speed.


Instruction message

• • • •

The hydraulic oil temperature (
Possible cause

• Hydraulic oil far below operating temperature! - Pre-heat hydraulic oil or warm up at low idle speed and reduced power. Test condition & Inspection

Procedure

Nominal value

► Keep the engine running at low idle.

The hydraulic oil temperature (< T1) is far below the operating temperature (T2)

Start to warm-up the hydraulic oil by running the engine in low idle or by pre-heating. As soon as the hydraulic oil temperature T1 is reached, the trouble message G00240 is no longer displayed. Continue warming-up until the hydraulic oil operating temperature T2 is reached. If it is a problem to warm-up the hydraulic oil up to the operating temperature T2, check the setting for the hydraulic oil specification in the service mode of VHMS. Also verify that the correct type of hydraulic oil is used (according to the ambient temperature). In case the setting for the hydraulic oil in VHMS would be wrong, correct the setting according to the specification of the used hydraulic oil. Hydraulic oil temperature table

PC4000-6 S/N 08199 and up

277

40 Troubleshooting

Part IV

G00242 - Engine 1 already running [1/1] Trouble code G00242

Trouble

Engine 1 already running

Contents of trouble

• This message informs the operator that the engine is already running.

Related information

• After this message is displayed, every further engine start is blocked as long as the engine is still running.



Problem that appears on machine Instruction message

278

22

- Engine runs (starter motor inactive).

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00243 - Fill up fuel tank [1/1] Trouble code G00243 Contents of trouble Related information

Trouble

Fill up fuel tank

• The fuel tank sensor 31B063 indicates that the fuel is on minimum level. • The system assumes that the fuel tank sensor 31B063 and its wiring circuit are not defective. -




• Risk, to run out of fuel.

Instruction message

23

Possible cause

• A fuel reserve only is still in the tank - Order tanker.


Procedure

Nominal value

Keep the main key switch 20S001 in ON position. Refill fuel according to the specification in the CUMMINS ENGINE OPERATION AND MAINTENANCE MANUAL. Do not overfill.

Information - Diesel fuel specifications The fuel tank is nearly empty

For the Diesel fuel specifications refer to the Cummins Operation and Maintenance Manual QSK45 and QSK60 Series Engines, section Fuel Recommendations and Specifications. Cummins recommends the use of ASTM number 2 Diesel fuel. The viscosity of the Diesel fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication. For a more detailed description of the Diesel fuel properties also refer to the Cummins Service Bulletin 3379001-10, Fuel for Cummins Engines.

PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV

G00245 - Engine shutdown from ground [1/2] Trouble code G00245

Trouble

Engine shutdown from ground

Contents of trouble

• The engine has been stopped from the ground manually via switch 54S051 and/or 54S052.

Related information

• If switch 54S051 or 54S052 is activated from ground while the engine is running, the engine shuts down. • After switch 54S051 or 54S052 has been activated from ground under the condition "Engine OFF & main key switch 20S001 ON", engine start is not possible.




• The engine is shut off and restart is not possible until switch 54S051 and/or 54S052 is manually switched back into its neutral position.


24

Step

• Engine shutdown has been actuated from ground man.


Procedure

Nominal value


The engine shutdown was manually activated from ground

1

Check the cause for the manually activated engine shutdown. Was switch 54S051 and/or 54S052 manually activated from ground?

Yes

Contact your supervisor and clarify the situation. After the cause for the engine shutdown is clarified, actuate switch 54S051 and/or 54S052 again and restart the engine.

No

Go to next step.


No input signal at the VHMS screen

Final check

280

2

3

Actuate switch 54S051/54S052 and verify the input signal via the VHMS real time monitor. Does the input signal of switches displays at the VHMS screen?

Yes

Switches may have been activated unintentionally. Go to final step 3.

No

Refer to the wiring diagram. Check switch 54S0051/54S0052 and its wiring. Locate the problem and repair as necessary. After repair, recheck switches for proper function.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagrams related to trouble code G00245 [2/2]

PC4000-6 S/N 08199 and up

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40 Troubleshooting

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G00246 - Hydraulic oil temperature [1/1] Trouble code G00246

Trouble


Contents of trouble

• Sensor 59B015 in the hydraulic oil tank signals that the hydraulic oil temperature is cold - below the operating temperature (T2). • Below the hydraulic oil operating temperature T2 the pump regulation is automatically set to ½Qmax. • The system assumes that the hydraulic oil temperature sensor 59B015 and its wiring circuit are not defective.

Related information




• The hydraulic oil temperature is below the operating temperature (T2). • Below the hydraulic oil operating temperature T2 the back pressure valve 40K601 is energized (24 V). The hydraulic return oil flow to the collector pipe is led directly through the filters into the hydraulic oil tank (not through the hydraulic oil coolers). • As soon as the hydraulic oil reaches the operating temperature, the back pressure valve 40K601 will be de-energized (0 V) and the hydraulic oil flow is led through the oil coolers.


25

• Hydraulic oil below operating temperature. - Operate with reduced power! Test condition & Inspection

Procedure

Nominal value

► Keep the engine running at high idle. Keep the engine running under operating conditions. As soon as the hydraulic oil temperature T2 is reached, the trouble message G00246 is no longer displayed. If it is a problem to warm-up the hydraulic oil up to the operating temperature T2, check the setting for the hydraulic oil specification in the service mode of VHMS. Also verify that the correct type of hydraulic oil is used (according to the ambient temperature). In case the setting for the hydraulic oil in VHMS would be wrong, correct the setting according to the specification of the used hydraulic oil. Hydraulic oil temperature table The hydraulic oil is too cold - below the operating temperature (T2)

282

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40 Troubleshooting

G00247 - Slew ring gear house break [1/1] Trouble code G00247

Trouble

Slew ring gear house break

Contents of trouble

• If the slew lock switch 20S029 is switched to position 1 while the engine is running, the slew parking brake (= slew ring gear house brake) is locked. • The system assumes that the relating wiring circuit is not defective.

Related information

• The system operates as a so called spring-loaded parking brake. Hydraulic pressure is NOT present: Spring force locks the brake Hydraulic pressure is present: The brake is released




• If the slew parking brake is locked, switch 20S029 in position 1, slew movement is impossible.


26

Step

• Slew ring gear house brake ON


Procedure

Nominal value


Switch 20S029 is switched to position 1. The slew parking brake is locked.

1

Final check

2

PC4000-6 S/N 08199 and up

In case the slew parking brake is activated (switch 20S029 in position 1), but slew movement is Release the slew parking brake by switching 20S029 to still possible, refer to position 0 (slew movement is possible). troubleshooting for symptoms SHY019 "Swing parking brake without function" and follow the respective instructions. Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.

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40 Troubleshooting

Part IV

G00252 - Emergency shut-down at access ladder G00253 - Emergency shut-down at valve block G00254 - Emergency shut-down at hydraulic control panel G00255 - Emergency shut-down in cabin [1/2] Trouble code G00252 ~ G00255

Trouble

G00252 - Emergency shut-down at access ladder G00253 - Emergency shut-down at valve block G00254 - Emergency shut-down at hydraulic control panel G00255 - Emergency shut-down in cabin

• Emergency shut-down switch was activated when the engine was running. Emergency shut-down switch Contents of trouble

Related information Action of controller Problem that appears on machine

Any emergency shut-off button was activated

Trouble code

70S033a

Access ladder

G00252

61S033b

Valve block

G00253

57S033c

Hydraulic control panel

G00254

20S036

Operator's cab

G00255

• The engine is shut off. • Restart is impossible. • Background colour of the trouble code information: red • It needs to be checked why the relating emergency shut-down switch was activated.

Instruction message

Possible cause

Location

10

Step

1

• Emergency shut-down switch was actuated. - Unlock before restarting. - If failure exist further, inform service. Test condition & Inspection

Check the cause for the emergency activation. Is any cause present?

Procedure

Yes

No

Rectify the cause or the problem. After that release the concerned emergency shut-down switch(es). Go to next step. Refer to the wiring diagram. Repair or replace the concerned switch or its wiring as necessary. After the repair go to final step 3.

The concerned emergency shut-off button or its wiring may be defective

2

Visually inspect the concerned switch, the switch contact, and the respective wiring.

Final check

3


284

Nominal value

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

Wiring diagram related to trouble codes G00252 - G00255


[2/2]

PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV

G00257 - Hydraulic oil temperature [1/1] Trouble code G00257

Trouble


Contents of trouble

• Sensor 59B015 in the hydraulic oil tank signals that the hydraulic oil temperature (
Related information




• The hydraulic oil temperature (

30

• Hydraulic oil far below operating temperature! - Pre-heat hydraulic oil or warm up at low idle speed and reduced power. Test condition & Inspection

Procedure

Nominal value

► Keep the engine running at low idle.

The hydraulic oil temperature (
286

Start to warm-up the hydraulic oil by running the engine in low idle or by pre-heating. As soon as the hydraulic oil temperature T1 is reached, the trouble message G00257 is no longer displayed. Continue warming-up until the hydraulic oil operating temperature T2 is reached. If it is a problem to warm-up the hydraulic oil up to the operating temperature T2, check the setting for the hydraulic oil specification in the service mode of VHMS. Also verify that the correct type of hydraulic oil is used (according to the ambient temperature). In case the setting for the hydraulic oil in VHMS would be wrong, correct the setting according to the specification of the used hydraulic oil. Hydraulic oil temperature table

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00261 - Maintenance safety switch [1/2] Trouble code G00261

Trouble


Contents of trouble

• The maintenance safety switch 50S058 is switched off when the engine is running.

Related information

• The engine is stopped because of emergency shut off via the maintenance safety switch 50S058. • Switch 50S058 is the maintenance safety switch which can be secured with padlocks.




• Engine start is impossible.

Instruction message

Possible cause

11

Step

• Engine switched off by maintenance safety switch in the engine room. - Unlock before restarting - If failure exists further, inform service. Test condition & Inspection

Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position The maintenance safety switch 50S058 has been switched off intentionally

1

Check the condition of the maintenance safety switch. Is the maintenance safety switch switched OFF?

Yes

Contact your supervisor and clarify the reason why the maintenance safety switch is switched off.

No

Go to next step.


Malfunction of the maintenance safety switch 50S058 or its wiring

Final check

2

3

PC4000-6 S/N 08199 and up

Yes

Switch 50S058 Repair or replace as necessary. Wiring of 50S058 Refer to the wiring diagram. Locate the problem and repair as necessary.

No

Verify if other trouble codes are displayed, which may cause the problem. If any suspicious trouble code is displayed, follow the relating troubleshooting chart.

Check the function of the maintenance safety switch and its wiring. Could you identify any trouble?


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40 Troubleshooting

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[2/2]

288

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00262 - Trouble screen at hydr. cooler entry clogged [1/2] Trouble code G00262

Trouble

Trouble screen at hydraulic cooler entry clogged

Contents of trouble

• Pressure sensors 40B165 & 40B166 signal pressures of 0-60 bar in front of and behind the strainer in the collector pipe leading to the hydraulic oil cooler. The pressure difference represent the pressure drop in the strainer. • The system assumes that the strainer is clogged if the pressure difference exceeds 2.5 bar.

Related information

• The system assumes that the pressure sensors 40B165 & 40B166 and their wiring are not defective.




• Risk, to run the machine with insufficient cooling of the hydraulic oil.

Instruction message Possible cause Pressure sensors 40B165 & 40B166 may have a malfunction

20

Step

1


Test condition & Inspection Check the pressure sensors for proper function. Is a pressure sensor faulty?

Procedure Yes

Replace pressure sensor and recheck for proper function.

No

Go to next step.

Nominal value

► Keep the main key switch 20S001 in OFF position. Remove the oil strainer in the collector pipe. Clean or replace the strainer as necessary.

The strainer in the collector pipe (oil flow → to the oil cooler) is clogged

2

Final check

3

Remark: If the strainer is clogged, the cause for the clogging needs to be found. Locate the problem and take adequate measures.

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290

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00417 - Communication failure PLC <==> VHMS controller [1/1] Trouble code G00417

Trouble

Communication failure PLC <==> VHMS controller

Contents of trouble

• The CAN bus communication between MTC (PLC) and VHMS controller is impossible.

Related information

• Communication between MTC (PLC) and VHMS controller takes place via a serial connection. • At the MTC the serial cable is connected to the COM2 port. • At the VHMS controller the serial cable is connected to the CN3A port.




• Data exchange (e.g. the monitoring function) and the memory function are disabled.


2

Step

• Inform service.


Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. Disconnection in the serial wiring between MTC and VHMS controller or the contact in any connector is defective

1

Visually check the serial harness and its connectors. Verify that the serial connector on the MTC side is connected to the COM2 port. Is the serial harness in proper condition and is the connector on the MTC side plugged into the COM2 port?

Yes

Go to next step.

No

Reconnect the serial connector orderly to the COM2 port of the MTC or locate the problem and repair as necessary.


The serial cable may be defective (no continuity)

Final check

2

3

Disconnect the serial connectors from MTC and VHMS controller and measure the wiring harness for continuity. Is continuity present?

Yes

Check the MTC & VHMS controller program for compatibility via CodeSys. Please contact KMG if further information is required.

No

Replace the CAN bus harness.

Rmax 1Ω


Serial harness and ports between MTC and VHMS controller

PC4000-6 S/N 08199 and up

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40 Troubleshooting

Part IV

G00420 - Connector sel error [1/1] Trouble code G00420

Trouble

Connector sel error

Contents of trouble

• The cable connectors at the VHMS controller are mixed up. • It is also possible that single wires of any wire harness at the VHMS controller are connected to wrong connector pins. • The wiring to the VHMS controller may be damaged (or short cut).

Related information

• It is necessary to check the repair history. In case any repair has been done at the VHMS wiring, the wiring needs a double-check.




• The monitoring system is disturbed.


2

Step

• Inform service.


Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. The cable connectors at the VHMS controller may be mixed up.

1

Check the cable connectors at the VHMS controller for their correct connection order. Are all connectors orderly plugged in?

Yes

Go to next step.

No

Plug in the connectors in their correct order.

► Keep the main key switch 20S001 in OFF position. Cables may be connected to wrong connector pins

2

In case any repair has been done at the system before, check if all cables are connected to their conforming connector pins. Are all cables connected to their conforming pins?

Yes

Go to next step.

No

Reconnect the cables to their conforming pins.

► Keep the main key switch 20S001 in OFF position. The wiring at the VHMS controller is damaged (or short cut)

3

Final check

4

292

Refer to the wiring diagram. Check the cables and their connectors at the VHMS controller for any damage. Disconnect the connectors from the VHMS controller and measure the wire harnesses for continuity.

Replace any defective component or repair any wiring malfunction as necessary.


PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00421 - Farm sys error [1/1] Trouble code G00421

Trouble

Farm sys error

Contents of trouble

• The firmware has a problem. • A new upload is necessary.

Related information

• The operation system has a basic problem.


• Background colour of the trouble code information: yellow • No VHMS operation.


• The VHMS system is inoperative.


2

Step

The firmware has a problem

1

Final check

2

PC4000-6 S/N 08199 and up

• Inform service.


Procedure

Nominal value

► Keep the main key switch 20S001 in ON position. Upload new firmware. Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.

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40 Troubleshooting

Part IV

G00422 - Can-net sys (J1939) [1/1] Trouble code G00422

Trouble

Can-net sys (J1939)

Contents of trouble

• The VHMS controller does not receive any signal from QUANTUM controler (engine control) via CAN bus no. 1.

Related information

• Engine speed >300 1/min


• Background colour of the trouble code information: yellow.




2

Step


Procedure

Nominal value


The connection between VHMS and the engine control systems CENSE and QUANTUM is impossible

1

Final check

2

294

• Inform service.

Check the wiring, connectors, and pins between VHMS and the engine control systems QUANTUM for proper order and connection. Repair or replace components as necessary. Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.

PC4000-6 S/N 08199 and up

Part IV

40 Troubleshooting

G00423 - Application sys error [1/1] Trouble code G00423

Trouble

Application sys error

Contents of trouble

• The software application has a problem relating to the VHMS controller. • A new software release is necessary.

Related information

• The software is inoperative.


• No VHMS operation. • Background colour of the trouble code information: yellow.




2

Step

• Inform service.


Procedure

Nominal value


The software has a problem

1

Final check

2

PC4000-6 S/N 08199 and up

A new release of the VHMS software is necessary - change VHMS controller. Contact the Service Dept. of Komatsu Mining Germany for further details. Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.

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40 Troubleshooting

Part IV

G00425 - Settings impossible to take over into the PLC [1/2] Trouble code G00425 Contents of trouble

Trouble

Settings impossible to take over into the PLC (/MTC)

• It is impossible to take over the settings into the MTC memory, which are input via the monitor MH801. • That means: any modification of the settings are impossible. • After the system failed 10 times to build up a connection between MH801 → VHMS controller → MTC, the trouble code G00425 is displayed.

Related information

Remark: Trouble codes G00417 and G00491 may be displayed as well. In case these trouble codes are displayed at the same time, first follow the instructions of G00417 and/or G00491 before starting troubleshooting according to G00425.




• It is impossible to modify any settings.


2

• Inform service.


Procedure

On condition that trouble codes G00417 & G00491 are not displayed, any software or hardware problem may be present

Re-load the program of the MTC & VHMS controller with CoDeSys or replace the units if necessary. Please contact KMG if further information is required.

Final check


296

Nominal value

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Part IV

40 Troubleshooting

Overview for G00425: Display (MH801) → VHMS controller → MTC [2/2]

PC4000-6 S/N 08199 and up

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Part IV

G00491 - Communication failure MH800 <==> VHMS-Controller [1/2] Trouble code G00491

Trouble

Communication failure MH800 (/MH801) <==>- VHMS-Controller

Contents of trouble

• The CAN bus 2 communication between the display MH801 and the VHMS controller is inoperative.

Related information

• Communication between display MH801 and VHMS-controller takes place via CAN bus 2. At the display MH801 the CAN bus is connected to the CN2 port via connectors 20X335e, 20X335d, 10X335c, 10X335b, and resistor 10R101 on connector 10X300a. At the VHMS controller the CAN bus is connected to the CN4A port.




• Communication between display MH801 and VHMS controller is impossible.


2

Step

• Inform service.


Procedure

Nominal value

► Keep the main key switch 20S001 in OFF position. Disconnection in the CAN bus wiring between display MH801 and VHMS controller, or the contact in any connector is defective.

1

- Visually check the condition of the CAN bus harness. - Visually check all connectors/pins for proper crimping and connection. - Make sure that the cables are fixed in the correct sequence inside the connectors. - Is the CAN bus harness in good condition? - Is the contact of connectors/pins alright? - Is the cable allocation in the connectors correct?

Yes

Go to next step.

No

Locate the problem and repair as necessary. If any CAN bus segment is damaged, replace the relating cable segment.


The CAN bus harness or the belonging resistor 10R101 may be defective (no continuity, wrong resistance)

Final check

298

2

3

Separate the CAN bus segments and measure their continuity. In addition separate resistor 10R101 from connector 10X300a and measure its resistance. - Is the continuity of the CAN bus segments alright? - Does the resistance of 10R101 meet the specification?

Yes

Re-place MH801 and/ or the VHMS controller, or replace the units if necessary. Please contact KMG if further information is required.

No

Replace the defective CAN bus segment or the resistor 10R101 as necessary.

CAN bus: Rmax 1Ω 10R101: 120Ω


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40 Troubleshooting

Overview for G00491: Display (MH801) → VHMS controller [2/2]

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Part IV

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Part V

40 Troubleshooting

Part V

Troubleshooting by symptoms Symptoms of the engine and related electrical system SEL001 - Engine does not start (engine does not rotate) [1/5] Trouble code SEL001

Trouble

Engine does not start (engine does not rotate)

Contents of trouble

• The engine does not start (the engine does not rotate). • Corresponding trouble messages are not displayed.

Related information

• If engine start is impossible (engine does not rotate), the following provided engine start blocking mechanisms or malfunctions may be the cause. - No or not enough battery power is present (below 17 Volt). - The safety lock lever is in down position during engine start. - The safety lock lever switch (20S105) is faulty. - The pre-lube process is not started or stopped. - The starter motors have an internal short circuit. - The starter motors are mechanically blocked (breakdown).


• The engine does not start (the engine does not rotate).

Possible causes

• Missing battery maintenance, internal short circuit in any battery or low battery voltage (below 17 V) • Handling error by the operator), safety lock lever in the wrong (down) position • Safety lock switch (20S105) or its wiring faulty • The pre-lube process is disturbed (it is not started or stopped) • Component's lifetime exceeded (starter motors internal disconnection or short circuit) • Component's lifetime exceeded (starter motors internal disconnection or damage)

Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 OFF and maintenance safety switch 50S058 locked. Neglected battery maintenance. Internal short circuit in any battery or low battery voltage (below 17 V).

1

Yes

Vbatt >24V (under load no drop below Replace the concerned 20V) battery/batteries. Electrolyte specific gravity >1.26

No

Go to next step.

Check for the correct lock lever position (UP) during engine start. Is lock lever 20S105 in the correct position (UP) for engine start?

Yes

Go to next step.

Refer to the wiring diagram, check the switch function (20S105) and the belonging wiring. Are safety lock switch 20S105 and its wiring ok?

Yes

Go to next step.

No

Repair or replace as necessary.

Check the capacity and condition of batteries 71G001–71G004. Also check the capacity and condition of batteries 13G008 & 13G009 in the cab base. Is any battery defective?

► Main key switch 20S001 ON

Handling error by the operator Safety lock lever in the wrong (down) position

2

Safety lock switch (20S105) or its wiring faulty

3

PC4000-6 S/N 08199 and up

Move the lock lever in the UP position and repeat the engine start. ► Main key switch 20S001 OFF and maintenance safety switch 50S058 locked. No

Wiring diagram

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40 Troubleshooting

Part V

SEL001 - Engine does not start (engine does not rotate) [2/5] Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 ON & engine start switch 20S004-1 activated

The pre-lube process is disturbed (it is not started or stopped)

4

When the start switch 20S004-1 is activated, the pre-lube pump 52G006-1 must start and run until an oil pressure of 0.17 bar is built up in the engine. As soon as the specified engine oil pressure is reached at the pressure switch 52B093-1, the pre-lube switch 52K030-1 initiates the start signal to the starter relays 52Q002a-1 and 52Q002b-1 of the starter motors. Refer to the wiring diagram and check the prelube process. Is the pre-lube process ok (including pre-lube start and stop)?

Yes

Go to next step.

No

Refer to wiring diagram and check the following components and the relating wiring: - Pre-lube pump 52G006-1 Wiring - Engine oil diagram pressure switch 52B093-1 (incl. switch function) - Pre-lube timing relay 52K030-1 - Starter relays 52Q002a-1 and 52Q002b-1

► Main key switch 20S001 ON and 20S004-1 activated Component's lifetime exceeded (starter motors internal disconnection or short circuit)

5

Check the relays 52Q002a-1 & 52Q002b-1 for Vbatt (approx. 24 V) input/power supply. Is Vbatt present at the input and output of these relays? Is Vbatt present at the starter motors?

Yes

Replace the starter motors.

No

Refer to the wiring diagram and repair/ replace the wiring as necessary.

Vbatt (approx. 24V)

► Main key switch 20S001 OFF and battery switches 71Q003 & 71Q004 OFF

Component's lifetime exceeded (starter motors internal disconnection or damage)

6

Final check

7

302

Yes

Replace the starter motors and recheck the system for proper function.

No

Check the engine flywheel for free mechanical rotation. Also refer to the Cummins Troubleshooting and Repair Manual. Repair or replace as necessary.

Disassemble or replace both starter motors and inspect them. Is any mechanical fault detectable?

Bring the machine back into the original condition. Start the machine and verify that the repair was successful.

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

Wiring diagram 1 related to trouble code SEL001 [3/5]

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[4/5] Legend for illustration Z 27977 (previous page) (52B093-1)

Engine oil pressure switch

(52G006-1)

Pre-lube pump

(52K030-1)

Pre-lube timing relay

(52M001-1)

Starter 1

(52M002-1)

Starter 2

(52Q002a-1)

Starter relay 1

(52Q002b-1)

Starter relay 2

(52Q030a-1)

Pre-lube pumpe relay

(71G001)

Battery

(71G002)

Battery

(71G003)

Battery

(71G004)

Battery

(71Q003)

Battery switch (for starter 52M001-1)

(71Q004)

Battery switch (for starter 52M002-1)

Legend for illustration Z 27978 (following page) A

(13G008 & 13G009)

Controller batteries (for stabilizing the control voltage)

(13Q003)

Battery switch for the controller batteries

B

(20S004-1)

Engine start switch

C

(51K001a-1)


D

(51K001b-1)

Engine start relay motor 1 (redundant)

304

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

Wiring diagram 2 related to trouble code SEL001 [5/5]

PC4000-6 S/N 08199 and up

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Part V

SEL002 - Engine stops while in operation [1/3] Trouble code SEL002

Trouble

Engine stops while in operation

Contents of trouble

• During operation the engine suddenly stops. • A corresponding trouble message is not displayed.

Related information

• Battery voltage and power supply at the start relays and at the starter motors are present.


• Engine shut-down from high or low idle. • Engine restart is impossible (engine rotates but does not start). • No exhaust smoke visible.

Possible causes

• Engine shut-down due to: - Lack of fuel in the fuel tank or contamination - Racor (water separator) and/or fuel filter clogged - Internal (or mechanical) fuel pump problems or wear

Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 ON

Yes

- Check the level in the fuel tank. Lack of Diesel fuel at the fuel filters

1

Go to next step.

Refer to the Cummins Engine Manual for fuel specifications.

- Check the fuel level and refuel if necessary.

- Check the fuel solenoid valve 31Q599 for proper function (31Q599 must be open during engine start). Is fuel supply present at the Racor and at the fuel filters? No

- Inspect the fuel tank and the bottom fuel line connection for contamination. - Check 31Q599 for proper function and repair if necessary. - Check the fuel supply line for free passage and repair if necessary.

► Main key switch 20S001 OFF and maintenance safety switch 50S058 locked.

Lack of Diesel fuel at the fuel pump

2

- Check the Racor and/or fuel filters for contamination. If necessary clean the Racor and/or replace the filter elements. Replace the fuel filter on the engine side.

Yes

Refer to the Cummins Engine Bleed the fuel pump and restart the engine. Manual for fuel specifications.

No

Check the supply hoses and unions for free passage and repair if necessary. Go to next step.

- Check the fuel shut-off circuit for proper function. Is fuel present at the fuel pump?

306

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40 Troubleshooting

SEL002 - Engine stops while in operation [2/3] Possible cause

Step


Procedure

Nominal value

► Inform the Cummins Service. Main key switch 20S001 ON. Connect the Cummins tester and start the "Insite" software.

Mechanical problems at the fuel system

Final check

3

4

PC4000-6 S/N 08199 and up

Yes

Repair as necessary and recheck the system for proper function.

No

Check the fuel specification and measure the water content in the Diesel fuel. Inspect the fuel system together with the Cummins Service. Repair or replace as necessary.

Monitor and check the starting process (fuel supply) with the "Insite" software. Could you locate the problem?

Refer to the Cummins specifications.


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40 Troubleshooting

Part V

View onto the fuel system water separator [3/3]

Legend for illustration Z 27346 (1)

Fuel tank

(2)

Fuel shut-off solenoid valve (31Q599)

(3)

Water separator filter

(4)

Fuel filters

308

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SEL003 - Engine speed is hunting during boom-up movement [1/1] Trouble code SEL003

Trouble

Engine speed is hunting during boom-up movement

Contents of trouble

• At high idle the engine speed is irregular. • During boom-up movement the engine speed is hunting • At high idle the engine speed is lower than specified

Related information

• First carry out troubleshooting with the Cummins Service and check for inactive / active trouble codes stored in the error memory (inactive / active trouble codes could disturb the ECM control during low or high idling). • Connect the Cummins tester and check with the "Insite" software tool.


• Lack of output power due to: - Improper machine operation because of engine hunting - Improper function of the hydraulic control system - Improper function of the pump regulation system

Possible causes

• Active / inactive trouble codes stored in the Quantum ECM memory disturb the RPM control • Lack of fuel • Wrong RPM adjustments

Possible cause

Step


Procedure

Nominal value

► Connect the Cummins tester and check with the "Insite" software tool Active / inactive trouble codes stored in the Quantum ECM memory disturb the RPM control

1

Check for pending active / inactive trouble codes and delete the error memory completely. Then recheck the engine running condition. Is the hunting problem solved?

Yes

Refer to the Go to the final step and Cummins then release the Engine shovel back to Manual for operation. fuel specifications.

No

Go to next step.

► Main key switch 20S001 OFF and maintenance safety switch 50S058 locked. The engine is hunting during boom up movement. Lack of fuel

2

Check all Racors / fuel filters for contamination. Is any filter clogged?

Yes

Refer to the Replace the fuel filter Cummins elements and clean the Engine Racor housing as Manual for necessary. fuel specifications.

No

Go to next step.

Connect the Cummins tester and check with the "Insite" software tool

At high idle the engine speed is lower than specified Wrong RPM adjustments

Final check

3

4

PC4000-6 S/N 08199 and up

Check and adjust the specified RPM. Also refer to the SERVICE MANUAL and to the PM-CLINIC sheets. Was the RPM adjustment successful?

Yes

Refer to the Go to the final step and Cummins then release the Engine shovel back to Manual for operation. fuel specifications.

No

Together with the Cummins Service work out the complete Fuel System sheet.


309

40 Troubleshooting

Part V

SEL004 - Engine does not stop [1/1] Trouble code SEL004

Trouble

Engine does not stop

Contents of trouble

• When the engine stop switch 20S005-1 is activated the engine does not stop.

Related information

• A corresponding trouble message is not displayed.


• It is not possible to stop the running engine.

Possible causes

• When the engine stop switch 20S005-1 is pressed the engine stop not activated. • It is not possible to activate the shut-off solenoid (QSK60, Quantum ECM fuel block).

Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 ON, engine stop switch 20S005-1 activated When the engine stop switch 20S005-1 is pressed, the engine stop is not activated

1

Check the circuits of 20S005-1 and the engine stop via node 20K309 for proper function. Is any problem present?

Yes

Refer to the wiring Vmin: 22V diagram. Locate the problem and repair as necessary. After that recheck the system for Vmax: 24V proper function.

No

Go to next step.

► Main key switch 20S001 ON, engine stop switch 20S005-1 activated

It is not possible to activate the shut-off function (QSK60, Quantum ECM fuel block)

Final check

310

2

3

Inform the Cummins Service. Connect the Cummins tester to the engine ECM and check the system with the "Insite" software tool. Is the shut-off function defective?

Yes

Repair or replace as necessary. After that Cummins recheck the system for proper function.

No

Using the Cummins tester, check for other pending trouble codes of the engine/fuel system. Continue search for faults and relating repairs according to the Cummins troubleshooting guide.


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SEL005 - Engine lacks output (no power) [1/2] Trouble code SEL005

Trouble

Engine lacks output (no power)

Contents of trouble

• When the engine stop switch 20S005-1 is activated, the engine does not stop.

Related information

• Refer to the following judgment table.


• Sufficient loading or moving is not possible.

Possible causes

• General causes for lack of output power: - Insufficient air intake - Insufficient fuel supply - Improper fuel injection condition - The used fuel does not meet the specifications - Overheating (in case of overheating combined with loss of power carry out troubleshooting for overheating)

Possible cause

Step


Procedure

Nominal value

► Test conditions according to the kind of inspection, when following the judgment table information.

Engine lacks output (no power)

1

Final check

2

PC4000-6 S/N 08199 and up

Refer to the following judgment table and identify the appropriate trouble cause(s).

Inspect the suspicious system, unit, or component for malfunction and repair or replace as necessary. After that recheck the system for proper function. Go to final step 2.


311

40 Troubleshooting

Part V

SEL005 - Engine lacks output (no power) [2/2]

Overheating

Clogged, leaking fuel piping

: Items to confirm the cause

Defective contact of valve and valve seat

: Possible causes due to length of use (used for a long period)

●

Wrong adjustment of valve clearance

◊

Clogged injector, wrong spray pattern

: Most probable causes (judging from Questions & Check items)

Clogged fuel filters, strainers

◙

Worn piston ring, cylinder liner

Legend Ο : Possible causes (judging from Questions & Check items)

Seized turbocharger, interference

Causes

Clogged air cleaner elements

Judgment Table

Confirm the recent repair history

Power was lost

Operated for a long period

◊

◊ ◊

Ο

Suddenly

◙ Ο

Replacement of filters has been carried out according to the OPERATION & MAINTENANCE MANUAL

◙

Ο

Ο

◙ ◙

Non-specified fuel is being used

◙

◙

Air cleaner clogging warning is displayed

◙

Black

◙ ◙

Blue under light load ◙

Noise of interference is heard from around the turbocharger

◙

Blow-by gas is excessive Check items

Ο

◙

Engine oil must be added more frequently

Colour of exhaust gas

◊

◙

Gradually

◙

Engine pickup is poor and combustion is abnormal

◙

High idle speed without load is normal, but speed suddenly drops when load is applied

Ο

◙

When touching the exhaust manifolds immediately after engine start, the temperature of some cylinders is low

◙ Ο

Engine is hunting (rotation is irregular)

Ο ◙

Clanging sound is heard from around the cylinder head

◙

Leakage at the fuel piping

◙

Coolant temperature signal is in red range ● ●

When rotating the turbocharger by hand, it is too heavy

●

Measured compression pressure it is too low

● ●

When inspecting fuel filters & strainers, clogging is found

●

Eng. speed does not change when any cylinder is disengaged

312

Clean

Correct

Clean

Replace

Replace

Clean

Remedy

Correct

●

When checking valve clearance, it doesn't meet the specification

Adjust

Troubleshooting

When inspecting the air filter elements, clogging is found

Carry out troubleshooting for overheating

Questions

Degree of use of the machine

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SEL006 - Exhaust smoke is black [1/2] Trouble code SEL006

Trouble

Exhaust smoke is black

Contents of trouble

• The exhaust smoke is black (incomplete combustion)

Related information



• Reduced engine efficiency • Poor emission quality

Possible causes

• General causes for black exhaust smoke: - Insufficient air intake - Excessive fuel injection

Possible cause

Step


Procedure

Nominal value


Exhaust smoke is black (incomplete combustion)

1

Final check

2

PC4000-6 S/N 08199 and up




313

40 Troubleshooting

Part V

SEL006 - Exhaust smoke is black [2/2]

◊ ◊

◊

Defective contact of valve and valve seat


Air leakage between turbocharger & cyl. head

●

Crushed, clogged muffler




◊

Clogged injector, wrong spray pattern

◙

Clogged air cleaner elements



Causes


Judgment Table



Operated for a long period Suddenly became black

◙

Gradually became black

◙

◙

Ο ◙

Blue under light load

◙

Engine oil must be added more frequently Power was lost

◙

Suddenly

Ο Ο

Gradually

Ο

Ο

Ο

◙

Noise of interference is heard from around the turbocharger

◙

Air cleaner clogging warning is displayed

◙

Blow-by gas is excessive Ο

Engine pickup is poor and combustion is abnormal

◙

When touching the exhaust manifolds immediately after engine start, the temperature of some cylinders is low Clanging sound is heard from around the cylinder head

Ο

◙ Ο

◙ ◙ ◙

Air leakage between turbocharger and cyl. head, loose clamp ●

When rotating the turbocharger by hand, it is too heavy

●

When inspecting the air filter elements, clogging is found

●


● ●

Eng. speed does not change when any cylinder is disengaged When the "delivery test" is made, wrong injection timing is found Injection pump test shows, that the injection amount is wrong

●

When checking valve clearance, it doesn't meet the specification

Adjust

Replace

Replace

Clean

Replace

Remedy

Replace

●

When muffler is removed, exhaust gas colour returns to normal

Replace

Troubleshooting

Ο

◙

Ο

Exhaust noise is abnormal

Ο

Muffler is crushed

314

Ο

Ο

Non-specified fuel is being used

Check items

◊

Correct

Questions


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SEL007 - Oil consumption is excessive [1/2] Trouble code SEL007

Trouble

Oil consumption is excessive

Contents of trouble

• The oil consumption is excessive (or the exhaust smoke is blue)

Related information



• Low output power. • Risk of an engine breakdown.

Possible causes

• See the following judgment table.

Possible cause

Step


Procedure

Nominal value


The oil consumption is excessive (or the exhaust smoke is blue)

1

Final check

2

PC4000-6 S/N 08199 and up




315

40 Troubleshooting

Part V

SEL007 - Oil consumption is excessive [2/2]

Worn valve (stem, guide), broken seal

Dust sucked in by the intake system

Worn, broken rear seal, Seal surface

Turbocharger Worn seal at blower end

Worn seal at turbine end


Leakage at the oil pan or cylinder head


●

Leakage at the oil drain plug

◊

Leakage at the oil piping


Leakage at the oil filter

◙

Broken piston ring


Clogged breather or breather hose

Causes


Judgment Table


◊

Ο

Ο

◙

Engine oil must be added more frequently Ο

Exhaust smoke is blue under light load Amount of blow-by gas

◊ ◊

◙

Engine oil becomes contaminated quickly

Check items

◊


Oil consumption suddenly increased

Excessive

◙

◙

◙

◙

◙

Ο

◙

None

◙

Area around the engine is contaminated with oil

◙

◙

◙ ◙

When exhaust pipe is removed, the inside is dirty with oil

Ο ◙

When the turbocharger air supply pipe is removed, the inside is dirty with oil

◙

Clamps of the intake system are loose ●

Troubleshooting


● ●

When the breather element is checked, it is clogged with dirty oil

●

External oil leakage at the engine

●

●

● ●

Excessive play of the turbocharger shaft

● ●

Inspect the rear seal directly

●

When the intake manifold is removed, dust is found inside

●

316

Correct

Correct

Replace

Replace

Correct

Correct

Correct

Correct

Clean

Replace

Remedy

Replace

When the intake manifold is removed, the inside is dirty with oil

Correct

Questions


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SEL008 - Oil becomes contaminated quickly [1/2] Trouble code

Trouble

SEL008

Oil becomes contaminated quickly

Contents of trouble

• The engine oil becomes contaminated quickly

Related information



• Low output power • Increased engine wear

Possible causes

• • • • •

Possible cause

Intake of exhaust gas due to internal wear Clogging of lubrication passages Improper fuel used Improper engine oil used Operation under excessive load

Step


Procedure

Nominal value


The engine oil becomes contaminated quickly

1

Final check

2

PC4000-6 S/N 08199 and up




317

40 Troubleshooting

Part V

SEL008 - Oil becomes contaminated quickly [2/2] Judgment Table

◊

Non-specified engine oil is used

Amount of blow-by gas

Exhaust smoke is black

◊

◙

Engine oil must be added more frequently

O ◙

Blue under light load

◙

Black ◙

Excessive

O

O

O

smoke is black

Check items

◊


◙

None

When the filter is inspected, metal particles are found

◙

O

O ◙ ◙

Engine oil temperature rises quickly ●


● ●

When the breather element is checked, hose is broken or it is clogged with dirty oil

●

When the oil filter is inspected, it is found to be clogged

●

Turbocharger drain tube is clogged

●

Excessive play at the turbocharger shaft

●

Replace

Clean

Replace

Replace

Clean

Remedy

Replace

When the safety valve is inspected, the spring is found to be catching or broken

Follow troubleshooting for: Exhaust


When exhaust pipe is removed, the inside is dirty with oil

318

Defective safety valve



Troubleshooting

Defective seal at turbocharger turbine end


Clogged turbocharger drain pipe


Worn valve, valve guide


Replace

Questions

: Possible causes (judging from Questions & Check items)

Clogged oil filter

Legend

Ο ◙ ◊ ●

Clogged breather or breather hose


Causes

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SEL009 - Fuel consumption is excessive [1/2] Trouble code SEL009 Contents of trouble

Trouble

Fuel consumption is excessive

• Fuel consumption highly exceeds the standard values Judgment table of fuel consumption Fuel Consumption [Liter/Hour] Fuel density (kg/l) = 0.86 Mining Conditions Shovel Type

Engine Model

Engine Output SAE 1995

PC4000-6

SDA 16 V 160 (QSK60)

1400

Related information

Spec. Fuel Consumption g/kWh

209

Max. Consumption

easy

average

heavy

load factor 70%

load factor 75%

load factor 83%

load factor 100%

238

255

282

340

• Engine oil consumption about 0.25% of the fuel consumption • Engine oil burning consumption by "Centinel System" about 0.25% of the fuel consumption • Power and consumption rates are up to 3600 m altitude. Higher altitude may need a deration of engine output and change the consumption figures. • Basic hydraulic regulation adjustment are successfully done. Problem that appears on machine

• Low output power • Engine generates excessive heat

Possible causes

• Fuel leakage (or loss) • Improper fuel injection condition • Excessive fuel injection amount

Possible cause

Step


Procedure

Nominal value


Fuel consumption highly exceeds the standard values

1

Final check

2

PC4000-6 S/N 08199 and up




319

40 Troubleshooting

Part V

SEL009 - Fuel consumption is excessive [2/2]


◊


●


Fuel leakage inside the cylinder head

◙

Defective fuel pump


External leakage at fuel piping, fuel filter

Causes

Defective injector holder, spray

Judgment Table

Ο

Ο

◊

Operated for a long period ◙

More than other machines of same model Condition of fuel consumption

Ο

Gradually increased Suddenly increased ◙

Black

Ο ◙

There is irregular combustion

◙

When touching the exhaust manifolds immediately after engine start, the temperature of some cylinders is low. External fuel leakage at the engine

◙ ◙

Engine oil level rises and smells of Diesel fuel

Ο

Engine low idle speed is high

Ο

◙

●

Replace

Remove cylinder head cover and inspect directly

Remedy

320

Ο

White

Seal on injection pump has come off

Adjust

Troubleshooting

Check items

Exhaust smoke colour

Correct


Correct

Questions


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SEL010 - Oil is in engine coolant [1/2] Trouble code SEL010

Trouble

Oil is in engine coolant

Contents of trouble

• Oil is in the engine coolant, the coolant sputters out, or the coolant level goes down.

Related information

• Precondition, first check: • The engine coolant pump is working properly and it has no internal leak.


• Low output power • Engine generates excessive heat • Excessive smoke coming out of the mufflers

Possible causes

• See the following judgment table.

Possible cause

Step


Procedure

Nominal value


Oil is in the engine coolant, or the coolant spurts back, or the coolant level goes down

1

Final check

2

PC4000-6 S/N 08199 and up




321

40 Troubleshooting

Part V

SEL010 - Oil is in engine coolant [2/2]


◊


●


Internal cracks in the cylinder block

◙

Broken liner O-ring, holes caused by pitting


Insufficient protrusion of cylinder liner

Causes

Broken cylinder head or head gasket

Judgment Table


◊

Operated for a long period Ο

Suddenly increased Oil level

Ο

Engine oil level has risen, oil is cloudy white

Ο

Ο

●

● Replace

Check items

Ο

Hard water is being used as engine coolant

Excessive air bubbles inside radiator, coolant sputters out

◙

Pressure-tightness test of cylinder head shows, there is a leakage

●

◙

●

Remove cylinder head and inspect directly

Replace

Replace

Remove oil pan and inspect directly

Remedy

322

Ο

Replace

Gradually increased

Troubleshooting

Questions


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SEL011 - Oil level rises [1/2] Trouble code SEL011

Trouble

Oil level rises

Contents of trouble

• The engine oil level rises (coolant or fuel in the oil) • The engine oil level rises due to a malfunction of the "Reserve Pump" in the Centinel system

Related information

• First verify the proper function of the "Oil Management Centinel System" and the "Reserve Pump System" (refer to the OPERATION & MAINTENANCE MANUAL and to the SERVICE MANUAL).


• Oil spills out of the engine breather hose.

Possible causes

• Coolant gets into the engine oil • Fuel gets into the engine oil (oil becomes diluted and smells of Diesel fuel) • Oil from any other component (e.g. Reserve System) gets into the engine oil.

Possible cause

Step


Procedure

Nominal value


The engine oil level rises

1

Final check

2

PC4000-6 S/N 08199 and up




323

40 Troubleshooting

Part V

SEL011 - Oil level rises [2/2]

◊


When the engine is first started, drops of water come from the muffler

◙

Exhaust smoke is white

◙

There is oil in the engine coolant

Ο

Leave the radiator cap open. When the engine is running without load, an abnormal number of bubbles appears, or coolant sputters out

Ο

Ο

◙

Ο ◙

Coolant pump breather hole is clean, coolant comes out

◙

Cracks inside the cylinder block

Ο

Engine oil smells of Diesel fuel

◙

◙

Fuel must be filled up more frequently

◙

◙

Ο

● ●


●

Remove coolant pump and inspect directly

●

Remove rear seal and inspect directly

●

Remove cylinder head cover and inspect directly

●

Remove injection pump and inspect directly

Replace

Correct

Correct

Replace

Replace

Remedy

Replace


324

Damaged liner O-ring, holes due to pitting

◊ Ο

Coolant pump breather hole is clogged with mud

Pressure-tightness test of cylinder head shows, there is a leakage Troubleshooting

◊ ◊

●

● Replace


Replace


Defective seal inside the fuel pump (flange type)


Fuel leakage inside the cylinder head cover

●

Worn damaged rear seal surface


Clogged coolant pump breather hole, defective seal


◊

Check items

◙

Questions


Broken cylinder head or head gasket (precombustion

Causes

Defective injector holder sleeve

Judgment Table

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SEL012 - Coolant temperature becomes too high (overheating) [1/2] Trouble code

Trouble

SEL012

Coolant temperature becomes too high (overheating)

Contents of trouble

• The engine coolant temperature becomes too high (overheating)

Related information

• When the monitor panel coolant temperature gauge is in normal range, start troubleshooting with a temperature gun and verify the adequate coolant temperature.


• Engine overheating - risk of a total engine breakdown and damage of internal components.

Possible causes

• • • •

Possible cause

Insufficient cooling air flow (radiator deformation, damaged fan) Clogged coolant radiator (inside or outside) Defective coolant circulation system (thermostat) Defective fan drive system

Step


Procedure

Nominal value


The engine coolant temperature becomes too high (overheating)

1

Final check

2

PC4000-6 S/N 08199 and up




325

40 Troubleshooting

Part V

SEL012 - Coolant temperature becomes too high (overheating) [2/2]

External leakage at the coolant piping

Damaged cylinder liner O-ring, holes due to pitting

Broken cylinder head or head gasket


Defective radiator pressure valve


●

Low or no fan RPM

◊

Defective coolant temperature gauge


Defective thermostat (does not open)

◙

Clogged radiator core


Clogged crushed radiator fins

Causes

Broken coolant pump

Judgment Table

Degree of use of the machine Condition of overheating Coolant temperature gauge

◊ ◊


◊ ◊

◙

Suddenly overheated

Ο ◙

Always tends to overheat

◙

Ο

Ο

◙

Rises quickly

◙

Does not go down

◙

Fan drive system malfunction

◙

Check items

Engine coolant flows out of the overflow hose

◙

Excessive air bubbles inside radiator, coolant spurts back

◙

Engine oil level has risen, oil is cloudy white Radiator shroud inside of underguard is clogged with dirt or mud

◙

Radiator clogged by dirt

◙ ◙

Coolant is leaking due to cracks in hose(s) or loose clamps ●

When thermostat function is tested, it does not open, even at the cracking temperature When coolant temperature is measured, it is normal

● ●

When measurement is made with the radiator cap tester, set pressure is found to be low (pressure is not kept) Measured compression pressure it is too low

● ● ●

326

Replace

Replace

Replace

Replace

Replace

Correct

Correct

Remedy

Replace


Replace

Troubleshooting

When coolant filler port is inspected, the core is found to be clogged

Correct or replace

Questions


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

Symptoms of the hydraulic system SHY001 - All the work equipment shows lack of power or slow movement (especially the "boom up" function) [1/2] Trouble code SHY001

Trouble

All the work equipment shows lack of power or slow movement (especially the "boom up" function)

Contents of trouble

• The work equipment shows lack of power or its movement (especially the "boom up" function) is too slow. • A corresponding trouble message is not displayed.

Related information

Before starting any troubleshooting work in detail: • Ask the operator for conspicuous failure symptoms and for the history. • Bring the shovel to the operating temperature → hydraulic oil temperature min. 60C°. • Recheck yourself all oil levels and functions and inspect for any leakage. • Before starting any adjustment work, operate the shovel yourself and test all affected functions. Check for noise or abnormal reactions. • Using a stop watch, test the cycle times of the work equipment (beginning at the movement start, measure the time between start stroke and end stroke of the cylinder). • Always use the PM-CLINIC sheet for comparing the taken measurements with the default values. • When carrying out tests use the recommended adjustment values only.


• The work performance of the shovel is poor and/or too slow.

Possible causes

• Wrong position of the change-over valve lever (253.1) for the hydraulic pump regulation mode at the valve and filter plate • Wrong adjustment of the pump regulation system • Wrong energy efficiency adjustment • Wrong hydraulic adjustments (SRV, MRV) or defective valves • Any hydraulic cylinder defective (internal leak) • Low engine power output

Possible cause

Wrong position of the emergency lever (253.1) at the valve and filter plate

Step

1


Check the emergency lever position at the valve and filter plate. Is the emergency lever set to E position?

Procedure Yes

Go to next step.

No

Move the emergency lever (253.1) to E position and bring the machine back to operation.

Nominal value

► Follow the respective requirements of the SERVICE MANUAL.

Wrong adjustment of the pump regulation system

2

Readjust the pump regulation system according to the procedures given in the SERVICE MANUAL (the emergency lever (253.1) at the valve and filter plate must be set to E position in any case). Is the pump regulation system working correctly?

Yes

Go to next step.

No

Adjust the pump regulation system according to the PMCLINIC sheet and as described in the SERVICE MANUAL.

Yes

Go to next step.

PMCLINIC

No

Adjust according to the PM-CLINIC sheet and as described in the SERVICE MANUAL.

SERVICE MANUAL PMCLINIC

SERVICE MANUAL PMCLINIC


Wrong energy efficiency adjustment

3

PC4000-6 S/N 08199 and up

The basic pump regulation adjustment is successfully completed. All values correspond to the PM-CLINIC sheet. Now check the additional pump regulation of the energy efficiency system. Carry out the test of the sprocket revolution time according to the PM-CLINIC sheet (item 37). Do the measured time values meet the specification?

327

40 Troubleshooting

Part V

SHY001 - All the work equipment shows lack of power or slow movement (especially the "boom up" function) [2/2] Possible cause

Step

Procedure

Nominal value

Yes

Adjust valves as necessary according to the PM-CLINIC sheet and as described in the SERVICE MANUAL.

SRV 350±5bar MRV 310+5bar

No

Go to next step.

Yes

If any cylinder leakage is found replace the defective hydraulic cylinder.

No

Go to next step.

Yes

After inspection clean the Racor and/or replace the fuel filter elements as PMnecessary. CLINIC Recheck the engine stall speed according to the PM-CLINIC data sheets.

No

Call the Cummins service for a complete engine check up.

Test condition & Inspection ► Keep the engine running at high idle.

Wrong hydraulic adjustments (SRV, MRV) or defective valves

4

Check the adjustments of the SRV (Safety Relief Valves) and MRV (Main Relief Valves) according to the SERVICE MANUAL and the PM-CLINIC sheet. Is any valve adjustment below the default value? ► Keep the engine running at high idle.

Any hydraulic cylinder defective (internal leak)

5

After the correct adjustment of the pump regulation system, including energy efficiency, is completed, the work attachment is still too slow, especially the "boom up" function. Using an infrared thermometer, check the boom cylinder temperature (refer to "Cylinder bypass test" in this manual) in order to locate an internal leakage. Could you determine any abnormality? ► Keep the engine running at high idle.

Low engine power output

Final check

328

6

7

Check the engine stall speed according the PM-CLINIC sheet. Even all adjustments are correctly done and even they correspond to the default values, the engine stall speed drops below the stall speed limits. Check the engine fuel supply system for sufficient fuel delivery capacity. Is any Racor (separator) or fuel filter clogged?


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY002 - Engine speed sharply drops or engine stalls too much [1/2] Trouble code SHY002

Trouble

Engine speed sharply drops or engine stalls too much

Contents of trouble

• The engine speed drops sharply during movement or the engine stalls too much during conjoint movements of the attachment. • A corresponding trouble message is not displayed.

Related information

Before starting any troubleshooting work in detail: • Ask the operator for conspicuous failure symptoms and for the history. • Bring the shovel to the operating temperature (hydraulic oil temperature at least T3). • Recheck yourself all oil levels and functions and inspect for any leakage. • Before starting any adjustment work, operate the shovel yourself and test all affected functions. Check for noise or abnormal reactions. • Using a stop watch, test the cycle times of the work equipment (beginning at the movement start, measure the time between start stroke and end stroke of the cylinder). • Always use the PM-CLINIC sheet for comparing the taken measurements with the default values. • When carrying out tests use the recommended adjustment values only.


• The work performance of the shovel is poor and/or too slow.

Possible causes

• The engine stalls too much. • Wrong adjustment of the pump regulation system or the Energy Efficiency.

Possible cause

Step


Procedure

Nominal value


The engine stalls too much

1

PC4000-6 S/N 08199 and up

Check the engine stall speed according the PM-CLINIC sheet. Even all adjustments are correctly done and even they correspond to the default values, the engine stall speed drops below the stall speed limits. Check all air filters for cleanness and check the cyclone dust streamer for proper function. Check the engine fuel supply system for sufficient fuel delivery capacity. Is any Racor (separator), fuel filter, or air filter clogged?

Yes

Clean the Racor, replace the fuel filter, or air filter if clogged. PMThen recheck the stall CLINIC speed according to the PM-CLINIC data sheet.

No

Call the Cummins service for a complete engine check up.

329

40 Troubleshooting

Part V

SHY002 - Engine speed sharply drops or engine stalls too much [2/2] Possible cause

Step


Procedure

Nominal value


Wrong adjustment of the pump regulation system or the Energy Efficiency.

Final check

330

2

3

Check the position of the emergency lever on the valve and filter plate. For the adjustment of the regulation system the lever must be in position for electronic pump regulation (E). Adjust the pump regulation (energy efficiency) system according to the SERVICE MANUAL and make sure to meet the correct values. Is the pump regulation system working correctly?

Yes

Check the bucket size and weight. Check the density (specific weight) of the material and compare to the bucket size and the mounted wear package on the bucket (overload). Confirm the actual operating altitude (higher than 3600 m?). Also refer to the latest version of PARTS & SERVICE NEWS AH05515.

No

Adjust the pump regulation system according to the PMCLINIC sheet and as described in the SERVICE MANUAL.

SERVICE MANUAL, PMCLINIC data sheet, PARTS & SERVICE NEWS AH05515 (latest version)


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY003 - No work equipment, travel or swing movement [1/1] Trouble code SHY003

Trouble

No work equipment, travel or swing movement

Contents of trouble

• Work equipment, travel or swing movement is impossible. • A corresponding trouble message is not displayed.

Related information

• Even no trouble code is displayed, any movement of the work equipment is impossible. • Ladder and service arm are in their correct upper position. • The engine is running at high idle and all safety functions are unlocked.


• No movement is possible.

Possible causes

• 11K111a and 11K111b are inoperative or burnt. • Pilot pressure is not available (PPC pump defective).

Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 in ON position. Relays 11K111a and 11K111b are inoperative or burnt

1

Check the circuits of 11K111a and 11K111b for proper function. Check the function of relays 11K111a and 11K111b manually. Could you identify any problem in the electrical system?

Yes

Repair or replace relays 11K111a & 11K111b and/or their sockets if damaged.

No

Go to next step.

Yes

Check for proper movement of the work equipment.

Output 24V


Pilot pressure is not available (PPC pump defective)

Final check

2

3

PC4000-6 S/N 08199 and up

Check the pilot pressure at the valve and cartridge block as described in the SERVICE MANUAL. Make sure that the pilot pressure is in the specified working range. Is specified pilot pressure available?

No

X4=60bar X2=45bar SERVICE MANUAL

Check the drive input of pilot pump. Check the pilot pump for damage (internal fault). Repair or replace as necessary.


331

40 Troubleshooting

Part V

SHY004 - Work equipment has too much hydraulic drift [1/2] Trouble code SHY004

Trouble

Work equipment has too much hydraulic drift

Contents of trouble

• In the neutral lever position the work equipment has too much visible drift.

Related information

• According to section "Cylinder bypass test" check and measure the existing drift at the cylinder circuit. Locate the affected hydraulic circuit. • Install pressure gauges at the main blocks of the affected circuit and monitor the pilot pressure for the respective main spool.


• Risk, to loose control of the shovel operation. • Damage or breakdown is possible due to contacting dump trucks.

Possible causes

• No or incorrect main spool movement (neutral spring damaged). • FSA - Floating valve internal leak or damage • Hydraulic cylinder damaged (internal leak).

Possible cause

Step


Procedure

Nominal value

► Keep the engine running at high idle & all PPC sections on the main blocks equipped with pressure gauges.

No or incorrect main spool movement (neutral spring damaged)

1

On the main blocks check all functions of the work equipment for increasing and decreasing times of the pilot pressure control, simultaneously to the lever movements. Is the pilot pressure increasing and decreasing simultaneously?

Yes

Go to next step.

No

Check the pilot pressure at the remote control valves. Check the remote control valves for proper function (electrical signal from the lever - via amplifier & ramp time module to the remote control valve).

35–45bar at the main block spools (when the lever is moved 'full stroke').

► Keep the engine running at high idle & all PPC sections on the main blocks equipped with pressure gauges.

FSA - Floating valve internal leak or damage

332

2

In the floating valves 60Q632, 60Q633, 60Q634 (stick in) or 61Q635 and main block (spool boom down) any leakage or damage of the inner spool is possible. Inspect the floating valves as described in the SERVICE MANUAL. Can you identify any leakage or damage?

Yes

No

Replace the affected valve and adjust as described in the SERVICE MANUAL and PM-CLINIC procedures.

SERVICE MANUAL PM-CLINIC

Go to next step.

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY004 - Work equipment has too much hydraulic drift [2/2] Possible cause

Step


Procedure

Nominal value


Hydraulic cylinder damaged (internal leak)

Final check

3

4

PC4000-6 S/N 08199 and up

Yes

Replace any defective cylinder by a new one. Bleed the new hydraulic cylinder(s). Min. test period Perform the bypass 20 minutes test again in order to make sure that no other cylinder is affected.

No

Check the SRV and suction valves for proper function. Repair or replace if necessary, and after that, verify that the hydraulic drift of the work equipment meets the specified range.

The function of the main blocks is ok. Refer to section "Cylinder bypass test" and check the suspicious cylinders for defective internal seals Can you find significant temperature differences during the cylinder bypass test?


333

40 Troubleshooting

Part V

SHY005 - Work equipment has big time lag [1/1] Trouble code SHY005

Trouble

Work equipment has big time lag

Contents of trouble

• The work equipment has a big time lag between lever actuation and movement of the attachment. • The PM-CLINIC procedures are done and all settings are adjusted to the nominal values.

Related information

• The reaction time of the attachment after lever movement is controlled and adjusted via the Ramp Time Modules.


• Due to a big time lag the machine can not be operated according to proper quality standards.

Possible causes

• Wrong adjustment of the Ramp Time Modules.

Possible cause

Step


Procedure

Nominal value

► Main key switch S1 in ON position.

Wrong adjustment of the Ramp Time Modules

Final check

334

1

2

Perform the basic adjustments of the Ramp Time Modules according to the procedures described in the SERVICE MANUAL. For the standard value table refer to your wiring diagram. Do the adjustment values meet the specified range?

Yes

Perform the complete measurements for the electrical levers, including the amplifier test. Refer to the SERVICE MANUAL. Refer to the latest version of PARTS & SERVICE NEWS AH09525.

No

Perform the basic adjustments according to the data in your wiring diagram.

Standard value table in the wiring diagram SERVICE MANUAL PARTS & SERVICE NEWS AH09525 (latest version)


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY006 - Machine deviates during travel movement [1/1] Trouble code SHY006

Trouble

Machine deviates during travel movement

Contents of trouble

• During machine traveling the shovel deviates to one side. • The machine is traveling only (no other movement is done). • Precondition: flat ground and same grip on both sides.

Related information

• The PM-CLINIC procedures were performed successfully. • The SRV and MRV adjustments meet the nominal values of the hydraulic diagram. • The left and right track wear measurements are on the same level.


• During machine traveling the shovel deviates to one side. • The operator has to stop the shovel after a couple of meters in order to correct the direction of travel to straight forward.

Possible causes

• Defective hydraulic travel motor. • Internal leak in the rotary joint.

Possible cause

Step


Procedure

Nominal value


Defective hydraulic travel motor Internal leak in the rotary joint

1

Connect high pressure gauges (400 bar) to the main blocks. Disconnect the parking brake solenoid valve 57Q516 in order to close the brake. Actuate the travel pedals and read the current pressure at the gauges. Is there any pressure difference between left and right, or loss of pressure?

Yes

No

Final check

2

PC4000-6 S/N 08199 and up

Disconnect the ports A and B at the travel motors (in order to exclude the travel motors). Plug the hoses and the inlet ports of the travel motors. Now check the pressure again. If the pressure values are still the same as before, replace the travel motor(s).

SRV: 310bar MRV: 315bar

If the pressure values are not the same as before, replace the rotary joint due to an internal leakage.


335

40 Troubleshooting

Part V

SHY007 - Hydraulic system has lack of power (energy efficiency) [1/2] Trouble code SHY007

Trouble

Hydraulic system has lack of power (energy efficiency)

Contents of trouble

• The hydraulic system has a lack of power. • The PM-CLINIC procedures were performed successfully. • The values of engine power output are ok.

Related information

• The energy efficiency is an improvement and was implemented on your shovel in a field campaign. • Follow the adjustment procedures in the SERVICE MANUAL, section "Energy Efficiency".


• The movement speed of the attachment and during traveling is too slow.

Possible causes

• Defective valve or wrong adjustment of the Energy Efficiency.

Possible cause

Step


Procedure

Nominal value

► Keep the engine running at high idle Check and adjust the energy efficiency according to the SERVICE MANUAL, section "Energy Efficiency". Inspection of the solenoid functions

Defective valve or wrong adjustment of the Energy Efficiency

1

• If any individual movement is selected (single movement), the pumps will deliver the maximum flow, with one exception. Pump 1 will deliver the half flow only if high speed swing is selected. This fact is important for PM-CLINIC and other tests. a) Individual movements of the Attachment are selected: → 57K646 OFF + 57K647 OFF + 57K648 OFF + 57K626 ON b) Only travel is selected: → 57K646 OFF + 57K647 OFF + 57K648 OFF + 57K626 ON c) Only swing (low speed) is selected: → 57K646 ON + 57K647 OFF + 57K648 ON + 57K626 ON d) Only swing (high speed) is selected: → 57K646 ON + 57K647 OFF + 57K648 OFF + 57K626 OFF

The basic setting (bench setting) of the PST valve is 18 bar. The sprocket rotation times conform to the nominal values.

Go to next step.

336

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY007 - Hydraulic system has lack of power (energy efficiency) [2/2] Possible cause

Step


Procedure

Nominal value


Pump flow control test values Sprocket No. Function

1

2

3 Check of the sprocket rotation times

2

4

5

6

Travel right only Travel right & swing (low speed) Travel right & swing (fast speed) Travel left only Travel left & swing (low speed) Travel left & swing (fast speed)

57K646 57K647 57K648 57K626 right

Sprocket left Time/5 rev [s]

[Volt]

[Volt]

[Volt]

[Volt]

0

0

0

24

50 ± 1

50 ± 1

24

24

24

24

65 ± 1

65 ± 1

24

0

0

0

65 ± 1

65 ± 1

0

0

0

24

50 ± 1

50 ± 1

24

24

24

24

65 ± 1

65 ± 1

24

0

0

0

65 ± 1

65 ± 1

Time/5 rev [s]

The basic setting (bench setting) of the PST valve is 18bar. The sprocket rotation times conform to the nominal values.

• Select the swing speed between low and high with 20S154 at the left control lever. • The 5 revolutions of the sprocket within 65 seconds are mandatory to determine the optimized pump flow. • The pressure control valve (152) is factory pre-adjusted to 18 bar. If necessary adjust or repair the system. Final check

3

PC4000-6 S/N 08199 and up


337

40 Troubleshooting

Part V

SHY008 - Machine does not swing [1/1] Trouble code SHY008

Trouble

Machine does not swing

Contents of trouble

• The machine does not swing when the lever is moved. • The swing parking brake is released (otherwise a corresponding info message is displayed on the VHMS monitor). • All other operating functions are going well.

Related information

• The electrical lever signal on the amplifier and ramp time modules is present (otherwise a corresponding error message is displayed on the VHMS monitor). • No swing movement (left or right) is possible.


• No swing movement is possible.

Possible causes

• No pressure increase at the 2-stage valve(s).

Possible cause

Step


Procedure

Nominal value

► Keep the engine running at high idle - swing parking brake switch 20S029 ON - attachment in ground position Follow the instructions for testing and adjusting the swing circuit as described in the SERVICE MANUAL. For better adjustment of the 2-stage valves disconnect and plug the pilot lines of the 2-stage valves. 1. Adjustment of the 330 bar stage No pressure increase at the two-stage valve

1

2.

Yes

Reconnect the pilot pressure hoses to the 2-stage valves and put For the target the shovel back to values operation.

Adjustment of the 130 bar stage

Remark: Remember that there are 2 swing gearboxes with mounted swing motors and the 2-stage valves. Both valves need to have the same pressure (synchronisation).

No

Replace both 2-stage valves and perform the basic adjustments.

refer to PM-CLINIC sheets. For the adjustment procedures refer to the SERVICE MANUAL.

Could you successfully adjust the 2-stage valves? Final check

338

2


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY009 - Swing acceleration is poor [1/2] Trouble code

Trouble

SHY009

Swing acceleration is poor

Contents of trouble

• The machine swing acceleration is poor (too long acceleration time or too short acceleration time). • The swing parking brake is released (otherwise a corresponding info message is displayed on the VHMS monitor). • All other operating functions are going well.

Related information

• For the basic adjustment procedures refer to the SERVICE MANUAL, section "Checks and adjustments for the swing circuit". • For the target adjustment values refer to PM-CLINIC sheets.


• The swing acceleration is poor and any fast swing & load movement is not possible.

Possible causes

• • • •

Possible cause

The 2-stage valve is defective or its adjustment is wrong. The swing brake valve is defective (internal leak in the anti-cavitation/suction valves). The O-ring at the spacer plate is leaking (oil flows from A to B side). The swing motor is defective (internal leakage).

Step


Procedure

Nominal value

► Engine running at high idle & swing lock switch 20S029 ON.

The 2-stage valve is defective or its adjustment is wrong

1

Perform the basic adjustments of the swing circuit according the SERVICE MANUAL and the PM-CLINIC sheets. Could you adjust the correct swing acceleration (swing cycle time)?

Yes

Go to next step.

No

Replace both 2-stage valves and perform the basic adjustments. If - after replacement of the 2-stage valves the swing acceleration is still poor, replace the complete swing brake valve blocks on top of the swing motors. Refer to next step.

SERVICE MANUAL PM-CLINIC sheets

► Main key switch 20S001 OFF & maintenance safety switch 50S058 locked. Perform the following steps according to the safety notes in the SERVICE MANUAL. Disconnect the high pressure hoses from the swing brake block. The swing brake valve is defective (internal leak in the anticavitation/suction valves)

2

Bring the shovel back to operation.

Remark: Before mounting the new block in the next work step, also see step 3 in this troubleshooting chart. Replace the complete block with new 2-stage valves and O-rings. Then perform the basic adjustments according to the SERVICE MANUAL and the PM-CLINIC sheets. Could you now adjust the correct swing acceleration (swing cycle time)?

PC4000-6 S/N 08199 and up

Yes


No

Go to next step

339

40 Troubleshooting

Part V

SHY009 - Swing acceleration is poor [2/2] Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.

Check the O-rings on the spacer plate and on the lower side of the swing brake block. Are these O-rings ok?

The O-ring at the spacer plate is leaking (oil flows from A to B side)

Yes

Go to next step.

No

Check the spacer plate for indications of corrosion or pitting. If necessary replace the spacer plate. Replace the O-rings and mount the swing brake valve. Then perform the basic adjustments for the swing system according the SERVICE MANUAL and the PM-CLINIC sheets.


3

Legend for figure Z 27356 (1) Swing brake valve (2) O-ring (3) Spacer plate (4) Swing motor

► Main key switch 20S001 OFF. ► For testing the leak oil keep the engine running at high idle. Check the leak oil flow at the swing motors. - Disconnect the leak oil hose from each swing motor and plug the hose opening. The swing motor is defective (internal leakage)

4

Does the amount of leak oil exceed the above recommendation?

340

5

Replace the defective swing motor(s).

No

Go to troubleshooting chart SME006 in the following section "Symptoms of the mechanical system". Check the swing motor drive shaft input at the swing gearbox. If any malfunction is found, repair as necessary.

- Mount an external hose to the swing motor leak oil port and drain the leak oil into a suitable container (min. volume: 20 liters). - Operate the swing movement for 1 minute and measure the leak oil amount (approx. 5 liters/min).

Final check

Yes


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY010 - Excessive overrun when stopping swing [1/2] Trouble code

Trouble

SHY010

Excessive overrun when stopping swing

Contents of trouble

• There is an excessive overrun when the swing movement of the superstructure is stopped.

Related information

• If during swing movement the control lever is moved into neutral position, the superstructure swing movement should be stopped within an angle of 70°. • If the superstructure does not stop within this angle, the superstructure overrun can be considered as to be excessive.


• The swing deceleration is poor (too long) and a correct positioning of the attachment is not possible.

Possible causes

• • • •

Possible cause

The 2-stage valve is defective or its adjustment is wrong. The swing brake valve is defective (internal leak in the anti-cavitation/suction valves). The O-ring at the spacer plate is leaking (oil flows from A to B side). The swing motor is defective (internal leakage).

Step


Procedure

Nominal value

► Engine running at high idle & swing lock switched ON.

The 2-stage valve is defective or its adjustment is wrong

1

Perform the basic adjustments of the swing circuit according the SERVICE MANUAL and the PM-CLINIC sheets. Could you adjust the correct swing deceleration?

Yes

Go to next step.

No

Replace both 2-stage valves and perform the basic adjustments. If - after replacement of the 2-stage valves the swing deceleration is still poor, replace the complete swing brake valve blocks on top of the swing motors. Refer to next step.


► Main key switch 20S001 OFF & maintenance safety switch 50S058 locked. Perform the following steps according to the Safety Notes in the SERVICE MANUAL. Disconnect the high pressure hoses from the swing brake block.

The swing brake valve is defective (internal leak in the anticavitation/suction valves)

2

Bring the shovel back to operation.

Remark: Before mounting the new block in the next work step, also see step 3 in this troubleshooting chart.

Replace the complete block with new 2-stage valves and O-rings. Then perform the basic adjustments according to the SERVICE MANUAL and the PM-CLINIC sheets. Could you now adjust the correct swing deceleration?

PC4000-6 S/N 08199 and up

Yes


No

Go to next step

341

40 Troubleshooting

Part V

SHY010 - Excessive overrun when stopping swing [2/2] Possible cause

Step


Procedure

Nominal value


Check the O-rings on the spacer plate and on the lower side of the swing brake block. Are these O-rings ok?

The O-ring at the spacer plate is leaking (oil flows from A to B side)

Yes

Go to next step.

No

Check the spacer plate for indications of corrosion or pitting. If necessary replace the spacer plate. Replace the O-rings and mount the swing brake valve. Then perform the basic adjustments for the swing system according the SERVICE MANUAL and the PM-CLINIC sheets.


3

Legend for figure Z 27356 (1) Swing brake valve (2) O-ring (3) Spacer plate (4) Swing motor

► Main key switch 20S001 OFF. ► For testing the leak oil, keep the engine running at high idle. Check the leak oil flow at the swing motors. - Disconnect the leak oil hose from each swing motor and plug the hose opening. The swing motor is defective (internal leakage)

4

Does the amount of leak oil exceed the above recommendation?

342

5

Replace the defective swing motor(s).

No

Go to troubleshooting chart SME006 in the following section "Symptoms of the mechanical system". Check the swing motor drive shaft input at the swing gearbox. If any malfunction is found, repair as necessary.

- Mount an external hose to the swing motor leak oil port and drain the leak oil into a suitable container (min. volume: 20 liters). - Operate the swing movement for 1 minute and measure the leak oil amount (approx. 5 liters/min).

Final check

Yes


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY011 - Floating system without function [1/1] Trouble code

Trouble

SHY011 Contents of trouble

Related information

Floating system without function (FSA only)

• The floating system for the functions "Stick In" and/or "Boom Down" is inoperative and/or its deactivation is impossible. • • • •

The floating system is divided in the two functions "Stick In" or "Boom Down". Floating valve 61Q635 is installed in the boom circuit. Floating valves 60Q632, 60Q633, 60Q634 are installed in the stick circuit. The electric circuit is faultless, but the floating system is inoperative and/or its deactivation is impossible (the spools in the hydraulic valves 60Q632-60Q634 or 61Q635 do not move).


• No floating function for "Stick In" and/or "Boom Down".

Possible causes

• The spools in the floating valves are mechanically stuck.

Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 in OFF position - maintenance safety switch 50S058 locked - the attachment must be in down and full reach position

The spools in the floating valves are mechanically stuck

1

- Find out in which circuit the problem occurs ("Stick In" and/or "Boom Down"). - Check the electrical signals at the solenoid valves. - Disassemble the defective floating valve and check the state of the inner spool and spring.

Final check

2

PC4000-6 S/N 08199 and up

Replace or repair the defective valve. Then perform the basic SERVICE MANUAL adjustment. Refer to the SERVICE PM-CLINIC MANUAL and to the PM-CLINIC sheets.


343

40 Troubleshooting

Part V

SHY012 - Abnormal noise coming from SRV or MRV [1/1] Trouble code SHY012

Trouble

Abnormal noise coming from SRV or MRV

Contents of trouble

• Abnormal noise is coming from the SRV or MRV sections.

Related information

• Due to a possible defect of the mechanical inner parts (spring or piston) in the SRV or MRV sections, an abnormal noise is possible when the valve is activated. • Also a wrong adjustment of SRV or MRV may cause abnormal noise in the system.


• Abnormal noise in the hydraulic system occurs during operation. • Any malfunction of the hydraulic circuit is possible. • Overheating of the hydraulic oil is possible.

Possible causes

• Wrong adjustment or malfunction of SRV or MRV. • Malfunction of any throttle valve or suction valve at the main blocks or at the manifold.

Possible cause

Step


Procedure

Nominal value

► Keep the engine running at high idle. Wrong adjustment or malfunction of SRV or MRV.

1

Perform a sectional troubleshooting and check the adjustment of SRV and MRV. Follow the instructions and specifications in the SERVICE MANUAL and PM-CLINIC sheets. Could you find any functional problem?

Yes

Adjust or replace as necessary.

No

Go to next step.

Yes

Replace or repair as necessary.

No

Perform the complete PM-CLINIC procedures.


► Keep the engine running at high idle. Malfunction of any throttle valve or suction valve at the main blocks or at the manifold

2

Final check

3

344

Check the suspicious hydraulic circuit for noise and locate the problem (temperature difference) with the infrared thermometer gun.

PM-CLINIC sheets


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY013 - Track tensioning system without function [1/1] Trouble code SHY013

Trouble

Track tensioning system without function

Contents of trouble

• The automatic track tensioning system does not work.

Related information

• The automatic track tensioning system works under the following condition: the engine is running at high idle and the ladder is in up position. • During a travel distance of approx. 20 m the track tension is built up automatically. • When the engine is stopped a system pressure of 35 bar is kept up, and in combination with an accumulator safety system (shock absorber), the correct track tension is always present.


• If the track tensioning is too low, the wear-out on track pads and sprockets increases. • Track-off may occur during traveling or any movements due to loose tracks.

Possible causes

• No or too low track tensioning pressure. • Accumulators insufficiently charged or defective. • Defective track tensioning cylinder(s).

Possible cause

Step


Procedure

Nominal value

► Keep the engine running at high idle - ladder in up position No or too low track tensioning pressure

1

Test and adjust the track tensioning pressure according to the instructions and specifications in the SERVICE MANUAL and PM-CLINIC sheets. Is adjustment possible and does the track tensioning system work orderly?

Yes

Bring the machine back to operation.

No

Go to next step.


► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked

Accumulators insufficiently charged or defective

2

Test and adjust the charging of the accumulators according to the instructions and specifications in the SERVICE MANUAL. Also refer to the latest version of PARTS & SERVICE NEWS AH03533. Is the function "charging the accumulators" possible and does the track tensioning system work orderly?

Yes

Bring the machine back to operation.

No

Go to next step.

SERVICE MANUAL PARTS & SERVICE NEWS AH03533 (latest version)

► Keep the engine running at high idle - ladder in up position

Defective track tensioning cylinder(s)

Final check

3

4

PC4000-6 S/N 08199 and up

The tests and adjustments in steps 1 and 2 have been completed successfully (that means a track tensioning pressure of 35 bar is present and the accumulators are charged orderly). But the track tensioning cylinders can not hold the supplied pressure. Disassemble the track tensioning cylinders and check the seals at the pistons. Are the seals in the track tensioning cylinders defective?

Yes

Check the track tensioning cylinders for swollen partitions. If necessary repair or replace the barrels alternatively replace complete track tensioning cylinders.

No

Replace the seals. Replace the track tensioning block no. 130 (car body) and flush the pipes and hoses of the track tensioning lines.


345

40 Troubleshooting

Part V

SHY014 - Ladder does not move, or slow movement [1/2] Trouble code

Trouble

SHY014

Ladder does not move, or slow movement

Contents of trouble

• The ladder does not move when the function "ladder up" or "ladder down" is requested, or the ladder movement is too slow.

Related information

• The electrical function of this circuit is already tested and ok. • The ladder pressure supply is charged by X2 pressure. • A 70 bar SRV is mounted in the ladder circuit.


• The ladder does not move when the function "ladder up" or "ladder down" is requested, or the ladder movement is too slow.

Possible causes

• • • • •

Possible cause

No or too low X2 pressure. Too low SRV pressure, or the valve is defective. Valve 57Q623a/b mechanically stuck. The ladder cylinder has an internal leakage (piston seal defective). The ladder bearing is defective or it is tightened too firmly.

Step


Procedure

Nominal value

► Keep the engine running at high idle. No or too low X2 pressure

1

Check the X2 pressure according to the instructions and specifications in the SERVICE MANUAL and PM-CLINIC sheets. Is the X2 pressure adjustment correct?

Yes

Go to next step.

No

Re-adjust and verify that the ladder is operated orderly.

Yes

Go to next step.

No

Re-adjust and verify that the ladder is operated orderly.

SERVICE MANUAL PM-CLINIC sheets 45bar

► Keep the engine running at low idle. Too low SRV pressure or the valve is defective

2

Check the SRV pressure in the ladder circuit according to the instructions and specifications in the SERVICE MANUAL and PM-CLINIC sheets. Is the SRV pressure adjustment correct?


► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked. Valve 57Q623a or 57K623b is mechanically stuck

3

Disassemble the solenoid valve 57Q623a/b and check the inner part of the spool for proper condition. Is the inner part of the spool in good condition?

Yes

Go to next step.

No

Replace valve 57Q623a/b.

Yes

Repair or replace the ladder cylinder.

No

Go to next step.


The ladder cylinder has an internal leakage (piston seal defective)

346

4

Activate the function "ladder up" or "ladder down" until the cylinder end position is reached, and measure the temperature difference between the cylinder rod and the cylinder bottom side with an infrared thermometer gun. Is the temperature difference in the piston area higher than 10°C?

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY014 - Ladder does not move, or slow movement [2/2] Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked. Inspect: - Is the standard ladder frame used (standard weight & size)? The ladder bearing is defective or it is tightened too firmly

5

Check the ladder bearing for proper condition and for the hand-tight tightening torque. Also refer to the ASSEMBLY MANUAL. Are the bearings in good condition and are they tightened correctly?

Yes

6

PC4000-6 S/N 08199 and up

ASSEMBLY MANUAL

Replace or repair as necessary. No

Final check

- Is the ladder or the ladder support defective or damaged by an accident?

Repair or replace the bearings as necessary and/or correct the tightening torque.


347

40 Troubleshooting

Part V

SHY015 - Refilling arm does not move, or slow movement [1/1] Trouble code

Trouble

SHY015

Refilling arm does not move, or slow movement

Contents of trouble

• The refilling arm does not move, or its movement is too slow.

Related information

• The electrical function of this circuit is already tested and ok. • The refilling arm pressure supply is charged by X2 pressure. • The refilling arm circuit has no SRV.


• The refilling arm does not move, or its movement is too slow.

Possible causes

• • • •

Possible cause

No or too low X2 pressure. Valve 57Q624a/b is mechanically stuck. The refilling arm cylinder has an internal leakage (piston seal defective). The refilling arm connection (pin and bushing) is defective.

Step


Procedure

Nominal value


1

Check the X2 pressure according to the instructions and specifications in the SERVICE MANUAL and PM-CLINIC sheets. Is the X2 pressure adjustment correct?

Yes

Go to next step.

No

Re-adjust and verify that the refilling arm is operated orderly.

SERVICE MANUAL PM-CLINIC sheets 45 bar

► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked. Valve 57K624a/b is mechanically stuck

2

Disassemble the solenoid valve 57Q624a/b and check the inner part of the spool for proper condition. Is the inner part of the spool in good condition?

Yes

Go to next step.

No

Replace valve 57Q624a/b.

Yes

Repair or replace the refilling arm cylinder.

No

Go to next step.

► Keep the engine running at high idle. The refilling arm cylinder has an internal leakage (piston seal defective)

3

Activate the function "refilling arm up" or "refilling arm down" until the cylinder end position is reached, and measure the temperature difference between the cylinder rod and the cylinder bottom side with an infrared thermometer gun. Is the temperature difference in the piston area higher than 10°C?

► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked.

The refilling arm connection (pin and bushing) is defective

Inspect: - Is the standard refilling arm used (standard weight & size)? 4

Check the refilling arm for proper function. Disconnect the hydraulic cylinder and check the free movement of the refilling arm. Is the refilling arm movement ok?

Yes

- Is the refilling arm or its support defective Refer to the SERVICE or damaged by an MANUAL accident? Replace or repair as necessary.

No Final check

348

5

Repair or replace the refilling arm or the pin/ bushing as necessary.


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY016 - The hydraulic driven grease pump does not move [1/1] Trouble code

Trouble

SHY016

The hydraulic driven grease pump does not move

Contents of trouble

• The hydraulic driven grease pump does not start or move correctly.

Related information

• • • •


• The grease system is inoperative because the pump does not work. • Any relevant trouble message may be displayed on VHMS monitor.

Possible causes

• • • • • •

Possible cause

The electrical function of this circuit is already tested and ok. The hydraulic driven grease pump pressure supply is charged by X4 pressure. The hydraulic oil flow and pressure at the hydraulic driven grease pump is reduced. Also refer to the information in the SERVICE MANUAL, section "Lubrication Systems".

No or too low X4 pressure. No or insufficient performance of the relief valve on the grease pump. No or insufficient performance of the "Q" volume reducing valve on the grease pump. Internal leakage or damage at the grease pump. Wrong grease pressure adjustment (grease pressure too high). The vent valve (62Q507a) causes a mechanical jam (grease pump overload).

Step


Procedure

Nominal value


1

Keep the engine running at high idle. Check the X4 pressure according to the instructions and specifications in the SERVICE MANUAL and PM-CLINIC sheets. Is the X4 pressure adjustment correct?

Yes

Go to next step.

No

Readjust and verify that the grease pump operation is orderly.

Check the pressure of the grease pump relief valve according to the instructions and specifications in the SERVICE MANUAL.

Yes

Go to next step.

Is the pressure adjustment of the grease pump relief valve correct?

No


Yes

Go to next step.

No


Yes

Go to next step.

No

Repair or replace the grease pump as necessary.


► Keep the engine running at high idle. No or insufficient performance of the relief valve on the grease pump

2

SERVICE MANUAL 45bar

► Keep the engine running at high idle. No or insufficient performance of the "Q" volume reducing valve on the grease pump

3

Check the volume adjustment of the grease pump volume reducing valve according to the instructions and specifications in the SERVICE MANUAL. Is the volume adjustment correct?

SERVICE MANUAL 16–19 doublestrokes per minute

► Keep the engine running at high idle. Internal leakage or damage at the grease pump

4

Check the adjustment and operation of the grease pump according to the instructions and specifications in the SERVICE MANUAL. Is the grease pump adjustment and operation correct?

SERVICE MANUAL

► Keep the engine running at high idle. Wrong grease pressure adjustment (grease pressure too high)

5

Check the grease pressure adjustment according to the instructions and specifications in the SERVICE MANUAL. Is the grease pressure correct?

Yes No

SERVICE MANUAL Readjust or replace the Grease pressure end of line switch. max.180 bar

Go to next step.


The vent valve causes a mechanical jam (grease pump overload)

6

Final check

7

PC4000-6 S/N 08199 and up

Test the vent valve operation according to the Repair or replace the vent valve SERVICE instructions and specifications in the SERVICE and test and adjust the grease MANUAL MANUAL. system if necessary. Bring the machine back into the original condition. Start the machine and verify that the repair was successful.

349

40 Troubleshooting

Part V

SHY017 - Trouble pump bearing lubrication [1/1] Trouble code SHY017

Trouble

Trouble pump bearing lubrication

Contents of trouble

• There is a malfunction in the external lubrication system for the pump bearing.

Related information

• The pump bearing lubrication pressure supply is charged by X4 pressure. • Also refer to the PARTS & SERVICE NEWS AH05510 (latest version).


• Due to no or insufficient pump bearing lubrication the lifetime of the main pump will be decreased.

Possible causes

• No or too low X4 pressure. • Wrong adjustment of the main pump bearing throttle valve.

Possible cause

Step


Procedure

Nominal value

► Engine running at high idle. No or too low X4 pressure

1

Check the X4 pressure adjustment according to the instructions and specifications in the SERVICE MANUAL and PM-CLINIC sheets. Is the X4 pressure adjustment correct?

Yes

Readjust and verify that the pump bearing lubrication operation is orderly.

No

Go to next step.


► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked. Wrong adjustment of the main pump bearing throttle valve

2

Final check

3

350

Follow the instructions in the PARTS & SERVICE NEWS AH05510 (latest version).

Verify that the pump bearing lubrication is working orderly. Go to final step 3.

PARTS & SERVICE NEWS AH05510


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY018 - Abnormal track chain movement during digging [1/1] Trouble code SHY018

Trouble

Abnormal track chain movement during digging

Contents of trouble

• Abnormal track chain movement in reverse direction during bucket filling - FSA. • Abnormal track chain movement in forward direction during bucket filling - BHA.

Related information

• During bucket filling movement (FSA) the track chain(s) make a self-movement in reverse direction. That means, the forward loading force will be eliminated by a self-reversing movement of the track system. • During bucket filling movement (BHA) the track chain(s) make a self-movement in forward direction. That means the reverse loading force will be eliminated by a self-forwarding movement of the track system.


• Insufficient digging or loading performance.

Possible causes

• Internal leakage at the rotary joint.

Possible cause

Step


Procedure

Nominal value


Internal leakage at the rotary joint

1

Final check

2

PC4000-6 S/N 08199 and up

Test and adjust the SRV pressure according to the instructions and specifications in the SERVICE MANUAL and PM-CLINIC sheets. → Measure the SRV pressure at the travel system with connected travel main lines (310±5 bar). Perform the following work steps: (1) Test the travel system during loading. (2) Measure the SRV pressure at the travel system with plugged (closed) travel main lines before the rotary joint inlet (310±5 bar). (3) If the pressure is ok replace or re-seal the rotary joint. (4) Test and adjust the MRVs of the travel system on the main blocks II & IV. After adjustment/repair/replacement verify that chain movement is no longer abnormal.

SERVICE MANUAL PM-CLINIC sheets SRV pressure 310±5bar


351

40 Troubleshooting

Part V

SHY019 - Swing parking brake without function [1/1] Trouble code SHY019

Trouble

Swing parking brake without function

Contents of trouble

• The swing parking brake is inoperative (the superstructure moves) although the swing parking brake switch 20S029 is switched to position "1" (brake closed). • The X2 pressure circuit is already tested and ok (X2 pressure (45 bar) at valve 57Q505). • The electrical circuit is already tested and ok.

Related information

• The swing parking brake is a disc brake mounted on the top of each swing gearbox. • The "Siebenhaar" swing gearbox has an external swing brake housing with a separate oil filling. • The "L&S" swing gearbox has an integrated swing brake system which is lubricated by the gearbox oil. • According to the safety regulations both swing parking brakes are working as a "Spring Loaded System". That means the pilot pressure opens the swing parking brakes. Without pilot pressure the springs close the swing parking brakes.


• The swing parking brake is inoperative.

Possible causes

• The pilot pressure in the swing parking brake circuit is not released. • The brake discs are burnt and/or the piston seals are defective.

Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked. The pilot pressure in the swing parking brake circuit is not released

1

The solenoid valve 57Q505 is mechanically stuck. The pilot pressure in the swing parking brake line is not released to the hydraulic oil tank. Is the piston of the solenoid valve stuck?

Yes

Replace the solenoid valve 57Q505.

No

Go to next step.

0 bar

► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked. Perform the following steps: - Disconnect the pilot pressure supply hoses for the swing parking brakes from the swing gearboxes. The brake discs are burnt and the piston seals are defective

2

Yes

Check for leaks or mixed-up connections 45bar, in the pilot supply lines kept up for 15 minutes for the swing parking brake system.

No

Repair or replace the swing parking brake(s) and check the swing parking brakes for proper operation.

- Install a manual hydraulic pump with 60 bar manometer in order to test the swing parking brake piston seals (perform the test for both swing gearboxes). - Use a manual pump and increase the pressure up to 45 bar. - The built-up pressure must be kept up for 15 minutes. Can you build-up 45 bar and is the pressure kept up for 15 minutes without further action?

Final check

352

3


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SHY020 - Travel parking brake without function [1/1] Trouble code SHY020

Trouble

Travel parking brake without function

Contents of trouble

• The travel parking brake is inoperative. • The X2 pressure circuit is already tested and ok (X2 pressure (45 bar) at solenoid valve 57Q516). • The electrical circuit is already tested and ok.

Related information

• The travel parking brake is a disc brake, mounted between the travel motors and the travel gearboxes. • According to the safety regulations both travel parking brakes are working as a "Spring Loaded System". That means the pilot pressure opens the travel parking brakes. Without pilot pressure the springs close the travel parking brakes.


• There is no automatic travel parking brake function when the ladder is down or the engine is stopped.

Possible causes

• The pilot pressure in the travel parking brake circuit is not released. • The pressure adjustment is too low, or pressure reducing valve no. 47 is defective. • The brake discs are burnt and/or the piston seals are defective.

Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked. The pilot pressure in the travel parking brake circuit is not released

1

The solenoid valve 57Q516 is mechanically stuck. The pilot pressure in the travel parking brake line is not released to the hydraulic oil tank. Is the piston of the solenoid valve stuck?

Yes

Replace the solenoid valve 57Q516.

No

Go to next step.

0bar

► Keep the engine running at high idle. The pressure adjustment is too low or valve no. 47 is defective

2

Check and adjust the pressure at valve no. 47 according to the instructions and specifications in the SERVICE MANUAL and PM-CLINIC sheets. Is it possible to adjust the pressure as specified?

Yes

Go to next step.

No

Replace valve no. 47.


► Main key switch 20S001 in OFF position & maintenance safety switch 50S058 locked. Perform the following steps: - Disconnect the pilot pressure supply hoses from the travel parking brake housings. The brake discs are burnt and/or the piston seals are defective

3

- The built-up pressure must be kept up for 15 minutes. Can you build-up 45 bar and is the pressure kept up for 15 minutes without further action? 4

PC4000-6 S/N 08199 and up

No

Refer to the instructions in the SERVICE MANUAL. Repair or replace the travel parking brakes and check the travel parking brakes for proper operation.

- Install a manual hydraulic pump with 60 bar manometer in order to test the travel parking brake piston seals (perform the test for both travel brake housings). - Using the manual pump increase the pressure up to 45 bar.

Final check

Yes

Check for leaks or mixed-up connections 45bar, in the pilot supply lines kept up for 15 minutes for the travel parking brake system.

SERVICE MANUAL


353

40 Troubleshooting

Part V

Symptoms of the mechanical system SME001 - Abnormal noise is made [1/2] Trouble code SME001

Trouble

Abnormal noise is made

Contents of trouble

• Abnormal noise coming from any engine related parts.

Related information

• At first judge whether the noise is an internal noise or an external noise.


• Abnormal noise. • The noisy component may cause an unexpected breakdown.

Possible causes

• Related parts, components or systems which may cause the noise, because they are loose, worn, misaligned, or defective: - Air intake system - Muffler system - Broken guards - Broken fire wall - Lost parts or tools etc. • Improper alignment between engine and PTO • Abnormal combustion

Possible cause

Step


Procedure

Nominal value


External noise (the abnormal noise is not coming from inside the engine)

1

Final check

2

354

Check all related parts and components for proper function. Check suspicious screw connections and mountings for proper tightening condition. Could you locate and rectify the cause for the abnormal noise?

Yes

Go to final step 2.

No

Refer to the following judgment table and locate the problem. When the cause for the noise is determined, perform the appropriate repair procedures as necessary. After the repair is completed, go to final step 2.


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SME001 - Abnormal noise is made [2/2]

Defect inside muffler (dividing board out of position)

Air leakage between turbocharger & cylinder head

Ο

Improper gear train backlash

Ο

Broken dynamic valve syst. (valve, rocker lever etc)




●

Deformed fan or defective fan hub

◊

Defective fuel pump


Clogged, seized injector

◙

Missing, seized bushing



Causes

Excessive wear of piston ring, cylinder liner

Judgment Table



◊

Condition of abnormal noise

Gradually occurred Suddenly occurred

Ο

PC4000-6 S/N 08199 and up

Ο

◙ ◙ ◙ ◙ ◙

Ο

Ο

◙ ◙ ◙ ◙

Ο

Ο

Ο

Ο

Ο ◙

Ο ◙ ◙ ◙

● ● ●

● ● ● ● ●

Replace

Replace

Replace

Correct

Replace

Correct

Correct

● Replace

Remedy

Ο Ο

Replace

Measured compression pressure it is too low When rotating the turbocharger by hand, it is too rough-running Remove the gear cover and inspect directly Eng. speed does not change when any cylinder is disengaged Fan is deformed or the fan hub is defective When checking valve clearance, it doesn't meet the specification Remove the cylinder head cover and inspect directly When the muffler is removed, abnormal noise disappears

Ο

Replace

Non-specified fuel is being used Engine oil must be added more frequently Blue under light load Colour of exhaust gas Black Metal particles are found in the oil filter Blow-by gas is excessive Noise of interference is heard from around the turbocharger Engine pickup is poor and combustion is abnormal When touching the exhaust manifolds immediately after engine start, the temperature of some cylinders is low Abnormal noise is loud when accelerating the engine Clanging sound is heard from around the cylinder head Air leakage between turbocharger & cylinder head, loose clamp Vibrating noise is heard from around the muffler

Replace

Troubleshooting

Check items

Questions


355

40 Troubleshooting

Part V

SME002 - Abnormal noise around the PTO / hydraulic pumps [1/2] Trouble code SME002

Trouble

Abnormal noise around the PTO / hydraulic pumps

Contents of trouble

• Abnormal or excessive noise coming from the PTO or from the hydraulic pumps.

Related information

• At first check all oil levels and oil qualities (PTO - pump bearing housings). • Refer to the OPERATION & MAINTENANCE MANUAL for detailed information concerning the correct oil specifications and oil qualities.


• Abnormal noise. • The noisy component may cause an unexpected breakdown.

Possible causes

• No oil or the oil level is too low in the PTO • No oil or the oil level is too low in the pump bearing housing • No or not enough external lubrication (X4 pressure) at the pump bearings (refer to the latest version of PARTS & SERVICE NEWS AH05510, latest version) • The internal throttle lubrication valve in the main pump housing is not opened enough or it is closed. • Main pump defective (internal mechanical damage) • Air entering the hydraulic system or air bubbles inside the hydraulic suction lines

Possible cause

Step


Procedure

Nominal value


No oil or the oil level is too low in the PTO

1

Check the oil level in the PTO housing using the dipstick. For details refer to the OPERATION & MAINTENANCE MANUAL. Is the oil level correct between the MIN and MAX marks?

Yes

Go to next step.

No

Refill specified oil up to the specified level and recheck if the abnormal noise has disappeared.

Between MIN & MAX


No oil or the oil level is too low in the pump bearing housing

2

Check the oil level and the oil quality in the pump bearing housing of the PTO gearbox. For details refer to the OPERATION & MAINTENANCE MANUAL and to the PARTS & SERVICE NEWS AH07515 (latest version). Is the oil level correct and does the oil quality meet the specification?

Yes

Go to next step.

No

Refill specified oil up to the specified level and recheck if the abnormal noise disappeared.

Oil specification and refill level reference: O&M MANUAL P&S NEWS AH07515 (latest version)

► Keep the engine running at high idle. No or not enough external lubrication (X4 pressure) at the pump bearings

356

3

Check the X4 pressure (60 bar) at the valve and filter plate. For details refer to the SERVICE MANUAL and to the PARTS & SERVICE NEWS AH05510 (latest version). Does the X4 pressure meet the specification?

Yes

Go to next step.

No

Adjust the specified X4 pressure.

60bar

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SME002 - Abnormal noise around the PTO / hydraulic pumps [2/2] Possible cause

Step


Procedure

Nominal value


The internal throttle lubrication valve in the main pump housing is not opened enough or it is closed.

4

Check the basic adjustment of the throttle lubrication valve. For details refer to the PARTS & SERVICE NEWS AH05510 (latest version). Is the throttle lubrication valve fully open and is X4 pressure present?

Throttle valve fully open

Yes

Go to next step.

No

Check the X4 pressure at this port and adjust 60bar the throttle valve to fully open position.

Note If the pump was operated after pump replacement, with the throttle valve closed or not fully open, the pump bearing was not enough lubricated! In this case, replace the complete main pump again and make sure that the throttle valve is set to "fully open" before operating the pump. New pumps are always delivered with closed throttle valves. ► Keep the engine running at high idle & move the attachment in working condition.

Main pump defective (internal mechanical damage)

5

Check for abnormal noise coming from around or directly from the main pumps. Use a vibration analyzer, take measurements at all 4 main pumps and compare the measurement results. Does any main pump show excessive noise generation?

Yes

Double-check the suspicious main pump for excessive noise generation. If it is confirmed, replace the noisy main pump.

No

All main pumps generate too much noise simultaneously. Got to next step.

► Keep the engine running at high idle & move the attachment in working condition.

Air entering the hydraulic system or air bubbles inside the hydraulic suction lines

Check the sight glass at the hydraulic tank for air bubbles. Also check the suction lines and clamps of sealed connections for air leakage. 6

7

PC4000-6 S/N 08199 and up

No

Check the lifetime of the PTO and the main pumps. The abnormal noise may be caused by normal wear due to component aging.

Remark: Suction lines always must be mounted with silicon applied to the pipes and they must be fixed with double-clamps. Could you locate air in the hydraulic tank or air bubbles in the suction lines?

Final check

Yes

If you located air bubbles in the hydraulic system refer to the latest version of PARTS & SERVICE NEWS AH01513 & AH00504 & 21.531 (latest versions) for bleeding the hydraulic cylinders.

There is no air in the hydraulic oil tank and in the suction lines.


357

40 Troubleshooting

Part V

SME003 - Vibration is excessive (engine mountings) [1/2] Trouble code SME003

Trouble

Vibration is excessive (engine mountings)

Contents of trouble

• Abnormal or excessive vibration coming from the engine or related parts.

Related information

• At first check all related parts for function and proper tightening. • Measure the alignment/incline of the engine (& PTO) mountings (horizontal & vertical). • For detailed information regarding Diesel engine suspension refer to the latest version of PARTS & SERVICE NEWS AH01521 (latest version).


• Abnormal vibration and the risk that a breakdown may occur. • The noisy component may cause an unexpected breakdown.

Possible causes

• Defective parts → mounting supports of engine and PTO. • Improper alignment → mixed mounting of old (worn and/or defective) and new mounting supports. • Abnormal combustion. • Defective front damper. • Defective rear damper (coupling to PTO).

Possible cause

Step


Procedure

Nominal value


Abnormal or excessive vibration coming from the engine or related parts

1

• Defective parts → mounting supports of engine and PTO. • Improper alignment → mixed mounting of old (worn and/or defective) and new mounting supports. • Abnormal combustion. • Defective front damper. • Defective rear damper (coupling to PTO).

No Check all related parts and components of the above items for proper function and condition. Check suspicious screw connections and mountings for proper tightening. Could you locate and rectify the cause for the abnormal vibration?

Final check

358

Yes

2

Go to final step 2. Refer to the following judgment table and locate the problem. When the cause for the noise is determined perform the appropriate repair procedures as necessary. After the repair is completed go to final step 2.


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SME003 - Vibration is excessive (engine mountings) [2/2]


Defective dynamic valve syst. (valve, rocker lever etc)


Improper gear train backlash

◊ ●


Broken part inside output shaft (damper)

◙

Loose engine mounting bolts, broken cushion


Worn balancer, cam bushing

Causes

Worn connecting rod, main bearing

Judgment Table



◊ ◊ ◊ Ο

Increased suddenly Condition of vibration

Ο

Ο

Non-specified oil is being used Metal particles are found in the oil filter

Ο ◙

Ο ◙

Metal particles are found when oil is drained

◙

◙

Oil pressure is low at low idle

Ο

Ο

Increased gradually

Ο

Ο

Vibrations occurs at mid-range speed (poor combustion)

Ο

Ο

Vibrations follows the engine speed (poor combustion)

Ο

Ο

Ο ◙

Exhaust smoke is black (poor combustion) ● ●

Check all engine supports for proper alignment/incline

PC4000-6 S/N 08199 and up

Replace

Remedy

Adjust

● Replace

●

Inspect front engine damper Replace

Inspect output shaft damper (coupling)

Replace

Troubleshooting

Inspect directly for loose engine mounting bolts, broken cushion

Replace

Check items

Questions


359

40 Troubleshooting

Part V

SME004 - Vibration is excessive (engine torsion) [1/1] Trouble code SME004 Contents of trouble

Trouble

Vibration is excessive (engine torsion)

• Vibration is excessive (abnormal vibration at the front engine damper or at the coupling). • In order to eliminate abnormal vibration and torque of the engine, the following components are mounted: - A damper at the engine front side → double-mass vibration damper - A damper at the engine rear side → coupling

Related information

The front damper (cooler side) is mounted on the crankshaft. For inspection and references refer to the Cummins Troubleshooting and Repair Manual for the QSK60 Engine (SDA 12V 160 Komatsu Engine). The rear damper in the form of a coupling is flange connected to the engine flywheel. • For further information refer to the Cummins engine documentation.


• Vibration is excessive (abnormal vibration at the front engine damper or at the coupling).

Possible causes

• Front double-mass vibration damper defective. • Rear coupling defective.

Possible cause

Step


Procedure

Nominal value

► Main key switch 20S001 OFF and maintenance safety switch 50S058 locked. Front double-mass vibration damper defective

1

Check the front double-mass vibration damper according to the specifications given in the Cummins Service Manual. Is the damper defective?

Yes

Replace the damper. Also check the rear coupling for wear (step 2).

No

Go to next step.

Cummins specification


Rear coupling defective

Final check

360

2

3

Yes

Replace the coupling. Also check the front double-mass vibration damper on the crankshaft (step 1).

No

Inform the Cummins Service and measure the blow-by pressure of the engine.

Check the rear coupling for wear and proper function. Is the coupling defective?

SERVICE MANUAL


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SME005 - There is a big shock when stopping swing [1/1] Trouble code SME005

Trouble

There is a big shock when stopping swing

Contents of trouble

• A big shock occurs when stopping the swing movement with the swing foot brake or by the counter swing function.

Related information

• A big shock occurs when the superstructure changes its swing direction.


• Excessive wear and in consequence further damage may occur.

Possible causes

• Wear in vertical & horizontal direction at the boom foot bushings and pins. • Excessive wear of the swing circle (causing heavy backlash).

Possible cause

Step


Procedure

Nominal value


Wear in vertical & horizontal direction at the boom foot bushings and pins

1

Move the attachment smoothly and check for excessive wear at the boom foot bushings. Is the movement too large?

Yes

Replace pins and bushings at the connection between boom and superstructure. After replacement measure the axial clearance at the connection between boom and superstructure. If the axial play is still out of range repair with the welding and lathe tool.

No

Go to next step.

Boom foot bushings & pins, max. clearance 2.5mm

Axial play between boom and superstructure, max. clearance 2.5mm


Yes

Excessive wear of the swing circle (causing heavy backlash)

2

Move the attachment smoothly and check for excessive wear and movement of the swing circle and backlash. Also refer to the latest version of PARTS & SERVICE NEWS AH02513. Is the wear out of range?

Replace the swing circle.

P&S NEWS AH02513 (latest version)

- Check the teeth around the swing circle.

No

- Also check the grease dummy wheel for the swing circle teeth (tightening). - Go to SME006 and refer to its troubleshooting procedures.

Final check

3

PC4000-6 S/N 08199 and up


361

40 Troubleshooting

Part V

SME006 - There is a big abnormal noise when moving/stopping swing [1/2] Trouble code

Trouble

SME006

There is a big abnormal noise when moving/stopping swing

Contents of trouble

• A big abnormal noise occurs when moving/stopping swing. • The abnormal noise may also exist permanently during the swing movement.

Related information

• • • • •


• Abnormal noise and in consequence any damage may occur.

Possible causes

Possible cause

• • • •

First check all oil levels at the swing gearboxes. Verify the oil level and the used oil viscosity in the swing gearboxes (CLP 220 only). Verify the oil level and the used oil viscosity in the swing parking brake housing (SAE 30 only). Verify the oil level and the used oil viscosity in the motor adapter housing (SAE 30 only). Also refer to the OPERATION & MAINTENANCE MANUAL and to the SERVICE MANUAL.

Swing gearbox - internal damage. Faulty bottom bearing of the swing gearbox pinion (external grease lubrication). Swing parking brake - internal damage (discs are welded with each other). Damaged mechanical connection between the swing hydraulic motor and the swing gearbox (motor adapter housing, excessive wear at the connection).

Step


Procedure

Nominal value

► Engine running at high idle & smooth swing movement of the superstructure.

Swing gearbox internal damage

1

Check for proper tightening of the swing gearboxes, and retighten if necessary. During swing movement, check and listen for noise at the gearboxes. Can you identify any abnormal noise coming from any swing gearbox?

Yes

Replace the defective swing gearbox.

No

Go to next step.

SERVICE MANUAL → Tightening chart

► Engine running at high idle & smooth swing movement of the superstructure.

Faulty bottom bearing of the swing gearbox pinion (external grease lubrication)

362

2

During swing movement check the movement of the swing gearbox pinion. During swing movement also check and listen for noise at the lower side of the respective swing gearbox. Check the grease supply and grease amount (injector adjustment) at the pinion bearing. Can you identify any abnormal noise or abnormal movement of the swing gearbox pinion?

Yes

Replace the defective swing gearbox.

No

Go to next step.

SERVICE MANUAL → Component structure and grease system.

PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SME006 - There is a big abnormal noise when moving/stopping swing [2/2] Possible cause

Step


Procedure

Nominal value

► Keep the engine running at high idle & smooth swing movement of the superstructure.

Swing parking brake internal damage (discs are welded together)

3

Check the swing parking brake for proper condition (parking brake switch in position "1" = brake closed). Carefully move the control lever to start swing movement. Can you identify any abnormal noise or abnormal swing movement?

Yes

Although the swing parking brake is closed the superstructure moves and causes noise or shock during stopping or starting the swing movement. - Inspect and replace SERVICE the defective swing MANUAL parking brakes as necessary. - Also check for contamination of the gearbox oil. Drain contaminated oil and refill fresh specified gearbox oil.

No

Go to next step.

► Keep the engine running at high idle & smooth swing movement of the superstructure.

Damaged mechanical connection between the swing hydraulic motor and the swing gearbox (motor adapter housing, excessive wear at the connection)

Final check

4

5

PC4000-6 S/N 08199 and up

Yes

Disconnect the hydraulic swing motor from the swing gearbox and check the connection between SERVICE both components. MANUAL If the connection is damaged, replace the swing gearbox and the hydraulic motor.

No

Check the hydraulic swing adjustment (two stage valve). Refer to the SERVICE MANUAL and the PMCLINIC sheets. Also see the troubleshooting charts of SHY008-010.

Check the swing movement for proper condition. (starting swing - stopping swing - counter swing - foot brake actuation - fast swing speed - low swing speed) Can you identify any abnormal noise, abnormal swing movement, or abnormal vibration?

SERVICE MANUAL & PMCLINIC


363

40 Troubleshooting

Part V

SME007 - Fan hub bearing noise is abnormal [1/1] Trouble code

Trouble

SME007

Fan hub bearing noise is abnormal

Contents of trouble

• Abnormal noise occurs when the hydraulic oil cooler/radiator fans are starting or stopping. • The abnormal noise may also exist permanently when the fan is running continuously.

Related information

• • • • •


• Abnormal noise and in consequence any cooler damage may occur.

Possible causes

• Fan hub bearing worn out. • A wrong oil viscosity is used (bearing sound during rotating). Short lifetime of the fan hub bearings. • Fan blades are loose or broken.

Possible cause

First check all oil levels at the fan hubs. Verify the oil level and the used oil viscosity in the fan hubs (CLP 220 only). Make sure that the vent valves on top of the fan hubs are clean. Check for horizontal & vertical movement of the fan hub bearing. Also refer to the OPERATION & MAINTENANCE MANUAL and to the SERVICE MANUAL.

Step


Procedure

Nominal value

► Main key switch 20S001 OFF & maintenance safety switch 50S058 locked. Fan hub bearing worn out

1

Check the fan hub bearings for wear. Move the fan manually and check for horizontal & axial movement. Can you identify any horizontal & axial fan movement?

Yes

Replace the worn or damaged fan hub(s).

No

Go to next step.

No horizontal & axial fan movement


A wrong oil viscosity is used (bearing sound during rotating). Short lifetime of the fan hub bearings.

2

Manually check the fan hub bearings for wear and rotating sound. Move the fan manually and check for horizontal & axial movement. Can you identify any horizontal & axial fan movement?

Yes

Replace the worn & noisy fan hub(s) and refer to the OPERATION & MAINTENANCE MANUAL in order to verify the correct oil viscosity. Only CLP 220 is approved replacement interval 3000 hrs.

No

Go to next step.

No horizontal & axial fan movement, no rotating sound


Fan blades are loose or broken

Final check

364

3

4

Yes

Check the lifetime of the concerned fan(s). If the lifetime exceeds 10,000 hrs, replace all fans.

No

Check the hydraulic cooler fan drive for overspeed. Adjust the specified speed if necessary.

Manually check the fan blades for proper connection. Turn the fan manually and check each blade. Is any fan blade loose?

No horizontal & axial fan movement

RPM max 1250±50


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SME008 - Abnormal noise coming from a travel gearbox [1/2] Trouble code

Trouble

SME008

Abnormal noise coming from a travel gearbox

Contents of trouble

• Abnormal noise occurs when the shovel starts or stops travelling. • The abnormal noise may also exist permanently when the shovel is travelling continuously.

Related information

• • • • •


• Abnormal noise and in consequence any capital damage may occur.

Possible causes

• Gearbox broken (housing or internal parts defective). Short-term failure. • A wrong oil viscosity is used (any planetary gear teeth and/or bearing defective). Long-term failure. • Hydraulic travel motor connection defective (no oil in the motor adapter housing).

Possible cause

First check the oil levels at both travel gearboxes. Verify the oil level and the used oil viscosity in the travel gearboxes (CLP 220 only). Make sure that the vent valves at the end of the breather hoses are clean (inside car body). Drain the oil of the travel gearboxes and check for particles, chippings, or pieces due to wear. Also refer to the OPERATION & MAINTENANCE MANUAL and to the SERVICE MANUAL.

Step

Procedure

Nominal value

Yes

Refer to the SERVICE MANUAL & PMCLINIC sheets and carry out the basic adjustment of the travel system. If the noise continues after the basic adjustment, replace the concerning travel gearbox.

SERVICE MANUAL PM-CLINIC

No

Go to step 3.

Yes

Refer to the SERVICE MANUAL & PMCLINIC sheets and carry out the basic adjustment of the travel system. If the noise continues after the basic adjustment, replace the concerning travel gearbox.

No

Go to next step.

Test condition & Inspection ► Keep the engine running at high idle.

Gearbox broken (housing or internal parts defective). Short-term failure.

1

Take the track off the ground - during rotation check each side for abnormal noise or shocks. Can you identify any abnormal noise or shock during track rotation?


A wrong oil viscosity is used (any planetary gear teeth and/or bearing defective). Long-term failure.

2

PC4000-6 S/N 08199 and up

Take the track off the ground - during rotation check each side for abnormal noise or shocks. Can you identify any abnormal noise or shock during track rotation?

SERVICE MANUAL & PMCLINIC

365

40 Troubleshooting

Part V

SME008 - Abnormal noise coming from a travel gearbox [2/2] Possible cause

Step


Procedure

Nominal value


Hydraulic travel motor connection defective (no oil in the motor adapter housing)

Final check

366

3

4

Disconnect the concerning travel motor from the adapter housing and check the connection at the motor and inside the motor adapter housing for any damage. Can you identify any damage (because of missing oil)?

Yes

Replace the concerning travel motor and replace the planetary gear pinion at the gearbox.

No

Check the travel motor(s) for internal and external leakage and replace if necessary. Also refer to the troubleshooting chart of SHY006.


PC4000-6 S/N 08199 and up

Part V

40 Troubleshooting

SME009 - Abnormal noise coming from the work equipment (lack of grease) [1/2] Trouble code

Trouble

SME009

Abnormal noise coming from the work equipment (lack of grease)

Contents of trouble

• Abnormal noise occurs when the attachment is moving. • The abnormal noise occurs due to lack of grease (CLS) at the pins and the bushings of the work equipment

Related information

• • • • •


• Abnormal noise and in consequence any capital damage of the pins and bushings may occur.

Possible causes

• A wrong grease quality is used. • Contaminated grease is used. • Daily fault messages of the CLS system occur - download the history data via VHMS and verify the system status.

Possible cause

First check the grease level at the CLS grease barrel. Verify that the barrel contains grease of the specified quality and viscosity. Verify that all injectors are in good condition and properly adjusted. Verify that the setting of the pause time (VHMS monitor) is correct. Also refer to the OPERATION & MAINTENANCE MANUAL and to the SERVICE MANUAL.

Step


Procedure

Nominal value


A wrong grease quality is used

1

PC4000-6 S/N 08199 and up

Yes

Go to next step.

No

Replace wrong grease by specified grease and replace the defective pins and bushings on the attachment side. Check all grease injectors for proper function. Pre-lubricate all pins and bushings through the injectors until the new grease flows out.

Recheck the grease quality and specification under consideration of the KMG recommendations in the OPERATION & MAINTENANCE MANUAL and in the latest version of the PARTS & SERVICE NEWS AH02539. Does the used grease correspond to the KMG recommendations?

SERVICE MANUAL PMCLINIC P&S NEWS AH02539 (latest version)

367


Machine model

Serial numbers

PC4000-6D

08199 and up

50 Disassembly and Assembly


PC4000-6D

1

2

PC4000-6D

Overview

Overview 1 INTRODUCTION 2 SAFETY 3 SUPERSTRUCTURE 4 UNDERCARRIAGE 5 ATTACHMENT 6 APPENDIX

Overview - 1

Overview

Overview - 2

Table of contents

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

SAFETY INSTRUCTIONS........................................................................................................ 2-2 2.1.1 METHOD OF USING THIS MANUAL .......................................................................... 2-2 2.1.2 GENERAL PRECAUTIONS ......................................................................................... 2-4 2.1.3 PREPARATIONS FOR WORK .................................................................................... 2-5 2.1.4 PRECAUTIONS DURING WORK................................................................................ 2-6 2.1.5 WARNING OF SPECIAL DANGERS........................................................................... 2-8 2.1.5.1 ELECTRICAL ENERGY ............................................................................... 2-8 2.1.5.2 GAS, DUST, STEAM AND SMOKE ............................................................. 2-9 2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT...... 2-10 2.1.5.4 NOISE ........................................................................................................ 2-10 2.1.5.5 HEAT.......................................................................................................... 2-11 2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES ......................... 2-11 2.1.5.7 HEIGHT...................................................................................................... 2-11 2.1.6 SPECIAL SAFETY EQUIPMENT .............................................................................. 2-13 2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........................................................... 2-13 2.1.6.2 INSTRUCTIONS FOR USE ....................................................................... 2-15 2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS .......... 2-17 2.1.6.4 INSTRUCTIONS FOR USE ....................................................................... 2-19

2.2

LIFTING GEARS .................................................................................................................... 2.2.1 WIRE ROPES ............................................................................................................ 2.2.2 SLING ACCESSORY................................................................................................. 2.2.3 WEIGHT TABLES ...................................................................................................... 2.2.3.1 SUPERSTRUCTURE................................................................................. 2.2.3.2 UNDERCARRIAGE.................................................................................... 2.2.3.3 BACKHOE ATTACHMENT (BHA) ............................................................. 2.2.3.4 FACESHOVEL ATTACHMENT (FSA) .......................................................

2-20 2-20 2-22 2-23 2-23 2-25 2-26 2-27

2.3

TORQUE CHARTS ACCORDING TO DIN ............................................................................ 2.3.1 METRIC STANDARD THREAD................................................................................. 2.3.2 METRIC FINE THREAD ............................................................................................ 2.3.3 CUMMINS MOTOR TORQUES - METRIC................................................................ 2.3.4 CUMMINS MOTOR TORQUES - U.S. CUSTOMARY............................................... 2.3.5 FLANGE CONNECTIONS .........................................................................................

2-29 2-29 2-30 2-31 2-31 2-32

TOC - 1

Table of contents

2.4

CONVERSATION TABLE ...................................................................................................... 2.4.1 METHOD OF USING THE CONVERSATION TABLE............................................... 2.4.2 MILLIMETER - INCH & KILOGRAM - POUND .......................................................... 2.4.3 LITER - U.S. GALLON & LITER - U.K. GALLON....................................................... 2.4.4 KGM - FT.LB .............................................................................................................. 2.4.5 BAR - PSI / PSI - BAR ............................................................................................... 2.4.6 BASIC VALUES IN OHM ACCORDING TO DIN 43 76 ............................................. 2.4.7 TEMPERATURE ........................................................................................................

2-33 2-33 2-34 2-35 2-36 2-37 2-38 2-39

2.5

EXPLANATION OF ABBREVIATIONS ................................................................................. 2-40

3 SUPERSTRUCTURE.......................................................................... 3-1 3.1

TOC - 2

DIESEL ENGINE ...................................................................................................................... 3-2 3.1.1 REMOVAL OF THE DIESEL ENGINE......................................................................... 3-2 3.1.2 REPLACEMENT OF THE DIESEL ENGINE ............................................................... 3-9 3.1.3 ENGINE TORQUE SUPPORT AND ENGINE/PTO MOUNTS .................................. 3-12 3.1.3.1 FLEXIBLE MOUNTS .................................................................................. 3-13 3.1.3.2 TORQUE SUPPORT.................................................................................. 3-15 3.1.4 ALTERNATOR ........................................................................................................... 3-16 3.1.4.1 REMOVAL OF THE ALTERNATOR .......................................................... 3-16 3.1.4.2 REPLACEMENT OF THE ALTERNATOR ................................................. 3-17 3.1.5 BATTERIES ............................................................................................................... 3-18 3.1.5.1 REMOVAL OF THE BATTERIES............................................................... 3-18 3.1.5.2 REPLACEMENT OF THE BATTERIES ..................................................... 3-20 3.1.6 RADIATOR FAN ........................................................................................................ 3-22 3.1.6.1 REMOVAL OF THE RADIATOR FAN ASSEMBLY ................................... 3-23 3.1.6.2 REPLACEMENT OF THE RADIATOR FAN ASSEMBLY .......................... 3-27 3.1.6.3 REMOVAL OF THE RADIATOR FAN........................................................ 3-29 3.1.6.4 REPLACEMENT OF THE RADIATOR FAN .............................................. 3-29 3.1.6.5 REMOVAL OF THE RADIATOR FAN DRIVE PUMP ................................ 3-30 3.1.6.6 REPLACEMENT OF THE RADIATOR FAN DRIVE PUMP ....................... 3-32 3.1.7 RADIATORS .............................................................................................................. 3-33 3.1.7.1 REMOVAL OF THE RADIATOR ASSEMBLY............................................ 3-33 3.1.7.2 REPLACEMENT OF THE RADIATOR ASSEMBLY .................................. 3-37 3.1.8 FUEL COOLER.......................................................................................................... 3-38 3.1.8.1 REMOVAL OF THE FUEL COOLER ......................................................... 3-38 3.1.8.2 REPLACEMENT OF THE FUEL COOLER................................................ 3-40 3.1.9 STARTER SYSTEM................................................................................................... 3-41 3.1.9.1 REMOVAL OF THE STARTER MOTOR ................................................... 3-41 3.1.9.2 REPLACEMENT OF THE STARTER MOTOR. ......................................... 3-41 3.1.10 GEISLINGER COUPLING ......................................................................................... 3-42 3.1.10.1 REMOVAL OF THE GEISLINGER COUPLING......................................... 3-43 3.1.10.2 REPLACEMENT OF THE GEISLINGER COUPLING ............................... 3-45

Table of contents

3.2

3.3

PTO ........................................................................................................................................ 3.2.1 MAIN PUMPS ............................................................................................................ 3.2.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL ......................... 3.2.1.2 REMOVAL OF MAIN PUMP 1 ................................................................... 3.2.1.3 REPLACEMENT OF MAIN PUMP 1.......................................................... 3.2.1.4 REMOVAL OF MAIN PUMP 2 ................................................................... 3.2.1.5 REPLACEMENT OF MAIN PUMP 2.......................................................... 3.2.1.6 REMOVAL OF MAIN PUMP 3 ................................................................... 3.2.1.7 REPLACEMENT OF MAIN PUMP 3.......................................................... 3.2.1.8 REMOVAL OF MAIN PUMP 4 ................................................................... 3.2.1.9 REPLACEMENT OF MAIN PUMP 4.......................................................... 3.2.2 PTO OIL CIRCULATION PUMP (AUXILIARY PUMP) .............................................. 3.2.2.1 REMOVAL OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) ...... 3.2.2.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) ....................................................................... 3.2.3 PUMP DISTRIBUTOR GEARBOX (PTO).................................................................. 3.2.3.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ................. 3.2.3.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO)........

3-46 3-46 3-47 3-50 3-51 3-53 3-55 3-57 3-59 3-60 3-62 3-63 3-63 3-65 3-66 3-68 3-71

HYDRAULICS ........................................................................................................................ 3-72 3.3.1 HYDRAULIC COOLER FAN DRIVE PUMP .............................................................. 3-72 3.3.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP .............. 3-72 3.3.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP .... 3-75 3.3.2 HYDRAULIC COOLER FAN ASSEMBLY ................................................................. 3-76 3.3.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY ......................... 3-76 3.3.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY................ 3-79 3.3.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR ...................... 3-80 3.3.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR ............. 3-82 3.3.3 HYDRAULIC OIL COOLERS ..................................................................................... 3-84 3.3.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS .................................... 3-86 3.3.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS ........................... 3-90 3.3.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME ......................... 3-92 3.3.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME................ 3-97 3.3.4 MAIN RELIEF VALVES (MRV) .................................................................................. 3-98 3.3.4.1 REMOVAL OF THE MRV .......................................................................... 3-98 3.3.4.2 REPLACEMENT OF THE MRV ................................................................ 3-99 3.3.5 PILOT OIL PUMP (GEAR PUMP) ........................................................................... 3-100 3.3.5.1 REMOVAL OF THE PILOT OIL PUMP)................................................... 3-100 3.3.5.2 REPLACEMENT OF THE PILOT OIL PUMP .......................................... 3-102 3.3.6 MAIN GATE VALVE................................................................................................. 3-102 3.3.6.1 REMOVAL OF THE MAIN GATE VALVE ................................................ 3-103 3.3.6.2 REPLACEMENT OF THE MAIN GATE VALVE....................................... 3-104 3.3.7 HYDRAULIC OIL RESERVOIR ............................................................................... 3-106 3.3.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR............................... 3-108 3.3.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR ..................... 3-115 3.3.8 MAIN CONTROL VALVE BLOCKS ......................................................................... 3-117 3.3.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS......................... 3-126 3.3.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS ............... 3-130 3.3.9 SERVICE LINE RELIEF VALVES (SRV) ................................................................. 3-131 3.3.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK .................... 3-131 3.3.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS......... 3-134

TOC - 3

Table of contents

3.3.10 ANTI-CAVITATION VALVES (ACV) ....................................................................... 3.3.10.1 REMOVAL OF ACV ON MANIFOLD ....................................................... 3.3.10.2 REPLACEMENT OF ACV ON MANIFOLD .............................................. 3.3.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS .................. 3.3.10.4 REPLACEMENT OF ACV ON MAIN CONTROL VALVE BLOCKS......... 3.3.11 THROTTLE CHECK VALVES ................................................................................. 3.3.11.1 REMOVAL OF THROTTLE CHECK VALVES ......................................... 3.3.11.2 REPLACEMENT OF THROTTLE CHECK VALVES................................ 3.3.12 MANIFOLD............................................................................................................... 3.3.12.1 REMOVAL OF THE MANIFOLD .............................................................. 3.3.12.2 REPLACEMENT OF THE MANIFOLD..................................................... 3.3.12.3 REMOVAL OF THE DIFFUSER ON THE MANIFOLD (FSA ONLY) ....... 3.3.12.4 REPLACEMENT OF DIFFUSER ON MANIFOLD (FSA ONLY) ..............

3-136 3-137 3-142 3-143 3-145 3-146 3-148 3-151 3-152 3-152 3-154 3-155 3-157

3.4

SLEW DRIVE........................................................................................................................ 3.4.1 SLEW GEAR............................................................................................................ 3.4.1.1 REMOVAL OF THE SLEW GEAR ........................................................... 3.4.1.2 REPLACEMENT OF THE SLEW GEAR.................................................. 3.4.2 SWING MOTOR....................................................................................................... 3.4.2.1 REMOVAL OF THE SWING MOTOR ...................................................... 3.4.2.2 REPLACEMENT OF THE SWING MOTOR............................................. 3.4.3 SLEW PARKING BRAKE......................................................................................... 3.4.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE ............. 3.4.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE .......... 3.4.4 DYNAMIC SLEW BRAKE ........................................................................................ 3.4.4.1 REMOVAL OF THE SLEW BRAKE VALVE............................................. 3.4.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE ................................... 3.4.5 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL) ................................. 3.4.5.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY....................... 3.4.5.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY .............

3-159 3-160 3-161 3-163 3-166 3-167 3-170 3-173 3-175 3-178 3-180 3-183 3-185 3-186 3-188 3-190

3.5

LUBRICATION PUMPS ....................................................................................................... 3-191 3.5.1 REMOVAL OF THE LUBRICATION PUMP............................................................. 3-191 3.5.2 REPLACEMENT OF THE LUBRICATING PUMP ................................................... 3-193

3.6

PUMP CONTROLLER MC7 ................................................................................................. 3-194 3.6.1 REMOVAL OF THE PUMP CONTROLLER MC7 .................................................... 3-194 3.6.2 REPLACEMENT OF THE PUMP CONTROLLER MC7 .......................................... 3-195

3.7

OPERATOR’S CAB ............................................................................................................. 3.7.1 REMOVAL OF THE OPERATOR’S CAB................................................................. 3.7.2 REPLACEMENT OF THE OPERATOR’S CAB ....................................................... 3.7.3 CAB-MOUNTS ......................................................................................................... 3.7.3.1 REMOVAL OF THE CAB-MOUNTS ........................................................ 3.7.3.2 REPLACEMENT OF THE CAB-MOUNTS ............................................... 3.7.4 FRONT WINDOW .................................................................................................... 3.7.4.1 REMOVAL OF THE FRONT WINDOW ................................................... 3.7.4.2 REPLACEMENT OF THE FRONT WINDOW .......................................... 3.7.5 OPERATOR’S SEAT ............................................................................................... 3.7.5.1 REMOVAL OF THE OPERATOR’S SEAT............................................... 3.7.5.2 REPLACEMENT OF THE OPERATOR’S SEAT ..................................... 3.7.6 VHMS....................................................................................................................... 3.7.6.1 REMOVAL OF THE VHMS-CONTROLLER ............................................ 3.7.6.2 REPLACEMENT OF THE VHMS-CONTROLLER ...................................

TOC - 4

3-196 3-199 3-204 3-205 3-205 3-207 3-208 3-208 3-209 3-210 3-210 3-211 3-212 3-212 3-213

Table of contents

3.7.7

3.7.8 3.7.9

ACCESS LADDER................................................................................................... 3.7.7.1 REMOVAL OF THE ACCESS LADDER .................................................. 3.7.7.2 REPLACEMENT OF THE ACCESS LADDER......................................... 3.7.7.3 REMOVAL OF THE ACCESS LADDER CYLINDER ............................... 3.7.7.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER ..................... REMOVAL OF THE CAB BASE .............................................................................. REPLACEMENT OF THE CAB BASE .....................................................................

3-214 3-217 3-219 3-221 3-223 3-224 3-226

3.8

COUNTERWEIGHT.............................................................................................................. 3-228 3.8.1 REMOVAL OF THE COUNTERWEIGHT ................................................................ 3-229 3.8.2 REPLACEMENT OF THE COUNTERWEIGHT....................................................... 3-231

3.9

SUPERSTRUCTURE LIFTING ............................................................................................ 3-232 3.9.1 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE ................. 3-232 3.9.2 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE................... 3-235

3.10 FUEL TANK ......................................................................................................................... 3-238 3.10.1 REMOVAL OF THE FUEL TANK ............................................................................ 3-239 3.10.2 REPLACEMENT OF THE FUEL TANK ................................................................... 3-242

4 UNDERCARRIAGE............................................................................. 4-1 4.1

TRAVEL SYSTEM.................................................................................................................... 4-2 4.1.1 TRACK GROUP........................................................................................................... 4-2 4.1.1.1 CHANGING OF THE TRACK GROUP ........................................................ 4-2 4.1.2 SPROCKET ................................................................................................................. 4-6 4.1.2.1 REMOVAL OF THE SPROCKET................................................................. 4-6 4.1.2.2 REPLACEMENT OF THE SPROCKET ..................................................... 4-10 4.1.3 GUIDE WHEELS ....................................................................................................... 4-12 4.1.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY ..................................... 4-12 4.1.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY ........................... 4-13 4.1.4 TRACK TENSIONING ACCUMULATORS ................................................................ 4-14 4.1.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS ...................... 4-14 4.1.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS ............. 4-16 4.1.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS ..................... 4-17 4.1.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS ............ 4-18 4.1.5 TRACK TENSION VALVE BLOCK ............................................................................ 4-19 4.1.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK ..................... 4-19 4.1.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK............ 4-20 4.1.6 HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM .............................. 4-21 4.1.6.1 SUBSTITUTE THE HYDRAULIC HOSES ................................................. 4-21 4.1.7 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE)........................................ 4-24 4.1.7.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK ............................. 4-25 4.1.7.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK .................... 4-27 4.1.8 TRACK TENSIONING CYLINDERS .......................................................................... 4-28 4.1.8.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS ......................... 4-28 4.1.8.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS ................ 4-29 4.1.9 TRAVEL MOTOR....................................................................................................... 4-30 4.1.9.1 REMOVAL OF THE TRAVEL MOTORS.................................................... 4-30 4.1.9.2 REPLACEMENT OF THE TRAVEL MOTORS .......................................... 4-32 4.1.10 TRAVEL PARKING BRAKE....................................................................................... 4-34 4.1.10.1 REMOVAL/DISASSEMBLY OF THE TRAVEL PARKING BRAKE............ 4-37 4.1.10.2 REPLACEMENT/ASSEMBLY OF THE TRAVEL PARKING BRAKE ........ 4-40

TOC - 5

Table of contents

4.2

4.1.11 TRAVEL GEARBOX .................................................................................................. 4.1.11.1 REMOVAL OF THE TRAVEL GEARBOX.................................................. 4.1.11.2 REPLACEMENT OF THE TRAVEL GEARBOX ........................................ 4.1.12 CARRIER ROLLER.................................................................................................... 4.1.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY............................... 4.1.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY ..................... 4.1.13 TRACK ROLLER........................................................................................................ 4.1.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY................................... 4.1.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY .........................

4-42 4-43 4-45 4-46 4-46 4-48 4-49 4-49 4-51

CAR BODY............................................................................................................................. 4.2.1 REMOVAL OF THE CAR BODY (PREVIOUS TYPE WITH MOUNTING PINS) ....... 4.2.2 REPLACEMENT OF THE CAR BODY (PREVIOUS TYPE WITH MOUNTING PINS)............................................................ 4.2.3 REMOVAL OF THE CAR BODY (NEW TYPE WITH BOLTED CONNECTION) ........................................................... 4.2.4 REPLACEMENT OF THE CAR BODY (NEW TYPE WITH BOLTED CONNECTION) ........................................................... 4.2.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS ................................................................................... 4.2.5 ROTARY JOINT......................................................................................................... 4.2.5.1 REMOVAL OF THE ROTARY JOINT ........................................................ 4.2.5.2 REPLACEMENT OF THE ROTARY JOINT ............................................... 4.2.6 SWING CIRCLE......................................................................................................... 4.2.6.1 REMOVAL OF THE SWING CIRCLE ........................................................ 4.2.6.2 REPLACEMENT OF THE SWING CIRCLE...............................................

4-52 4-52 4-56 4-60 4-65 4-70 4-74 4-76 4-79 4-80 4-82 4-84

5 ATTACHMENT.................................................................................... 5-1 5.1

TOC - 6

BACKHOE................................................................................................................................ 5-2 5.1.1 BOOM .......................................................................................................................... 5-4 5.1.1.1 REMOVAL OF THE BOOM.......................................................................... 5-4 5.1.1.2 REPLACEMENT OF THE BOOM ................................................................ 5-8 5.1.1.3 REMOVAL OF BOOM CYLINDERS .......................................................... 5-10 5.1.1.4 REPLACEMENT OF BOOM CYLINDERS................................................. 5-15 5.1.2 STICK......................................................................................................................... 5-18 5.1.2.1 REMOVAL OF THE STICK ........................................................................ 5-18 5.1.2.2 REPLACEMENT OF STICK....................................................................... 5-22 5.1.2.3 REMOVAL OF STICK CYLINDERS........................................................... 5-24 5.1.2.4 REPLACEMENT OF STICK CYLINDERS ................................................. 5-29 5.1.3 BUCKET..................................................................................................................... 5-32 5.1.3.1 REMOVAL OF THE BUCKET .................................................................... 5-32 5.1.3.2 REPLACEMENT OF THE BUCKET........................................................... 5-35 5.1.3.3 REMOVAL OF BUCKET CYLINDERS....................................................... 5-36 5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS ............................................. 5-41 5.1.4 BUCKET LINK ROD AND STEERING RODS ........................................................... 5-43 5.1.4.1 REMOVAL OF THE BUCKET LINK ROD .................................................. 5-43 5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD......................................... 5-45 5.1.4.3 REMOVAL OF THE STEERING RODS..................................................... 5-46 5.1.4.4 REPLACEMENT OF THE STEERING RODS ........................................... 5-49 5.1.5 GROUND ENGAGING TOOLS (GET)....................................................................... 5-50 5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET....................................... 5-50

Table of contents

5.1.6

HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT....................................... 5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES .................................................. 5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES ........................................ 5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES ........................................ 5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES ....................................

5-52 5-52 5-56 5-60 5-64

5.2

FACESHOVEL ....................................................................................................................... 5-69 5.2.1 BOOM ........................................................................................................................ 5-70 5.2.1.1 REMOVAL OF THE BOOM ....................................................................... 5-70 5.2.1.2 REPLACEMENT OF THE BOOM .............................................................. 5-75 5.2.1.3 REMOVAL OF THE BOOM CYLINDERS .................................................. 5-80 5.2.1.4 REPLACEMENT OF THE BOOM CYLINDERS ........................................ 5-85 5.2.2 STICK ........................................................................................................................ 5-88 5.2.2.1 REMOVAL OF THE STICK........................................................................ 5-88 5.2.2.2 REPLACEMENT OF THE STICK .............................................................. 5-92 5.2.2.3 REMOVAL OF THE STICK CYLINDERS .................................................. 5-94 5.2.2.4 REPLACEMENT OF THE STICK CYLINDERS ......................................... 5-99 5.2.3 BULLCLAM BUCKET .............................................................................................. 5-102 5.2.3.1 REMOVAL OF THE BULL CLAM BUCKET ............................................. 5-102 5.2.3.2 REPLACEMENT OF THE BULL CLAM BUCKET ................................... 5-108 5.2.3.3 REMOVAL OF THE BUCKET CYLINDERS ............................................ 5-110 5.2.3.4 REPLACEMENT OF THE BUCKET CYLINDERS ................................... 5-114 5.2.3.5 REMOVAL OF THE CLAM CYLINDERS ................................................. 5-118 5.2.3.6 REPLACEMENT OF THE CLAM CYLINDERS ....................................... 5-122 5.2.4 GROUND ENGAGING TOOLS (GET)..................................................................... 5-124 5.2.4.1 REMOVAL AND REPLACEMENT OF THE GET .................................... 5-124 5.2.5 HYDRAULIC HOSES AT THE FACESHOVEL ATTACHMENT .............................. 5-126 5.2.5.1 SUBSTITUTE THE BOOM ARC HOSES ................................................ 5-126 5.2.5.2 SUBSTITUTE THE BOOM CYLINDER HOSES ...................................... 5-130 5.2.5.3 SUBSTITUTE THE STICK ARC HOSES ................................................. 5-134 5.2.5.4 SUBSTITUTE THE STICK CYLINDER HOSES ...................................... 5-138 5.2.5.5 SUBSTITUTE THE BUCKET CYLINDER HOSES .................................. 5-142 5.2.5.6 SUBSTITUTE THE CLAM CYLINDER HOSES ....................................... 5-146

5.3

METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT ........................... 5-154 5.3.1 REMOVAL OF THE METERING VALVES (GREASE INJECTORS)....................... 5-154 5.3.2 REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS) ............. 5-155

5.4

CYLINDER BYPASS TEST ................................................................................................. 5-156

6 APPENDIX .......................................................................................... 6-1 6.1

FUEL AND LUBRICANTS ....................................................................................................... 6-2

6.2

FILLING CAPACITIES ............................................................................................................. 6-4

6.3

TOOLS LIST............................................................................................................................. 6-6 6.3.1 USED SPECIAL TOOLS (OVERVIEW) ....................................................................... 6-6 6.3.2 KOMATSU TOOLS CATALOGUE

6.4

WORK INSTRUCTIONS ........................................................................................................ 6-12 6.4.1 REMOVE / INSTALL THE CRAWLER CARRIER ..................................................... 6-12 6.4.2 USE OF THE HYDRAULIC TORQUE WRENCH (SUPPLIER’S DOCUMENTATION) ........................................................................... 6-13

TOC - 7

Table of contents

6.5

TOC - 8

SERVICE BULLETINS ........................................................................................................... 6-15 6.5.1 AH00511D Installation procedure for the swing circle / Slew Ring (SR) ...................................... 6-17 6.5.2 AH00514 Track group - Hints for sprocket exchange ................................................................ 6-19 6.5.3 AH00519 Adhesive lubricants for the Slew Ring Gear ............................................................... 6-21 6.5.4 AH01512 Setup - procedure of the VHMS Integrated Tool Soft ................................................ 6-23 6.5.5 AH01521A Diesel engine suspension .......................................................................................... 6-25 6.5.6 AH01531A Hydraulic accumulators - testing and refilling ............................................................. 6-27 6.5.7 AH02513B Testing wear and tear of the swing circle bearing ...................................................... 6-29 6.5.8 AH02521 Track group – wear measurement ............................................................................. 6-31 6.5.9 AH03506B Hydraulic oil cooler and water cooler fan bearings .................................................... 6-33 6.5.10 AH03509A Slew gear GFB 174 E 9017 (Part No. 917 915 40) .................................................... 6-35 6.5.11 AH03510 ESCO bucket tooth system ........................................................................................ 6-37 6.5.12 AH03526A Downloading of VHMS Data from VHMS memory to a connected PC/Laptop .......... 6-39 6.5.13 AH03538 Replacing of the VHMS - Controller on PC4000-6 ..................................................... 6-41 6.5.14 AH04518 Welding procedure for welded counterweight ............................................................ 6-43 6.5.15 AH05510 Bearing flushing of the A4VS variable displacement axial piston pump .................... 6-45 6.5.16 AH05511 Dual cone seal ring mouting ....................................................................................... 6-47 6.5.17 AH05546 Automatic lubrication system - Vent valve (PN 769 879 73) ...................................... 6-49 6.5.18 AH06524 Hydraulic cylinder ....................................................................................................... 6-51 6.5.19 AH06530 Relieving of the track chain tension ........................................................................... 6-53

Introduction

1 INTRODUCTION

1 -1

Contents of the binder

1.1


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.

1 -2

Introduction

Introduction

1.2

Foreword

FOREWORD

Observe the instructions in these manuals for: z

Your Personal SAFETY

z


z

READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

With this R&R Procedures Manual, KOMATSU provides you with the description of changing or repairing worn out or broken parts to assure the function of the major systems of the Hydraulic Excavator PC 4000-6 D. 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 CONTENTS all the functions and components 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 Information Department 8151.40 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY

FROM THE PRACTICE - FOR THE PRACTICE -

1 -3

Foreword

Introduction

WARNING Personnel entrusted with work on the machine must have read the Assembly Manual, the Operation-, Lubrication-, Service,- and Maintenance Manual and in particular the section on safety before beginning work. Reading the instructions after work has begun is too late.

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.

1 -4

Safety

2 SAFETY

2 -1

Safety Instructions

2.1

SAFETY INSTRUCTIONS

2.1.1

METHOD OF USING THIS MANUAL

z

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.

z

Tightening torques according to DIN are not explicitly given in the installation procedures. For tightening torques according to DIN, refer to Section 2.3 on page 2-29.

z

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.

z

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.

z

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 6.3 on page 6-6.

z

The following symbols are used in the manual to designate additional information: 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 DIN, refer to Section 2.3 on page 2-29 (e.g. 129 Nm). General information concerning a section, e.g. tightening torques according to DIN, refer to Section 2.3 on page 2-29.

Special authorized personnel is required.

z

Service Bulletins which are mentioned in the operation procedures are listed at the end of chapter 6. For the list, refer to Section 6.5 on page 6-15.

2 -2

Safety

Safety

z

Safety Instructions

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.

2 -3

Safety Instructions

2.1.2

Safety

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, chapter 4, section "FIRE PREVENTION".

z

If welding repairs are needed, refer to the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS".

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.

z

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.

2 -4

Safety

Safety Instructions

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 BULLETIN No. "AH04518" for expelling the gases from the counterweight chambers.

2.1.3

PREPARATIONS FOR WORK 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 stands 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.

2 -5

Safety Instructions

2.1.4

Safety

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 water and oil in the circuits are hot when the engine is stopped, so be careful not to get burnt. Wait for the oil and water to cool before carrying out work on the oil or water circuits.

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


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 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.

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.

2 -6

Safety

Safety Instructions

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.

2 -7

Safety Instructions

2.1.5

Safety

WARNING OF SPECIAL DANGERS

2.1.5.1 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

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them. Caution, danger! Check out the prescribed safety distances.

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

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

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.

2 -8

Safety

Safety Instructions

WARNING 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

Before starting work on high-voltage assemblies and after cutting off the power supply, the feeder cable must be grounded and components such as capacitors shortcircuited with a grounding rod.

2.1.5.2 GAS, DUST, STEAM AND SMOKE WARNING z

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. Observe the regulations in force at the respective site.

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 BULLETIN 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 surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

2 -9

Safety Instructions

Safety

2.1.5.3 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.

2.1.5.4 NOISE WARNING z

During operation, all sound baffles must be closed.

z

Always wear the prescribed ear protectors.

2 - 10

Safety

Safety Instructions

2.1.5.5 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

Fuel

z

Engine coolant

z

Hydraulic oil

z

Engine oil

z

Grease

Use gloves when handling hot machine parts.

2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES WARNING z

When handling oil, grease, and other chemical substances, observe the product-related safety regulations given in the material safety data sheet (MSDS).

z

Be careful when handling hot materials (risk of burning or scalding).

2.1.5.7 HEIGHT WARNING When working in heights above 1.00 m, a special safety harness is required, refer to Section 2.1.6 on page 2-13.

2 - 11

Safety Instructions

Fig. 2-1 Safety harness in conformity with EN 361 2 - 12

Safety

Safety

2.1.6

Safety Instructions

SPECIAL SAFETY EQUIPMENT

2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) The safety harness (Fig. 2-1) 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. 2-1: (1)

Safety harness according to EN 361

(2)

Strap-type fall absorber according to DIN 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. 2-1, Pos. 1) in conjunction with strap-type fall absorber (Fig. 2-1, Pos. 2), before mounting onto the loader attachment or other unsecured places of the shovel.

NOTE: The illustration (Fig. 2-1) shows a typical use of the safety harness. Shovels with the new type operator’s cab are not equipped with ladder (Fig. 2-1, Pos. 3), because the air conditioner unit of the new type cab is located on the back wall of the cab.

2 - 13

Safety Instructions


Safety

Safety

Safety Instructions

2.1.6.2 INSTRUCTIONS FOR USE Open the lock and lift the harness by the catch hook (Fig. 2-2, Pos. C). The blue straps (leg straps Fig. 2-2, Pos. J) must be at the bottom. The harness is being put on just like a jacket. Pull the belly strap (Fig. 2-2, 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. 2-2, 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. 2-2, Pos. C) is aligned in the center 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.

2 - 15

Safety Instructions


Safety

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.

2.1.6.3 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.

2 - 17

Safety Instructions


Safety

Safety

Safety Instructions

2.1.6.4 INSTRUCTIONS FOR USE Strap-type fall absorber according to DIN EN 355 (type E.K.N.BFD) Use Within a fall-arrest system, the strap-type fall absorber (Fig. 2-4, Pos. 2) has to be used in conjunction with a safety harness (Fig. 2-4, Pos. 1) according 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, according 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 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.

2 - 19

Lifting Gears

2.2

Safety

LIFTING GEARS 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.

2.2.1 z

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.

2 - 20

Safety

Lifting Gears

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. 2-5.

z

Do not sling a heavy load with one rope alone, but sling it with two or more ropes wound symmetrically around the load.

Fig. 2-5

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

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 2-6 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. 2-6

2 - 21

Lifting Gears

2.2.2

Safety

SLING ACCESSORY WARNING

Always attend to local standards when using sling accessory.

z

Do not use rigit 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 universal articulated hoist ring. DANGER

Using eye bolts or sling accessory which is not articulated or not suitable can result in serious accidents

z


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.

2 - 22

Safety

2.2.3

Lifting Gears

WEIGHT TABLES

2.2.3.1 SUPERSTRUCTURE Part or assembly

Weight

Diesel engine

7956 kg

Roof plate engine housing

310 kg max.

Alternator

62 kg

Radiator fan

85 kg

Hydraulic fan motor

18 kg

Bearing block

84 kg

Radiator fan drive pump

48.5 kg

Radiator

2120 kg

100 kg

Starter motor

26 kg

Geislinger coupling assembly

165 kg

Roof plate engine housing

205 kg

Main pump 1 assembly

500 kg


526 kg


526 kg


500 kg

Walkway frame with all gratings

90 kg

Oil circulation pump (auxilliary pump)

26 kg

Control frame assembly

2685 kg 645

Hydraulic cooler fan drive pump

50 kg

Hydraulic cooler fan assembly

95 kg


275 kg

Hydraulic oil cooler frame incl. Hydraulic oil coolers

3854 kg

Pilot oil pump

each

86 kg

Fuel cooler:

PTO (pump distributor gearbox)

depending on type

38.25 kg

Batterie

Roof plate over radiator

Remark

each element

26 kg

Main gate valve

16.5 kg

Hydraulic oil reservoire incl. Back pressure valve

3200 kg

Main control valve block 1

310 kg


310 kg

2 - 23

Lifting Gears

Safety

Part or assembly

Weight


315 kg


310 kg

Anti cavitation valve incl. Throttle check valve

7.3 kg

Throttle check valves on manifold

20.5 kg

Manifold without valves

375 kg

Diffuser on manifold

14 kg

Slew gear

1670 kg

Swing motor

120 kg

Bearing ring of the slew parking brake (L&S)

112 kg

Slew brake valve

97

Pinion cover

2.5 kg

Lubrication pinion assembly

14 kg

Lubrication pump

28 kg

Operator's cab

2700 kg

Viscous mount

5 kg

Absorber plate 1 incl. 2 viscous mount

13 kg

Absorber plate 2 incl. 2 viscous mounts

21 kg

Front window

112 kg

Operator's seat

62 kg

Access ladder

76 kg

Access ladder cylinder

18 kg

Cab base

3810 kg

Support frame

862 kg

Counterweight

37,000 k

Superstructure incl. Diesel engine without counterweight, attachment and fluids

110,500 kg

Fuel tank (empty)

3,600 kg

2 - 24

Remark

Safety

Lifting Gears

2.2.3.2 UNDERCARRIAGE Part or assembly

Weight

Track group 1200 mm

25,100 kg

Track group 1500 mm

27,510 kg

Pin between track shoes

13.3 kg

Sprocket

3050 kg

Hollow shaft

360 kg

Drive shaft

630 kg

Guide wheel assembly

2350 kg

Low pressure accumulator

12 kg

High pressure accumulator

23 kg

Track tensioning valve block

40 kg

Hydraulic hoses of the track tensioning system

23 kg max

Travel brake valve block

95 kg

Track tensioning cylinder

230 kg

Travel motor

161 kg

Travel gearbox

2990 kg

Carrier roller assembly

189 kg

Track roller assembly

466 kg

Remark

depending on type

each

Car body without crawler carrier

29,000 kg

Crawler carrier assembly (track widht 1200 mm))

56,300 kg

each

Crawler carrier assembly (track widht 1500 mm)

58,000 kg

each

Rotary joint

261 kg

Swing circle

6700 kg

2 - 25

Lifting Gears

Safety

2.2.3.3 BACKHOE ATTACHMENT (BHA) Part or assembly Boom

Weight 30,340 kg

Pin boom/superstructure

194 kg

Pin boom cylinder/boom

101 kg

Pin boom cylinder/superstructure

100 kg

Boom cylinder

4250 kg

Stick

14,502 kg

Pin stick/boom

1100 kg

Stick cylinder

3150 kg

Pin stick cylinder/stick

86 kg

Pin stick cylinder/boom

123 kg

Bucket

23,300 kg

Pin bucket/stick

738 kg

Pin bucket/bucket link rod

514 kg

Bucket cylinder

2330 kg

Pin bucket cylinder/stick

71 kg

Pin bucket cylinder/steering rod

711 kg

Pin bucke bucket/bucket link rodt

514 kg

Bucket link rod

1805 kg

Steering rod

1128 kg

Pin steering rod/bucket link rod

711 kg

Pin steering rod/stick

426 kg

Point

Remark

rh, lh

92 kg

HENSLEY ®

Tooth (center) adapter

201 kg

HENSLEY ®

Corner adapter

402 kg

HENSLEY ®

Shroud

182 kg

HENSLEY ®

Wear cap

53 kg

HENSLEY ®

Point

95 kg

ESCO ®


193 kg

ESCO ®

Corner adapter

402 kg

ESCO ®

Shroud

144 kg

ESCO ®

Wear cap

30 kg

ESCO ®

Boom arc hose

40 kg 26 kg

depending on type

2 - 26

Safety

Lifting Gears

Part or assembly

Weight

Boom cylinder hoses

20.4 kg

Stick cylinder hoses

24.4 kg

Bucket cylinder hoses

27.2 kg

Metering valve

<25 kg

Remark

2.2.3.4 FACESHOVEL ATTACHMENT (FSA) Part or assembly Boom with attached stick and boom cylinders

Weight 34,600 kg

Pin boom/superstructure

194 kg

Pin boom cylinder/boom

150 kg

Pin boom cylinder/superstructure

100 kg

Boom cylinder

3521 kg

Stick

14,350 kg

Pin stick/boom

197 kg

Stick cylinder

2400 kg

Pin stick cylinder/stick

58 kg

Pin stick cylinder/boom

50 kg

Bucket (without lip)

Remark

24,275 kg

Pin bucket cylinder/bucket

125 kg

Pin bucket/stick

180 kg

Bucket cylinder

2730 kg

Pin bucket cylinder/boom

108 kg

Clam cylinder

585 kg

Upper pin at clam cylinder

30 kg

Lower pin at clam cylinder

40 kg

Point

* kg

HENSLEY ®


* kg

HENSLEY ®

Corner adapter

* kg

HENSLEY ®

Shroud

* kg

HENSLEY ®

Wear cap

* kg

HENSLEY ®

Point

48 kg

ESCO ®


287 kg

ESCO ®

Corner adapter

674 kg

ESCO ®

NOTE: * = Ask local dealer 2 - 27

Lifting Gears

Safety

Part or assembly

Weight

Remark

Shroud

163 kg

ESCO ®

Wear cap

45 kg

ESCO ®

Boom arc hose

40 kg 26 kg

depending on type

Boom cylinder hose

26 kg 27 kg

depending on type

Stick arc hose

26 kg 18 kg

depending on type

Stick cylinder hose

26 kg 17.6 kg

depending on type

Bucket cylinder hose

27 kg 19.2 kg

depending on type

Clam cylinder hose at stick

24.6 kg

Clam cylinder hose at clam cylinder

9...11 kg

Metering valve

< 25 kg

2 - 28

depending on length

Safety

Torque charts according to DIN

2.3

TORQUE CHARTS ACCORDING TO DIN

2.3.1

METRIC STANDARD THREAD

Bolt diameter

Wrench size [mm]


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.

2 - 29


2.3.2

Safety

METRIC FINE THREAD

Bolt diameter

Wrench size [mm]


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 Bulletin AH00511 last edition!

2 - 30

Safety


2.3.3

CUMMINS MOTOR TORQUES - METRIC

Grade

8.8

10.9

12.9

Body size

Torque

Torque

Torque

Diameter

Cast iron

Aluminium

Cast iron

Aluminium

Cast iron

Aluminium

[mm]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

6

9

5

7

4

13

10

7

4

14

9

7

4

7

14

9

11

7

18

14

11

7

23

18

11

7

8

23

17

18

14

33

25

18

14

40

29

18

14

10

45

33

30

25

65

50

30

25

70

50

30

25

12

80

60

55

40

115

85

55

40

125

95

55

40

14

125

90

90

65

180

133

90

65

195

145

90

65

16

195

140

140

100

280

200

140

100

290

210

140

100

18

280

200

180

135

390

285

180

135

400

290

180

135

20

400

290

-

-

550

400

-

-

-

-

-

-

2.3.4

CUMMINS MOTOR TORQUES - U.S. CUSTOMARY Grade

5 (three radial lines on cap)

8 (six radial lines on cap)

Body size

Torque

Torque

Diameter - threads

Cast iron

Aluminium

Cast iron

Aluminium

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

1/4 - 20

9

7

8

6

15

11

8

6

1/4 - 28

12

9

9

7

18

13

9

7

5/16 - 18

20

15

16

12

30

22

16

12

5/16 - 24

23

17

19

14

33

24

19

14

3/8 - 16

40

30

25

20

55

40

25

20

3/8 - 24

40

30

35

25

60

45

35

25

7/16 - 14

60

45

45

35

90

65

45

35

7/16 - 20

65

50

55

40

95

70

55

40

1/2 - 13

95

70

75

55

130

95

75

55

1/2 - 20

100

75

80

60

150

110

80

60

9/16 - 12

135

100

110

80

190

140

110

80

2 - 31


2.3.5

FLANGE CONNECTIONS

Fig. 2-7 Torques for SAE-flange connections

2 - 32

Safety

Safety

Conversation table

2.4

CONVERSATION TABLE

2.4.1

METHOD OF USING THE CONVERSATION 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.

2 - 33

Conversation table

2.4.2

2 - 34

MILLIMETER - INCH & KILOGRAM - POUND

Safety

Safety

2.4.3

Conversation table

LITER - U.S. GALLON & LITER - U.K. GALLON

2 - 35

Conversation table

2.4.4

2 - 36

KGM - FT.LB

Safety

Safety

2.4.5

Conversation table

BAR - PSI / PSI - BAR Conversion Table bar / PSI bar - PSI

bar 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

PSI 14,5033 73 145 218 290 363 435 508 580 653 725 798 870 943 1015 1088 1160 1233 1305 1378 1450 1523 1595 1668 1740 1813 1885 1958 2030 2103 2175 2248 2321 2393 2466 2538 2611 2683 2756 2828 2901

PSI - bar bar 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

PSI 2973 3046 3118 3191 3263 3336 3408 3481 3553 3626 3698 3771 3843 3916 3988 4061 4133 4206 4278 4351 4424 4496 4569 4641 4714 4786 4859 4931 5004 5076 5149 5221 5294 5366 5439 5511 5584 5656 5729 5801

PSI 1 75 150 225 300 375 450 525 600 675 750 825 900 975 1050 1125 1200 1275 1350 1425 1500 1575 1650 1725 1800 1875 1950 2025 2100 2175 2250 2325 2400 2475 2550 2625 2700 2775 2850 2925 3000

bar 0,06895 5,17 10 16 21 26 31 36 41 47 52 57 62 67 72 78 83 88 93 98 103 109 114 119 124 129 134 140 145 150 155 160 165 171 176 181 186 191 197 202 207

PSI 3075 3150 3225 3300 3375 3450 3525 3600 3675 3750 3825 3900 3975 4050 4125 4200 4275 4350 4425 4500 4575 4650 4725 4800 4875 4950 5025 5100 5175 5250 5325 5400 5475 5550 5625 5700 5775 5850 5925 6000

bar 212 217 222 228 233 238 243 248 253 259 264 269 274 279 284 290 295 300 305 310 315 321 326 331 336 341 346 352 357 362 367 372 378 383 388 393 398 403 409 414

PSI bar

x

14,5033 = PSI

=

bar

14,5033

2 - 37

Conversation table

2.4.6

Safety

BASIC VALUES IN OHM ACCORDING TO DIN 43 76

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

16067

2 - 38

Safety

2.4.7

Conversation table

TEMPERATURE

The figures in the table below 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.

2 - 39

Explanation of abbreviations

2.5

Safety

EXPLANATION OF ABBREVIATIONS

Abbre.

Definition

A

Ampere

AC

Alternating Current

ACV

Anti-cavitation valve

API


BHA

Backhoe Attachment

°C

Degree Celsius

CLS


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

LED


MRV

Main Relief Valve

PIV

Pressure Increasing Valve

PTO


Qmax

Maximum pump delivery = maximum swash plate angle

Qmin

Minimum pump delivery = minimum swash plate angle

1/2 Qmax

1/2 pump delivery

SLS


SRV


V

Volt

WFT

Wet paint film thickness [1/1000 inch]

1/min

Revolutions Per Minute (RPM)

2 - 40

Superstructure

3 SUPERSTRUCTURE

3 -1

Diesel Engine

3.1

Superstructure

DIESEL ENGINE

The excavator is powered by a Komatsu Diesel engine: Model:

SDA 16V 160

Type:

4-cycle, water-cooled, direct injection

Aspiration:

Turbocharged with intercooler

Number of cylinders:

16

Rated power:

1400 kW (1904 HP) @ 1800 rpm

3.1.1

REMOVAL OF THE DIESEL ENGINE

Special tools:

n/a

Additional equipment:

Crane Universal articulated hoist rings: 4 x M24 Blind plugs: BUZ 28-L, PN 371 858 99 and ROV 28-PL, PN 509 377 98 2 x BUZ 20-S, PN 371 858 99 and 2 x ROV 20-PS, PN 512 005 98 BUZ 22-L, PN 371 857 99 and ROV 22-PL, PN 513 788 98 Roof plate: 310 kg max. Diesel engine: 7956 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 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.

3 -2

Superstructure

Diesel Engine

WARNING Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below 50 °C. Disobedience may result in personal injury from heated coolant or steam.

Drain the engine coolant, approx. 475 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

Drain the engine oil from the engine oil pan, approx. 290 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

Drain the engine oil reserve tank, approx. 580 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

z

Disconnect the fuel feeding hose (Fig. 3-1, Pos. 1) from the fuel filters.

z

Disconnect the fuel return hose (Fig. 3-1, Pos. 2).

NOTE: When a fuel hose is disconnected, the fuel inside the hose will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. DANGER Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result. DO NOT smoke or use an open flame when working around inflammable fuels.

z

Fig. 3-1

Disconnect the hoses to the injector valves of the cold start system.

3 -3

Diesel Engine

Superstructure

DANGER Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result. DO NOT smoke or use an open flame when working around inflammable gases.

z

Disconnect the coolant hoses (Fig. 3-2, Pos. 1) leading to the heating of the operator’s cab.

Fig. 3-2 z

Remove the suction elbows (Fig. 3-3, Pos. 1) from the turbo chargers.

z

Remove the flexible exhaust hoses (Fig. 3-3, Pos. 2).

z

Disconnect the (upper) main coolant lines (Fig. 3-3, Pos. 3) and remove its brackets from the roof plates.

z

Disconnect the (lower) main coolant return lines.

NOTE: For further information about the coolant lines, refer to section 3.1.7.1 on page 3-33.

Fig. 3-3 z

Disconnect all wire harnesses leading to the engine (Fig. 3-4).

Fig. 3-4

3 -4

Superstructure

Diesel Engine

z

Disconnect all oil hoses of the oil management system (Fig. 3-5).

z

Disconnect the oil filling hose leading from the engine oil pan to the service arm.

Fig. 3-5 z

Suck off the refrigerant from the air conditioning. WARNING

The air conditioning must be serviced by authorized refrigeration specialists only.

z

Disconnect the refrigerant hoses of the air conditioning from the compressor.

z

Cap the openings with blind plugs to avoid cantamination of the air conditioning system.

z

Remove the Geislinger coupling, refer to section 3.1.10.1 on page 3-43.

z

Remove the bolts attaching the PTO to the engine.

z

Remove all cables which lead through the roof plates. 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.

3 -5

Diesel Engine

Superstructure

NOTE: Depending on the serial number of the excavator, different types of roof constructions have been assembled. Carry out the following steps in accordance with the proper serial number. z

For serial numbers up to 08170 & 08172 & 08173: z

Remove the gratings (Fig. 3-6, Pos. 1), the engine air cleaners (Fig. 3-6, Pos. 2), and the exhaust mufflers (Fig. 3-6, Pos. 3) from the roof.

z

If equipped, remove the extinguishing agent tank assemblies (Fig. 3-6, Pos. 4) from the roof. 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 and tubes of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional.

z

Fig. 3-6

For serial number 08171 & 08174 and up: z

Remove the gratings (Fig. 3-7, Pos. 1), the engine air cleaners (Fig. 3-7, Pos. 2), the exhaust mufflers (Fig. 3-7, Pos. 4), and the air duct (Fig. 3-7, Pos. 3) from the roof.

z

Dismount all cables which lead to the control frame from the inner side of the roof plate.

Fig. 3-7

3 -6

Superstructure

Fig. 3-8

Diesel Engine

Roof plate removal

(1)

Bolt

(2)

Resilient sleeve

(3 to 6)

Roof plate

(7)

Beam

(8)

Moulding

z

Clear all wire harnesses from the roof plates (Fig. 3-8, Pos. 3 to 6) and from the beam (Fig. 3-8, Pos. 7).

z

Dismount all attached parts from the roofplates.

z

Remove all bolts (Fig. 3-8, Pos. 1) and resilient sleeves (Fig. 3-8, Pos. 2) of the roof plates (Fig. 3-8, Pos. 3 to 6).

z

Remove the roof plates (Fig. 3-8, Pos. 3 to 6) with a crane using universal articulated hoist rings.

NOTE: Remove the mouldings (Fig. 3-8, Pos. 8). z

Remove the beam (Fig. 3-8, Pos. 7). 3 -7

Diesel Engine

z

Superstructure

Attach the engine to a crane using the four lifting shackles (Fig. 3-9, arrow) at the engine.

Fig. 3-9 z

Remove eight rear engine mounting bolts (Fig. 3-10, Pos. 1) on both sides.

Fig. 3-10 z

Remove the engine mounting bolts (Fig. 3-11, Pos. 1) from the engine torque support (Fig. 3-11, Pos. 2).

z

Move the engine with the crane away from the PTO at first and then lift it out of the engine house. DANGER

Risk of falling weights! Death or serious injury may result. When removing the engine, make sure that nobody steps below the weight.

z

Remove the bolts (Fig. 3-11, Pos. 3 and 4) and remove the engine torque support (Fig. 3-11, Pos. 2) from the engine mounts (Fig. 3-11, Pos. 5).

NOTE: For further information on the engine torque support, refer to section 3.1.3 on page 3-12.

3 -8

Fig. 3-11

Superstructure

3.1.2

Diesel Engine

REPLACEMENT OF THE DIESEL ENGINE

Special tools:

n/a


Crane Universal articulated hoist rings: 4 x M24 Roof plate: 310 kg max. Diesel engine: 7956 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

z

Replace all flexible bearings and rubber-bounded metal bars of the flexible mounts (Fig. 3-12, Pos. 5). Refer to PART & SERVICE BULLETIN No. "AH01521a"

z

Mount the engine torque support (Fig. 3-12, Pos. 2) onto the flexible mounts.

z

Install the bolts (Fig. 3-12, Pos. 3 and 4) and tighten the bolts hand-tight.

z

Attach the new engine to the crane and move it into its mounting position and install the engine mounting bolts (Fig. 3-12, Pos. 1) DANGER

Risk of falling weights! Death or serious injury may result. Fig. 3-12 When installing the engine, make sure that nobody steps below the weight.

z

Install a new Geislinger coupling, refer to section 3.1.10.2 on page 3-45.

3 -9

Diesel Engine

Superstructure

z

Reinstall the mounting bolts attaching the PTO to the engine.

z

Install eight rear engine mounting bolts (Fig. 3-13, Pos. 1) on both sides and tighten them to the specified torque. Tightening torque for rear engine mounting bolts: 510 Nm

Fig. 3-13 z

Tighten all bolts at the engine torque support, refer to section 3.1.3 on page 3-12 or to the PART & SERVICE BULLETIN No. "AH01521a".

z

Reinstall the roof frame in reverse order to removal.

z

Connect the refrigerant hoses of the air conditioning to the compressor.

z

Evacuate the air conditioning and add refrigerant. WARNING

The air conditioning must be filled with refrigerant "R134a" by authorized refrigeration specialists only.

z

Carry out further installation in reverse order to removal. Refill the engine coolant, approx. 475 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM".

Refill the engine oil pan with engine oil, approx. 290 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM".

Refill the engine oil reseerve tank with engine oil, approx. 580 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM".

3 - 10

Superstructure

z

Diesel Engine

Bleed the fuel lines to the engine: z

Assure that the emergency shut off valve is opened.

z

Disconnect the feeding line at the engine fuel filter.

z

Wait until the fuel flows out.

NOTE: Catch the leaking fuel in an oil pan. z

Reconnect the feeding line to the engine fuel filter.

z

Disconnect the feeding line at the engine fuel pump.

z



Reconnect the feeding line to the engine fuel pump.

3 - 11

Diesel Engine

3.1.3

ENGINE TORQUE SUPPORT AND ENGINE/PTO MOUNTS

Fig. 3-14 Engine and PTO mounts with torque support

3 - 12

Superstructure

Superstructure

Diesel Engine

Legend for Fig. 3-14: Quantity

Size

Grade

WS*

Torque

(1)

Flexible bearing

14

(2)

Bolt with self-locking nut

4 per mount

M10x35

8.8

17

43

(3)

Tie bolt

4

M24x400

10.9

36

snug

(4)

Rubber-bounded metal bar

4

(5)

Self locking nut

4

M24

8

36

snug

(6)

Bolt with self locking nut

28

M16x80

10.9

24

265

(7)

Cup springs

7 per bolt

(8)

Stop bolt

2

M36x250

10.9

55

-

(9)

Nut

2

M36

10

55

-

(10)

Bolt

10

M24x200

10.9

36

880

(11)

Bolt

16

M20x120

10.9

30

510

(12)

Resilient sleeve

16

(13)

Bolt

4

M30x200

10.9

46

1770

(14)

Resilient sleeve

4

* Wrench Size

3.1.3.1 FLEXIBLE MOUNTS The flexible mounts are installed to absorb the vibrations and the torsional forces. They carry the total weight of the engine and the pump distributor gear with all hydraulic pumps. For this reason, all connections must be checked frequently according to the maintenance manual (high-strength bolt connections) or when engine or PTO were replaced. In the case of fatigue or damage of a metal rubber guide (Fig. 3-14, Pos. 1), all metal rubber guides and their fastening bolts (Fig. 3-14, Pos. 2) with nuts must be replaced. Also inspect the metal-rubber-bar (Fig. 3-14, Pos. 4) for fatigue or damage and replace if necessary. The bolt (Fig. 3-14, Pos. 3) must not have any axial play. If necessary, re-tighten the nut (Fig. 3-14, Pos. 5) until rubber is squeezed slightly out of rubber bar (Fig. 3-14, Pos. 4). NOTE: For further information, refer to PART & SERVICE BULLETIN No. "AH01521a".

3 - 13

Diesel Engine

Fig. 3-15 Engine and PTO mounts with torque support

3 - 14

Superstructure

Superstructure

Diesel Engine

3.1.3.2 TORQUE SUPPORT To absorb the torque force, the front engine support is additionaly supported with a cup spring package. Check the cup springs (Fig. 3-15, Pos. 7) of both supports for fatigue or damage regularly and replace them if necessary. Turn the bolt (Fig. 3-15, Pos. 4) down until it slightly pre-stresses the cup spring and secure with the lock nut. (Distance between engine torque support and bolt head "B" = 29 mm) NOTE: The lock nuts (Fig. 3-15, Pos. 9) can be re-used 3 to 4 times. Assumed the bolt (Fig. 3-15, Pos. 3) thread is cleaned thoroughly before turning the nut on or off, otherwise the locking part of the nut will be damaged and the lock is not ensured.

3 - 15

Diesel Engine

3.1.4

Superstructure

ALTERNATOR

3.1.4.1 REMOVAL OF THE ALTERNATOR Special tools:

n/a


n/a Alternator: 38.25 kg

z

Prepare an area of flat ground large enough to accommodate the machine and boom.

z


z


z

Remove the keys from the battery main switches WARNING

Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below 50 °C. Disobedience may result in personal injury from heated engine parts..

z

Remove the generator belt guard (Fig. 3-16, Pos. 1).

z

Remove all electrical connections from the alternator and remove the alternator.

NOTE: A second person is required to remove the alternator. For further information refer to the Engine Operaton & Maintenance Manual.

Fig. 3-16

3 - 16

Superstructure

Diesel Engine

3.1.4.2 REPLACEMENT OF THE ALTERNATOR Special tools:

n/a


Belt tension gauge Alignment chart (steel ruler) Alternator: 38.25 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

z

Carry out installation in reverse order to removal.

NOTE: A second person is required to remove the alternator. z

Check the alignment of the pulleys using an alignment chart.

NOTE: For the correct belt tension and use of the belt tension gauge, refer to the Engine Operaton & Maintenance Manual and the User Instructions delivered together with the belt tension gauge. z

Check charging current of the new alternator.

3 - 17

Diesel Engine

3.1.5

Superstructure

BATTERIES

3.1.5.1 REMOVAL OF THE BATTERIES Special tools:

n/a


Crane or forklift Battery: 62 kg each

Dogman/rigger

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. 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!

3 - 18

Superstructure

z

Diesel Engine

Remove the keys from the battery main switches (Fig. 3-17, Pos. 1).

NOTE: The batteries are located below the walkway floor in two separate boxes. z

Remove floor plate fastening bolts and open the hinged floor plates (Fig. 3-17, Pos. 2).

NOTE: Wash the dirt of the floor plates (Fig. 3-17, Pos. 2) as they can be very heavy. z

Secure the open floor plates against falling down using the safety chains provided.

Fig. 3-17 z

Disconnect the cables from the batteries (Fig. 3-18, Pos. 1). DANGER

Risk of electrical and fire hazard! Death, serious injury, shock, or burns may result. Disconnect the ground cables (-) of both batteries first.

z

Remove the angles (Fig. 3-18, Pos. 2) from the batteries.

z

Take the batteries out of the battery boxes.

Fig. 3-18

WARNING Use the provided loops to carry the batteries. Do not drop the battery.

CAUTION Never run the engine with disconnected batteries. This may cause alternator damage.

3 - 19

Diesel Engine

Superstructure

3.1.5.2 REPLACEMENT OF THE BATTERIES Special tools:

n/a


n/a Battery: 62 kg each

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. z

Carry out installation in reverse order to removal. DANGER

Risk of electrical and fire hazard! Death, serious injury, shock, or burns may result. Connect the positive cables (+) of the batteries first.

WARNING Avoid spilling any electrolyte on hands or clothing. Repair or replace all broken wires immediately. All terminals must be clean and securely fastened. Never paint connections.

3 - 20

Superstructure

Diesel Engine


3 - 21

Diesel Engine

3.1.6

RADIATOR FAN

Fig. 3-19 Radiator fan assembly

3 - 22

Superstructure

Superstructure

Diesel Engine


Fan cage

(2)

Cover

(3)

Bolt

(4)

Locking plate

(5)

Radiator fan

(6)

Bolt

(7)

Fan bearing block

(8)

Hydraulic fan motor

(9)

Bolt

The engine cooling system is a dual-circuit cooling circulation system. One cooling circuit cools the engine crankcase and the cylinder heads, the other circuit lowers the temperature of the aftercooling system.

3.1.6.1 REMOVAL OF THE RADIATOR FAN ASSEMBLY Special tools:

n/a


Crane Chain hoist Oil drain pan Blind plugs: 2 x SAE A1 1/4-6000, PN 506 581 98 2 x SAE B1 1/4-6000, PN 506 526 98 BUZ 18-L, PN 371 856 99 and ROV 18-PL, PN 513 787 98 Radiator fan: 85 kg Hydraulic fan motor: 18 kg Bearing block: 84 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and carne.

z




z

Open the PVG sound silencer gate on the right side of the engine housing.

3 - 23

Diesel Engine


3 - 24

Superstructure

Superstructure

z

Diesel Engine

Remove the radiator fan, refer to section 3.1.6.3 on page 3-29.

NOTE: Carry out the following four steps only if the hydraulic fan motor must be removed. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Close the hand wheel (Fig. 3-25, Pos. 1) of the main gate valve between suction oil reservoir and main oil reservoir.

z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP".

z

Disconnect the hydraulic hoses from the hydraulic fan motor (Fig. 3-20, Pos. 8).

Fig. 3-21

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

Remove the bolts (Fig. 3-20, Pos. 9) and pull the hydraulic fan motor (Fig. 3-20, Pos. 8) out of the fan bearing block (Fig. 3-20, Pos. 7).

NOTE: The hydraulic lines may still be connected at the hydraulic fan motor if only the bearing block (Fig. 3-20, Pos. 7) is being removed. NOTE: Check if a lifting eye (Fig. 3-22, 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". Fig. 3-22

3 - 25

Diesel Engine


3 - 26

Superstructure

Superstructure

Diesel Engine

z

Sling the bearing block (Fig. 3-23, Pos. 7).

z

Remove the bolts (Fig. 3-23, Pos. 6) and remove the bearing block using the chain hoist.

z

Remove the parts to be replaced through the PVG sound silencer gate using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the parts through the PVG sound silencer gate, make sure that nobody steps below the weight.

3.1.6.2 REPLACEMENT OF THE RADIATOR FAN ASSEMBLY Special tools:

Rotational speed infrared probe DS03, PN 793 788 73 (if hydraulic fan motor was replaced)


Chain hoist Radiator fan: 85 kg Hydraulic fan motor: 18 kg Bearing block: 84 kg

Dogman/rigger



NOTE: If the hydraulic fan motor (Fig. 3-23, Pos. 8) was replaced, the fan speed needs to be adjusted, refer to the Service Manual for further information. 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

Add hydraulic oil up to the specified level.

3 - 27

Diesel Engine

Fig. 3-24 Removal and replacement of the radiator fan

3 - 28

Superstructure

Superstructure

Diesel Engine

3.1.6.3 REMOVAL OF THE RADIATOR FAN Special tools:

n/a


n/a Radiator fan: 85 kg

z


z

Remove the two upper fan cage halfs (Fig. 3-24, Pos. 1) from the fan cover (Fig. 3-24, Pos. 2).

z

Remove the six attaching bolts (Fig. 3-24, Pos. 3) with the three locking plates (Fig. 3-24, Pos. 4).

NOTE: Discard the locking plates. z

Remove the radiator fan (Fig. 3-24, Pos. 5) from the cover (Fig. 3-24, Pos. 2). WARNING

Fan blades could have sharp edges. Use gloves!

CAUTION Remove the assembly carefully in order not to damage the radiator or the fan blades.

NOTE: A second person is required to remove the radiator fan.

3.1.6.4 REPLACEMENT OF THE RADIATOR FAN Special tools:

n/a


n/a Radiator fan: 85 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

NOTE: Use new locking plates (Fig. 3-24, Pos. 4). z


NOTE: A second person is required to install the radiator fan.

3 - 29

Diesel Engine

Superstructure

3.1.6.5 REMOVAL OF THE RADIATOR FAN DRIVE PUMP Special tools:

n/a


Crane Chain hoist Oil drain pan Blind plugs: SAE A1-6000, PN 506 519 98; SAE B1-6000, PN 506 524 98 SAE A2 1/2-3000, PN 506 585 98; SAE B2 1/2-3000, PN 506 530 98 Radiator fan drive pump: 48.5 kg

Dogman/rigger

z


z




z


z


z

Close the hand wheel (Fig. 3-25, Pos. 1) of the main gate valve between suction oil reservoir and main oil reservoir.

z


Fig. 3-25

3 - 30

Superstructure

Diesel Engine

NOTE: Check if a lifting eye (Fig. 3-26, 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". Fig. 3-26 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. 3-27, Pos. 1) and the suction hose (Fig. 3-27, Pos. 2) from the radiator fan drive pump (Fig. 3-27, Pos. 5).

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

Dismantle the hose mounting plate (Fig. 3-27, Pos. 3) between the radiator fan drive pump (Fig. 3-27, Pos. 5) and the hydraulic cooler fan drive pump.

z

Sling the pump, remove the bolts (Fig. 3-27, Pos. 4) and remove the radiator fan drive pump (Fig. 3-27, Pos. 5) by pulling it out of the PTO using a chain hoist.

Fig. 3-27

NOTE: To simplify the removal, move the pump assembly lightly up and down. When the pump assembly 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 radiator fan drive pump through the PVG sound silencer gate using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the radiator fan drive pump through the PVG sound silencer gate, make sure that nobody steps below the weight.

3 - 31

Diesel Engine

Superstructure

3.1.6.6 REPLACEMENT OF THE RADIATOR FAN DRIVE PUMP Special tools:

Rotational speed infrared probe DS03, PN 793 788 73


Paste "Optimol White" PN 999 039 Radiator fan drive pump: 48.5 kg

Dogman/rigger



NOTE: Use "Optimol White" on the spline shafts of the pumps. Allways use new O-rings at the SAE-flange connections. Use new bolts (Fig. 3-27, Pos. 4) with grade 10.9 at the mounting flanges. Tighten the bolts with the specified torque. Tightening torque for mounting bolts: 265 Nm

z

Refill the oil collector reservoire (Fig. 3-78, Pos. 1) for the spline shaft housing between the radiator fan drive pump (Fig. 3-78, Pos. 3) and the hydraulic cooler fan drive pump (Fig. 3-78, Pos. 2) with lubricant. For the proper lubricant, refer to section 6.1 on page 6-2.

Fig. 3-28 z


z


z

Check for leaks and proper operation.

z

Check the hydraulic oil level again and add oil if required.

z

Check and adjust the speed of the radiator fan, refer to the Operation & Maintenance Manual, chapter 2, section "RADIATOR FAN DRIVE SPEED ADHJUSTMENT".

3 - 32

Superstructure

3.1.7

Diesel Engine

RADIATORS

The engine cooling system is a dual-circuit cooling circulation system. One cooling circuit cools the engine crankcase and the cylinder heads, the other circuit lowers the temperature of the aftercooling system. Both circuits have seperate radiators built in one single assembly.

3.1.7.1 REMOVAL OF THE RADIATOR ASSEMBLY Special tools:

n/a


Universal articulated hoist rings: 2 x M16 Crane Empty coolant storage tank Roof plate: 86 kg Radiator assembly: 2120 kg

Dogman/rigger

z


z



Isolate the machine according to local regulations. WARNING

Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below 50 °C. Disobedience may result in personal injury from hot coolant or steam.

Drain the engine coolant, approx. 475 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

3 - 33

Diesel Engine

z

Remove the rail (Fig. 3-29, Pos. 1).

z

Open the radiator sound silencer gate (Fig. 3-29, Pos. 2).

Superstructure

Fig. 3-29 NOTE: Depending on the serial number of the excavator, different types of roof constructions have been assembled. Carry out the following steps in accordance with the proper serial number. z

For serial numbers up to 08170 & 08172 & 08173: z

Remove the gratings (Fig. 3-30, Pos. 1...4) from the roof.

z

If equipped, remove the extinguishing agent tank assemblies (Fig. 3-6, Pos. 4) from the roof.

Fig. 3-30

z


Remove the gratings (Fig. 3-31, Pos. 1) from the roof.

Fig. 3-31

3 - 34

Superstructure

z

Remove all bolts (Fig. 3-32, Pos. 2) and resilient sleeves (Fig. 3-32, Pos. 3) of the roof plate (Fig. 3-32, Pos. 1).

z

Clear all coolant lines from the roof plate inside the mashine house.

z

Sling the roof plate and remove it using a crane.

Diesel Engine

Fig. 3-32 z

Remove the radiator fan assembly, refer to section 3.1.6.1 on page 3-23.

z

Open the hose clips (Fig. 3-33, Pos. 1) and disconnect the upper coolant hoses (Fig. 3-33, Pos. 2) from the radiator assembly.

z

Disconnect the bypass hoses (Fig. 3-33, Pos. 3) and remove the unions (Fig. 3-33, Pos. 4).

Fig. 3-33 z

Open the hose clips (Fig. 3-34, Pos. 1) and disconnect the coolant hoses (Fig. 3-34, Pos. 2) from the radiator assembly (Fig. 3-34, Pos. 3).

Fig. 3-34

3 - 35

Diesel Engine

z

Remove all mounting bolts (Fig. 3-35, Pos. 1) and resilient sleeves (Fig. 3-35, Pos. 2) attaching the radiator assembly (Fig. 3-35, Pos. 4) to the mount (Fig. 3-35, Pos. 3).

z

Sling the radiator assembly (Fig. 3-35, Pos. 4) and remove the radiator assembly from the machine house.

Superstructure

Fig. 3-35 z

Insert universal articulated hoist rings (Fig. 3-36, arrow).

z

Sling the radiator assembly (Fig. 3-36, Pos. 1) at the universal articulated hoist rings and remove the radiator assembly from the machine house.

Fig. 3-36

3 - 36

Superstructure

Diesel Engine

3.1.7.2 REPLACEMENT OF THE RADIATOR ASSEMBLY Special tools:

n/a


Crane Roof plate: 86 kg Radiator assembly: 2120 kg

Dogman/rigger


Carry out installation in reverse order to removal. Fill up the engine coolant, approx. 475 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

z

Run engine to circulate the coolant through the system.

z

Check the coolant level again. Refer to the Operation & Maintenance Manual, chapter 3, section "CHECKS BEFORE STARTING THE ENGINE". Add coolant if required.

3 - 37

Diesel Engine

3.1.8

Superstructure

FUEL COOLER

3.1.8.1 REMOVAL OF THE FUEL COOLER Special tools:

n/a


Crane Fuel cooler: 100 kg

Dogman/rigger

z


z




z

Remove the rail (Fig. 3-29, Pos. 1).

z

Open the radiator sound silencer gate (Fig. 3-29, Pos. 2).

Fig. 3-37

3 - 38

Superstructure

z

Diesel Engine

Disconnect the fuel lines (Fig. 3-38, Pos. 1) from the fuel cooler (Fig. 3-38, Pos. 2).

NOTE: When the fuel lines are disconnected, the fuel inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. DANGER Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result. Fig. 3-38 DO NOT smoke or use an open flame when working around inflammable fuels.

z

Remove the fuel cooler (Fig. 3-38, Pos. 2) with brackets (Fig. 3-38, Pos. 3).

3 - 39

Diesel Engine

Superstructure

3.1.8.2 REPLACEMENT OF THE FUEL COOLER Special tools:

n/a


Crane Fuel cooler: 100 kg

Dogman/rigger



z



z


z




z


z



3 - 40


Superstructure

3.1.9

Diesel Engine

STARTER SYSTEM

3.1.9.1 REMOVAL OF THE STARTER MOTOR Special tools:

n/a


n/a Starter motor: 26 kg

z


z

Remove the keys from the battery main switches. WARNING

Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below 50 °C. Disobedience may result in personal injury from heated parts or oil.

z

Disconnect the positive cable (Fig. 3-39, Pos. 1) from the starter motor (Fig. 3-39, Pos. 2).

z

Disconnect the positive cable (Fig. 3-39, Pos. 3) and the control cables from the starter solenoid switch.

z

Remove the multi-point mounting bolts (Fig. 3-39, Pos. 4) and remove the starter motor.

NOTE: A second person is required to remove the starter motor.

Fig. 3-39

3.1.9.2 REPLACEMENT OF THE STARTER MOTOR. Special tools:

n/a


n/a Starter motor: 26 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

z

Carry out installation in reverse order to removal. Tightening torque for starter motor mounting bolts (multi-point): 195 Nm

3 - 41

Diesel Engine

3.1.10 GEISLINGER COUPLING

Fig. 3-40 Geislinger coupling (1)

Coupling assembly

(2)

Input drive flange

(3)

Leaf spring assembly

(4)

Output drive flange

(5)

Dip stick

(6)

Bleeder plug

(7)

O-rings

(8)

Spacer

(E)

Engine input flange

(G)

Gear box output flange

3 - 42

Superstructure

Superstructure

Diesel Engine

The combination of the high elasticity of its leaf springs with complimentary viscous damping by oil displacement, ensures that the GEISLINGER-COUPLING removes major critical speeds outside the engine speed range and dampens minor torsional vibrations effectively. The widest engine speed range free of vibration periods and dangerous resonance is thus obtained. Furthermore, employment of these couplings with their highly dampening characteristics generally results in lower stress in all engine driving shafts and gears as well as in the crankshaft permitting further power development on standard components. In any similar application, a simple vibration damper and/or a pure flexible coupling would not confer the same advantages. The springs (Fig. 3-40, Pos. 3) together with the inner driving and outer driven member, form the chambers A and B (Fig. 3-40, Pos. A and B), which are filled with oil. If the outer member is displaced in relation to the inner member, the deflection of the leaf springs displaces oil from one chamber to the next, by this action the relative movements of the two members of the coupling are braked and the vibrations are dampened. The spacer (Fig. 3-40, Pos. 8) limits the movement of the leaf springs.

3.1.10.1 REMOVAL OF THE GEISLINGER COUPLING Special tools:

n/a


Universal articulated hoist ring: M 16 Chain hoist Crane Coupling assembly: 165 kg

Dogman/rigger

z


z




3 - 43

Diesel Engine

z

Superstructure

Remove the guard (Fig. 3-41, Pos. 1) of the coupling.

Fig. 3-41 NOTE: Check if a lifting eye (Fig. 3-42, 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". Fig. 3-42 z

Install a universal articulated hoist ring at the thread (Fig. 3-43, Pos. 1) in the engine flange of the coupling.

z

Sling coupling using the universal articulated hoist ring and dismantle the coupling assembly from the drive using a chain hoist.

Fig. 3-43

3 - 44

Superstructure

Diesel Engine

z

Remove the bolts (Fig. 3-44, Pos. 1 and 2) attaching the coupling assembly (Fig. 3-44, Pos. 3) to the PTO input flange and to the spacer (Fig. 3-44, Pos. 5).

z

Sling coupling. Dismantle the coupling assembly (Fig. 3-44, Pos. 3) from the drive using a chain hoist.

NOTE: The coupling (Fig. 3-44, Pos. 3) must be compressed to dismantle it from the PTO input flange. z

Remove the bolts (Fig. 3-44, Pos. 4) and demount the spacer (Fig. 3-44, Pos. 5).

z

Open the PVG sound silencer gate on the right side of the engine housing and remove the coupling through the gate using a crane.

Fig. 3-44

3.1.10.2 REPLACEMENT OF THE GEISLINGER COUPLING Special tools:

n/a


Universal articulated hoist ring: M 16 Chain hoist Crane Coupling assembly: 165 kg

Dogman/rigger


Insert the new coupling into the engine housing through the PVG sound silencer gate using a crane.

z


NOTE: Before installing the guard (Fig. 3-45, Pos. 1) check the oil level of the new Geislinger coupling and correct the oil level if required. Refer to the Operation & Maintenance Manual, chapter 4, section "FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL".

Tightening torque for the coupling guard mounting bolts: 20 Nm

Fig. 3-45

3 - 45

PTO

Superstructure

3.2

PTO

3.2.1

MAIN PUMPS

Fig. 3-46 Main pumps assembly (1)

Main pump 1

(2)

Main pump 2

(3)

Main pump 3

(4)

Main pump 4

(5)

O-ring

(6)

Pump distributor gear box

3 - 46

Superstructure

PTO

The rotative energy from the main motor or engine propels the gears in the pump distributor gear box (Fig. 3-46, Pos. 6) and the gears propel the main and auxiliary pumps. The pumps create a hydraulic oil flow to the cylinders or hydraulic motors. The main high pressure hydraulic circuits are supplied from four swash plate type variable displacement pumps (Fig. 3-46, Pos. 1 to 4). Main pump 2 and 3 are additionally equipped with pilot oil pumps (gear pumps).

3.2.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL Special tools:

n/a


Universal articulated hoist rings 4 x M16 Crane Roof plate: 205 kg

Dogman/rigger

z


z




z


z

Close the hand wheel (Fig. 3-47, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

Fig. 3-47

3 - 47

PTO

Superstructure

z

Loosen the vent plugs (Fig. 3-48, Pos. 1) on the main pumps to accelerate the draining of oil from the pump.

z


NOTE: The following steps indicate the standard procedure for main pump removal. It is also possible to access the main pump assemblies with a crane by opening the PVG sound silencer gate on the right side of the engine house. Carry out the following steps only if you refer to the standard procedure. z

Remove all cables which lead through the roof plates over the pumps.

Fig. 3-48

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.

NOTE: Depending on the serial number of the excavator, different types of roof constructions have been assembled. Carry out the following steps in accordance with the proper serial number. z

For serial numbers up to 08170 and 08172 & 08173: z

Remove the gratings (Fig. 3-49, Pos. 1 and 2) from the roof.

Fig. 3-49 z


Remove the grating (Fig. 3-50, Pos. 1) from the roof.

z

Remove the engine air cleaner (Fig. 3-50, Pos. 2).

z

Dismount all cables which lead to the control frame from the inner side of the roof plate.

Fig. 3-50

3 - 48

Superstructure

PTO

Fig. 3-51 Right roof plate removal (1)

Roof plate

(2)

Bolt

(3)

Resilient sleeve

z

Remove all bolts (Fig. 3-51, Pos. 2) and resilient sleeves (Fig. 3-51, Pos. 3) of the roof plate.

z

Remove the roof plate (Fig. 3-51, Pos. 1 and 2) with a crane using universal articulated hoist rings.

3 - 49

PTO

Superstructure

3.2.1.2 REMOVAL OF MAIN PUMP 1 Special tools:

n/a


Crane Oil drain pans Blind plugs: 3x ROV 10L; ROV 12L; 3 x BUZ 10-L, PN 371 852 99 and 3 x ROV 10-PL, PN 513 789 98 BUZ 12-L, PN 371 854 99 and ROV 12-PL, PN 513 547 98 BUZ 35-L, PN 371 859 99 and ROV 35-PL, PN 516 770 98 BUZ 22-L, PN 371 857 99 and ROV 22-PL, PN 513 788 98 SAE A2-6000, PN 506 582 98 and SAE B2-6000, PN 506 527 98 Main pump 1 assembly: 500 kg

Dogman/rigger

z

Carry out the preparatory work, refer to section 3.2.1.1 on page 3-47. 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

Mark all pipes and hoses at main pump 1 assembly.

z

Disconnect the leak oil hose and all control hoses from the control block (Fig. 3-52, Pos. 3).

z

Disconnect the bearing flushing/lubrication hose from the right side of pump mounting flange.

z

Disconnect the high pressure hose (Fig. 3-52, Pos. 1) from the main pump 1 assembly.

z

Disconnect the suction hose (Fig. 3-52, Pos. 2) at the bottom side of the pump.

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.

3 - 50

Fig. 3-52

Superstructure

PTO

z

Sling pump assembly as shown in Fig. 3-53.

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. 3-53

When the pump assembly is removed, oil will flow out of the spline shaft housing. Catch it in an oil pan. z

Check the O-ring (Fig. 3-53, Pos. 1) at the pump assembly flange and replace it if required.

3.2.1.3 REPLACEMENT OF MAIN PUMP 1 Special tools:

n/a


Crane Paste "Optimol White" PN 999 039 Main pump 1 assembly: 500 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: When mounting a new pump, aktivate the external flushing of bearing. Refer to PARTS & SERVICE BULLETIN No. "AH05510". z


NOTE: Use "Optimol White" on the spline shaft of the pump. Use new bolts with grade 10.9 at the mounting flanges of the main pump. Tighten the bolts with the specified torque. Tightening torque for the mounting bolts: 510 Nm

3 - 51

PTO

Superstructure

NOTE: Always use new O-rings at the SAE-flange connections. Refill lubricant at the level plug (Fig. 3-54, Pos. 1) at the cover of the spline shaft housing (Fig. 3-54, Pos. 3). For the proper lubricant, refer to section 6.1 on page 6-2. Fill up to lower edge of level plug opening (Fig. 3-54, Pos. 2).

Fig. 3-54 z


z


z

Adjust main pump 1. Refer to the Service Manual for further information.

z


z

Check the hydraulic oil level again and correct the oil level if required.

3 - 52

Superstructure

PTO


n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (articulated boom) Oil drain pans Blind plugs: 3 x BUZ 10-L, PN 371 852 99 and 3 x ROV 10-PL, PN 513 789 98 BUZ 12-L, PN 371 854 99 and ROV 12-PL, PN 513 547 98 BUZ 35-L, PN 371 859 99 and ROV 35-PL, PN 516 770 98 BUZ 22-L, PN 371 857 99 and ROV 22-PL, PN 513 788 98 SAE A2-6000, PN 506 582 98 and SAE B2-6000, PN 506 527 98 SAE A1 1/4-3000, PN 506 584 98; SAE B1 1/4-3000, PN 517 479 98 SAE A1 1/2-3000, PN 506 522 98; SAE B1 1/2-3000, PN 506 528 98 Main pump 2 assembly: 526 kg Walkway frame with all gratings: 90 kg

Dogman/rigger

z



z

Remove all hoses from the hydraulic pilot oil pump (Fig. 3-55, Pos. 4), refer to section 3.3.5.1 on page 3-100.



z


z

Disconnect the bearing flushing/lubrication hose from the right side of the pump mounting flange.

z


z


Fig. 3-55

3 - 53

PTO

Superstructure


Dismantle the hose mounting plate between main pump 2 and main pump 3.

z

Sling and remove the walkway frame (Fig. 3-56, Pos. 1) with the gratings (Fig. 3-56, Pos. 2) to gain access to the main pump 2 assembly.

NOTE: The frame is only disposed in the machine house. 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.

DANGER Risk of downfall! Death or serious injury may result. Carry out the next steps very carefully because of the missing gratings.

Fig. 3-56

Watch your steps. Always wear a Safety harness while working when the walk way frame is removed.

z

Sling the pump assembly as shown in Fig. 3-57.

z

Remove the mounting bolts. Then remove the 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.



3 - 54

Fig. 3-57

Superstructure

PTO


n/a


Paste "Optimol White" PN 999 039 Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (articulated boom) Main pump 2 assembly: 526 kg Walkway frame with all gratings: 90 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: When mounting a new pump, aktivate the external flushing of bearing. Refer to PARTS & SERVICE BULLETIN No. "AH05510". DANGER Risk of downfall! Death or serious injury may result. Always wear a Safety harness while working at the main pumps when the walk way frame is removed.

z




Fig. 3-58

3 - 55

PTO

z


z


z


z


z


3 - 56

Superstructure

Superstructure

PTO


n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (articulated boom) Oil drain pans Blind plugs: 3 x BUZ 10-L, PN 371 852 99 and 3 x ROV 10-PL, PN 513 789 98 BUZ 12-L, PN 371 854 99 and ROV 12-PL, PN 513 547 98 BUZ 35-L, PN 371 859 99 and ROV 35-PL, PN 516 770 98 BUZ 22-L, PN 371 857 99 and ROV 22-PL, PN 513 788 98 SAE A2-6000, PN 506 582 98 and SAE B2-6000, PN 506 527 98 SAE A1 1/4-3000, PN 506 584 98; SAE B1 1/4-3000, PN 517 479 98 SAE A1 1/2-3000, PN 506 522 98; SAE B1 1/2-3000, PN 506 528 98 Main pump 3 assembly: 526 kg Walkway frame with all gratings: 90 kg

Dogman/rigger

z

Carry out the preparatory work, refer to section 3.2.1.1 on page 3-47.

z

Remove all hoses from the PTO oil circulation pump (Fig. 3-59, Pos. 4), refer to section 3.2.2.1 on page 3-63.



z


z


z


z


Fig. 3-59


3 - 57

PTO

Superstructure

z

Dismantle the hose mounting plate between main pump 2 and main pump 3.

z




Fig. 3-60


z

Sling the pump assembly as shown in Fig. 3-61.

z


Risk of falling weights! Death or serious injury may result. When removing the main pump assembly make sure that nobody steps below the weight.



3 - 58

Fig. 3-61

Superstructure

PTO


n/a


Paste "Optimol White" PN 999 039 Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (articulated boom) Main pump 3 assembly: 526 kg Walkway frame with all gratings: 90 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: When mounting a new pump, aktivate the external flushing of bearing. Refer to PARTS & SERVICE BULLETIN No. "AH05510". DANGER Risk of downfall! Death or serious injury may result. Always wear a Safety harness while working at the main pumps when the walk way frame is removed.

z




Fig. 3-62

3 - 59

PTO

Superstructure

z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z


z


z


z



n/a


Crane Oil drain pans Blind plugs: 3 x BUZ 10-L, PN 371 852 99 and 3 x ROV 10-PL, PN 513 789 98 BUZ 12-L, PN 371 854 99 and ROV 12-PL, PN 513 547 98 BUZ 35-L, PN 371 859 99 and ROV 35-PL, PN 516 770 98 BUZ 22-L, PN 371 857 99 and ROV 22-PL, PN 513 788 98 SAE A2-6000, PN 506 582 98 and SAE B2-6000, PN 506 527 98 Main pump 4 assembly: 500 kg

Dogman/rigger

z



3 - 60

Superstructure

PTO

z


z


z


z


z

Disconnect the suction hose (Fig. 3-63, Pos. 2) at the bottom side of the pump. Fig. 3-63

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. NOTE: Sling the pump assembly as shown in Fig. 3-64. z


Risk of falling weights! Death or serious injury may result. When removing the main pump assembly, make sure that nobody steps below the weight.


Fig. 3-64


3 - 61

PTO

Superstructure


n/a


Crane Paste "Optimol White" PN 999 039 Main pump 4 assembly: 500 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: When mounting a new pump, aktivate the external flushing of bearing. Refer to PARTS & SERVICE BULLETIN No. "AH05510". z



NOTE: Always use new O-rings at the SAE-flange connections. Refill lubricant at the level plug (Fig. 3-65, Pos. 1) at the cover of the spline shaft housing (Fig. 3-65, Pos. 3). For the proper lubricant, refer to section 6.1 on page 6-2. Fill up to lower edge of level plug opening (Fig. 3-65, Pos. 2). 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". Fig. 3-65

z


z

Adjust main pump 4. Refer to Service Manual for further information.

z


z


3 - 62

Superstructure

3.2.2

PTO

PTO OIL CIRCULATION PUMP (AUXILIARY PUMP)

The oil circulation pump aspirates gear oil from the gear box sump and pumps it through a cooler back to the PTO. The oil circulation pump is attached to the main pump 3 assembly.

3.2.2.1 REMOVAL OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (articulated boom) Oil drain pans Blind plugs: SAE A1 1/4-3000, PN 506 584 98; SAE B1 1/4-3000, PN 517 479 98 SAE A1 1/2-3000, PN 506 522 98; SAE B1 1/2-3000, PN 506 528 98 Oil circulation pump: 26 kg Walkway frame with all gratings: 90 kg

Dogman/rigger

z


z

Sling and remove the frame (Fig. 3-66, Pos. 1) with the gratings (Fig. 3-66, Pos. 2) to gain access to the main pump 3 assembly.



Fig. 3-66


3 - 63

PTO

z

Superstructure

Disconnect the SAE-flanges of pressure hose and suction hose from the oil circulation pump.


Remove four nuts (Fig. 3-67, Pos. 1) and pull the oil circulation pump (Fig. 3-67, Pos. 2) out of the main pump 3 assembly (Fig. 3-67, Pos. 4).

NOTE: Check the joint element (Fig. 3-67, Pos. 3) for wear and replace it if required.

Fig. 3-67

3 - 64

Superstructure

PTO

3.2.2.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) Special tools:

Hydraulic testing kit, PN 232 315 40


Paste "Optimol White" PN 999 039 Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (articulated boom) Oil circulation pump: 26 kg Walkway frame with all gratings: 90 kg

Dogman/rigger


DANGER Risk of downfall! Death or serious injury may result. Always wear a Safety harness while working at the main pumps when the walk way frame is removed.

z


NOTE: Use "Optimol White" on the spline shaft of the pump. z

Run machine to warm, test pressure of the circulation pump and adjust if required. Refer to the Service Manual for further information.

3 - 65

PTO

3.2.3

Superstructure

PUMP DISTRIBUTOR GEARBOX (PTO)

Fig. 3-68 Pump distributor gearbox

3 - 66

Superstructure

PTO


Oil level gauge

(2)

Oil filler plug

(3)

Breather filter

(4)


(5)

Breather filter with oil level gauge (drive shaft housing)

(6)

Main pump drive shaft housings

(7)

Oil level plug of main pump drive shaft housing

(8)


(9)

Oil drain plug of main pump drive shaft housing

(10)

Oil drain plug of PTO gear

(11)

Flange for heater studs

(12)

Gear oil temperature sensor mounting bore

(13)

Thermostat switch mounting bore cover plate

(14)

Suction port to PTO lubrication pump

(15)

Return line connection from gear oil cooler

(16)

Return line connection from cooling system relief valve

(D)

Drive flange

(M)

Power take off for main pumps

(R)

Power take off for engine radiator fan drive pump

(C)

Power take off for hydraulic oil cooler fan drive pump

The pump distribution gear (PTO gear) is from a spur gear design and driven by a Diesel engine. It is equipped with an external lubrication/cooling system. The PTO gear runs in anti friction 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. The O-rings included in the delivery seal the unit statically and reliably. The gear box housing is a one-piece design and made of grey cast iron. Gear box design allows a direct attachment to the diesel engine via a connection flange. The gear box has been provided with connections for a separate cooling system or for a preheating system. Always check gear box oil level with unlocked dip stick and stopped engine.

3 - 67

PTO

Superstructure

3.2.3.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (articulated boom) Oil drain pans Blind plugs: SAE A3-3000, PN 512 570 98; SAE B3-3000, PN 512 571 98 2 x BUZ 28-L, PN 371 858 99 and 2 x ROV 28-PL, PN 509 377 98 2 x BUZ 18-L, PN 371 856 99 and 2 x ROV 18-PL, PN 513 787 98 BUZ 15-L, PN 371 855 99 and ROV 15-PL, PN 507 051 98 BUZ 10-L, PN 371 852 99 and ROV 10-PL, PN 513 789 98 PTO: 2685 kg Control frame assembly: 645 kg

Dogman/rigger

z

Carry out the preparatory work, refer to section 3.2.1.1 on page 3-47. Drain the gear oil of the PTO, approx. 150 liters. Drain oil of the spline shaft housings. Refer to the Operation & Maintenance Manual, chapter 4, section "PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL".

z

Remove main pump 1 and main pump 4, refer to section 3.2.1 on page 3-46.

z

Remove the radiator fan drive pump, refer to section 3.1.6.5 on page 3-30.

z

Remove the hydraulic cooler fan drive pump, refer to section 3.3.1.1 on page 3-72.

3 - 68

Superstructure

PTO

z

Remove the cover (Fig. 3-69, Pos. 1) and the lamp at the backside of the control frame assembly (Fig. 3-69, Pos. 2).

z

Mark and disconnect all hydraulic lines and elcetrical wires leading to the control frame assembly (Fig. 3-69, Pos. 2).


Sling the control frame assembly (Fig. 3-69, Pos. 2).

z

Dismount the control frame assembly (Fig. 3-69, Pos. 2) from the roof frame and remove it using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the controll frame assembly make sure that nobody steps below the weight.

z

Fig. 3-69

Disconnect all lubrication pressure hoses and lines from the PTO.

NOTE: When the lubrication 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.

Fig. 3-70 z

Disconnect the lubrication suction hose (Fig. 3-71, Pos. 1) from the PTO.

NOTE: When the suction 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

Disconnect the temperatur sensor (Fig. 3-71, Pos. 2).

z

Disconnect the heating and the thermo switch if equipped.

Fig. 3-71 z

Remove main pump 2 and main pump 3, refer to section 3.2.1 on page 3-46.

3 - 69

PTO

Superstructure

z

Remove the Geislinger coupling, refer to section 3.1.10.1 on page 3-43.

z

Remove the bolts (Fig. 3-72, Pos. 1) with resilient sleeves (Fig. 3-72, Pos. 2) attaching the PTO to the support (Fig. 3-72, Pos. 3).

Fig. 3-72 z

Attach the PTO to a crane, using the lifting eyes (Fig. 3-73, arrows).

Fig. 3-73 z

Remove the bolts attaching the PTO to the engine.

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.

3 - 70

Superstructure

PTO

3.2.3.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO) Special tools:



Paste "Optimol White" PN 999 039 Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (articulated boom) PTO: 2685 kg Control frame assembly: 645 kg

Dogman/rigger


If required, install the temperature sensor, the heating, and the thermo switch to the replacement PTO. DANGER

Risk of downfall! Death or serious injury may result. Always wear a Safety harness while working at the main pumps when the walk way frame is removed.

z


NOTE: Always use new O-rings at all SAE-flange connections. NOTE: Use the specified tightening torque for PTO mounting bolts (Fig. 3-74, Pos. 1) at the support (Fig. 3-74, Pos. 2). Tightening torque for the PTO mounting bolts: 1770 Nm

Refill gear oil of the PTO, approx. 150 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "PTO (PUMP DISTRIBUTOR GEAR) CHANGE OIL.

Fig. 3-74 z

Run machine to warm, test pressure of the circulation pump and adjust if required. Refer to the Service Manual for further information.

3 - 71

Hydraulics

Superstructure

3.3

HYDRAULICS

3.3.1

HYDRAULIC COOLER FAN DRIVE PUMP

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. 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 an 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.

3.3.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP Special tools:

n/a


Chain hoist Crane Oil drain pan Blind plugs: SAE A1-6000, PN 506 519 98; SAE B1-6000, PN 506 524 98 SAE A2 1/2-3000, PN 506 585 98; SAE B2 1/2-3000, PN 506 530 98 Hydraulic cooler fan drive pump: 50 kg

Dogman/rigger

z


z




z


3 - 72

Superstructure

Hydraulics

z


z


z


Fig. 3-75 NOTE: Check if a lifting eye (Fig. 3-76, 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". Fig. 3-76 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. 3-77, Pos. 1) and the suction hose (Fig. 3-77, Pos. 2) from the hydraulic cooler fan drive pump (Fig. 3-77, Pos. 5).


Dismantle the hose mounting plate (Fig. 3-77, Pos. 3) between the radiator fan drive pump and the hydraulic cooler fan drive pump (Fig. 3-77, Pos. 5).

z

Sling the pump, remove the bolts (Fig. 3-77, Pos. 4), and remove the hydraulic cooler fan drive pump (Fig. 3-77, Pos. 5) by pulling it out of the PTO using a chain hoist.

Fig. 3-77

3 - 73

Hydraulics

Superstructure


Check the O-ring at the pump flange and replace it if required.

z

Remove the hydraulic cooler fan drive pump through the PVG sound silencer gate using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic cooler fan drive pump through the PVG sound silencer gate, make sure that nobody steps below the weight.

3 - 74

Superstructure

Hydraulics

3.3.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP Special tools:



Crane Chain Hoist Paste "Optimol White" PN 999 039 Hydraulic cooler fan drive pump: 50 kg

Dogman/rigger



NOTE: Use "Optimol White" on the spline shaft of the pump. Allways use new O-rings at the SAE-flange connections. Use new bolts (Fig. 3-77, Pos. 4) with grade 10.9 at the mounting flanges. Tighten the bolts with the specified torque. Tightening torque for the mounting bolts: 265 Nm

z

Refill the oil collector reservoire (Fig. 3-78, Pos. 1) for the spline shaft housing between the radiator fan drive pump (Fig. 3-78, Pos. 3) and the hydraulic cooler fan drive pump (Fig. 3-78, Pos. 2). For the proper lubricant, refer to section 6.1 on page 6-2.

Fig. 3-78 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".Add hydraulic oil up to the specified level.

z

Check and adjust the speed of the hydraulic cooler fan. Refer to the Service Manual for further information.

3 - 75

Hydraulics

3.3.2

Superstructure

HYDRAULIC COOLER FAN ASSEMBLY

There are four (temperature range up to 40 °C) hydraulic oil coolers in front of the hydraulic oil reservoir on the right-hand side of the platform. Two cooler elements are mounted in one frame at a time, one above the other. So two frames are installed with two cooler elements installed in each frame. The air stream needed for the cooling is produced by hydraulicaly 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 are driven by hydraulic motors. The motors are supplied by one hydraulic pump. The fans are mounted directly to the hydraulic motors drive shaft.

3.3.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY Special tools:

n/a


Oil drain pan Crane Blind plugs: 2 x BUZ 25-S, PN 371 867 99 and 2 x ROV 25-PS, PN 508 033 98 BUZ 15-L, PN 371 855 99 and ROV 15-PL, PN 507 051 98 Hydraulic cooler fan assembly: 95 kg

Dogman/rigger

z


z




z


3 - 76

Superstructure

Hydraulics

Fig. 3-79 Position of the hydraulic cooler fan assembly z

Remove the hydraulic fan guard (Fig. 3-79, Pos. 1) 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.

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 hydraulic pressure hoses (Fig. 3-79, Pos. 3) and the leak oil hose (Fig. 3-79, Pos. 2) from the hydraulic motor. 3 - 77

Hydraulics

Superstructure

NOTE: When the hoses are removed, the oil inside the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic cooler fan assembly (Fig. 3-80, Pos. 1) from the main cooler frame support, supported by using a crane. WARNING


CAUTION Remove the assembly carefully in order not to damage the oil cooler or the fan blades.

DANGER Risk of falling weights! Death or serious injury may result. When removing the hydraulic cooler fan drive pump through the PVG sound silencer gate, make sure that nobody steps below the weight.

3 - 78

Fig. 3-80

Superstructure

Hydraulics

3.3.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY Special tools:



Crane Hydraulic cooler fan assembly: 95 kg

Dogman/rigger


Carry out installation in reverse order to removal. WARNING


CAUTION Install the assembly carefully in order not to damage the oil cooler or the fan blades.

z


z


z

Check and adjust the speed of the hydraulic cooler fan. refer to the Service Manual for further information.

3 - 79

Hydraulics

Superstructure

3.3.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR

z

Special tools:

n/a


Oil drain pan

Remove the hydraulic cooler fan assembly, refer to section 3.3.2.1 on page 3-76.

Fig. 3-81 Hydraulic cooler fan assembly

3 - 80

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)


(10)

Bearing

(11)

Circlip

(12)

O-ring

(13)

Hydraulic motor

(14)

Bolt

WARNING Fan blades could have sharp edges. Use gloves!

NOTE: Carry out the two following two steps only if cooler fan needs to be removed.

z

z

Remove the attaching bolts (Fig. 3-81, Pos. 1) with the locking plates (Fig. 3-81, Pos. 2). Discard the locking plates.

z

Remove the cooler fan (Fig. 3-81, Pos. 3) from the drive shaft (Fig. 3-81, Pos. 4).

Remove the four bolts (Fig. 3-81, Pos. 14) and remove the hydraulic motor (Fig. 3-81, Pos. 13) from the bearing group carrier (Fig. 3-81, Pos. 9). Discard the O-ring (Fig. 3-81, 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. 3-81, Pos. 11), extract the drive shaft (Fig. 3-81, Pos. 4) out of the bearing group carrier (Fig. 3-81, Pos. 9), and remove the drive shaft seal (Fig. 3-81, Pos. 6), the bearings (Fig. 3-81, Pos. 7 and 10), and the sleeves (Fig. 3-81, Pos. 5 and 8).

3 - 81

Hydraulics

Superstructure

3.3.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR Special tools:

n/a


n/a If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

Fig. 3-82 Hydraulic cooler fan assembly z


NOTE: If the drive shaft (Fig. 3-82, Pos. 4) is removed, check the drive shaft. Refer to PARTS & SERVICE BULLETIN No. "AH03506B". Check drive shaft seal (Fig. 3-82, Pos. 6) for wear and damage. Replace if required. NOTE: Use a new O-ring (Fig. 3-82, Pos. 12) and new locking plates (Fig. 3-82, Pos. 2).

3 - 82

Superstructure

Hydraulics

WARNING Fan blades could have sharp edges. Use gloves!

z

Install the hydraulic cooler fan assembly, refer to section 3.3.2.2 on page 3-79.

NOTE: Check the oil level in the bearing group carrier (Fig. 3-82, Pos. 9) and add oil if required, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC COOLER FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER".

3 - 83

Hydraulics

3.3.3

Superstructure

HYDRAULIC OIL COOLERS

Fig. 3-83 Hydraulic oil cooler circuit 3 - 84

Superstructure

Hydraulics


Back pressure valve

(2)

Solenoid valve (4/2-directional control valve)

(3)

Return lines from control blocks

(4)

Supply line for the anticavitation circuit of the swing motors

(5)

Return oil collector tube

(6)

Restrictor (shock absorbers for the hydraulic oil cooler)

(7)

Lines to cooler (hot oil)

(8)


(9)

Lines to hydraulic oil reservoir

(10)


The returning oil from the system flows via the lines (Fig. 3-83, Pos. 3) into the collector tube (Fig. 3-83, Pos. 5). On the top side of it the back pressure valve (Fig. 3-83, Pos. 1) is installed. The back pressure valve causes a back pressure which forces most of the relative hot oil through the lines (Fig. 3-83, Pos. 7) to the cooler (Fig. 3-83, Pos. 8). On the flow to the cooler the hydraulic oil passes the restrictor, gets cooled in the cooler and then flows through the lines (Fig. 3-83, Pos. 9) into the filter chamber of the hydraulic oil reservoir (Fig. 3-83, Pos. 10). 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. 3-83, Pos. 1) is wide open, because the solenoid valve (Fig. 3-83, Pos. 2) 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. 3-83, Pos. 2) 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. NOTE: Each oil cooler contains the hydraulic oil cooler and PTO gear oil cooler. The machine is equipped with four oil coolers.

3 - 85

Hydraulics

Superstructure

3.3.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Oil drain pans Blind plugs (for each cooler): 2 x BUZ 42-L, PN 371 860 99 and 2 x ROV 42-PL, PN 513 790 98 2 x BUZ 22-L, PN 371 857 99 and 2 x ROV 22-PL, PN 513 788 98 Hydraulic oil cooler: 275 kg each

Dogman/rigger

z


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 "FUNCTION OF THE TRANSFER PUMP".

z

Open the hydraulic oil cooler door. Refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY". WARNING

z


z

Always wear a safety harness when working at the hydraulic oil coolers.

3 - 86

Fig. 3-84

Superstructure

z

Hydraulics

Disconnect the hoses (Fig. 3-85, Pos. 1 and 2) from the PTO gear 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. 3-85

z

Disconnect all inlet hoses (Fig. 3-86, Pos. 2) and outlet hoses (Fig. 3-86, Pos. 1) 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. 3-86 z

Sling the oil cooler (Fig. 3-87).

Fig. 3-87

3 - 87

Hydraulics

Superstructure

Fig. 3-88 Removal of the oil cooler z

Remove the bolts (Fig. 3-88, Pos. 2), the washers (Fig. 3-88, Pos. 3) and locking plates (Fig. 3-88, Pos. 4), and clear the oil cooler (Fig. 3-88, Pos. 1) from the angle (Fig. 3-88, Pos. 8).

z

Using a crane, lift the oil cooler (Fig. 3-88, Pos. 1) out of the radiator mounting (Fig. 3-88, Pos. 9). 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.

3 - 88

Superstructure

Hydraulics


3 - 89

Hydraulics

Superstructure

3.3.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Glue PN 256 952 40 Hydraulic oil cooler: 275 kg each

Dogman/rigger


Fig. 3-89 Installation of the oil cooler

3 - 90

Superstructure

Hydraulics

WARNING Always wear a safety harness when working at the hydraulic oil coolers.

z

Exchange the orifice (Fig. 3-83, Pos. 8) from the old oil cooler to the new oil cooler.

z

Apply glue PN 256 952 40 to the profiled joints (Fig. 3-89, Pos. 5 to 7) and attach them in the same manner as they were fixed to the old oil cooler.

z

Carry out further installation in reverse order to removal.

NOTE: Use new locking plates (Fig. 3-89, Pos. 4). z


z


z

Add PTO gear oil to the specified level.

3 - 91

Hydraulics

Superstructure

3.3.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Oil drain pans Blind plugs: 4 x SAE A2-3000, PN 506 523 98; 4 x SAE B2-3000, PN 506 529 98 4 x BUZ 42-L, PN 371 860 99 and 4 x ROV 42-PL, PN 513 790 98 2 x BUZ 28-L, PN 371 858 99 and 2 x ROV 28-PL, PN 509 377 98 2 x BUZ 30-S, PN 371 868 99 and 2 x ROV 30-PS, PN 507 021 98 BUZ 15-L, PN 371 855 99 and ROV 15-PL, PN 507 051 98 Hydraulic oil cooler frame: 3854 kg

Dogman/rigger

z


z




z


3 - 92

Superstructure

Hydraulics

z


z


z

Open the hydraulic oil cooler door. Refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLERS - CLEAN AND ISPECT IF NECESSARY". WARNING

z


z

Always wear a safety harness when working at the hydraulic oil cooler frame.

Fig. 3-90

3 - 93

Hydraulics

Fig. 3-91 Location of the electrical components z

Disconnect all wiring harness connectors at the lamps (Fig. 3-91, Pos. H50 and H50A) and at the sensor (Fig. 3-91, Pos. B46) and clear the wiring harness from the hydraulic oil cooler frame.

3 - 94

Superstructure

Superstructure

z

Remove the Fuel cooler from the hydraulic oil cooler frame, refer to section 3.1.8.1 on page 3-38.

z

Disconnect hydraulic inlet hoses (Fig. 3-92, Pos. 1) from the hydraulic cooler fan motor (Fig. 3-92, Pos. 2).

Hydraulics

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. 3-92 z

Disconnect the return hose (Fig. 3-93, Pos. 1) and the leak oil hose (Fig. 3-93, Pos. 2) from the hydraulic cooler fan motor.


Fig. 3-93 z

Disconnect hydraulic hoses (Fig. 3-94, Pos. 1 and 2) at the shown joints (Fig. 3-94, Arrow).


Fig. 3-94

3 - 95

Hydraulics

z

Superstructure

Disconnect return hoses (Fig. 3-95, Pos. 1).


Fig. 3-95 z

Sling hydraulic oil cooler frame (Fig. 3-96, Pos. 1) at the hoist ring delivered with the machine.

z

Remove mounting bolts (Fig. 3-96, Pos. 2 and 3) and remove the hydraulic oil cooler frame (Fig. 3-96, 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, make sure that nobody steps below the weight.

z

Rest the hydraulic oil cooler frame on the ground on an appropriate stand and carry out the following steps if required. Fig. 3-96

z

If required, remove the hydraulic oil cooler from the hydraulic oil cooler frame, refer to section 3.3.3.1 on page 3-86.

z

If required, remove the cooler fan assembly from the hydraulic oil cooler frame, refer to section 3.3.2.1 on page 3-76.

3 - 96

Superstructure

Hydraulics

3.3.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Hydraulic oil cooler frame: 3854 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the hydraulic oil cooler frame.

z


NOTE: Use new mounting bolts (Fig. 3-97, Pos. 1 and 2) of grade 10.9 and tighten the mounting bolts with the specified tightening torque. Tightening torque for mounting bolts (Fig. 3-97, Pos. 1 and 2): 1770 Nm.

Fig. 3-97 z

Bleed the fuel system, refer to section 3.1.8.2 on page 3-40.

z


z


z

Add PTO gear oil to the specified level.

3 - 97

Hydraulics

3.3.4

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.

3.3.4.1 REMOVAL OF THE MRV Special tools:

36 mm Socket wrench, PN 232 374 40


n/a

NOTE: For additional information about the MRV on the main control valve blocks, refer to section 3.3.8 on page 3-117. z


z


z


z


Fig. 3-98

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

Remove the MRV (Fig. 3-99, 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. 3-99

3 - 98

Superstructure

Hydraulics

3.3.4.2 REPLACEMENT OF THE MRV Special tools:

36 mm Socket wrench, PN 232 374 40 Hydraulic testing kit, PN 232 315 40


n/a

NOTE: Fit new O-rings to the MRV. z


NOTE: Tighten the MRV to the specified torque. Tightening torque for MRV: 300 Nm z


z


z

Check and adjust the MRV. Refer to the Service Manual for further information. WARNING

Wear hearing protection when checking relief pressure.

3 - 99

Hydraulics

3.3.5

Superstructure

PILOT OIL PUMP (GEAR PUMP)

The pilot pump generates the pilot pressure that is used for all hydraulic control operations. The pilot oil pump is attached to the main pump 2 assembly.

3.3.5.1 REMOVAL OF THE PILOT OIL PUMP) Special tools:

n/a


Blind plugs: SAE A1 1/4-3000, PN 506 584 98; SAE B1 1/4-3000, PN 517 479 98 SAE A1 1/2-3000, PN 506 522 98; SAE B1 1/2-3000, PN 506 528 98 Pilot oil pump: 26 kg Walkway frame with all gratings: 90 kg

z


z



DANGER Risk of downfall! Death or serious injury may result. Carry out the next steps very carefully because of the missing gratings. Watch your steps. Always wear a Safety harness while working when the walk way frame is removed.

z

Disconnect the SAE-flanges of pressure hose and suction hose from the pilot oil pump.


3 - 100

Fig. 3-100

Superstructure

z

Hydraulics

Remove four nuts (Fig. 3-101, Pos. 1) and pull the pilot oil pump (Fig. 3-101, Pos. 2) out of the main pump 2 assembly (Fig. 3-101, Pos. 4).

NOTE: Check the joint element (Fig. 3-101, Pos. 3) for wear and replace it if required.

Fig. 3-101

3 - 101

Hydraulics

Superstructure

3.3.5.2 REPLACEMENT OF THE PILOT OIL PUMP Special tools:



Paste "Optimol White" PN 999 039 Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (articulated boom) Pilot oil pump: 26 kg Walkway frame with all gratings: 90 kg

Dogman/rigger


DANGER Risk of downfall! Death or serious injury may result. Always wear a Safety harness while working at the main pumps when the walk way frame is removed.

z


NOTE: Use "Optimol White" on the spline shaft of the pump. z


z


z

Check and adjust the pilot pressure if required. Refer to the Service Manual for further information.

3.3.6

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 an engine 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 operators dashboard.

3 - 102

Superstructure

Hydraulics

3.3.6.1 REMOVAL OF THE MAIN GATE VALVE Special tools:

n/a


Oil tank (4000 liters) Main gate valve: 16.5 kg

z


z




z


z


Fig. 3-102

Drain hydraulic oil from the hydraulic oil reservoir, approx. 3900 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

3 - 103

Hydraulics

Superstructure

z

Disconnect the harness connector S31 from the proximity switch at the main gate valve. Refer to Fig. 3-111 on page 3-111.

z

Remove the bolts (Fig. 3-103, Pos. 1), dismantle the compensator (Fig. 3-103, Pos. 2), and the main gate valve (Fig. 3-103, Pos. 3).

NOTE: When the main gate valve (Fig. 3-103, Pos. 3) and the compensator (Fig. 3-103, Pos. 2) are removed some oil inside the piping will flow out. Catch it in an oil pan. Fig. 3-103

3.3.6.2 REPLACEMENT OF THE MAIN GATE VALVE Special tools:

n/a


Oil tank (4000 liters) Main gate valve: 16.5 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

z

Carry out installation in reverse order to removal. Fill hydraulic oil into the hydraulic oil reservoir, approx. 3900 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z


z


3 - 104

Superstructure

Hydraulics


3 - 105

Hydraulics

3.3.7

Superstructure

HYDRAULIC OIL RESERVOIR

Fig. 3-104 Hydraulic oil reservoir

3 - 106

Superstructure

Hydraulics


View from machine center

(B)

View from pump compartment

(C)

Top view

(1)

Main hydraulic oil reservoir

(2)

Oil level sight gauge

(3)

Auxiliary return oil connections

(4)

Breather filter

(5)

Leakage oil line connections

(6)

Back-pressure valve, temperature controlled

(7)

Return oil collector tube with strainer

(8)

Oil reservoir outlet (suction pipe)

(9)

Main gate valve

(10)

Drain coupling an collector pipe

(11)

Mounting brackets

(12)

Compensator

(13)

Drain coupling, main oil reservoir

(14)

Access cover

(15)

Return oil filters (four)

(16)

Refill plug

(17)

Leakage oil filter (one)

3 - 107

Hydraulics

Superstructure

3.3.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR Special tools:

Socket wrench 46 mm, PN 232 377 40


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform 4 x Universal articulated hoist rings: M 36 Blind plugs: 3 x BUZ 15-L, PN 371 855 99 and 3 x ROV 15-PL, PN 507 051 98 BUZ 18-L, PN 371 856 99 and ROV 18-PL, PN 513 787 98 3 x BUZ 22-L, PN 371 857 99 and 3 x ROV 22-PL, PN 513 788 98 4 x BUZ 28-L, PN 371 858 99 and 4 x ROV 28-PL, PN 509 377 98 BUZ 30-S, PN 371 868 99 and ROV 30-PS, PN 507 021 98 9 x BUZ 35-L, PN 371 859 99 and 9 x ROV 35-PL, PN 516 770 98 5 x BUZ 42-L, PN 371 860 99 and 5 x ROV 42-PL, PN 513 790 98 2 x SAE A3-3000, PN 512 570 98; 2 x SAE B3-3000, PN 512 571 98 4 x SAE A2-3000, PN 506 523 98; 4 x SAE B2-3000, PN 506 529 98 Hydraulic oil reservoir incl. back pressure valve: 3200 kg

Dogman/rigger

z


z




Always wear a safety harness when working at the hydraulic oil reservoir.

3 - 108

Superstructure

z

Remove the main gate valve, refer to section 3.3.6.1 on page 3-103.

z

Remove the plates (Fig. 3-105, Pos. 1) beside the threads (Fig. 3-105, Pos. 2).

z

Insert universal articulated hoist rings (M 36) into the threads (Fig. 3-105, Pos. 2).

Hydraulics

Fig. 3-105 z

Remove the rails (Fig. 3-106, Pos. 1) from the hydraulic oil reservoir (Fig. 3-106, Pos. 2).

Fig. 3-106 z

Disconnect the hydraulic lines (Fig. 3-107, Pos. 1), leading to the hydraulic coolers, from the hydraulic oil reservoir.


Fig. 3-107

3 - 109

Hydraulics

z

Loosen all clamps (Fig. 3-108, Pos. 2) mounted at the hydraulic oil reservoir to clear all hydraulic lines from the hydraulic oil reservoir (Fig. 3-108, Pos. 3).

z

Mark and disconnect all hydraulic lines (Fig. 3-108, Pos. 1) from the hydraulic oil reservoir.

Superstructure

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. 3-108

z

Disconnect all hydraulic lines from the standpipe (Fig. 3-109, Pos. 7).

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. z

Shut the cock valves at the hoses (Fig. 3-109, Pos. 2 - 4) and disconnect the hoses behind the transfer pump (Fig. 3-106, Pos. 1) but directly in front of the cock valves.

z

Loosen the clamps (Fig. 3-109, Pos. 5) to clear hoses from the hydraulic oil reservoir.

z

Remove the grating (Fig. 3-109, Pos. 6).

Fig. 3-109 z

Disconnect all hydraulic lines (Fig. 3-110, Pos. 1) from the standpipe below the hydraulic oil reservoir.

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

Loosen all clamps (Fig. 3-110, Pos. 2) below the hydraulic oil reservoir to clear all hydraulic lines from the hydraulic oil reservoir.

Fig. 3-110

3 - 110

Superstructure

Hydraulics

Fig. 3-111 Location of the electrical components z

Disconnect all wiring harness connectors (Fig. 3-111, Pos. Bxx, Y101) and the head light assembly (Fig. 3-111, Pos. H49b).

3 - 111

Hydraulics

Superstructure

z

Remove the wiring harnesses from the hydraulic oil reservoir.

z

Attach the hydraulic oil reservoir to a crane.

z

Remove two mounting bolts (Fig. 3-112, Pos. 1) from each mounting flange (Fig. 3-112, Pos. 3) of the hydraulic oil reservoir (Fig. 3-112, Pos. 2).

z

Lift the hydraulic oil reservoir (Fig. 3-112, 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.

Fig. 3-112

3 - 112

Superstructure

Hydraulics

Fig. 3-113 Filter assembly/provided parts

z

(R)

Return oil filter location

(L)

Leakage oil filter location

(1)

Mounting bolt

(2)


(3)

Filter cover assembly

(4)

Return and leakage filter unit

(5)

Oil filler plug

(6)

Gasket

(7)

Cover

(8)

Breather filter

Remove filters and all provided parts (Fig. 3-113, Pos. 1 - 8) from the top of the old hydraulic oil reservoir if required.

NOTE: Check O-rings and replace if required. Discard the gasket (Fig. 3-113, Pos. 6).

3 - 113

Hydraulics

z

Superstructure

Carry out the following steps only if required: z

Remove the back pressure valve (Fig. 3-114, Pos. 2) and discard the gasket (Fig. 3-114, Pos. 3).

z

Remove the whole standpipe (Fig. 3-114, Pos. 4).

z

Remove all covers (Fig. 3-114, Pos. 5).

z

Remove all plugs (Fig. 3-114, Pos. 6) .

z

Remove the oil level plate (Fig. 3-114, Pos. 8) and hydraulic oil level sight gauge (Fig. 3-114, Pos. 7).

Fig. 3-114

3 - 114

Superstructure

Hydraulics

3.3.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR Special tools:

Socket wrench 46 mm, PN 232 377 40 Hydraulic testing kit, PN 232 315 40


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Hydraulic oil reservoir incl. back pressure valve: 3200 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the hydraulic oil reservoir.

z

If required, install all provided parts (Fig. 3-113, Pos. 1 - 8) at the new hydraulic oil reservoir.

NOTE: Use new gasket (Fig. 3-113, Pos. 6) at the cover (Fig. 3-113, Pos. 7). Use new filter units (Fig. 3-113, Pos. 4). Check O-rings and replace if required.

z

Replace the return oil strainer (Fig. 3-115, Pos. 1) in the center part of the stand pipe (Fig. 3-115, Pos. 3).

NOTE: Use new gaskets (Fig. 3-115, Pos. 2)

Fig. 3-115 z

If required, install all provided parts (Fig. 3-114, Pos. 1 - 8) at the new hydraulic oil reservoir.

NOTE: Use new gaskets (Fig. 3-114, Pos. 1 and 3) at the back pressure valve (Fig. 3-114, Pos. 2). Check O-rings and replace if required.

3 - 115

Hydraulics

z

Superstructure


NOTE: Use new bolts (Fig. 3-116, Pos. 1) with grade 10.9 at the mounting flanges (Fig. 3-116, Pos. 3) of the hydraulic oil reservoir (Fig. 3-116, Pos. 2). Tighten the bolts (Fig. 3-116, Pos. 1) with the specified torque. Tightening torque for the mounting bolts: 1770 Nm

Fill hydraulic oil into the hydraulic oil reservoir, approx. 3900 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER". z


z


z

Check and adjust the back pressure if required, refer to the Service Manual for further information. Fig. 3-116

3 - 116

Superstructure

3.3.8

Hydraulics

MAIN CONTROL VALVE BLOCKS

Fig. 3-117 Main control valve blocks overview (1)


(2)


(3)


(4)


(5)

High pressure filter 1

(6)


(7)


(8)


There are four main control valve blocks. Each main control valve block is supplied from one main pump. The pump and block number are always the same, e.g. main pump 1 supplies oil to main control valve block 1. Block 1 and 3 are equipped with four spool valves and block 2 and 4 are equipped with three spool valves. Individual valve plugs are mounted on each main control valve block. These valves are anti-cavitation valves (ACV), service line relief valves (SRV), or main relief valves (MRV).

3 - 117

Hydraulics

Fig. 3-118 Main control valve blocks 1 and 3 (BHA)

3 - 118

Superstructure

Superstructure

Hydraulics

Legend for Fig. 3-118: Main control valve block 1 (BHA) (1)

SRV (66.4), stick cylinder piston side

(2)

MRV block 1

Main control valve block 3 (BHA) (3)

SRV (66.3), boom cylinder rod side

(4)

MRV block 3

NOTE: The numbers in brackets behind the valve type (ACV/SRV) are component numbers for the hydraulic diagram

3 - 119

Hydraulics

Fig. 3-119 Main control valve blocks 2 and 4 (BHA)

3 - 120

Superstructure

Superstructure

Hydraulics

Legend for Fig. 3-119: Main control valve block 2 (BHA) (7)

ACV (68.3), travel motor

(8)


(9)


(10)

SRV (66.5), boom cylinder piston side

(11)

MRV block 3

Main control valve block 4 (BHA) (1)


(2)


(3)


(4)


(5)


(6)

MRV block 1

NOTE: The numbers in brackets behind the valve type (ACV/SRV) are component numbers for the hydraulic diagram.

3 - 121

Hydraulics

Fig. 3-120 Main control valve blocks 1 and 3 (FSA)

3 - 122

Superstructure

Superstructure

Hydraulics

Legend for Fig. 3-120: Main control valve block 1 (FSA) (1)

MRV block 1

(2)

SRV (66.4), stick cylinder rod side

(3)

ACV (68.1), stick cylinder piston side

Main control valve block 3 (FSA) (4)

SRV (66.2), bucket cylinder rod side

(5)

MRV block 3

(6)

SRV (66.1), bucket cylinder piston side


3 - 123

Hydraulics

Fig. 3-121 Main control valve blocks 2 and 4 (FSA)

3 - 124

Superstructure

Superstructure

Hydraulics

Legend for Fig. 3-121: Main control valve block 2 (FSA) (10)


(11)

MRV block 2

(12)

ACV (68.2), clam cylinder rod side

(13)

SRV (45), boom cylinder piston side

(14)


(15)


Main control valve block 4 (FSA) (1)


(2)


(3)

SRV (66.12), stick cylinder rod side

(4)


(5)

SRV (66.9), bucket cylinder piston side

(6)

SRV (66.10), bucket cylinder rod side

(7)


(8)

SRV (66.8), boom cylinder rod side

(9)

MRV block 4


3 - 125

Hydraulics

Superstructure

3.3.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS Special tools:

n/a


Crane Oil drain pan Blind plugs: 8 x BUZ 12-L, PN 371 854 99 and 8 x ROV 12-PL, PN 513 547 98 9x SAE A2-6000, PN 506 582 98; 9 x SAE B2-6000, PN 506 527 98 SAE A3-3000, PN 512 570 98; SAE B3-3000, PN 512 571 98 Main control valve block 1, 2, and 4: 310 kg Main control valve block 3: 315 kg

Dogman/rigger

z


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 "FUNCTION OF THE TRANSFER PUMP". WARNING


z

Remove all SRVs from the main control valve block, refer to section 3.3.9.1 on page 3-131.

z

Remove all ACVs from the main control valve block, refer to section 3.3.10.3 on page 3-143.

z

If required remove the load holding valves from the main control valve block (4 from each block).

3 - 126

Fig. 3-122

Superstructure

Hydraulics

Fig. 3-123 z

Disconnect all inflexible hydraulic lines (Fig. 3-123) at the respective main control valve block.

z

Disconnect all pilot lines from the spool valves (Fig. 3-123, Pos. 1) 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. 3-123, Pos. 2) of the SAE-flanges.

3 - 127

Hydraulics

Fig. 3-124 Pressure lines and return lines, removal z

Disconnect the return line (Fig. 3-124, Pos. 1) and discard the O-ring (Fig. 3-124, Pos. 2) of the SAE-flange.

z

Remove the pressure filter (Fig. 3-124, Pos. 4) and discard the O-ring (Fig. 3-124, Pos. 3) at the pressure filter.

NOTE: When the return line and the pressure filter are removed, the oil inside will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the harness connectors and clear the wiring harness from the main control valve block.

3 - 128

Superstructure

Superstructure

Hydraulics

z

Disconnect the harness connectors and clear the wiring harness from the main control valve block.

z

Sling main control valve block at the installed lifting eye.

z

Remove the mounting bolts and dismantle the main control valve block from the control valve carrier using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the slew gear, make sure that nobody steps below the weight.

3 - 129

Hydraulics

Superstructure

3.3.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS Special tools:



Crane Main control valve block 1, 2, and 4: 310kg Main control valve block 3: 315 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. 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. 3-125, Pos. 1 and 4) of grade 10.9 for the main control valve blocks. Tightening torques for the mounting bolts (Fig. 3-125, Pos. 1 and 4) at the main control valve blocks: 265 Nm NOTE: Use new mounting bolts (Fig. 3-125, Pos. 2) of grade 10.9 for the pressure filters (Fig. 3-125, Pos. 3). Tightening torques for the mounting bolts (Fig. 3-125, Pos. 2) at the main control valve blocks: 265 Nm

Fig. 3-125 z


z


z

Check pressure of all circuits of the control valve block (use 400 bar gauge).

3 - 130

Superstructure

3.3.9

Hydraulics

SERVICE LINE RELIEF VALVES (SRV)

The service 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 build and in the throttle check valves, refer to section 3.3.11.1 on page 3-148. NOTE: SRVs are also installed in the travel system, refer to section 4.1.7.1 on page 4-25.

3.3.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK Special tools:

n/a


Oil drain pan

NOTE: For additional information about the SRV on the main control valve blocks, refer to section 3.3.8 on page 3-117. 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


z


Fig. 3-126

3 - 131

Hydraulics

Fig. 3-127 SRV on the main control valve blocks (BHA)

Fig. 3-128 SRV on the main control valve blocks (FSA)

3 - 132

Superstructure

Superstructure

Hydraulics


z

Disconnect the hose (Fig. 3-127 or Fig. 3-128, Pos. 1) from the SRV (Fig. 3-127 ore Fig. 3-128, Pos. 3).

z

Remove the four bolts (Fig. 3-127 or Fig. 3-128, Pos. 2) attaching the SRV to the main control valve block.

z

Remove the SRV (Fig. 3-127 or Fig. 3-128, Pos. 3) and cap the openings with blind plugs to avoid contamination.

z

Remove the O-rings (Fig. 3-129, Pos. 1) and discard them.

NOTE: Carry out the following steps only if required: z

Remove the support rings (Fig. 3-129, Pos. 2) from the valve body (Fig. 3-129, Pos. 4).

z

Remove the pressure relief valve (Fig. 3-129, Pos. 3) from the valve body (Fig. 3-129, Pos. 4). 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.

Fig. 3-129

3 - 133

Hydraulics

Superstructure

3.3.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS Special tools:




NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Fit new O-rings (Fig. 3-129, Pos. 1) to the SRV.

z


NOTE: If the pressure relief valve (Fig. 3-129, Pos. 3) was removed from the valve body (Fig. 3-129, Pos. 4) tighten it to the specified torque: Tightening torque for the built-in SRV: 300 Nm z


z


z

Check and adjust the SRV. Refer to the Service Manual for further information.

3 - 134

Superstructure

Hydraulics


3 - 135

Hydraulics

Superstructure

3.3.10 ANTI-CAVITATION VALVES (ACV)

Fig. 3-130 Anti cavitation valve (ACV) (1)

ACV housing

(2)

Valve cone

(3)

Valve guide and cover

(4)

Valve spring

(5)

O-ring

(6)

Valve seat

(7)

Connecting port from tank line

(8)

Connecting port to cylinder

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.

3 - 136

Superstructure

Hydraulics

The circuit pressure in the connecting port to the cylinder (Fig. 3-130, Pos. 8) holds the valve cone (Fig. 3-130, Pos. 2) closed. The pressure of the supply line (Fig. 3-130, Pos. 7) allows the necessary oil supply into the circuit at the moment when the pressure in port (Fig. 3-130, Pos. 8) is lower than in port (Fig. 3-130, Pos. 7). The ACVs are installed at the attachment manifold and at the main control valve blocks. In total six ACVs are fitted to the manifold and ten ACVs on the main control valve blocks.

3.3.10.1 REMOVAL OF ACV ON MANIFOLD Special tools:

n/a


Crane Oil drain pan Blind plugs: BUZ 42-L, PN 371 860 99 and ROV 42-PL, PN 513 790 98 4 x SAE A2-6000, PN 506 582 98 4 x SAE B2-6000, PN 506 527 98 Anti cavitation valve: 7.3 kg

Dogman/rigger

z


z




z


3 - 137

Hydraulics

Superstructure

z


z


Fig. 3-131

Fig. 3-132 Positions of the ACV at the BHA manifold (1)

ACV

(2)

ACV with attached plug plate

(3)

ACV with attached throttle check valves

(4)

ACV with attached intermediate block

NOTE: For further information about of the ACV at the BHA manifold, refer to the Service Manual.

3 - 138

Superstructure

Hydraulics

Fig. 3-133 Positions of the ACV at the FSA manifold (1)

ACV

(2)

ACV with attached diffuser

(3)

ACV with attached plug plate

(4)

ACV with attached non return valve

(5)

ACV with attached throttle check valve

NOTE: For further information about of the ACV at the FSA manifold, refer to the Service Manual.

3 - 139

Hydraulics

Superstructure

NOTE: In the following steps the ACV at port "F" of the FSA manifold ist removed exemplarily. The procedure is identical for all the ACV, except for the valves with other valves attached, so carry out the following four steps only if required: 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

If required, remove the throttle check valve to gain access to the anti-cavitation valve, refer to section 3.3.11.1 on page 3-148.

z

If required, remove the non return valve (analogously to throttle check valve removal) to gain access to the anticavitation valve, refer to section 3.3.11.1 on page 3-148.

z

If required, remove the intermediate block to gain access to the anti-cavitation valve.

z

If required, remove the diffuser (FSA only), refer to section 3.3.12.3 on page 3-155.

z

Remove the four bolts attaching the oil pipe (Fig. 3-134, Pos. 3) to the main control valve block and the four bolts (Fig. 3-134, Pos. 2) at the ACV (Fig. 3-134, Pos. 1) end.

z

Remove the oil pipe and the two flange seals (Fig. 3-134, Pos. 4). Discard the seals.

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. 3-134 z

Disconnect the flex hoses (Fig. 3-135, Pos. 2) and remove the joint (Fig. 3-135, Pos. 3) from the anti-cavitation valve (Fig. 3-135, Pos. 1).

NOTE: When the flex hose is disconnected, the oil inside the hose and the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination

Fig. 3-135

3 - 140

Superstructure

z

Remove the four bolts (Fig. 3-136, Pos. 1) attaching the ACV to the manifold.

z

Remove the ACV (Fig. 3-136, Pos. 2) and the O-ring (Fig. 3-136, Pos. 3). Discard the O-ring.

z

If required, repeat the procedure to remove the other ACV from the manifold.

Hydraulics

Fig. 3-136

3 - 141

Hydraulics

Superstructure

3.3.10.2 REPLACEMENT OF ACV ON MANIFOLD Special tools:

n/a


Crane Anti cavitation valve: 7.3 kg

Dogman/rigger



Fit a new O-ring (Fig. 3-137, Pos. 3) to the new ACV (Fig. 3-137, Pos. 2).

z

Aligne the new ACV to the manifold and insert the mounting bolts (Fig. 3-137, Pos. 1).

Fig. 3-137 z


NOTE: Carry out the following four steps only if required: z

If required, install the throttle check valve onto the ACV, refer to section 3.3.11.2 on page 3-151.

z

If required, install the non return valve (analogously to the throttle check valve installation), refer to section 3.3.11.2 on page 3-151.

z

If required, install the intermediate block.

z

If required, install the diffuser (FSA only) refer to section 3.3.12.4 on page 3-157.

z


z


3 - 142

Superstructure

Hydraulics

3.3.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS Special tools:

n/a


Oil drain pan

NOTE: For additional information aboutthe ACV on the main control valve blocks, refer to section 3.3.8 on page 3-117. z


z


z


z


Fig. 3-138

3 - 143

Hydraulics

Fig. 3-139 ACV on the main control valve blocks (BHA)

Fig. 3-140 ACV on the main control valve blocks (FSA)

3 - 144

Superstructure

Superstructure

Hydraulics


z

Remove the four bolts (Fig. 3-139 or Fig. 3-140, Pos. 2) attaching the ACV to the main control valve block.

z

Remove the ACV (Fig. 3-139 or Fig. 3-140, Pos. 1).

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. z

Remove the O-rings (Fig. 3-141, Pos. 1) and discard them.

z

Remove the support rings (Fig. 3-141, Pos. 2) from the valve body (Fig. 3-141, Pos. 3) only if required.

Fig. 3-141

3.3.10.4 REPLACEMENT OF ACV ON MAIN CONTROL VALVE BLOCKS Special tools:

n/a



NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings to the ACV (Fig. 3-141, Pos. 1). z


z


z


3 - 145

Hydraulics

3.3.11 THROTTLE CHECK VALVES

Fig. 3-142 Throttle check valve with built-in SRV

3 - 146

Superstructure

Superstructure

Hydraulics

Legend for Fig. 3-142: NOTE: The illustration shows the valve block up side 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)


(Y)

Control oil drain port

The maximum permissible cylinder speed is set by the pin (Fig. 3-142, Pos.1). Depending on the pin setting, the radial holes (Fig. 3-142, Pos. 9.1) in the valve sleeve (Fig. 3-142, Pos. 9) will be opened partially to achieve the required throttling of the oil flow. The safety holes (Fig. 3-142, Pos. 9.2) prevent the valve from becoming completely closed. For the lifting operation the valve sleeve which is guided by the spindle (Fig. 3-142, Pos. 1) is pressed against the spring (Fig. 3-142, Pos. 7) so that the valve will be completely open. The buildt-in SRV (Fig. 3-142, Pos. 13) limits the maximum system pressure from the cylinder and relieves oil to the tank line when the pressure reaches the valve setting.

3 - 147

Hydraulics

Superstructure

3.3.11.1 REMOVAL OF THROTTLE CHECK VALVES Special tools:

n/a


Crane Oil drain pan Blind plugs: 2 x SAE A1 1/2-6000, PN 506 581 98 2 x SAE B1 1/2-6000, PN 506 526 98 BUZ 20-S, PN 371 858 99 and ROV 20-PS, PN 512 005 98 BUZ 10-L, PN 371 852 99 and ROV 10-PL, PN 513 789 98 Throttle check valve: 20.5 kg

Dogman/rigger

Fig. 3-143 Positions of the throttle check valves BHA

3 - 148

Superstructure

Hydraulics

Fig. 3-144 Positions of the throttle check valves FSA z


z




z


3 - 149

Hydraulics

Superstructure

z


z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP". WARNING


z

Disconnect the flex hose (Fig. 3-146, Pos. 5) from the throttle check valve (Fig. 3-146, Pos. 1).

z

Remove the four bolts (Fig. 3-146, Pos. 2) and remove the pipe (Fig. 3-146, Pos. 3) from the throttle check valve (Fig. 3-146, Pos. 1).

Fig. 3-145

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. 3-146 z

Remove the four bolts (Fig. 3-147, Pos. 5) attaching the throttle check valve (Fig. 3-147, Pos. 1) to the manifold (Fig. 3-147, Pos. 2).

z

Remove the throttle check valve (Fig. 3-147, Pos. 1) and the O-ring (Fig. 3-147, 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. 3-147, Pos. 4) from the throttle check valve. Fig. 3-147

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. 3-142, Pos. 13) from the throttle check valve’s housing (Fig. 3-142, Pos. 11).

3 - 150

Superstructure

Hydraulics

3.3.11.2 REPLACEMENT OF THROTTLE CHECK VALVES Special tools:

n/a


Crane Throttle check valve: 20.5 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit a new O-ring (Fig. 3-147, Pos. 3) to the throttle check valve (Fig. 3-147, Pos. 1). z


NOTE: If the built-in SRV (Fig. 3-142, Pos. 13) has been removed from the housing (Fig. 3-142, Pos. 11) tighten it to the specified 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 for further information.

z

Check and adjust the built-in SRV in the throttle check valves if required. Refer to the Service Manual for further information.

3 - 151

Hydraulics

Superstructure

3.3.12 MANIFOLD 3.3.12.1 REMOVAL OF THE MANIFOLD Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Blind plugs: 39 x SAE A1 1/2-6000, PN 506 581 98 39 x SAE B1 1/2-6000, PN 506 526 98 10 x SAE A2-6000, PN 506 582 98 10 x SAE B2-6000, PN 506 527 98 Manifold: 375 kg

Dogman/rigger

z


z




z


z


z


Fig. 3-148

3 - 152

Superstructure

Hydraulics


z

Disconnect all hydraulic hoses (Fig. 3-149, Pos. 1) leading to the attachment. WARNING

Always wear a safety harness when working at the front side of the manifold.

z

Disconnect the hydraulic piping (Fig. 3-149, Pos. 2) at the front of 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

Remove the anti cavitation valves (ACV) from the manifold, refer to section 3.3.10.1 on page 3-137.

z

Remove the throttle check valves from the manifold, refer to section 3.3.11.1 on page 3-148.

z

Remove the diffuser from the manifold, refer to section 3.3.12.3 on page 3-155 (FSA only).

z

Sling the manifold.

z

Remove four mounting bolts (Fig. 3-149, Pos. 3). Separate the plate (Fig. 3-149, Pos. 4) from the filter assembly.

z

Remove the manifold by using a crane.

Fig. 3-149

DANGER Risk of falling weights! May result in death or serious injury When removing the manifold, make sure that nobody steps below the weight.

3 - 153

Hydraulics

Superstructure

3.3.12.2 REPLACEMENT OF THE MANIFOLD Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Manifold: 375 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings to the SAE-flanges. WARNING Always wear a safety harness when working at the front side of the manifold.

z


z


z


3 - 154

Superstructure

Hydraulics

3.3.12.3 REMOVAL OF THE DIFFUSER ON THE MANIFOLD (FSA ONLY) Special tools:

n/a


Oil drain pan Blind plugs: 2 x SAE A1 1/2-6000, PN 506 581 98 2 x SAE B1 1/2-6000, PN 506 526 98 Diffusor: 14 kg

NOTE: Diffusers are installed at the ports "L" and "D" on the manifold. z


z


z


z


z


z


Fig. 3-150

3 - 155

Hydraulics

Superstructure


z

Remove the four bolts (Fig. 3-151, Pos. 2) and remove the hydraulic oil pipe (Fig. 3-151, Pos. 3) from the diffuser (Fig. 3-151, Pos. 1). Discard the O-ring (Fig. 3-151, Pos. 4).

NOTE: When the hydraulic oil pipe is removed, the oil inside the the pipe will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-151 z

Remove the four bolts (Fig. 3-152, Pos. 1) attaching the diffuser (Fig. 3-152, Pos. 2) to the ACV (Fig. 3-152, Pos. 3).

z

Remove the diffuser (Fig. 3-152, Pos. 2) and the O-ring. Discard the O-ring.

Fig. 3-152

3 - 156

Superstructure

Hydraulics

3.3.12.4 REPLACEMENT OF DIFFUSER ON MANIFOLD (FSA ONLY) Special tools:

n/a


n/a Diffusor: 14 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings to the diffuser and to the hydraulic pipe (Fig. 3-151, Pos. 4). z


z


z


3 - 157

Hydraulics

Superstructure


3 - 158

Superstructure

3.4

Slew Drive

SLEW DRIVE

Fig. 3-153 The PC4000-6 is equipped with a two speed slew system with two slew gear arrangements. For further information, refer to the Service Manual. Multi disc brakes (Fig. 3-153, Pos. 3) are installed between the swing motors (Fig. 3-153, Pos. 2) and the gear boxes (Fig. 3-153, Pos. 4). These brakes are safety brakes, applied by spring force and released by oil pressure. To operate the rotary motion, slew brake valves (Fig. 3-153, Pos. 1) are directly flanged to the swing motor heads. For further information, refer to the Service Manual.

3 - 159

Slew Drive

3.4.1

Superstructure

SLEW GEAR

Fig. 3-154 Slew gear unit (L & S)

3 - 160

Superstructure

Slew Drive

3.4.1.1 REMOVAL OF THE SLEW GEAR Special tools:

n/a


Crane Universal articulated hoist rings: 3 x M20 Swing motor with attached slew service brake valve: 220 kg Slew gear: 1670 kg

Dogman/rigger

z


z




z


z

Remove the swing motor (Fig. 3-154, Pos. 1) from the slew gearbox (Fig. 3-154, Pos. 8), refer to section 3.4.2.1 on page 3-167. Leave the hydraulic hoses and the slew service brake valve attached to the swing motor.

z

Remove the nuts (Fig. 3-154, Pos. 5), the bolts (Fig. 3-154, Pos.11), and the washers (Fig. 3-154, Pos. 6 and 10).

z

Remove the cover plates (Fig. 3-154, Pos. 7). DANGER


z

Disconnect the oil pressure line from the slew parking brake.

NOTE: When the oil pressure line is removed, hydraulic oil from inside the line and the brake will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

3 - 161

Slew Drive

Fig. 3-155 Slew gear unit (L&S)

3 - 162

Superstructure

Superstructure

Slew Drive

z

Remove the protection caps (Fig. 3-155, Pos. 2) from the bolt heads and remove the slew gear mounting bolts (Fig. 3-155, Pos. 3) and washers (Fig. 3-155, Pos. 4). Discard the bolts.

z

Disconnect the lubrication lines below the slew gear.

z

Install universal articulated hoist rings (M20) displaced by 120° into the threads of the swing motor mounting bolts and attach a crane.

z

Remove the slew gear (Fig. 3-155, Pos. 8) using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the slew gear, make sure that nobody steps below the weight.

z

Remove the oil drain valve (Fig. 3-155, Pos. 9) from the slew gear (Fig. 3-154, Pos. 8). The oil inside the slew gear will flow out. Drain the gear oil from the slew gear, approx. 42 liters.

3.4.1.2 REPLACEMENT OF THE SLEW GEAR Special tools:

Feeler gauge (customary)


Crane Universal articulated hoist rings: 3 x M20 Swing motor with attached slew service brake valve: 220 kg Slew gear: 1670 kg

Dogman/rigger


WARNING New slew gears are delivered without gear oil.


Install the oil drain valve (Fig. 3-155, Pos. 9) at the new slew gear (Fig. 3-155, Pos. 8).

3 - 163

Slew Drive

Fig. 3-156 Slew gear unit (L&S)

3 - 164

Superstructure

Superstructure

Slew Drive

z

Install universal articulated hoist rings (M20) displaced by 120° to the threads of the swing motor mounting bolts and attach a crane.

z

Insert the new slew gear (Fig. 3-156, Pos. 8) and mount it to the superstructure with the bolts (Fig. 3-156, Pos. 3) and the washers (Fig. 3-156, Pos. 4).

NOTE: Use new slew gear mounting bolts (Fig. 3-156, Pos. 3) of grade 12.9 and tighten them to the specified torque. Tightening torque for the slew gear mounting bolts: 1030 Nm z

Connect the lubrication lines.

z

Carry out further installation in reverse order to removal. Fill gear oil into the slew gear, approx. 42 liters. Fill gear 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".

WARNING Make sure to use the specified bolts and tightening torque for the swing motor mounting bolts, refer to section 3.4.2.2 on page 3-170.

z

Check the tooth backlash between slew ring and slew pinion with a feeler gauge. Refer to PARTS & SERVICE BULLETIN No. "AH00511d".

3 - 165

Slew Drive

3.4.2

Superstructure

SWING MOTOR

Fig. 3-157 Swing motor assembly (1)

Bolt

(2)

Slew brake valve

(3)

O-ring

(4)

Bolt

(5)

Intermediate plate

(6)

O-ring

(7)

Bolt

(8)

Washer

(9)

Swing motor

(10)

Slew gear

(11)

Bolt

(12)

Washer

(13)

Expansion tank of the slew gear

(14)

Sleeve

3 - 166

Superstructure

Slew Drive

3.4.2.1 REMOVAL OF THE SWING MOTOR Special tools:

n/a


Crane Oil drain pan Blind plugs: 2 x SAE A1 1/2-6000, PN 506 581 98 2 x SAE B1 1/2-6000, PN 506 526 98 BUZ 18-L, PN 371 856 99 and ROV 18-PL, PN 513 787 98 Swing motor: 120 kg

Dogman/rigger

z


z




z


z


z


Fig. 3-158

Drain gear oil from 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".

3 - 167

Slew Drive

Superstructure


z

Disconnect the leak oil line (Fig. 3-159, Pos. 1) from the swing motor (Fig. 3-159, Pos. 2).

NOTE: When the leak oil line is removed, hydraulic oil from inside the line and the swing motor will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-159

Fig. 3-160 Removal of the swing motor

3 - 168

Superstructure

z

Slew Drive

Remove the four mounting bolts (Fig. 3-160, Pos. 1) and take the slew brake valve (Fig. 3-160, Pos. 2) off. Discard the O-ring (Fig. 3-160, Pos. 3). For further information, refer to section 3.4.4.1 on page 3-183.

NOTE: The hydraulic hoses remain at 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 four bolts (Fig. 3-160, Pos. 4) and take off the intermediate plate (Fig. 3-160, Pos. 5). Discard the O-ring (Fig. 3-160, Pos. 6).

z

Remove the bolts (Fig. 3-160, Pos. 7 and 11), the washers (Fig. 3-160, Pos. 8 and 12), and the sleeves (Fig. 3-160, Pos. 14) and put the expansion tank (Fig. 3-160, Pos. 13) of the slew gear aside. Discard the bolts.

z

Sling the swing motor (Fig. 3-160, Pos. 9).

z

Using a crane, pull the swing motor out of the slew gear (Fig. 3-160, Pos. 10) and place it on the ground. DANGER

Risk of falling weights! May result in death or serious injury When removing the swing motor, make sure that nobody steps below the weight.

3 - 169

Slew Drive

Superstructure

3.4.2.2 REPLACEMENT OF THE SWING MOTOR Special tools:



Crane Paste "Optimol White" PN 999 039 Swing motor: 120 kg

Dogman/rigger


Fig. 3-161 Installation of the swing motor

3 - 170

Superstructure

Slew Drive

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings (Fig. 3-161, Pos. 3 and 6). z

Apply "Optimol White" to the spline shaft of the motor.

z


NOTE: Use new swing motor mounting bolts (Fig. 3-161, Pos. 7) of grade 10.9 and tighten them to the specified torque. Tightening torque for the swing motor mounting bolts: 265 Nm z


z

Add hydraulic oil up to the specified level. Fill gear 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".

z

Check the slew brake valve and adjust it if required. Refer to the Service Manual for further information.

3 - 171

Slew Drive

Superstructure


3 - 172

Superstructure

3.4.3

Slew Drive

SLEW PARKING BRAKE

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 X2 is about 45 bar. NOTE: The slew parking brake must only be applied with the superstructure at a complete standstill. Applying the parking brake with 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.

3 - 173

Slew Drive

Superstructure

Fig. 3-162 Slew parking brake (L & S) (1)

Disc housing

(15)

Bearing ring

(2)

Thrust washer

(16)

Rotary shaft seal

(3)

Inner discs

(17)

Cylinder assembly

(4)

Outer discs

(5)

Sinus spacer ring

(6)

Piston

(7)

Quad ring with back up ring

(8)

Quad ring with back up ring

(9)

Springs

(10)

Thrust washer

(11)

Circlip

(12)

Drive shaft

(13)

Oil pressure port

(14)

Bolt

3 - 174

Superstructure

Slew Drive

3.4.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE Special tools:

n/a


Crane Universal articulated hoist rings: 3 x M20 Bearing ring: 112 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 3.4.2.1 on page 3-167.

NOTE: For further information relating the parking brake, refer to PARTS & SERVICE BULLETIN No. "AH03509a". z

Install universal articulated hoist rings (M20) displaced by 120° to the threads of the swing motor mounting bolts and attach a crane.

z

Remove the mounting bolts (Fig. 3-163, Pos. 1) at the swing motor flange.

z

Remove the inner snap ring (Fig. 3-163, Pos. 2).

z

Dismantle the bearing ring (Fig. 3-163, Pos. 3) from the slew gearbox using a crane

Fig. 3-163

3 - 175

Slew Drive

Superstructure

Fig. 3-164 Slew parking brake (L&S) z

Check rotary shaft seal (Fig. 3-164, Pos. 16) for wear and damage. Replace it if required.

z

Disconnect the pressure hose from the oil pressure port (Fig. 3-164, Pos. 13).

NOTE: When the pressure hose is removed, the oil inside the hose and the cylinder (Fig. 3-164, Pos. 17) will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. WARNING The piston (Fig. 3-164, Pos. 6) of the break assembly is spring loaded.

z

Remove the two socket head cap bolts (Fig. 3-164, Pos. 14) and relieve the spring load of the springs (Fig. 3-164, Pos. 9) on the piston (Fig. 3-164, Pos. 6).

z

Take off the cylinder assembly (Fig. 3-164, Pos. 17).

3 - 176

Superstructure

z

Dismount 10 inner discs (Fig. 3-164, Pos. 3), 11 outer discs (Fig. 3-164, Pos. 4), and 10 sinus spacer rings (Fig. 3-164, Pos. 5) from the disc housing (Fig. 3-164, Pos. 1).

z

Remove the drive shaft (Fig. 3-164, Pos. 12).

z

Remove the thrust washer (Fig. 3-164, Pos. 2) from the disc housing (Fig. 3-164, Pos. 1).

z

Check the inner discs (Fig. 3-164, Pos. 3), the outer discs (Fig. 3-164, Pos. 4), the sinus spacer rings (Fig. 3-164, Pos. 5), and the thrust washer (Fig. 3-164, Pos. 2) for wear and damage. Replace if required.

Slew Drive

3 - 177

Slew Drive

Superstructure

3.4.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE Special tools:

n/a


Crane Paste "Optimol White" PN 999 039 Hydraulic power unint (60 bar) with fitting (M18 x 1.5) Bearing ring: 112 kg

Dogman/rigger


Fig. 3-165 Slew parking brake (L&S)

3 - 178

Superstructure

Slew Drive

NOTE: Replace all O-rings. For further information relating the parking brake, refer to PARTS & SERVICE BULLETIN No. "AH03509a". z

Install the thrust washer (Fig. 3-165, Pos. 2).

z

Install the drive shaft (Fig. 3-165, 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. 3-165, Pos. 4), then an inner disc (Fig. 3-165, Pos. 3), and then a sinus spacer ring (Fig. 3-165, Pos. 5). Apply oil to the discs.

NOTE: Before reinstallation, apply pressure (max. 60 bar) to the cylinder assembly (Fig. 3-165, Pos. 17), otherwise the two socket head cap bolts (Fig. 3-165, Pos. 14) are prestressed (spring loaded). z

Install the cylinder assembly (Fig. 3-165, Pos. 17).

z

Carry out further installation in reverse order to removal. WARNING

Make sure to use the specified bolts and torque for the swing motor mounting bolts, refer to section 3.4.2.2 on page 3-170.

Fill gear 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". z


z

Check slew parking brake for proper function. Refer to the Service Manual for further information.

3 - 179

Slew Drive

3.4.4

Superstructure

DYNAMIC SLEW BRAKE

Fig. 3-166 Slew brake valve

3 - 180

Superstructure

Slew Drive


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’)


(B)

Service line from main control valve block

(B’)


(MA)

Check point circuit A

(MB)

Check point circuit B

When ever a swing motion is carried out or the foot brake is used pilot pressure pends at port X of the pressure increase valve (Fig. 3-166, 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. 3-166, Pos. 4 and 5) and opens the check valves (Fig. 3-166, Pos. 2 and 3). That means the service lines are connected to the pressure increase valve by the check valves (Fig. 3-166, Pos. 2 and 3). When ever 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.

3 - 181

Slew Drive

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. 3-167 Pressure increase valve Whenever a swinging motion is carried out or the foot brake is used, pilot pressure pends 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. 3-167, Pos. 12), the pretension of the spring (Fig. 3-167, 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 pends at the main piston (Fig. 3-167, Pos. 13) and via the jet bore (Fig. 3-167, Pos. 6) also in the chamber of the spring (Fig. 3-167, Pos. 7) as well. System pressure also pends at the pressure relief valve cone (Fig. 3-167, Pos. 9) via the jet bore (Fig. 3-167, Pos. 8). Due to the force balance, the piston (Fig. 3-167, Pos. 13) is kept in its position, supported by the spring (Fig. 3-167, Pos. 7). If the system pressure is higher than the setting of the valve (Fig. 3-167, Pos. 9) the valve opens a channel to the drain port Y. Due to the drop of pressure, the piston (Fig. 3-167, Pos. 13) is moved by the spring (Fig. 3-167, 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.

3 - 182

Superstructure

Superstructure

Slew Drive

3.4.4.1 REMOVAL OF THE SLEW BRAKE VALVE Special tools:

n/a


Crane Blind plugs: BUZ 10-L, PN 371 852 99 and ROV 10-PL, PN 513 789 98 BUZ 12-L, PN 371 854 99 and ROV 12-PL, PN 513 547 98 BUZ 42-L, PN 371 860 99 and ROV 42-PL, PN 513 790 98 2 x SAE A1 1/2-6000, PN 506 581 98 2 x SAE B1 1/2-6000, PN 506 526 98 Slew brake valve: 97 kg

Dogman/rigger

z


z




z


z


z


Fig. 3-168

3 - 183

Slew Drive

Superstructure


z

Disconnect the service hoses (Fig. 3-169, Pos. 2), the return hose (Fig. 3-169, Pos. 3), the leak oil hose (Fig. 3-169, Pos. 4), and the pilot hose (Fig. 3-169, Pos. 5) from the slew brake valve (Fig. 3-169, 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. 3-169, Pos. 6).

z

Remove the four mounting bolts (Fig. 3-169, Pos. 1) and demount the slew brake valve (Fig. 3-169, Pos. 6) from the swing motor (Fig. 3-169, Pos. 7) using a crane. DANGER

Risk of falling weights! May result in death or serious injury 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. 3-169, 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.

3 - 184

Fig. 3-169

Superstructure

Slew Drive

3.4.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE Special tools:



n/a Slew brake valve: 97 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings below the slew brake valve and the SAEflanges. z


z


z


z

Check and adjust the slew brake valve. Refer to the Service Manual for further information.

z

Check dynamic slew brake for proper function. Refer to the Service Manual for further information.

3 - 185

Slew Drive

3.4.5

Superstructure

SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL)

Fig. 3-170 Slew ring lubrication

3 - 186

Superstructure

Slew Drive


Lubrication pump station

(4)

Main pump control solenoid valve (pump on/off)

(8)


(9)

Lubricant pressure relieve solenoid valve

(12)

End line pressure switch

(13)

Injectors

(14)

Lubricant feed line from injector to lubrication pinion

(18)

Lubricant container

(23)

Lubrication pinion

(24)

Lubrication pinion center shaft with distributing drillings

(25)

Lubricant outlet

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. 3-170, Pos. 1) is the same as for the central lubrication system (CLS), refer to section 3.5 on page 3-191. To apply the lubricant equably to the outer slew ring gear teeth (Fig. 3-170, Pos. 26), a special lubrication pinion (Fig. 3-170, Pos. 23) is mounted near the drive pinion of each slew gear. The lubrication pinion (Fig. 3-170, Pos. 23) distributes the lubricant from the injectors (Fig. 3-170, Pos. 13) evenly to the teeth. Normally two or more small SL1 injectors (Fig. 3-170, Pos. 13) are parallel connected to supply the required amount of lubricant to the lubrication pinion. The pinion center shaft (Fig. 3-170, Pos. 24) acts as a rotary joint and distributes lubricant through radial drillings only to the teeth, witch are in contact with the outer slewring gear teeth. Outlet bores (Fig. 3-170, Pos. 25) on different position of the pinion gear distribute the lubricant equably to the outer slewring gear teeth (Fig. 3-170, Pos. 26). NOTE: The PC4000-6 is equipped with two lubrication pinions, one at each slew gear.

3 - 187

Slew Drive

Superstructure

3.4.5.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY Special tools:

n/a


Safety harness in conformity with DIN EN 361 Mobile elevator working platform Pinion cover: 2.5 kg Lubrication pinion assembly: 14 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, stop the engine and remove ignition key in order to prevent operation of the lubrication system. Assure that the system pressure of the lubrication system is relieved before maintenance.

z

Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-172, Pos. 2) by hand, refer to PARTS & SERVICE BULLETIN 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.

3 - 188

Superstructure

Slew Drive

Fig. 3-171 Lubrication pinion assembly, removal and replacement z

Remove all nuts (Fig. 3-171, Pos. 1) and remove the pinion cover (Fig. 3-171, Pos. 2 or 3).

NOTE: A second person is required for this work. z

Disconnect the lubrication line (Fig. 3-171, Pos. 4).

z

Remove the nuts (Fig. 3-171, Pos. 7)and take the lubrication pinion assembly (Fig. 3-171, Pos. 6) with plate (Fig. 3-171, Pos. 5) off the superstructure.

NOTE: A second person is required for this work.

3 - 189

Slew Drive

Superstructure

3.4.5.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY Special tools:

n/a


Safety harness in conformity with DIN EN 361 Mobile elevator working platform Pinion cover: 2.5 kg Lubrication pinion assembly: 14 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

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. Activate the switch S26 at the dash board until the correct pressure is reached.

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"".

3 - 190

Superstructure

3.5

Lubrication pumps

LUBRICATION PUMPS

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 inside and reaches into the lubricant.

3.5.1

REMOVAL OF THE LUBRICATION PUMP

Special tools:

n/a


Crane Lubrication pump: 28 kg

Dogman/rigger

z


z




Before maintenance, stop the engine and remove ignition key in order to prevent operation of the lubrication system. Assure that the system pressure of the lubrication system is relieved before maintenance.

3 - 191

Lubrication pumps

z

Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-172, Pos. 1) by hand, refer to PARTS & SERVICE BULLETIN No. "AH05546".

z

Disconnect the hydraulic lines (Fig. 3-172, Pos. 2) from the lubrication pump.

z

Disconnect the quick coupling of the grease supply line (Fig. 3-172, Pos. 3) from the lubrication pump.

Superstructure

Fig. 3-172 z

Remove the bolt (Fig. 3-173, Pos. 1) and pull the lubrication pump out of the grease barrel.

Fig. 3-173

3 - 192

Superstructure

3.5.2

Lubrication pumps

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. 3-174, Pos. 1).

Fig. 3-174 z

Adjust the lubrication pump speed. Refer to the Service Manual for further information.

z

Adjust the lubrication pump pressure. Refer to the Service Manual for further information.

3 - 193

Pump controller MC7

Superstructure

3.6

PUMP CONTROLLER MC7

3.6.1

REMOVAL OF THE PUMP CONTROLLER MC7

Special tools:

n/a


n/a

z


z

Remove the keys from the battery main switches.

z

Remove the wiring harness connector X14 (Fig. 3-175, Pos. 2) from the electronic pump controller MC7 (Fig. 3-175, Pos. 3).

z

Remove four bolts and remove the pump controller MC7 from the wall of the cab base (Fig. 3-175, Pos. 1).

Fig. 3-175

3 - 194

Superstructure

3.6.2

Pump controller MC7

REPLACEMENT OF THE PUMP CONTROLLER MC7

Special tools:

n/a



z


z

Check and adjust the parameters. Refer to the Service Manual for further information.

3 - 195

Operator’s Cab

3.7

OPERATOR’S CAB

Fig. 3-176 Operator’s cab overview 3 - 196

Superstructure

Superstructure

Operator’s Cab

Legend for Fig. 3-176: A

Rear View of Operator’s Cab

(1)

Door handle

(2)

Door latch (with door fully opened)

(3)

Door locking pin, engages into 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 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.

3 - 197

Operator’s Cab

Superstructure

This page was left blank intentionally

3 - 198

Superstructure

3.7.1

Operator’s Cab

REMOVAL OF THE OPERATOR’S CAB

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Tank for coolant storage Oil drain panBlind plugs: 2 x BUZ 18-L, PN 371 856 99 and 2 x ROV 18-PL, PN 513 787 98 2 x BUZ 16-S, PN 371 866 99 and ROV 15-PL, PN 507 051 98 Operator’s cab: 2700 kg

Dogman/rigger

z


z




z

Remove the keys from the battery main switches. WARNING

Always wear a safety harness when working at the operator’s cab. Do not carry out the following work on a hot machine. Wait until the temperature of the coolant is below 50 °C. Disobedience may result in personal injury from heated coolant or steam.

Drain the engine coolant, approx. 475 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM" and the Engine Operation & Maintenance Manual.

3 - 199

Operator’s Cab

z

Dismount the grommet plate (Fig. 3-177, Pos. 1) inside the cab base.

z

Disconnect all harness connectors at the back side of the grommet plate.

z

Disconnect the blue power wire from terminal no. 1 at X2C and pull it out of the grommet plate.

z

Disconnect three wires of the red harness from terminals no. 95, 96 and 98 at X2C and pull it out of the grommet plate.

z

Unplug the CAN-Bus wire from the plug X35B at the right side of the X2-board and pull it out of the grommet plate.

Superstructure

Fig. 3-177 z

Remove the ground cable (Fig. 3-178, Pos. 1) in the cab base (Fig. 3-178, Pos. 2) from the left lower fixing bolt at the X2board and pull it out of the grommet plate.

Fig. 3-178 z

Remove the air hose (Fig. 3-179, Pos. 1) inside the cab base.

Fig. 3-179

3 - 200

Superstructure

Operator’s Cab

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.

z

Suck off the refrigerant from the air condition. WARNING

The air conditioning must be serviced by authorized service specialists only.

z

Open the plate (Fig. 3-180, Pos. 3) and disconnect the refrigerant couplings (Fig. 3-180, Pos. 1) at the refrigerant hoses below the cab support (Fig. 3-180, Pos. 2).

z

Cap the openings with blind plugs to avoid contamination of the air conditioning system.

Fig. 3-180 z

Sling the operator’s cab (Fig. 3-181, Pos. 2) at the lifting eye bolts (Fig. 3-181, Pos. 1) delivered with the cab.

Fig. 3-181

3 - 201

Operator’s Cab

Fig. 3-182 Removal overview (1)

Operator’s cab

(2)

Bolt

(3)

Resilient sleeve

(4)

Viscous mount

(5)

Hose clip

(6)

Water hose

(7)

Heating hose

(8)

Gratings

(9)

Support frame

3 - 202

Superstructure

Superstructure

z

Operator’s Cab

Remove the hoses (Fig. 3-182, Pos. 7) of the operator’s cab heating from inside the cab base.

NOTE: When the hoses of the operator’s cab heating are removed, fluid from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Open the hose clips (Fig. 3-182, Pos. 5) and remove the water hoses (Fig. 3-182, Pos. 6).

z

Remove the gratings (Fig. 3-182, Pos. 8) from the cab support (Fig. 3-182, Pos. 9).

z

Remove the bolts (Fig. 3-182, Pos. 2) and resilient sleeves (Fig. 3-182, Pos. 3) from the viscous mounts (Fig. 3-182, Pos. 4).

z

Remove operator’s cab (Fig. 3-182, Pos. 1) using a crane. 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.

3 - 203

Operator’s Cab

3.7.2

Superstructure

REPLACEMENT OF THE OPERATOR’S CAB

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Operator’s cab: 2700 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the operator’s cab.

z


NOTE: Use new bolts (Fig. 3-182, Pos. 2) of the grade 10.9 at the viscous mounts (Fig. 3-182, Pos. 4) and teighten the bolts with the specified torque. Tightening torque for the mounting bolts: 108 Nm z

Evacuate the air conditioning and add refrigerant. WARNING

The air conditioning must be filled with refrigerant "R134a" by authorized service specialists only.

Refill the engine coolant, approx. 475 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

3 - 204

Superstructure

3.7.3

Operator’s Cab

CAB-MOUNTS

3.7.3.1 REMOVAL OF THE CAB-MOUNTS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Operator’s cab: 2700 kg Viscous mount: 5 kg Absorber plate incl. 2 viscous mounts: 13 kg Absorber plate incl. 2 viscous mounts: 21 kg

Dogman/rigger

z


z




Always wear a safety harness when working at the operator’s cab.

z

Sling the operator’s cab (Fig. 3-181, Pos. 2) at the lifting eye bolts (Fig. 3-181, Pos. 1) delivered with the cab.

Fig. 3-183

3 - 205

Operator’s Cab

Fig. 3-184 Removal of the cab-mounts, overview z

Remove the gratings (Fig. 3-184, Pos. 8) from the cab support (Fig. 3-184, Pos. 9).

z

Remove the bolts (Fig. 3-184, Pos. 2) and resilient sleeves (Fig. 3-184, Pos. 3) from the viscous mounts (Fig. 3-182, Pos. 4).

z

Raise the operator’s cab (Fig. 3-182, Pos. 1) only a view milimeters, just enough to clear the viscous mounts (Fig. 3-182, Pos. 4).

z

Remove the bolts (Fig. 3-184, Pos. 5) from the absorber plate (Fig. 3-184, Pos. 6) and remove the absorber plate with the viscous mounts.

z

Remove the bolts (Fig. 3-184, Pos. 7) and dismount the viscous mounts (Fig. 3-182, Pos. 4) from the absorber plate (Fig. 3-184, Pos. 6).

3 - 206

Superstructure

Superstructure

Operator’s Cab

3.7.3.2 REPLACEMENT OF THE CAB-MOUNTS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Operator’s cab: 2700 kg Viscous mount: 5 kg Absorber plate incl. 2 viscous mounts: 13 kg Absorber plate incl. 2 viscous mounts: 21 kg

Dogman/rigger



z


3 - 207

Operator’s Cab

3.7.4

Superstructure

FRONT WINDOW

3.7.4.1 REMOVAL OF THE FRONT WINDOW Special tools:

n/a


Suction lifters with hoist rings Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Front window: 112 kg

Dogman/rigger

z


z




Always wear a safety harness when working at the operator’s cab.

z

Remove the wiper arms (Fig. 3-185, Pos. 1).

z

Use suction lifters with hoist rings at the front window (Fig. 3-185, Pos. 4) to sling the front window.

z

Remove the bolts (Fig. 3-185, Pos. 2). Hold nut (Fig. 3-185, Pos. 3) from inside the cab.

z

Remove the front window (Fig. 3-185, Pos. 4) using a crane.

Fig. 3-185

3 - 208

Superstructure

Operator’s Cab

3.7.4.2 REPLACEMENT OF THE FRONT WINDOW Special tools:

n/a


Suction lifters with hoist rings Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Front window: 112 kg

Dogman/rigger



z


3 - 209

Operator’s Cab

3.7.5

Superstructure

OPERATOR’S SEAT

3.7.5.1 REMOVAL OF THE OPERATOR’S SEAT Special tools:

n/a


Crane Operator’s seat: 62 kg

Dogman/rigger

z


z




z

Disconnect the wire harness connector (Fig. 3-186, Pos. 1) of the air suspension.

z

Remove both control lever carriers (Fig. 3-186, Pos. 2 and 3).

z

Remove all mounting bolts (Fig. 3-186, Pos. 4) from the cover plate (Fig. 3-186, Pos. 5).

z

Remove the cover plate (Fig. 3-186, Pos. 5) by removing all seat mounting bolts (Fig. 3-186, Pos. 6) and nuts (Fig. 3-186, Pos. 7) from the operator’s seat (Fig. 3-186, Pos. 8).

NOTE: A second person is required to carry the the operator’s seat out of the the operator’s cab. z

Sling the operator’s seat and lift it off the machine using a crane.

3 - 210

Fig. 3-186

Superstructure

Operator’s Cab

3.7.5.2 REPLACEMENT OF THE OPERATOR’S SEAT Special tools:

n/a


Crane Operator’s seat: 62 kg

Dogman/rigger


Remove both control lever carriers from the new seat.

z


NOTE: A second person is required to carry the the operator’s seat into the the operator’s cab.

3 - 211

Operator’s Cab

3.7.6

Superstructure

VHMS

The PC4000 is equipped with the VHMS (Vehicle Health Monitoring System). The VHMS consists of a display in the operator console and the VHMS-controller in the cab support.

3.7.6.1 REMOVAL OF THE VHMS-CONTROLLER Special tools:

n/a


PC/Laptop with Data transfer cable and analysis tool box refer to PARTS & SERVICE BULLETIN No. "AH03526a"

z


z

Follow the instructions given in PARTS & SERVICE BULLETIN No. "AH03538" .

z

For the equipment for downloading data, refer to PARTS & SERVICE BULLETIN No. "AH03526a" .

z

For information about setting up the PC/Laptop software, refer to PARTS & SERVICE BULLETIN No. "AH01512" .

z

Remove the nuts (Fig. 3-187, Pos. 1) and take the VHMScontroller (Fig. 3-187, Pos. 2) from the rubber bearings (Fig. 3-187, Pos. 3).

Fig. 3-187

3 - 212

Superstructure

Operator’s Cab

3.7.6.2 REPLACEMENT OF THE VHMS-CONTROLLER Special tools:

n/a


PC/Laptop with Data transfer cable and analysis tool box refer to PARTS & SERVICE BULLETIN No. "AH03526a" If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

z


z

For the setup of the new VHMS-controller, follow the instructions given in PARTS & SERVICE BULLETIN No. "AH03538".

3 - 213

Operator’s Cab

3.7.7

ACCESS LADDER

Fig. 3-188 Access ladder assembly

3 - 214

Superstructure

Superstructure

Operator’s Cab


Access ladder

(2)

Stop

(3)

Access ladder cylinder

(4)

Silent block

(5)

Silent block

(6)

Self-locking nut

(7)

Nut

(12)

Pin

(13)

Pin

(14)

Washer

(15)

Cotter pin

(16)

Washer

(17)

Ladder bearing assembly

(18)

Dowel screw

(19)

Distance sleeve

(20)

Bearing

(21)

Shaft seal

(22)

Washer

(23)

Hydraulic hose

(24)

Hydraulic hose

(25)

Socket

3 - 215

Operator’s Cab

Fig. 3-189 Access ladder removal

3 - 216

Superstructure

Superstructure

Operator’s Cab

3.7.7.1 REMOVAL OF THE ACCESS LADDER Special tools:

n/a


Safety harness in conformity with DIN EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder: 76 kg

Dogman/rigger

z


z



Isolate the machine according to local regulations with the access ladder (Fig. 3-189, Pos. 1) lowered to the ground.

z


NOTE: Relieve the remaining pilot pressure. WARNING z

Provide an adequate working platform for safe access to the access ladder bearing.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. 3-189, Pos. 3) in its position.

z

Clear the access ladder (Fig. 3-189, Pos. 1) by removing the pin (Fig. 3-189, Pos. 13) from the access ladder cylinder moving rod. CAUTION

Assure that the pressure in the hydraulic system is completely relieved before removing the pivot pin (Fig. 3-189, Pos. 13).

3 - 217

Operator’s Cab

Fig. 3-190 Access ladder replacement

3 - 218

Superstructure

Superstructure

Operator’s Cab

z

Sling the access ladder and remove the self locking nuts (Fig. 3-190, Pos. 6) from the ladder bearing assemblies (Fig. 3-190, Pos. 17).

z

Remove the ladder bearing assemblies and the ladder. Rest it on the ground.

3.7.7.2 REPLACEMENT OF THE ACCESS LADDER Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Access ladder: 76 kg

Dogman/rigger


WARNING z

Provide an adequate working platform for safe access to the access ladder bearing.

z


z

Carry out installation in reverse order to removal. Tightening procedure for the self-locking nuts (Fig. 3-190, Pos. 6): New nuts: 440 Nm Used nuts: 350 Nm NOTE: Use a new nut, if the clamping torque of the uswed nut is less than 12 Nm.

NOTE: Apply grease to the pin (Fig. 3-190, Pos. 13) at the access ladder cylinder moving rod.

3 - 219

Operator’s Cab

Fig. 3-191 Access ladder cylinder removal

3 - 220

Superstructure

Superstructure

Operator’s Cab

3.7.7.3 REMOVAL OF THE ACCESS LADDER CYLINDER Special tools:

n/a


Safety harness in conformity with DIN EN 361 Oil drain pan Crane Mobile elevator working platform Blind plugs: 2 x BUZ 12-L, PN 371 854 99 and 2 x ROV 12-PL, PN 513 547 98 Access ladder cylinder: 18 kg

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and elevator working platform.

z



Isolate the machine according to local regulations with the access ladder (Fig. 3-191, Pos. 1) lowered to the ground.

z


NOTE: Relieve the remaining pilot pressure. WARNING z


z


z

Assure that the pressure in the hydraulic system is completely relieved before removing the pivot pin (Fig. 3-191, Pos. 6) or disconnecting any hydraulic hoses.

z

Remove hydraulic hoses (Fig. 3-191, Pos. 23 and 24) from the access ladder cylinder (Fig. 3-191, Pos. 3).

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

Support the access ladder cylinder (Fig. 3-191, Pos. 3) from the bottom side.

3 - 221

Operator’s Cab

z

Remove the pins (Fig. 3-191, Pos. 12 and 13) and remove the access ladder cylinder (Fig. 3-191, Pos. 3).

Fig. 3-192 Access ladder cylinder installation

3 - 222

Superstructure

Superstructure

Operator’s Cab

3.7.7.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER Special tools:

n/a


Safety harness in conformity with DIN EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder cylinder: 18 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

WARNING z


z


z


NOTE: Apply grease to the pins (Fig. 3-192, Pos. 12 and 13). z


z


3 - 223

Operator’s Cab

3.7.8

Superstructure

REMOVAL OF THE CAB BASE

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 795 922 73 46 mm hexagon impact socket wrench (1"), PN 232 265 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform Empty fuel starage tank Crane Blind plugs: 2 x BUZ 18-L, PN 371 856 99 and 2 xROV 18-PL, PN 513 787 98 Support frame: 862 kg Cab base: 3810 kg

Dogman/rigger

z

the machine, boom, and crane.

z




z

Remove the keys from the battery main switches.

z

Remove the operator’s cab, refer to section 3.7.1 on page 3-199.

z

Disconnect the harness connectors (Fig. 3-193, Pos. 1) from the cab base.

z

Pull the harnesses out of the cable channels of the cab base (Fig. 3-193, Pos. 2) and of the tank (Fig. 3-193, Pos. 1). Z 26172

Fig. 3-193

3 - 224

Superstructure

Operator’s Cab

z

Sling the support frame (Fig. 3-194, Pos. 2).

z

Remove the bolts (Fig. 3-194, Pos. 1) from within the cab base (Fig. 3-194, Pos. 3) and remove the support frame (Fig. 3-194, Pos. 2) using a crane.

Fig. 3-194 z

Sling cab base (Fig. 3-195, Pos. 1), refer to Fig. 3-196.

z

Remove bolts (Fig. 3-195, Pos. 2) attaching the cab base to the superstructure (Fig. 3-195, Pos. 2).

Fig. 3-195 z

Remove the cab base using a crane. DANGER

Risk of falling weights! May result in death or serious injury When moving cab base, make sure that nobody steps below the lifted cab base.

Fig. 3-196

3 - 225

Operator’s Cab

3.7.9

Superstructure

REPLACEMENT OF THE CAB BASE

Special tools:



Safety harness in conformity with DIN EN 361 Mobile elevator working platform Empty fuel starage tank Crane Compound "Epple 28" Compound "Loctite 222" Support frame: 862 kg Cab base: 3810 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the cab base.

z

Sling the new cab base and align it with the superstructure using a crane (Fig. 3-197). DANGER

Risk of falling weights! May result in death or serious injury When moving cab base, make sure that nobody steps below the lifted cab base.

Fig. 3-197

3 - 226

Superstructure

z

Operator’s Cab

Install bolts (Fig. 3-198, Pos. 2) attaching the cab base (Fig. 3-198, Pos. 1) to the superstructure (Fig. 3-198, Pos. 2).

NOTE: Use new mounting bolts (Fig. 3-198, Pos. 2) of grade 10.9 and tighten the mounting bolts with the specified tightening torque.

Fig. 3-198

Tightening torque for fuel tank mounting bolts (Fig. 3-198, Pos. 2): 3100 Nm.

z

Apply sealing compound "Epple 28" onto the whole contact surfaces (Fig. 3-199, arrows) of the cab base.

z

Install the support frame (Fig. 3-199, Pos. 2) using a crane.

z

Apply compound "Loctite 222" on the threats of all bolts (Fig. 3-199, Pos. 1).

z

Install bolts (Fig. 3-199, Pos. 1) attaching the support frame (Fig. 3-199, Pos. 2) to the cab base (Fig. 3-199, Pos. 3).

NOTE: Use new mounting bolts (Fig. 3-199, Pos. 1) of grade 10.9 and tighten the mounting bolts with the specified tightening torque. Fig. 3-199

Tightening torque for fuel tank mounting bolts (Fig. 3-199, Pos. 1): 295 Nm. z


3 - 227

Counterweight

3.8

Superstructure

COUNTERWEIGHT

Fig. 3-200 Counterweight (A1)

Lifting eye (fix mounted)

(A2)

Lifting eye (fix mounted)

(A3)

Lifting eye

(1)

Instruction label

(2)

Lifting situation for horizontal transport

(3)

Lifting situation for vertical transport

(4)

Lifting situation for raising up the counterweight

WARNING Make sure that the maximum rope angle depending on the lifting situation (Fig. 3-200, Pos. 2 to 4) is not exceeded.

3 - 228

Superstructure

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 PARTS & SERVICE BULLETIN No. "AH04518" for expelling the gases from the counterweight chambers!

NOTE: 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 PARTS & SERVICE BULLETIN No. "AH04518" for expelling the gases from the counterweight chambers.

3.8.1

REMOVAL OF THE COUNTERWEIGHT

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 795 922 73 65 mm hexagon impact socket wrench (1 1/2"), PN 232 521 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform 2 x Crane Counterweight: 37,000 kg

Dogman/rigger Crane operators trained in dual crane lift

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

z

Park the machine on the prepared flat area and position the bucket on the ground.



3 - 229

Counterweight

Superstructure

WARNING Always wear a safety harness when working at the counter weight.

z

Using two cranes, secure the counterweight at the lifting eyes A1 and A2 (Fig. 3-200, Pos. 3). WARNING

Make sure that the maximum rope angle of 40° is not exceeded. Refer to Fig. 3-200, Pos. 3.

z

Remove the rails (Fig. 3-201, Pos. 1) from the counterweight (Fig. 3-201, Pos. 2).

z

Remove all additional equipment from the counterweight, if required.

z

Remove the tanks and wires of the Fire Detection and Suppression System, if required. 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

Remove all mounting bolts (Fig. 3-201, Pos. 3). WARNING

Before lifting the counterweight, make sure that the crane operators are trained in dual crane lift.

z

Remove counterweight using two cranes. DANGER

Risk of falling weights! Death or serious injury may result. When moving counterweight, make sure that nobody steps below the lifted counterweight.

3 - 230

Fig. 3-201

Superstructure

3.8.2

Counterweight

REPLACEMENT OF THE COUNTERWEIGHT

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 795 922 73 65 mm hexagon impact socket wrench (1 1/2"), PN 232 521 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform 2 x Crane Compound "KP2K", PN 324 969 40 Counterweight: 37,000 kg

Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

WARNING Always wear a safety harness when working at the counter weight.

NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. z

Carry out installation in reverse order to removal. WARNING

Make sure that the maximum rope angle of 40° is not exceeded. Refer to Fig. 3-200, Pos. 3.

NOTE: Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts. Tighten the mounting bolts with the specified tightening torque. Tightening torque for the mounting bolts: 4950 Nm

3 - 231

Superstructure Lifting

Superstructure

3.9

SUPERSTRUCTURE LIFTING

3.9.1

REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE

Special tools:



Safety harness in conformity with DIN EN 361 Mobile elevator working platform 2x crane Blind plugs: 4 x SAE A2-6000, PN 506 582 98 4 x SAE B2-6000, PN 506 527 98 BUZ 15-L, PN 371 855 99 and ROV 15-PL, PN 507 051 98 BUZ 20-S, PN 371 858 99 and ROV 20-PS, PN 512 005 98 2 x BUZ 28-L, PN 371 858 99 and 2 x ROV 28-PL, PN 509 377 98 BUZ 35-L, PN 371 859 99 and ROV 35-PL, PN 516 770 98 Superstructure without counterweight, attachment and fluids: 110,500 kg Dogman/rigger Crane operators trained in dual crane lift

z


z




z


3 - 232

Superstructure


z

Relief pressure in the track tensioning system, refer to the PART & SERVICE BULLETIN No. "AH06530".

z


z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP". WARNING

Always wear a safety harness when working in height.

Fig. 3-202

3 - 233


Fig. 3-203 Superstructure lifting z

Remove the counterweight from the superstructure, refer to section 3.8.1 on page 3-229.

z

Remove the complete attachment, refer to section 5.1 on page 5-2.

z

Disconnect all hydraulic hoses leading to the superstructure from the rotary joint, refer to section 4.2.5.1 on page 4-76.

3 - 234

Superstructure

Superstructure


WARNING Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

z

Attach the superstructure to two cranes.

z

Remove all bolts (Fig. 3-203, Pos. 1) and washers (Fig. 3-203, Pos. 2) attaching the slew ring to the undercarriage.

z

Lift off the superstructure using the two cranes and rest it on wooden blocks 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.

3.9.2

INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 795 922 73 55 mm hexagon impact socket wrench (1"), PN 232 264 40 Gauge device for testing bolts M36, PN 376 762 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform 2x crane Compound "KP2K", PN 324 969 40 2 thread pins (M 36 x 200) Superstructure without counterweight, attachment and fluids: 110,500 kg Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

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.

3 - 235


Superstructure

Fig. 3-204 Superstructure lifting z

Clean the contact surfaces of the slew ring and the undercarriage very carefully and thoroughly. WARNING

Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

z

Attach the superstructure to two cranes and lift it up. Refer to Fig. 3-204.

3 - 236

Superstructure


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 punchmarked with an "S" at the inner resp. outer side of each slew ring (Fig. 3-205, Pos. 1 and 2). z

Align the spots (Fig. 3-205, Pos. S) to each other.

z

Prepare new bolts and sleeves. Lubricate the threads and the head surface of the bolts with compound "KP2K", PN 324 969 40.

Fig. 3-205 z

Remove the torque support lever of the rotary joint before installing the superstructure, refer to section 4.2.5.1 on page 4-76.

z

Align the superstructure to the undercarriage and lower the superstructure.

z

To simplify the alignment of the slew ring to the undercarriage, install two thread pins (M 36 x 200) displaced by 180° at the outer slew ring.

z

Insert 4 bolts (Fig. 3-204, Pos. 1) with washers (Fig. 3-204, Pos. 2) displaced by 90° and lower the superstructure.

z

Remove the two thread pins from the outer slew ring.

z

Install all remaining bolts and tight them manually. Tighten all bolts crosswise to the required torque, refer to PART & SERVICE BULLETIN No. "AH00511d" last edition.

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. WARNING

Make sure to use the specified bolts and torque for the torque support lever mounting bolts, refer to section 4.2.5.2 on page 4-79.

z


3 - 237

Fuel Tank

Superstructure

3.10 FUEL TANK

Fig. 3-206 Fuel tank, overview (1)

Fuel tank

(2)

Breather valve

(3)

Fuel shut-off cock

(4)

Drain plug (to drain fuel, water, and sediments)

(5)

Shut-off cock for pressure transducer

(6)

Pressure transducer for fuel level indication

3 - 238

Superstructure

Fuel Tank

3.10.1 REMOVAL OF THE FUEL TANK Special tools:



Safety harness in conformity with DIN EN 361 Mobile elevator working platform Empty fuel starage tank Crane Blind plugs: BUZ 28-L, PN 371 858 99 and ROV 28-PL, PN 509 377 98 BUZ 35-L, PN 371 859 99 and ROV 35-PL, PN 516 770 98 2 x BUZ 42-L, PN 371 860 99 and 2 x ROV 42-PL, PN 513 790 98 Fuel tank (empty): 3,600 kg

Dogman/rigger

z


z




Always wear a safety harness when working at the fuel tank..

z

Remove the operator’s cab (Fig. 3-207, Pos. 3), refer to section 3.7.1 on page 3-199.

z

Remove the handrails (Fig. 3-207, Pos. 1), the handelbar (Fig. 3-207, Pos. 2), and the gratings from the fuel tank.

NOTE: For safety, the handrail (Fig. 3-207, Pos. 3) at the steps will not be removed.

Fig. 3-207 z

Open the hinged cover below the fuel tank.

3 - 239

Fuel Tank

z

Superstructure

Attach a drain hose and open drain coupling (Fig. 3-206, Pos. 4). Drain fuel, approx. 6400 liters (max.).

DANGER Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result. DO NOT smoke or use an open flame when working around inflammable fuels.

z

Disconnect the harness connectors (Fig. 3-208, Pos. 1) from the cab base.

z

Pull the harnesses out of the cable channels of the cab base (Fig. 3-208, Pos. 2) and of the tank (Fig. 3-209, Pos. 1). Z 26172

Fig. 3-208 z

Remove the brackets and clear all hoses (Fig. 3-209, Pos. 2 and 3) from the tank.

z

Disconnect all fuel lines from the tank. DANGER

Danger of fuel pressure! May result serious injury, permanent disfigurement and scarring, or death! Fuel lines are pressurized by hydrostatic pressure due to the unknown amount of fuel in the tank. Be sure that the fuel is completely drained before opening any fuel lines.

NOTE: When the fuel hoses are disconnected, the fuel inside the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Open the clamps and clear the hoses of the air conditioning from the tank.

3 - 240

Z 26173

Fig. 3-209

Superstructure

Fuel Tank

z

Disconnect the wire harness connectors B63 and Y99 (Fig. 3-210).

z

Attach the fuel tank to a crane.

Fig. 3-210 z

Remove the mounting bolts (Fig. 3-211, Pos. 1) and lift the fuel tank (Fig. 3-211, Pos. 5) from the machine. Discard the mounting bolts (Fig. 3-211, Pos. 1). DANGER

Risk of falling weights! May result in death or serious injury When moving fuel tank, make sure that nobody steps below the lifted fuel tank.

z

Dismantle the handrail at the steps.

z

If required, remove all plugs (Fig. 3-211, Pos. 2) and the plate (Fig. 3-211, Pos. 3). Discard the gasket (Fig. 3-211, Pos. 4).

Fig. 3-211

3 - 241

Fuel Tank

Superstructure

3.10.2 REPLACEMENT OF THE FUEL TANK Special tools:



Safety harness in conformity with DIN EN 361 Mobile elevator working platform Crane Fuel tank (empty): 3,600 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the fuel tank.

z

If required, install all plugs (Fig. 3-212, Pos. 2) and the plate (Fig. 3-212, Pos. 3) to the new tank.

NOTE: Use a new gasket (Fig. 3-212, Pos. 4). Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. z

Install the handrail at the steps at first.

z


Fig. 3-212

3 - 242

Superstructure

Fuel Tank

NOTE: Use new mounting bolts (Fig. 3-212, Pos. 1) of grade 10.9 and tighten them to the specified torque. Tightening torque for the fuel tank mounting bolts (Fig. 3-211, Pos. 1): 1770 Nm. Refill the fuel tank, approx. 6400 liters.

z



z


z




z


z




3 - 243

Fuel Tank

Superstructure


3 - 244

Undercarriage

4 UNDERCARRIAGE

4 -1

Travel System

Undercarriage

4.1

TRAVEL SYSTEM

4.1.1

TRACK GROUP

4.1.1.1 CHANGING OF THE TRACK GROUP Special tools:

n/a


Dozer Chain hoist Slide hammer Welding equipment Brass drift Track group 1500 mm: 27,510 kg Track group 1200 mm: 25,100 kg Pin: 13.3 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: Make sure that the waer of the track group was measured according to the PART & SERVICE BULLETIN No. "AH02521". z

Prepare an area of flat ground twice as large to accommodate the machine, the boom and the dozer.

z




z

Relieve pressure in the track tensioning system, refer to the PART & SERVICE BULLETIN No. "AH06530".

NOTE: Make sure that the slack in the track group is at the lower part of the guide wheel.

4 -2

Undercarriage

z

Travel System

Flame-cut the nuts (Fig. 4-1, Pos. 3) from the locking bolts (Fig. 4-1, Pos. 1). Remove the locking bolts (Fig. 4-1, Pos. 1), washers (Fig. 4-1, Pos. 2), and nuts (Fig. 4-1, Pos. 3) from one track shoe (Fig. 4-1, Pos. 5). WARNING

Ensure nothing flammable is in the working area when flamecutting the nuts.

z

Pull out two pins (Fig. 4-1, Pos. 4) to open the track group using a sliding hammer.

Fig. 4-1

NOTE: Open the track group at the guide wheel. 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. DANGER

Danger of getting overrunned 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. 4-2 z

Drive the excavator and the dozer backwards slowly and reroll the track group from the excavator (Fig. 4-2).

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.

4 -3

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. 4-3. z

Align the new track group on the ground behind the old track group.

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 overrunned 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. 4-3

z

Drive the excavator and the dozer foreward slowly and pick up the track group with the sprocket.

z

Continue to drive the excavator and the dozer foreward slowly to pull up the track group (Fig. 4-4).

NOTE: Assure that excavator and dozer have the same speed.

Fig. 4-4 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. 4-5.

z

Unchain the dozer.

Fig. 4-5 4 -4

Undercarriage

Travel System

z

Align the holes (Fig. 4-6, Pos. 3) in the two open track shoes (Fig. 4-6, Pos. 2) in front of the guide wheel (Fig. 4-6, Pos. 1) using a hoist.

z

Insert the pins (Fig. 4-7, Pos. 4) into the holes (Fig. 4-6, Pos. 3).

Fig. 4-6 z

Install the locking bolts (Fig. 4-7, Pos. 1), washers (Fig. 4-7, Pos. 2), and nuts (Fig. 4-7, Pos. 3) to the track shoes (Fig. 4-7, Pos. 5).

z

Weld the nuts (Fig. 4-7, Pos. 3) to the bolts (Fig. 4-7, 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 REPAIR". Fig. 4-7

CAUTION The bolts (Fig. 4-8, Pos. 1) lock the pins (Fig. 4-8, 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. 4-8, arrow) of the bolt heads are marked.

Fig. 4-8

4 -5

Travel System

4.1.2

Undercarriage

SPROCKET

4.1.2.1 REMOVAL OF THE SPROCKET Special tools:

n/a


Personal Protective Equipment (PPE) 2 x Crane Pulling bolts M30 Sprocket: 3050 Kg Hollow shaft: 360 kg Drive shaft: 630 kg

Dogman/rigger

NOTE: Only for removal of the sprocket it is not necessary to remove the travel gear. If changing the sprocket (Fig. 4-9, Pos. 2) it is recommended to change the flange bearings (Fig. 4-9, Pos. 1 + Pos. 3) too. Therefor the travel gear (Fig. 4-9, Pos. 4) has to be removed, refer to section 4.1.11.1 on page 4-43.

Fig. 4-9 WARNING Ensure appropriate (PPE) Personal Protective Equipment is used for handing during the task. There maybe sharp edges on the worn sprocket that is being removed.

4 -6

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.

Travel System



z


Drain oil of the final drive housing, approx. 145 liters. Refer to Operation & Maintenance Manual, chapter 4, section "FINAL DRIVE HOUSINGS - CHANGE OIL". z

Open the track group at the sprocket end, refer to section 4.1.1.1 on page 4-2.

NOTE: Track group does not have to be fully removed to remove sprocket. If the track group is opened at the sprocket end the machine can be driven forward and the upper end of the track tied to the rear carrier roller. Machine then can be driven backwards so that the lower end of the track is located under the rear track roller next to the sprocket. Carry out this steps according to section 4.1.1.1 on page 4-2.. z

Sling sprocket (Fig. 4-10).

NOTE: The travel parking brake may need to be released to allow sprocket to turn slightly to find centre of gravity.

Fig. 4-10

4 -7

Travel System

Undercarriage

Fig. 4-11 Removal of the sprocket z

Remove the bolts (Fig. 4-11, Pos. 1) and the cover (Fig. 4-11, Pos. 10).

NOTE: When the cover is removed, oil may flow out. Catch it in an oil pan. z

Discard the O-ring (Fig. 4-11, Pos. 9).

z

Pull the drive shaft (Fig. 4-11, Pos. 6) out of the hollow shaft (Fig. 4-11, Pos. 5). WARNING

Sling the drive shaft as soon as it it possible and support it using a crane to prevent the shaft from falling.

DANGER Risk of falling weights! May result in death or serious injury When lifting the drive shaft, make sure that nobody steps below the weight.

4 -8

Undercarriage

Travel System

CAUTION Make sure that the hollow shaft (Fig. 4-11, Pos. 5) is not weight loaded before removing the flange bearing (Fig. 4-11, Pos. 8).

z

Remove mounting bolts (Fig. 4-11, Pos. 1) and extract the flange bearing (Fig. 4-11, Pos. 8) including bush (Fig. 4-11, Pos. 7) from the crawler carrier using pulling bolts

z

Extract the hollow shaft (Fig. 4-11, Pos. 5) from the sprocket (Fig. 4-11, Pos. 3) and remove it using a crane. WARNING

Sling the drive shaft as soon as it it possible and support it using a crane to prevent the shaft from falling.

DANGER Risk of falling weights! May result in death or serious injury When lifting the hollow shaft, make sure that nobody steps below the weight.

z

Lift the sprocket out of the crawler carrier. DANGER

Risk of falling weights! May result in death or serious injury When lifting the sprocket, make sure that nobody steps below the weight.

z

Discard the dual-cone seals (Fig. 4-11, 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 BULLETIN No. "AH05511".

4 -9

Travel System

Undercarriage

4.1.2.2 REPLACEMENT OF THE SPROCKET Special tools:

Assembly tool for dual-cone seals (locally made)


2 x Crane Sprocket: 3050 kg Hollow shaft: 360 kg Drive shaft: 630 kg

Dogman/rigger


Fig. 4-12 Replacement of the sprocket NOTE: Before reassembly of the sprocket, the axial play has to be determined, refer to PARTS & SERVICE BULLETIN No. "AH00514". Adjust the axial play if necessary, refer to PARTS & SERVICE BULLETIN No. "AH00514".

4 - 10

Undercarriage

Travel System

NOTE: For mounting the dual-cone seals (Fig. 4-11, Pos. 2 and Pos. 4), an assembly tool has to be manufactured, refer to PARTS & SERVICE BULLETIN No. "AH05511". z

Mount new dual-cone seals (Fig. 4-11, Pos. 2 and Pos. 4) into the flange bearing on the gear side and into the flange bearing (Fig. 4-11, Pos. 8) on the opposite side, refer to PARTS & SERVICE BULLETIN No. "AH05511".

z

Mount new dual-cone seals (Fig. 4-11, Pos. 2 and Pos. 4) into the sprocket hub, refer to PARTS & SERVICE BULLETIN No. "AH05511".

z


NOTE: Use new mounting bolts (Fig. 4-11, Pos. 1) of grade 8.8 with washers and nuts to attach the flange bearing (Fig. 4-11, Pos. 8) with bush (Fig. 4-11, Pos. 7) to the track frame and tighten the bolts to the specified torque. Tightening torque for flange bearing mounting bolts (Fig. 4-11, Pos. 1): 1250 Nm

Refill oil in the final drive housing, approx. 145 liters. Refer to Operation & Maintenance Manual, chapter 4, section "FINAL DRIVE HOUSING - CHANGE OIL".

4 - 11

Travel System

4.1.3

Undercarriage

GUIDE WHEELS

4.1.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY Special tools:

Safety unit for changing track rollers, PN 921 159 40


Crane Guide wheel assembly: 2350 kg

Dogman/rigger

z


z




z


z

Remove the track group from the guide wheel, refer to section 4.1.1.1 on page 4-2.

z

Remove bolts (Fig. 4-13, Pos. 2), washers (Fig. 4-13, Pos. 1) and remove the stop plates (Fig. 4-13, Pos. 3) from both sides of the guide wheel assembly (Fig. 4-13, Pos. 4).

z

De-isolate the machine according to local regulations.

z

Jack up the machine with the work equipment and secure the machine using the safety unit for changing track rollers, PN 921 159 40 and lower the machine, according to section 4.1.13.1 on page 4-49.

z

Isolate the machine according to local regulations. Fig. 4-13

4 - 12

Undercarriage

z

Travel System

Sling guide wheel assembly (Fig. 4-14) and pull the guide wheel assembly out of the crawler carrier. WARNING

Ensure to keep hands away for the component sliding surfaces during removal.

Fig. 4-14

4.1.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY Special tools:

n/a


Crane Guide wheel assembly: 2350 kg

Dogman/rigger



NOTE: Observe the mounting position of the sliding blocks (Fig. 4-15, Pos. 3). Assure that the oil plug (Fig. 4-15, Pos. 2) at the guide wheel (Fig. 4-15, Pos. 1) is facing the inner side of the excavator.

Fig. 4-15

4 - 13

Travel System

4.1.4

Undercarriage

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. 4-16, Pos. 1 and 2). Two different types of pressure accumulators are installed: A high pressure (150 bar) bladder accumulator (Fig. 4-16, Pos. 1) and a low pressure (31 bar) diaphragm type accumulator (Fig. 4-16, Pos. 2). Fig. 4-16

4.1.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS Special tools:

n/a


Oil drain pan Blind plugs: BUZ 20-S, PN 371 853 99 and ROV 20-PS, PN 512 005 98 Low pressure accumulator: 12 kg

z


z

Remove the cover (Fig. 4-17, Pos. 1).

z

Relieve pressure in the track tensioning system, refer to the PART & SERVICE BULLETIN No. "AH06530". 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. Fig. 4-17 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.

4 - 14

Undercarriage

z

Travel System

Disconnect the pressure hose (Fig. 4-18, 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. 4-18, Pos. 2) and remove the pressure accumulator (Fig. 4-18, Pos. 3).

z

Remove socket (Fig. 4-18, Pos. 4) and union (Fig. 4-18, Pos. 5).

Fig. 4-18

4 - 15

Travel System

Undercarriage

4.1.4.2 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 DIN, refer to section 2.3 on page 2-29.

z


z

Fill the pressure accumulator with nitrogen gas (N2). Refer to PARTS & SERVICE BULLETIN No. "AH01531A". DANGER

Danger of explosion! May result in blindness, serious injury, permanent disfigurement, scaring, or death. 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 Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z


z

Check the track tension system and adjust if required. Refer to Service Manual for further information.

4 - 16

Undercarriage

Travel System

4.1.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS Special tools:

n/a


Blind plugs: BUZ 25-S, PN 371 867 99 and ROV 25-PS, PN 508 033 98 High pressure accumulator: 23 kg

z


z




z

Disconnect the pressure hose assembly (Fig. 4-19, 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. 4-19, Pos. 2) and remove the pressure accumulator (Fig. 4-19, Pos. 3).

z

Remove the union (Fig. 4-19, Pos. 4) from the pressure accumulator (Fig. 4-19, Pos. 3).

Fig. 4-19

4 - 17

Travel System

Undercarriage

4.1.4.4 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 DIN, refer to section 2.3 on page 2-29.

z


z

Fill the pressure accumulator with nitrogen gas (N2). Refer to PARTS & SERVICE BULLETIN No. "AH01531A". DANGER

Danger of explosion! May result in blindness, serious injury, permanent disfigurement, scaring, or death. Only fill pressure accumulators with nitrogen gas (N2). Do not use any other gases due to explosion hazard!

z


z


z

Check the track tension system and adjust if required. Refer to the Service Manual for further information.

4 - 18

Undercarriage

4.1.5

Travel System

TRACK TENSION VALVE BLOCK

4.1.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK Special tools:

n/a


Chain host Oil drain pan Blind plugs: 5 x BUZ 20-S, PN 371 853 99 and 5 x ROV 20-PS, PN 512 005 98 2 x BUZ 15-L, PN 371 855 99 and 2 x ROV 15-PL, PN 507 051 98 Track tensioning valve block: 40 kg

z


z




z

Disconnect all piping (Fig. 4-20, Pos. 2) from the track tensioning valve block (Fig. 4-20, 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. 4-20, Pos. 1).

z

Remove four mounting bolts and let down the track tensioning valve block (Fig. 4-20, Pos. 1) using the chain hoist.

Fig. 4-20

4 - 19

Travel System

Undercarriage

z

Remove the pressure increase valve (Fig. 4-21, Pos. 1) from the track tensioning valve block.

z

Remove the check valves (Fig. 4-21, Pos. 2) from the track tensioning valve block.

z

Remove the unions (Fig. 4-21, Pos. 3) from the track tensioning valve block.

Fig. 4-21

4.1.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK Special tools:

n/a


Chain host Track tensioning valve block: 40 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

z


z


z


z

Check the track tension system and adjust if required. Refer to the Service Manual for further information.

4 - 20

Undercarriage

4.1.6

Travel System

HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM

4.1.6.1 SUBSTITUTE THE HYDRAULIC HOSES Special tools:

n/a


Oil drain pan Blind plugs (per hose): 2 x BUZ 16-S, PN 371 866 99 and 2 x ROV 15-PL, PN 507 051 98 Hydraulic hose: 23 kg max. If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

z

Prepare an area of flat ground large enough to accommodate the machine.

z


z


z

Relief pressure in the track tensioning system, refer to the PART & SERVICE BULLETIN No. "AH06530". WARNING



NOTE: In the following descriptions, the hydraulic hoses are replaced one at a time.

4 - 21

Travel System

Fig. 4-22 Hydraulic hoses of the track tensioning system

4 - 22

Undercarriage

Undercarriage

Travel System

Replacing the hydraulic hoses (Fig. 4-22, Pos. 1): z


z

Clear the hydraulic hose to be removed by opening the clamp (Fig. 4-22, Type. D).

z

Disconnect both ends of the hydraulic hose to be removed.

NOTE: When the hose is disconnected, hydraulic oil from inside the piping and/or the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Pull out the hydraulic hose compleately.

z

Insert a new hydraulic hose. Slide the new hydraulic hose through the hose (Fig. 4-22, Pos. 7) at the joint (Fig. 4-22, Type. A) between car body and crawler carrier.

z

Reinstall the cover (Fig. 4-23, Pos. 1).

Fig. 4-23

Replacing the hydraulic hoses (Fig. 4-22, Pos. 3, 4 and 6): z


z

Remove the cover (Fig. 4-24, Pos. 2) only if the hoses for the track tensioning cylinders will be repleaced.

z

Disconnect both ends of the hydraulic hose to be removed and replace the hose by a new one.

NOTE: When the hose is disconnected, hydraulic oil from inside the piping and/or the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Fig. 4-24 z

Reinstall the cover(s) (Fig. 4-24, Pos. 1, 2).

Replacing the hydraulic hoses (Fig. 4-22, Pos. 2 and 5): z

Disconnect both ends of the hydraulic hose to be removed and replace the hose by a new one.

NOTE: When the hose is disconnected, hydraulic oil from inside the piping and/or the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

4 - 23

Travel System

Subsequent work z


z


z

Check the track tension system and adjust if required. Refer to the Service Manual for further information

4.1.7

TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE)

Fig. 4-25 Travel brake valve blocks (1)

Travel brake valve block

(2)

Travel motor

The travel brake valve blocks (Fig. 4-25, Pos. 1) protect the travel motors (Fig. 4-25, Pos. 2) from overspeed during downhill travel. Two travel brake valve blocks are installed, one valve block for each travel motor.

4 - 24

Undercarriage

Undercarriage

Travel System

4.1.7.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK Special tools:

n/a


Chain hoist Oil drain pan Blind plugs: BUZ 10-L, PN 371 852 99 and ROV 10-PL, PN 513 789 98 4 x SAE A1 1/2-6000, PN 506 581 98 4 x SAE B1 1/2-6000, PN 506 526 98 Travel brake valve block: 95 kg

z


z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM". WARNING



4 - 25

Travel System

z

Disconnect the pressure hoses (Fig. 4-26, Pos. 2) to the rotary joint from the travel brake valve block (Fig. 4-26, Pos. 1).

z

Disconnect the hydraulic lines (Fig. 4-26, Pos. 5) to the travel motors from the travel brake valve block (Fig. 4-26, Pos. 1).

z

Disconnect the leakage oil line from the travel brake valve block (Fig. 4-26, Pos. 1).

Undercarriage

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. 4-26, Pos. 3).

z

Sling the travel brake valve block (Fig. 4-26, Pos. 1) at the installed hoist rings.

z

Remove the mounting bolts (Fig. 4-26, Pos. 4) and lift off the travel brake valve block (Fig. 4-26, Pos. 1) using a chain hoist..

z

Remove the relief valve (Fig. 4-27, Pos. 1) from the travel brake valve block (Fig. 4-27, Pos. 2).

Fig. 4-26

Fig. 4-27

4 - 26

Undercarriage

Travel System

4.1.7.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK Special tools:

n/a


Chain hoist Travel brake valve block: 95 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

z


NOTE: Tighten the relief valve (Fig. 4-27, Pos. 1) to the specified torque. Tightening torque for relief valve (Fig. 4-27, Pos. 1): 300 Nm z


z

Add hydraulic oil up to the specified level

z

Check the travel system and adjust if required. Refer to the Service Manual for further information.

4 - 27

Travel System

4.1.8

Undercarriage

TRACK TENSIONING CYLINDERS

4.1.8.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS Special tools:

n/a


Crane Oil drain pan Blind plugs: BUZ 20-S, PN 371 853 99 and ROV 20-PS, PN 512 005 98 Track tension cylinder: 230 kg each

Dogman/rigger

z


z




z

Relief pressure in the track tensioning system, refer to the PART & SERVICE BULLETIN No. "AH06530".

z

Remove the guide wheel assembly, refer to section 4.1.3.1 on page 4-12.

z

Remove the cover (Fig. 4-28, Pos. 1). WARNING


Fig. 4-28

4 - 28

Undercarriage

Travel System


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 cylinder and pull the cylinder out of its guidance.

4.1.8.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS Special tools:

n/a


Crane Track tension cylinder: 230 kg each

Dogman/rigger



z


z


z

Check the track tensioning system and adjust if required. Refer to the Service Manual for further information.

4 - 29

Travel System

4.1.9

Undercarriage

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.

4.1.9.1 REMOVAL OF THE TRAVEL MOTORS Special tools:

n/a


Crane Oil drain pan Blind plugs: BUZ 28-L, PN 371 858 99 and ROV 28-PL, PN 50937798 2 x SAE A1 1/2-6000, PN 506 581 98 2 x SAE B1 1/2-6000, PN 506 528 98 Travel motor: 161 kg

Dogman/rigger

z


z




z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM". Drain oil of the motor adapter housing, approx. 0.6 liters. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL".

4 - 30

Undercarriage

Travel System



z

Mark and remove the pressure hoses (Fig. 4-29, Pos. 1) and the leak oil hose (Fig. 4-29, Pos. 4) from the travel motor (Fig. 4-29, 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 (Fig. 4-29, Pos. 2).

Fig. 4-29 z

Sling travel motor (Fig. 4-30, Pos. 1) and remove the mounting bolts (Fig. 4-30, Pos. 2). Discard the bolts.

z

Using a crane, remove travel motor (Fig. 4-30, Pos. 1) by pulling it out of the motor adapter housing (Fig. 4-30, Pos. 3) of the travel parking brake. DANGER

Risk of falling weights! May result in death or serious injury When lifting the travel motor, make sure that nobody steps below the weight. Fig. 4-30

4 - 31

Travel System

Undercarriage

4.1.9.2 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 DIN, refer to section 2.3 on page 2-29. 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 (Fig. 4-31, Pos. 1) before attaching the travel motor to the motor adapter housing (Fig. 4-31, Pos. 3).

Fig. 4-31 z


NOTE: Use new mounting bolts (Fig. 4-31, Pos. 2) of grade 8.8 and tighten to the specified torque. Tightening torque for travel motor mounting bolts: 360 Nm z

Add hydraulic oil up to the specified level. Refill oil of the motor adapter housing, approx. 0.6 liters. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL".

4 - 32

Undercarriage

Travel System


4 - 33

Travel System

4.1.10 TRAVEL PARKING BRAKE

Fig. 4-32 Travel parking brake assembly

4 - 34

Undercarriage

Undercarriage

Travel System


Radial seal rings

(2)

Retainer

(3)

Springs

(4)

O-ring

(5)

Piston

(6)

Plug screw

(7+8)


(9)

Control pressure port to release the brake

(10+11)


(12)

O-ring

(13)

Intermediate ring

(14)

Outer discs (lamellas)

(15)

Inner discs

(16)

Outer disc carrier

(17)

O-ring

(18)

Snap ring

(19)

Bolt

(20)

Retainer

(21)

O-ring

(22+25)

Snap ring

(23)

Inner disc carrier

(24)

Radial seal ring

Brake applied: The outer discs (Fig. 4-32, Pos. 14) engaged to the housing by serration and the inner discs (Fig. 4-32, Pos. 15) in serration connection with the disc carrier are pressed together by the springs (Fig. 4-32, Pos. 3). This results in a fixed connection between housing and disc carrier (Fig. 4-32, Pos. 23). Brake released: Oil pressure via the control pressure port (Fig. 4-32, Pos. 9) forces the piston (Fig. 4-32, Pos. 5) against the springs (Fig. 4-32, Pos. 3) toward the retainer (Fig. 4-32, Pos. 2). This function eliminates the spring force onto the discs, thus the brake is released. The minimum release pressure is 21-23 bar, the maximum permissible pressure is 100 bar.

4 - 35

Travel System

Undercarriage


4 - 36

Undercarriage

Travel System

4.1.10.1 REMOVAL/DISASSEMBLY OF THE TRAVEL PARKING BRAKE Special tools:

n/a


Hydraulic power unit (100 bar) with fitting (M22 x 1.5) Oil drain pan Blind plugs: BUZ 15-L, PN 371 855 99

NOTE: The travel parking brake is removed by disassembling it. 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. 0.5 liters. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL".

NOTE: The brakes must be released for draining the oil. 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

Remove the travel motor, refer to section 4.1.9.1 on page 4-30. WARNING



4 - 37

Travel System

Undercarriage

Fig. 4-33 z

Disconnect the hydraulic control pressure hose from the travel parking brake. Connect a hydraulic power unit to the port (Fig. 4-33, Pos. 9).

NOTE: When the control pressure hose is removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the opening in the hose with a blind plug to avoid contamination. z

Apply pressure (23...100 bar) to the control pressure port of the travel parking brake to release the brake. WARNING

Make sure that the brake is released before removing the snap ring (Fig. 4-33, Pos. 18). Otherwise the snap ring (Fig. 4-33, Pos. 18) is pre-stressed (spring loaded).

4 - 38

Undercarriage

z

Remove the snap ring (Fig. 4-33, Pos. 18).

z

Slowly relief the pressure at the control pressure port (Fig. 4-33, Pos. 9). Check if the retainer (Fig. 4-33, Pos. 20) slides smooth and does not cant.

z

Take off the retainer (Fig. 4-33, Pos. 20) and the O-ring (Fig. 4-33, Pos. 17)

z

Check radial shaft seals (Fig. 4-33, Pos. 24) for wear and damage. Replace if required.

z

Dismount 8 outer discs (Fig. 4-33, Pos. 14) and 7 inner discs (Fig. 4-33, Pos. 15) from the disc carriers (Fig. 4-33, Pos. 16 and Fig. 4-33, Pos. 23).

z

Check inner discs (Fig. 4-33, Pos. 15) and outer discs (Fig. 4-33, Pos. 14) for wear and damage. Replace if required.

z

Remove the first snap ring (Fig. 4-33, Pos. 25), the inner disc carrier (Fig. 4-33, Pos. 23) and than the second snap ring (Fig. 4-33, Pos. 22).

z

Remove the bolts (Fig. 4-33, Pos. 19) and take off the outer disc carrier (Fig. 4-33, Pos. 16).

z

Remove the intermediate ring (Fig. 4-33, Pos. 13) and take off the the quad-ring (Fig. 4-33, Pos. 11) with the back-up rings (Fig. 4-33, Pos. 10) in front and behind.

z

Remove the piston (Fig. 4-33, Pos. 5) and take off the quadring (Fig. 4-33, Pos. 8) with the back-up rings (Fig. 4-33, Pos. 7) in front and behind.

z

Remove the retainer (Fig. 4-33, Pos. 2) and check radial shaft seals (Fig. 4-33, Pos. 1) for wear and damage. Replace if required.

Travel System

4 - 39

Travel System

Undercarriage

4.1.10.2 REPLACEMENT/ASSEMBLY OF THE TRAVEL PARKING BRAKE Special tools:

n/a


Hydraulic power unit (100 bar) with fitting (M22 x 1.5) Paste "Optimol White" PN 999 039 If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

Fig. 4-34

4 - 40

Undercarriage

Travel System

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Replace all O- and quad-rings. z

Carry out assembly in reverse order to disassembly. z

Apply oil at the discs (Fig. 4-34, Pos. 2 and 3).

z

Before fixing the retainer (Fig. 4-34, Pos. 5) with the snap ring (Fig. 4-34, Pos. 4), apply pressure (min. 23 bar) to the brake assembly by the release control pressure port (Fig. 4-34, Pos. 1). The Brake must be released, otherwise the snap ring (Fig. 4-34, Pos. 4) can not get into its groove.

NOTE: Apply "Optimol White" at the spline shaft of the travel motor. z

Add hydraulic oil up to the specified level. Refill oil in the motor adapter housing, approx. 0.6 liters. Refill oil in the brake housing, approx. 0.5 liters. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL".

NOTE: Filling of the brake housing has to be done with the engine stopped and the brakes applied to prevent overfilling. Be sure to fill the brake housing and motor adapter housing with engine oil or hydraulic oil as specified, refer to section 6.1 on page 6-2. z

Perform a function check of the travel parking brake. Refer to the Service Manual for further information.

4 - 41

Travel System

4.1.11 TRAVEL GEARBOX

Fig. 4-35 Travel gearbox removal (1)

Drive shaft

(2)

O-ring

(3)

Travel gearbox

(4)

Travel motor

(5)

Mounting bolts for travel motor

(6, 7, 8)

Mounting bolts, nuts, and washers for travel gear to crawler carrier

(9)

Crawler carrier

4 - 42

Undercarriage

Undercarriage

Travel System

4.1.11.1 REMOVAL OF THE TRAVEL GEARBOX Special tools:

n/a


Crane Oil drain pan Blind plugs: BUZ 15-L, PN 371 855 99 and ROV 15-PL, PN 507 051 98 Travel gearbox: 2990 kg

Dogman/rigger

z


z


NOTE: If the ground condition is too poor to garantee 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

Place wedges at front and rear side of both crawlers and lower the bucket onto the ground. Drain oil of the motor adapter housing, approx. 0.6 liters, and of the brake housing, approx. 0.5 liters. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL".

NOTE: The brakes must be released for draining the oil. z


z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM". Drain oil of the final drive housing, approx. 145 liters and of the travel gear housing, approx. 155 liters. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL" and "FINAL DRIVE HOUSINGS - CHANGE OIL".

4 - 43

Travel System

Undercarriage



z

Remove the travel motor (Fig. 4-36, Pos. 2) with the pressure hoses connected, refer to section 4.1.9.1 on page 4-30.

z

Remove breather hoses from the motor adapter housing (Fig. 4-36, Pos. 3), the travel gearbox (Fig. 4-36, Pos. 5), and from the final drive housing (Fig. 4-36, Pos. 6)

z

Remove the pressure hose from the travel parking brake (Fig. 4-36, Pos. 1).

NOTE: When the pressure hose is 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

Remove the driving performance meter (Fig. 4-36, Pos. 4) and cap the opening to avoid contamination.

z

Sling the travel gearbox (Fig. 4-37, Pos. 1) at the installed hoist ring (Fig. 4-37, Pos. 1).

z

Remove the mounting bolts (Fig. 4-37, Pos. 2) with nuts (Fig. 4-37, Pos. 5) and washers (Fig. 4-37, Pos. 4). Discard the bolts, nuts and washers.

z

Extract the travel gearbox (Fig. 4-37, Pos. 1) from the crawler carrier (Fig. 4-37, Pos. 6) using a crane.

Fig. 4-36

DANGER Risk of falling weights! May result in death or serious injury When lifting the travel gearbox, make sure that nobody steps below the weight. Fig. 4-37 z

Remove the O-ring (Fig. 4-37, Pos. 3) and discard it.

4 - 44

Undercarriage

Travel System

4.1.11.2 REPLACEMENT OF THE TRAVEL GEARBOX Special tools:

n/a


Crane Paste "Optimol White" PN 999 039 Travel gearbox: 2990 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Apply "Optimol White" at the drive shaft (Fig. 4-38, Pos. 1).

z

Insert a new O-ring (Fig. 4-38, Pos. 2).

z

Align the travel gearbox (Fig. 4-38, Pos. 3) to the drive shaft (Fig. 4-38, Pos. 1) and flange it to the crawler carrier.

z

Insert new mounting bolts (Fig. 4-38, Pos. 4) of grade 10.9, new nuts (Fig. 4-38, Pos. 6), as well as washers (Fig. 4-38, Pos. 5) and tighten to the specified torque.

z

Tightening torque for travel gearbox mounting bolts (Fig. 4-38, Pos. 4) and nuts: 3100 Nm z

Fig. 4-38

Carry out further installation in reverse order to removal. Refill oil in the final drive housing, approx. 145 liters, and in the travel gear housing, approx. 155 liters. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL" and "FINAL DRIVE HOUSINGS - CHANGE OIL".

NOTE: Be sure to fill in the correct oil as specified, refer to section 6.1 on page 6-2.

4 - 45

Travel System

Undercarriage

Refill oil in the motor adapter housing, approx. 0.6 liters, and oil in the brake housing, approx. 0.5 liters. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL". NOTE: Filling of the brake housing has to be done with the engine stopped and the brakes applied to prevent overfilling. Be sure to fill in the correct oil as specified, refer to section 6.1 on page 6-2. z

Perform a function check of the travel parking brake. Refer to the Service Manual for further information.

4.1.12 CARRIER ROLLER 4.1.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY Special tools:

n/a


Hydraulic jack 18 tonnes Forklift (as the most econimical device) Chain hoist Carrier roller assembly: 189 kg

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and forklift.

z




4 - 46

Undercarriage

Travel System

z


z

Using hydraulic jack (Fig. 4-39, Pos. 1), push up track shoe assembly (Fig. 4-39, Pos. 3) at the carrier roller assembly (Fig. 4-39, Pos. 2) to be removed.

NOTE: Fig. 4-39 shows the bolted crawler carrier, this step is accordingly identical for the crawler carrier with mounting pins.

Fig. 4-39 z

Carry out the following steps at the bolted crawler carrier only: z

Shove the forks (Fig. 4-40, Pos. 1) together that far, that the carrier roller (Fig. 4-40, 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. 4-40

z

Carry out the following step at the crawler carrier with mounting pins only: z

Sling the carrier roller assembly (Fig. 4-41, Pos. 1) at both sides and connect the slings to the forks (Fig. 4-41, Pos. 2) of a forklift.

Fig. 4-41 z

Remove the carrier roller assembly mounting bolts and lift off the carrier roller assembly using a 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.

4 - 47

Travel System

Undercarriage

4.1.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY Special tools:

n/a


Hydraulic jack 18 tonnes Forklift (as the most econimical device) Chain hoist Carrier roller assembly: 189 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

z


NOTE: Observe the mounting position of the carrier rollers. The oil plug must face the outside of the excavator. DANGER Danger of crush or pinch injuries to hands and fingers! Exercise extreme care when aligning the carrier roller assembly to the side frame.

4 - 48

Undercarriage

Travel System

4.1.13 TRACK ROLLER 4.1.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY Special tools:

Safety unit for changing track rollers, PN 921 159 40 Tool for changing track rollers, PN ??? (P&S-news in development)


Crane Track roller assembly: 466 kg

Dogman/rigger

z


z




z

Jack up the machine with the work equipment.

z

Support two track rollers with the safety unit for changing track rollers, PN 921 159 40 (Fig. 4-42, Pos. 1).

z

Lower the machine and place the work equipment on the ground.

z


z

Support the track roller assembly (Fig. 4-42, Pos. 2) from the bottom side with the changing tool for track rollers (Fig. 4-43).

z

Remove the track roller mounting bolts (Fig. 4-42, Pos. 3) and lower the tool. Fig. 4-42

4 - 49

Travel System

Undercarriage

NOTE: Make sure that both sides of the tool are balanced (e.g. with the new track roller assembly). z

Remove the track roller assembly. DANGER

Risk of falling weights! May result in death or serious injury When lifting the track roller, make sure that nobody steps below the weight.

NOTE: A PART & SERVICE BULLETIN for this tool is under development.

4 - 50

Fig. 4-43

Undercarriage

Travel System

4.1.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY Special tools:

Safety unit for changing track rollers, PN 921 159 40 Tool for changing track rollers, PN ??? (P&S-news in development)


Crane Track roller assembly: 466 kg

Dogman/rigger



NOTE: Observe the mounting position of the track rollers. The oil plug must face the outside of the excavator.

4 - 51

Car body

Undercarriage

4.2

CAR BODY

4.2.1

REMOVAL OF THE CAR BODY (PREVIOUS TYPE WITH MOUNTING PINS)

Special tools:

n/a


Crane Lift bar Oil drain pan Blind plugs: 2 x BUZ 16-S, PN 371 866 99 and 2 x ROV 15-PL, PN 507 051 98 Car body: 29,000 kg Crawler carrier assembly: 56,300 kg each (track widht 1200 mm) Crawler carrier assembly: 58,000 kg each (track widht 1500 mm)

Dogman/rigger

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. NOTE: Isolate the machine according to local regulations. z


z



4 - 52

Undercarriage

Car body


z

Remove the superstructure from the car body, refer to section 3.9.1 on page 3-232.

z

Disconnect all hydraulic lines from both travel motors, refer to section 4.1.9.1 on page 4-30.

z

Disconnect the hydraulic lines(Fig. 4-44, Pos. 1) from both travel parking brakes.

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.

Fig. 4-44 z

Disconnect all breather hoses from the travel motor adapterhousings, the travel gearboxes, and from the final drive housings.

z

Disconnect the pressure hoses (Fig. 4-45, Pos. 1) for the track tensioning from the shut-off cocks (Fig. 4-45, 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 the crawler carrier.

Fig. 4-45

4 - 53

Car body

z

Undercarriage

Attach the undercarriage to a crane (Fig. 4-46) and lift it up. DANGER

Risk of falling weights! May result in death or serious injury When lifting the undercarriage, make sure that nobody steps below the weight.

Fig. 4-46

Fig. 4-47 Crawler carrier mounting z

Rest the car body on appropriate stands so that all of the track rollers are clear of the track roller path. CAUTION

Stands need to be substantial enough to carry total weight of crawler carrier assemblies and carbody, total weight 145,000 kg.

4 - 54

Undercarriage

Car body

z

Attach the left crawler carrier assembly (Fig. 4-47, Pos. 1) to a crane.

z

Remove all bolts (Fig. 4-47, Pos 6) and the retainer plates (Fig. 4-47, Pos. 7).

z

Remove the nuts (Fig. 4-47, Pos. 2), the inner retainer plates (Fig. 4-47, Pos. 3), and the thread pins (Fig. 4-47, Pos. 4) only if required (changing to a replacement car body).

z

Pull out the four mounting pins (Fig. 4-47, Pos. 5) just enough to clear the crawler carrier assembly (Fig. 4-47, Pos. 1) from the car body as shown in (Fig. 4-47).

z

Remove the left crawler carrier assembly (Fig. 4-47, Pos. 1) using a crane. DANGER

Risk of falling weights! May result in death or serious injury When lifting the crawler carrier, make sure that nobody steps below the weight.

z

Carry out the same procedure to remove the right crawler carrier assembly.

z


Remove the rotary joint from the car body, refer to section 4.2.5.1 on page 4-76.

z

Remove the high pressure accumulators from the car body, refer to section 4.1.4.3 on page 4-17.

z

Remove the track tensioning valve from the car body, refer to section 4.1.5.1 on page 4-19.

z

Remove the travel brake valve blocks from the car body, refer to section 4.1.7.1 on page 4-25.

z

Remove all hydraulic hoses from the car body, refer to section 4.1.6.1 on page 4-21.

4 - 55

Car body

4.2.2

Undercarriage

REPLACEMENT OF THE CAR BODY (PREVIOUS TYPE WITH MOUNTING PINS)

Special tools:

Water level gauge


AL-Compound, PN 509 623 98 Car body: 29,000 kg Crawler carrier assembly: 56,300 kg each (track widht 1200 mm) Crawler carrier assembly: 58,000 kg each (track widht 1500 mm)

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. z

z


Install all hydraulic hoses into the new car body, refer to section 4.1.6.1 on page 4-21.

z

Install the rotary joint in the new car body, refer to section 4.2.5.2 on page 4-79.

z

Install the high pressure accumulators in the new car body, refer to section 4.1.4.4 on page 4-18.

z

Install the track tensioning valve in the new car body, refer to section 4.1.5.2 on page 4-20.

z

Install the travel brake valve blocks in the new car body, refer to section 4.1.7.2 on page 4-27.

z

Install new inner bushings (Fig. 4-48, Pos. 5) and new outer bushings (Fig. 4-48, Pos. 7) in the new car body.

z

Install the thread pins (Fig. 4-48, Pos. 4) and the inner retainer plates (Fig. 4-48, Pos. 3) with nuts (Fig. 4-48, Pos. 2) and washers at the new car body.

Align right crawler carrier horizontally (in both directions) very precisely.

NOTE: Use a water level gauge on the steel structure of crawler carrier (Fig. 4-48, Pos. 10) to align it. z

Attach the car body (Fig. 4-48, Pos. 1) to the crane. Fig. 4-48 DANGER

Risk of falling weights! May result in death or serious injury When lifting the car body, make sure that nobody steps below the weight.

4 - 56

Undercarriage

Car body

NOTE: The oil supply lines to the travel motors must be aligned in the direction of the travel motors. z

Align car body (Fig. 4-48, Pos. 1) with the right crawler carrier (Fig. 4-48, Pos. 10).

NOTE: Insert the hydraulic lines for track tensioning into the crawler carrier before installing it. z

Insert four mounting pins (Fig. 4-48, Pos. 6).

z

Install the retainer plates (Fig. 4-48, Pos. 9) and bolts (Fig. 4-48, Pos. 8) inclusive washers.

NOTE: Lubricate pins (Fig. 4-48, Pos. 6) with AL-Compound, PN 509 623 98.

Fig. 4-49 Assembly of the car body z

Lift the car body on the left side using a crane.

z

Support left side of the car body with appropriate stands (Fig. 4-49, Pos. 10). Lower the car body on the stands.

4 - 57

Car body

Undercarriage

CAUTION Stands need to be substantial enough to carry a total weight of 73,000 kg.

NOTE: For easyier mounting of the second crawler carrier assembly, the free side should be approx. 100 mm higher than the attached side.

Fig. 4-50 Assembly of the car body z

Install new inner bushings (Fig. 4-50, Pos. 5) and new outer bushings (Fig. 4-50, Pos. 7) if required.

z

Install the thread pins (Fig. 4-50, Pos. 4) and the inner retainer plates (Fig. 4-50, Pos. 3) with nuts (Fig. 4-49, Pos. 2) and washers if required.

z

Lift the left crawler carrier assembly (Fig. 4-50, Pos. 1) with the crane and align it with the car body.

4 - 58

Undercarriage

Car body

DANGER Risk of falling weights! May result in death or serious injury When lifting the car body, make sure that nobody steps below the weight.

z

Insert four mounting pins (Fig. 4-50, Pos. 6).

z

Install the retainer plates (Fig. 4-50, Pos. 9) and bolts (Fig. 4-48, Pos. 8) inclusive washers.

NOTE: Lubricate pins (Fig. 4-50, Pos. 6) with AL-Compound, PN 509 623 98. z

Lift the undercarriage as far as it is necessary to remove the stands.

z

Rest the undercarriage to the ground.

z

Carry out further installaition in reverse order to removal.

4 - 59

Car body

4.2.3

Undercarriage

REMOVAL OF THE CAR BODY (NEW TYPE WITH BOLTED CONNECTION)

NOTE: "New" means new design with screw connection. At the press date of this manual this design is not yet state of the art and it will be used in future models of the PC 4000-6.

Special tools:

Hydraulic torque wrench, PN 793 376 73 + PN 793 374 73 Electro-hydraulic pump set, PN 795 922 73


Crane Lift bar Blind plugs: 2 x BUZ 16-S, PN 371 866 99 and 2 x ROV 15-PL, PN 507 051 98 Car body: 29,000 kg Crawler carrier assembly: 56,300 kg each (track widht 1200 mm) Crawler carrier assembly: 58,000 kg each (track widht 1500 mm)

Dogman/rigger

z


z




z


z



4 - 60

Undercarriage

Car body


z

Remove the superstructure from the car body, refer to section 3.9.1 on page 3-232.

z

Disconnect all hydraulic lines from both travel motors, refer to section 4.1.9.1 on page 4-30.

z

Disconnect the hydraulic lines from both travel parking brakes, refer to section 4.1.11.1 on page 4-43.

z

Disconnect the breather hoses from both travel gearboxes, refer to section 4.1.11.1 on page 4-43.

z

Disconnect the pressure hoses (Fig. 4-51, Pos. 1) for the track tensioning from the shut-off cocks (Fig. 4-51, 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 the crawler carrier.

Fig. 4-51

4 - 61

Car body

Undercarriage

Fig. 4-52 z

Attach the undercarriage to a crane (Fig. 4-52) and lift it up using the crane. DANGER

Risk of falling weights! May result in death or serious injury When lifting the undercarriage, make sure that nobody steps below the weight.

4 - 62

Undercarriage

z

Car body

Support the carbody with appropriate stands so that all of the track rollers are clear of the track roller path.

NOTE: Place stands between the cross-ties (Fig. 4-53, Pos. 1) in a manner that the mounting bolts can be removed.

Fig. 4-53 CAUTION Stands need to be substantial enough to carry total weight of crawler carrier assemblies and carbody, total weight 145,000 kg.

Fig. 4-54 Crawler carriers attached to crane z

Attach the left crawler carrier assembly to a crane (Fig. 4-54).

4 - 63

Car body

Fig. 4-55 Crawler carrier mounting bolts 4 - 64

Undercarriage

Undercarriage

z

Car body

Remove all mounting bolts (Fig. 4-55, Pos. M48) and the two measuring bolts (Fig. 4-55, Pos. 7) attaching the left crawler carrier assembly to the car body. Discard the bolts.

NOTE: Use the hydraulic torque wrench PN 793 376 73 + PN 793 374 73, refer to section 6.4.1 on page 6-12. z

Remove the left crawler carrier assembly using a crane.

z

Carry out the same procedure to remove the right crawler carrier assembly.

z

Carry out the following five steps only if required: z

Remove the rotary joint from the car body, refer to section 4.2.5.1 on page 4-76.

z

Remove the high pressure accumulators from the car body, refer to section 4.1.4.3 on page 4-17.

z

Remove the track tensioning valve from the car body, refer to section 4.1.5.1 on page 4-19.

z

Remove the travel brake valve blocks from the car body, refer to section 4.1.7.1 on page 4-25.

z

Remove all hydraulic hoses from the car body, refer to section 4.1.6.1 on page 4-21.

4.2.4

REPLACEMENT OF THE CAR BODY (NEW TYPE WITH BOLTED CONNECTION)

NOTE: "New" means new design with screw connection. At the press date of this manual this design is not yet state of the art and it will be used in future models of the PC 4000.

Special tools:

Hydraulic torque wrench, PN 793 376 73 + PN 793 374 73 Electro-hydraulic pump set, PN 795 922 73 Water level gauge


Crane Compound No. 2, PN 324 969 40 Car body: 29,000 kg Crawler carrier assembly: 56,300 kg each (track widht 1200 mm) Crawler carrier assembly: 58,000 kg each (track widht 1500 mm)

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. 4 - 65

Car body

z

Carry out the following five steps only if required: z

Install all hydraulic hoses into the new car body.

z

Install the rotary joint in the new car body, refer to section 4.2.5.2 on page 4-79.

z

Install the high pressure accumulators in the new car body, refer to section 4.1.4.4 on page 4-18.

z

Install the track tensioning valve in the new car body, refer to section 4.1.5.2 on page 4-20.

z

Install the travel brake valve blocks in the new car body, refer to section 4.1.7.2 on page 4-27.

Fig. 4-56 Assembly of the car body

4 - 66

Undercarriage

Undercarriage

z

Car body

Align right crawler carrier horizontally (in both directions) very precisely.

NOTE: Use a water level gauge on the steel structure of crawler carrier to align it. z

Attach the car body to the crane (Fig. 4-56) and lift it up. DANGER

Risk of falling weights! May result in death or serious injury When lifting the car body, make sure that nobody steps below the weight.

NOTE: The oil supply lines to the travel motors must be aligned in the direction of the travel motors. z

Align car body with the right crawler carrier (Fig. 4-56). Support the left side using appropriate stands.

z

Support the carbody with appropriate stands so that all of the track rollers are clear of the track roller path.

NOTE: Place stands between the cross-ties (Fig. 4-57, Pos. 1) in a manner that the mounting bolts can be removed.

Fig. 4-57 CAUTION Stands need to be substantial enough to carry total weight of crawler carrier assemblies and carbody, total weight 145,000 kg.

4 - 67

Car body


Undercarriage

Undercarriage

Car body

NOTE: Insert the hydraulic lines for track tensioning into the crawler carrier before installing it. z

Insert new bolts (Fig. 4-58, Pos. M48) and two measuring bolts (Fig. 4-58, Pos. 7) with a resilient sleeve and pretighten with the specified pretightening torque.

NOTE: Lubricate all bolts (Fig. 4-58, Pos. M48) with compound No. 2, PN 324 969 40. Clean bottom and top surface of the resilient sleeves and contact areas completely free of paint. Use the hydraulic torque wrench PN 793 376 73 + PN 793 374 73, refer to section 6.4.1 on page 6-12. Pretightening torque for crawler carrier mounting bolts: 2100 Nm z

Lift the car body on the left side using a crane.

z

Support left side of the car body with appropriate stands. The left side should be approx. 200 mm higher than the other side (Fig. 4-56). Lower the car body on the stands.

z

Lift the left crawler carrier with the crane according to Fig. 4-54 and align it with the car body.

z

Insert the bolts (Fig. 4-58, Pos. M48) and two measuring bolts (Fig. 4-58, Pos. 7) with a resilient sleeve and pretighten with the specified pretightening torque.

NOTE: Lubricate all bolts (Fig. 4-58, Pos. M48) with compound No. 2, 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. 4-58, Pos. 7) into the upper corners. The measuring bolts are part of the measuring device, PN 928 476 40. Pretightening torque for crawler carrier mounting bolts: 2100 Nm z

Lift the undercarriage as far as it is necessary to remove the stands.

z

Rest the undercarriage to the ground.

z

Tighten the crawler carrier mounting bolts to the specified torque, refer to section 4.2.4.1 on page 4-70.

z

Carry out further installaition in reverse order to removal.

z

Check the torque of the crawler carrier mounting bolts after 1000 operating hours, refer to section 4.2.4.1 on page 4-70.

4 - 69

Car body

Undercarriage

4.2.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS Special tools:


Hydraulic torque wrench, PN 793 376 73 + PN 793 374 73 Electro-hydraulic pump set, PN 795 922 73 Measuring device, PN 928 476 40

Undercarriage

Car body

The required tightening torque for all fastening bolts has to be determined with the 4 measuring bolts (Fig. 4-59, Pos. 7), which dimension is analogous to the fastening bolts (Fig. 4-59, 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. 4-59, Pos. 1 - 6) is composed of the following items and will be delivered with each new machine. Refer to Fig. 4-59: 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. 4-59, Pos. 7). Do not lubricate the measuring bolts again.

z

Tighten the 4 measuring bolts (Fig. 4-59, Pos. 7) to 150 Nm.

z

Install the measuring device (Fig. 4-59, Pos. 1 - 6).

z

Set the dial gauge (Fig. 4-59, Pos. 2) to zero.

z

Install the special hydraulic torque wrench, PN 793 374 73 + PN 793 376 73, refer to section 6.4.1 on page 6-12.

4 - 71

Car body

Fig. 4-60 Crawler carrier mounting bolts

4 - 72

Undercarriage

Undercarriage

Car body

z

Adjust the pressure at the hydraulic torque wrench to 2100 Nm and tighten the measuring bolt (Fig. 4-60, 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 1.0 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 optain an average value.

z

Loosen one mounting bolt (Fig. 4-60, 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.

4 - 73

Car body

4.2.5

Undercarriage

ROTARY JOINT

Fig. 4-61 Rotary joint

4 - 74

Undercarriage

Car body

Legend for illustration Fig. 4-61: (1)

Stator, housing of rotary joint

(2)

Rotor, center part of rotary joint

(3)

Cover plate

(4)

Trust washer

(5)

O-ring seal between cover plate and stator

(6)

Guide ring

(7)

Shaft seal ring between rotor and stator

(7a)

Back-up ring, O-ring

(8)

Dust seal ring

(9)

Plug

(10)

Longitudinal bores

(11)

Stator connecting ports, cross holes

(12)

Torque support lever

(13)

Rotor connecting ports

(14)

Ring grooves

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. Although the travel motors must be supplied with hydraulic oil in each position in which the superstructure is slewing as against the undercarriage. When slewing, the superstructure moves the stator (Fig. 4-61, Pos. 1) via the torque support lever (Fig. 4-61, Pos. 12) and the cover plate (Fig. 4-61, Pos. 3). Hydraulic hoses from the main control valve blocks and auxiliary systems from the superstructure are connected to the stator ports (Fig. 4-61, Pos. 11). The main pressure service lines to the travel motor are connected to the service line ports (Fig. 4-61, Pos. A, B, C, D) at the stator (Fig. 4-61, Pos. 1). The rotor (Fig. 4-61, Pos. 2) is fix bolted to the undercarriage and turns in the stator (Fig. 4-61, Pos. 1) while swinging. Oil flows from the stator connecting ports (Fig. 4-61, Pos. A, B, C, D) via cross holes (Fig. 4-61, Pos. 11) through ring grooves (Fig. 4-61, Pos. 14) and longitudinal bores (Fig. 4-61, Pos. 10) of the rotor to the outlet port (Fig. 4-61, Pos. A, B, C, D) of the rotor (Fig. 4-61, Pos. 2). The ring grooves from the rotor are sealed with special seal rings (Fig. 4-61, Pos. 7). Each seal ring is supported by an O-ring (Fig. 4-61, Pos. 7a). To prevent dust contamination between the rotor (Fig. 4-61, Pos. 2) and stator (Fig. 4-61, Pos. 1), a dust seal (Fig. 4-61, Pos. 8) is mounted.

4 - 75

Car body

Undercarriage

The stator is locked to the rotor axially with the trust washer (Fig. 4-61, Pos. 4) which consists of two half segments for disassembling purposes. The stator is guided radially by the guide rings (Fig. 4-61, Pos. 6).

4.2.5.1 REMOVAL OF THE ROTARY JOINT Special tools:

n/a


Crane Blind plugs: 12 x SAE A2-6000, PN 506 582 98 12 x SAE B2-6000, PN 506 527 98 2 x BUZ 15-L, PN 371 855 99 and 2 x ROV 15-PL, PN 507 051 98 3 x BUZ 20-S, PN 371 858 99 and 3 x ROV 20-PS, PN 512 005 98 BUZ 22-L, PN 371 857 99 and ROV 22-PL, PN 513 788 98 2 x BUZ 28-L, PN 371 858 99 and 2 x ROV 28-PL, PN 509 377 98 BUZ 35-L, PN 371 859 99 and ROV 35-PL, PN 516 770 98 Rotary joint: 261 kg

Dogman/rigger

z


z




z


z


4 - 76

Undercarriage

Car body

z

Close the hand wheel (Fig. 4-62, Pos. 1) of main gate valve between suction oil reservoir and main oil reservoir.

z

Transfuse oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP".

Fig. 4-62 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

Mark and disconnect all hydraulic hoses and pipes from the rotary joint. Discard the O-rings of the SAE-flange connections.

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

Sling rotary joint.

NOTE: The rotary joint is accessible from above, from between the pipework at the manifold at the center of the machine (Fig. 4-63, Arrow). CAUTION Move the sling carefully between the pipework/hoses at the manifold to prevent the pipework from being damaged or ripped off.

Fig. 4-63

4 - 77

Car body

Undercarriage

z

Remove the mounting bolts (Fig. 4-64, Pos. 1) and remove the torque support lever (Fig. 4-64, Pos. 2) from the rotary joint (Fig. 4-64, Pos. 3).

z

Remove eight mounting bolts (Fig. 4-64, Pos. 4) and lift the rotary joint (Fig. 4-64, Pos. 3) off the center frame (Fig. 4-64, Pos. 5).

z

Move the rotary joint downward to the floor. DANGER

Risk of falling weights! May result in death or serious injury When moving the rotary joint, make sure that nobody steps below the weight or is within the swing range. Fig. 4-64

4 - 78

Undercarriage

Car body

4.2.5.2 REPLACEMENT OF THE ROTARY JOINT Special tools:

n/a


Crane Rotary joint: 261 kg

Dogman/rigger


Install the torque support lever to the new rotary joint (Fig. 4-64, Pos. 3). Use new mounting bolts (Fig. 4-64, Pos. 1) of grade 8.8. Tightening torque for torque support lever mounting bolts (Fig. 4-64, Pos. 1): 179 Nm.

z

Place the new rotary joint (Fig. 4-64, Pos. 3) at the center frame (Fig. 4-64, Pos. 5) using a crane.

z

Insert new mounting bolts (Fig. 4-64, Pos. 4) of grade 10.9 and tighten to the specific torque. Tightening torque for rotary joint mounting bolts (Fig. 4-64, Pos. 4): 265 Nm.

z


z


z


4 - 79

Car body

4.2.6

Undercarriage

SWING CIRCLE

Fig. 4-65 Slew ring assembly

4 - 80

Undercarriage

Car body


Upper internal bearing ring

(2)

Seal ring

(3)

Axial roller bearing top

(4)

Radial roller bearing

(5)

Axial roller bearing bottom

(6)

External ring gear

(7)

Lower internal bearing ring

(8)

Mounting thread to car body

(9)

Mounting bore to superstructure

The swing circle is the movable connection between the superstructure and the undercarriage. The bearing has a cylindrical roller design with three roller paths. Two for axial guiding (Fig. 4-65, Pos. 3), (Fig. 4-65, Pos. 5) and one for radial guiding (Fig. 4-65, Pos. 4). The outer gear is directly machined to the outer bearing ring (Fig. 4-65, Pos. 6). 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, refer to PARTS & SERVICE BULLETIN No. "AH02513b". For additional information, refer to PARTS & SERVICE BULLETIN No. "AH00511d" last edition.

4 - 81

Car body

Undercarriage

4.2.6.1 REMOVAL OF THE SWING CIRCLE Special tools:

Mounting cross, PN 379 128 40


2 x Crane Swing circle: 6,700 kg

Dogman/rigger

z


z




z

Remove the superstructure from the car body (counterweight, fluids and attachment removed), refer to section 3.9.1 on page 3-232.

z

Disconnect all lubrication lines from the inner slew ring.

z

Before removing swing circle, mark location of both slew rings to superstructure and the car body as well for further investigations.

z

Place the superstructure (Fig. 4-66, Pos. 3) on appropriate stands with the swing circle (Fig. 4-66, Pos. 2) resting on the mounting cross, PN 379 128 40 (Fig. 4-66, Pos. 1). CAUTION

Stands need to be substantial enough to carry total weight of the superstructure (without counterweight, fluids and attachment), total weight 110,500 kg.

z

z

Remove the mounting bolts of the inner slew ring to dismount the swing circle (Fig. 4-66, Pos. 2) from the superstructure (Fig. 4-66, Pos. 3). Lift the superstructure (Fig. 4-66, Pos. 3) and rest it on appropriate stands.

4 - 82

Fig. 4-66

Undercarriage

z

Car body

Install four universal articulated hoist rings evemly distributed at the inner slew ring and remove the swing circle from the mounting cross using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the swing circle, make sure that nobody steps below the weight.

4 - 83

Car body

Undercarriage

4.2.6.2 REPLACEMENT OF THE SWING CIRCLE

Special tools:

Mounting cross, PN 379 128 40 Gauge device to test bolt M36, PN 376 762 40 Lifting device for swing circle Laser device for checking the level of bearing area Appropriate device to rest superstructure


2 x Crane Compound No. 2, PN 324 969 40 Swing circle: 6,700 kg

Dogman/rigger


Check the level of bearing area with a laser device before installing a new slew ring. Refer to PARTS & SERVICE BULLETIN No. "AH00511d".

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 BULLETIN No. "AH00511d" last edition. 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 articulated hoist rings evemly distributed in screw circle of the inner slew ring.

4 - 84

Undercarriage

Car body

NOTE: When replacing the swing circle, all fastening bolts must also be replaced. z

Install four universal articulated hoist rings evemly distributed at the inner slew ring and lift it using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the swing circle, make sure that nobody steps below the weight.

z

Place the mounting cross PN 379 128 40 on an appropriate lifting device. CAUTION

The lifting device must be able to lift the swing circle, total weight 6,700 kg.

z

Place the swing circle (Fig. 4-67, Pos. 2) onto the mounting cross (Fig. 4-67, Pos. 1).

z

Center the swing circle (Fig. 4-67, Pos. 2) on the mounting cross (Fig. 4-67, Pos. 1) using the transport star.

z

Lift the superstructure (Fig. 4-67, Pos. 3) and rest it on appropriate stands, high enough to use the lifting device for the swing circle below it. CAUTION

Stands need to be substantial enough to carry total weight of the superstructure (without counterweight, fluids and attach- Fig. 4-67 ment), total weight 110,500 kg.

DANGER Risk of falling weights! May result in death or serious injury When lifting the superstructure, make sure that nobody steps below the weight.

4 - 85

Car body

Fig. 4-68 Swing circle installation z

Mating surfaces must be absolutely fat-free. Even the solvent must be rinsed away before assembling.

z

Check flatness of the mating surfaces.

z

Prepare new bolts (Fig. 4-68, Pos. 3) and washers (Fig. 4-68, Pos. 4). Lubricate the threads and the head surface of the bolts with compound No. 2, PN 324 969 40.

4 - 86

Undercarriage

Undercarriage

Car body

NOTE: The unhardened spot of race surfaces (changeover area between beginning and end of hardening process) is punchmarked with an "S" at the inner resp. outer side of each slew ring (Fig. 4-68, Pos. 1 and 2). These spots "S" must not be placed within the main load aerea 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. 4-68. z

Align the "S-spots".

z

Remove the transport cross.

z

Lift the swing circle (Fig. 4-68, Pos. 5) to approx. 10 mm below the platform of the superstructure (observe unhardened "S-spots").

z

Install bolts (Fig. 4-68, Pos. 3) and washers (Fig. 4-68, Pos. 4) to the inner slew ring.

z

Lift the swing circle (Fig. 4-68, Pos. 5) to the supporting surface by tightening the bolts crosswise manually.

NOTE: Check mating surfaces with feeler gauge. z

Connect all lubrication lines at the inner slew ring.

z

Check the tooth backlash between slew ring and slew pinion with a feeler gauge. Refer to PARTS & SERVICE BULLETIN No. "AH00511d". Tighten all bolts (Fig. 4-68, Pos. 3) of the inner slew ring crosswise to the required torque, refer to PART & SERVICE BULLETIN No. "AH00511d" last edition.

z

Lift the superstructure (Fig. 4-68, Pos. 6) and install the superstructure onto the undercarriage, refer to section 3.9.2 on page 3-235. DANGER

Risk of falling weights! May result in death or serious injury When lifting the superstructure, make sure that nobody steps below the weight.

z


z


z


4 - 87

Car body

Undercarriage


4 - 88

Attachment

5 ATTACHMENT

5 -1

Backhoe

Attachment

5.1

BACKHOE

Fig. 5-1

Backhoe attachment overview

(1)

Undercarriage with car body and side frames

(2)

Superstructure

(3)

Boom

(4)

Stick

(5)

Bucket (backhoe)

(6)

Boom cylinder

(7)

Stick cylinder

(8)

Bucket cylinder

(9)

Bucket link rod

(10)

Steering rod

5 -2

Attachment

Backhoe


5 -3

Backhoe

5.1.1

Attachment

BOOM

5.1.1.1 REMOVAL OF THE BOOM

Fig. 5-2

5 -4

Boom, removal and installation

Attachment

Backhoe


Stick cylinder

(2)

Boom cylinder

(3)

Boom

(4)

Bolt

(5)

Shackle

(6)

Pin

(7)

Bush

(8)

Seal

(9)

Bush

(10)

Seal

(11)

Bush

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Blind plugs: 8 x SAE A2-6000, PN 506 582 98 8 x SAE B2-6000, PN 506 527 98 6 x SAE A1 1/2-6000, PN 506 581 98 6 x SAE B1 1/2-6000, PN 506 526 98 BUZ 25-S, PN 371 867 99 and ROV 25-PS, PN 508 033 98 Boom: 30,340 kg Pin boom/superstructure: 194 kg

Dogman/rigger

z


z

Park the machine on the prepared flat ground area and position the bucket with its flat side (underside) on the ground.


Use blocks and support the bucket from behind to secure the bucket.

z


5 -5

Backhoe

Attachment

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Remove the stick, refer to section 5.1.2 on page 5-18.

z

Support the boom with appropriate stands (Fig. 5-3, Pos. 1) of approx. 1 m height.

z

Remove the boom cylinders, refer to section 5.1.1.3 on page 5-10.

z

Remove the hydraulic hoses from the boom which are leading to the manifold, refer to section 5.1.6 on page 5-52.

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 the grease feed lines leading to the boom.

z

Sling the boom (Fig. 5-4).

Fig. 5-3

Fig. 5-4 z

Remove the two bolts (Fig. 5-5, Pos. 1), and the shackle (Fig. 5-5, Pos. 2) securing the pin (Fig. 5-5, Pos. 3).

z

Remove the pin (Fig. 5-5, Pos. 3) connecting the boom to the superstructure. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling.

Fig. 5-5

5 -6

Attachment

Backhoe

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the superstructure, make sure that the boom is fixed in its position and secured with a crane.

z

Remove the boom using a crane and place it on the ground and in an appropriate position. 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

If required, remove all provided parts and hydraulic pipings from the boom.

5 -7

Backhoe

Attachment

5.1.1.2 REPLACEMENT OF THE BOOM Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Boom: 30,340 kg Pin boom/superstructure: 194 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-6, Pos. 2) and install new seals! Insert new bushes (Fig. 5-6, Pos. 1) if required! Put the appropriate grease in every bush on assembly! z


Never put hands into the holes when aligning the boom to the superstructure.

z


z

Bleed air from the hydraulic system, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z


z

Check for leaks and the cylinders operation.

z


5 -8

Fig. 5-6

Attachment

Backhoe


5 -9

Backhoe

Attachment

5.1.1.3 REMOVAL OF BOOM CYLINDERS

Fig. 5-7

5 - 10

Boom cylinder, removal and installation

Attachment

Backhoe


O-ring

(2)

Pipe

(3)

Boom cylinder

(4)

Superstructure

(5)

Pin

(6)

Shackle

(7)

Bolt

(8)

Pin

(9)

Catch

(10)

Shackle

(11)

Bolt

(12)

Bush

(13)

Seal

(14)

Bush

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Oil drain pans Blind plugs (per cylinder): 2 x SAE A2-6000, PN 506 582 98 2 x SAE B2-6000, PN 506 527 98 Boom cylinder: 4250 kg each Pin cylinder/boom: 101 kg Pin cylinder/superstructure: 100 kg

Dogman/rigger

WARNING z


z


z


5 - 11

Backhoe

z

Attachment

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended position (Fig. 5-8).



Fig. 5-8 z


z

Remove grease feed lines and fittings from the boom cylinder(s) to be removed.

z

Sling the boom cylinder (Fig. 5-9, Pos. 6).

z

Ease the load of the pin (Fig. 5-9, Pos. 4) in the boom (Fig. 5-9, Pos. 5) by lifting the cylinder lightly.

z

Remove the bolts (Fig. 5-9, Pos. 1) and the shackle (Fig. 5-9, Pos. 2) securing the pin (Fig. 5-9, Pos. 4).

NOTE: The catches (Fig. 5-9, Pos. 3) are welded to the boom. z

Remove the pin (Fig. 5-9, Pos. 4) connecting the boom cylinder to the boom. WARNING


DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the boom, make sure that the cylinder is fixed in its position and secured with a crane. Fig. 5-9 NOTE: Check bushes for wear and damage. Replace if required. Note the seals (Fig. 5-7, Pos. 13) at the cylinder.

5 - 12

Attachment

Backhoe

NOTE: Pull the pin (Fig. 5-9, Pos. 4) by using two puller bolts at the threaded holes (Fig. 5-10, Pos. 1). (Fig. 5-10 is an example)

Fig. 5-10 z


z

At low idle, retract the cylinder to be removed.

z


z


z

Tie the moving rod to the cylinder body with a wire rope (refer to Fig. 5-39).

z

Lower the cylinder into a horizontal position (Fig. 5-11). Fig. 5-11 WARNING



z

Disconnect the main hydraulic hoses from the cylinder, refer to section 5.1.6.2 on page 5-56.

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. 5 - 13

Backhoe

Attachment

z

In addition, sling the second side (moving rod side) of the cylinder as well (Fig. 5-12).

z


z

Remove the pin (Fig. 5-12, Pos. 2) connecting the boom cylinder to the superstructure. WARNING


DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the superstructure, make sure that the cylinder is fixed in its position and secured with a crane.

NOTE: Check bushes (Fig. 5-12, Pos. 1) for wear and damage. Replace if required. Note the seals (Fig. 5-7, Pos. 13) at the cylinder. z

Lower the boom cylinder to the ground and place it in an appropriate position using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the cylinder, make sure that nobody steps below the lifted cylinder.

z

If required, disconnect the other boom cylinder from the boom and remove it using the same procedure as above.

z

If required, remove the pipe work from the removed cylinder(s). Discard the O-rings and fit caps to the cylinder(s) openings to avoid environmental contamination.

5 - 14

Fig. 5-12

Attachment

Backhoe

5.1.1.4 REPLACEMENT OF BOOM CYLINDERS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Boom cylinder: 4250 kg each Pin cylinder/boom: 101 kg Pin cylinder/superstructure: 100 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-7, Pos. 13) and install new seals! Prior to assembly all bushes must be inspected and replaced as required! Put the appropriate grease in every bush on assembly! z

Flush out and clean all the pipes.

z

Install the hydraulic pipe at the boom cylinder, if required.

5 - 15

Backhoe

z

Attachment

Position the replacement cylinder using a crane (Fig. 5-13). DANGER


z

Install the pin (Fig. 5-13, Pos. 2) connecting the boom cylinder to the superstructure. DANGER

Never put hands into the holes when aligning the cylinder to the superstructure.

NOTE: Put the suitable grease into the bushes (Fig. 5-13, Pos. 1). z

Install the bolts (Fig. 5-13, Pos. 3) and the shackle (Fig. 5-13, Pos. 4) to secure the pin (Fig. 5-13, Pos. 2).

z

Connect the main hydraulic hoses to the boom cylinder, refer to section 5.1.6.2 on page 5-56.

Fig. 5-13

NOTE: Always use new O-rings at the SAE-flange connections.

z

Remove the wire rope from the moving rod.

z

Lift up the boom cylinder (Fig. 5-14) using a crane.

z


z

Perform the bleeding procedure for the replacement boom cylinder(s). Refer to PARTS & SERVICE BULLETIN No. "AH06524".

Fig. 5-14

5 - 16

Attachment

Backhoe

z

Extend the moving rod and align it to the required position to insert the pin (Fig. 5-15, Pos. 4) into the boom (Fig. 5-15, Pos. 5).

z

Install the pin (Fig. 5-15, Pos. 4). DANGER

Never put hands into the holes when aligning the cylinder to the boom.

NOTE: Align the pin’s head to the catches (Fig. 5-15, Pos. 3). z


z

Install the shackle (Fig. 5-15, Pos. 2) and the bolts (Fig. 5-15, Pos. 1) to secure the pin (Fig. 5-15, Pos. 4).

Fig. 5-15 z


z


z


z


z


z


5 - 17

Backhoe

5.1.2

Attachment

STICK

5.1.2.1 REMOVAL OF THE STICK

Fig. 5-16 Stick assembly

5 - 18

Attachment

Backhoe


Bucket

(2)

Bucket link rod

(3)

Bucket cylinder

(4)

Stick cylinder

(5)

Steering rod

(6)

Bushes

(7)

Bushes

(8)

Washers

(9)

Bushes

(10)

Stick

Special tools:

Thread protector PN 409 329 40


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Blind plugs: 4 x SAE A2-6000, PN 506 582 98 4 x SAE B2-6000, PN 506 527 98 BUZ 25-S, PN 371 867 99 and ROV 25-PS, PN 508 033 98 Stick: 14,502 kg Pin stick/boom: 1100 kg

Dogman/rigger

WARNING z


z


z


z


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 any location with appropriate ground condition.

5 - 19

Backhoe

Attachment

z

Use blocks and support the bucket from behind to secure the it.

z

Remove the bucket, refer to section 5.1.3.1 on page 5-32.

z

Remove the bucket link rod and the steering rod(s), refer to section 5.1.4 on page 5-43.

z

Remove the stick cylinders, refer to section 5.1.2.3 on page 5-24.

z

Disconnect the grease feeding lines leading to the stick.

z

Sling the stick (Fig. 5-17).

Fig. 5-17 z

Undo the lock and remove the nut-cap (Fig. 5-18, Pos. 2) from the pin (Fig. 5-18, Pos. 4), then fit the "thread protector" PN 409 329 40.

z

Pull the pin (Fig. 5-18, Pos. 4) out completely to clear boom (Fig. 5-18, Pos. 3) and stick. WARNING


NOTE: Check the O-ring (Fig. 5-18, Pos. 1) for wear or damage. Replace if required.

5 - 20

Fig. 5-18

Attachment

Backhoe

NOTE: Pull the pin (Fig. 5-18, Pos. 4) by using two puller bolts at the threaded holes (Fig. 5-19, Pos.1). (Fig. 5-19 is an example) DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the boom, make sure that the stick is fixed in its position and secured with a crane.

z

Remove the stick using a crane.

Fig. 5-19

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

Lower the stick to the ground and rest it in an appropriate position.

5 - 21

Backhoe

Attachment

5.1.2.2 REPLACEMENT OF STICK Special tools:



Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Stick: 14,502 kg Pin stick/boom: 1100 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-20, Pos. 2) and install new seals! Insert new bushes (Fig. 5-20, Pos. 1) if required! Put the appropriate grease in every bush on assembly! z


Never put hands into the holes when aligning the stick to the boom.

z


z


z


z


z


5 - 22

Fig. 5-20

Attachment

Backhoe


5 - 23

Backhoe

5.1.2.3 REMOVAL OF STICK CYLINDERS

Fig. 5-21 Stick cylinder, removal and installation

5 - 24

Attachment

Attachment

Backhoe


Stick cylinder

(2)

Stick

(3)

Boom

(4)

Bolt

(5)

Shackle

(6)

Pin

(7)

Seal

(8)

Bolt

(9)

Shackle

(10)

Catch

(11)

Pin

(12)

Pipe

(13)

O-ring

(14)

Seal

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Oil drain pan Blind plugs (per cylinder): 2 x SAE A2-6000, PN 506 582 98 2 x SAE B2-6000, PN 506 527 98 Stick cylinder: 3150 kg each Pin cylinder/stick: 86 kg Pin cylinder/boom: 123 kg

Dogman/rigger

WARNING z


z


z


5 - 25

Backhoe

z

Attachment

Park the machine on the prepared flat area and position the bucket on the ground with the cylinders in partially extended position (Fig. 5-22).



z


z

Remove grease feed lines and fittings from the stick cylinder(s) to be removed.

z

Sling the cylinder (Fig. 5-23, Pos. 1) to be removed.

Fig. 5-22

Fig. 5-23

z

Ease the load of the pin (Fig. 5-24, Pos. 4) by lifting the cylinder (Fig. 5-24, Pos. 1) lightly.

z

Remove the bolts (Fig. 5-24, Pos. 2), washers, and the shackle (Fig. 5-24, Pos. 3) securing the pin (Fig. 5-24, Pos. 4).

z

Remove the pin (Fig. 5-24, Pos. 4) connecting the stick cylinder to the stick. Remove the two seals (Fig. 5-24, Pos. 5). WARNING


DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the cylinder, make sure that the cylinder is fixed in its position and secured with a crane.

5 - 26

Fig. 5-24

Attachment

Backhoe

z


z

At low idle, fully retract the cylinder(s) to be removed.

z


z


z


z

Support the cylinder (Fig. 5-25, Pos. 6) to be removed with blocks (Fig. 5-25, Pos. 7) between stick cylinder and boom. WARNING



z

Disconnect the main hydraulic hoses from the stick cylinder, refer to section 5.1.6.3 on page 5-60.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan.

Fig. 5-25

Cap the openings with blind plugs to avoid contamination. z

Remove the bolts (Fig. 5-25, Pos. 1), the washers, and the shackle (Fig. 5-25, Pos. 2) securing the pin (Fig. 5-25, Pos. 4).

NOTE: The catches (Fig. 5-25, Pos. 3) are welded to the boom. z

Remove the pin (Fig. 5-25, Pos. 4) connecting the stick cylinder to the boom (Fig. 5-25, Pos. 5).

5 - 27

Backhoe

Attachment

NOTE: Pull the pin (Fig. 5-25, Pos. 4) by using two puller bolts at the threaded holes (Fig. 5-26, Pos. 1). (Fig. 5-26 is an example) WARNING Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling.

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the cylinder, make sure that the cylinder is fixed in its position and secured with a crane.

z

Note the seals (Fig. 5-21, Pos. 14) between the boom and the stick cylinder.

z

Remove the stick cylinder using a crane.

z

Lower the stick cylinder to the ground and place it in an appropriate position. DANGER


z

If required, remove the other stick cylinder from the boom using the same procedure as above.

z

If required, remove the hydraulic pipe from the removed cylinder(s). Discard the O-rings and fit caps to the cylinder(s) openings to avoid environmental contamination.

5 - 28

Fig. 5-26

Attachment

Backhoe

5.1.2.4 REPLACEMENT OF STICK CYLINDERS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Stick cylinder: 3150 kg each Pin cylinder/stick: 86 kg Pin cylinder/boom: 123 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Prior to assembly all bushes must be inspected and replaced as required! Put the appropriate grease in every bush on assembly! z

Flush out and clean all pipes.

z

Clean the mating surfaces at the cylinder mounting hole on the boom.

z

If required, install the hydraulic pipe at the cylinder(s).

5 - 29

Backhoe

z

Attachment

Using a crane, position the replacement cylinder (Fig. 5-27, Pos. 6). DANGER


z

Support the cylinder with appropriate stands (Fig. 5-27, Pos. 7).

z

Install the pin (Fig. 5-27, Pos. 4). CAUTION

Never put hands into the holes when aligning the cylinder to the boom.

NOTE: Align the pin’s head to the catches (Fig. 5-27, Pos. 3). z

Install the shackle (Fig. 5-27, Pos. 2) and the bolts (Fig. 5-27, Pos. 1) with washers to secure the pin (Fig. 5-27, Pos. 4).

z

Install the hydraulic pipe(s) to the stick cylinders, if required.

z

Connect the main hydraulic hoses to the cylinder.

NOTE: Always use new O-rings at the SAE-flange connections. z


z


z

Perform the bleeding procedure for the replacement stick cylinder(s). Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z

At low idle, extend the moving rod to the required position to install the pin into the stick. WARNING

Never put hands into the holes when aligning the cylinder to the stick.

z


5 - 30

Fig. 5-27

Attachment

z

Install the pin (Fig. 5-28, Pos. 4) connecting the stick cylinder (Fig. 5-28, Pos. 1) to the stick. Install the two seals (Fig. 5-28, Pos. 5).

z

Install the two bolts (Fig. 5-28, Pos. 2), washers, and the shackle (Fig. 5-28, Pos. 3) to secure the pin (Fig. 5-28, Pos. 4).

Backhoe

Fig. 5-28 z


z


z


z


5 - 31

Backhoe

5.1.3

Attachment

BUCKET

5.1.3.1 REMOVAL OF THE BUCKET

Fig. 5-29 Bucket assembly (1)

Bucket

(2)

Bucket link rod

(3)

Seal fixing ring

(4)

Seal

(5)

Seal fixing ring

(6)

Seal

5 - 32

Attachment

Backhoe

Special tools:



Crane Pin bucket/stick: 738 kg Pin bucket/bucket link rod: 514 kg Bucket (if lifted): 23,300 kg

Dogman/rigger

z


z



Use blocks and support the bucket from behind to secure the it.

z


z


z

Remove grease feeding line from the bucket mounting pin and from the link rod.

z

Remove the seal fixing rings (Fig. 5-30, Pos. 1) located on both sides of the link rod (Fig. 5-30, Pos. 5).

z

Undo the lock (Fig. 5-30, Pos. 2) and remove the nut-cap (Fig. 5-30, Pos. 3) from the pin (Fig. 5-30, Pos. 4), then fit the "thread protector" PN 409 329 40.

Fig. 5-30

5 - 33

Backhoe

Attachment

z

Remove the seal fixing rings (Fig. 5-31, Pos. 1) located on both sides of the stick (Fig. 5-31, Pos. 5).

z

Undo the lock (Fig. 5-31, Pos. 2) and remove the nut-cap (Fig. 5-31, Pos. 3) from the pin (Fig. 5-30, Pos. 4), then fit the "thread protector" PN 409 329 40. CAUTION

Tie the link rod to the stick with a wire rope to prevent it from swinging when the pin is pulled out.

Fig. 5-31 z

Pull the pin (Fig. 5-32, Pos. 1) out completely to clear bucket (Fig. 5-32, Pos. 5) and link rod. WARNING


z

Pull the pin (Fig. 5-32, Pos. 2) out completely to clear bucket (Fig. 5-32, Pos. 5) and stick. Remove the washers (Fig. 5-32, Pos. 3). WARNING


z

Check bushes (Fig. 5-32, Pos. 4) for wear and damage. Replace if required. Fig. 5-32

NOTE: Pull the pins by using two puller bolts at the threaded holes (Fig. 5-33, Pos. 1), (Fig. 5-33 is an example). z


z

At low idle, lift the stick to clear the bucket.

z


Fig. 5-33

5 - 34

Attachment

Backhoe

5.1.3.2 REPLACEMENT OF THE BUCKET Special tools:



Crane Pin bucket/stick: 738 kg Pin bucket/bucket link rod: 514 kg Bucket (if lifted): 23,300 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. 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


5 - 35

Backhoe

5.1.3.3 REMOVAL OF BUCKET CYLINDERS

Fig. 5-34 Bucket cylinder, removal and installation

5 - 36

Attachment

Attachment

Backhoe


Seal fixing ring

(2)

Bucket link rod

(3)

Lock

(4)

Nut-cap

(5)

Right-hand steering rod

(6)

Pin

(7)

Thread hole

(8)

Left-hand steering rod

(9)

Moving rod

(10)

Cylinder body

(11)

Bolt

(12)

Shackle

(13)

Pin

(14)

Seal

(15)

Pipe

(16)

Seal

(17)

Seal

(18)

Bush

Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Oil drain pan Blind plugs (per cylinder): 2 x SAE A2-6000, PN 506 582 98; 2 x SAE B2-6000, PN 506 527 98 Bucket cylinder: 2330 kg each Pin cylinder/stick: 71 kg Pin cylinder/steering rods: 711 kg

Dogman/rigger

WARNING z


z


5 - 37

Backhoe

Attachment

z


z

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended position (Fig. 5-35).



z


z

Remove grease feed lines and fittings from the cylinder(s) to be removed.

z

Remove the seal fixing rings (Fig. 5-36, Pos. 1) located on both sides of the cylinder moving rods (Fig. 5-36, Pos. 2).

z

Undo the lock (Fig. 5-36, Pos. 3) and remove the nut-cap (Fig. 5-36, Pos. 4) from the pin (Fig. 5-36, Pos. 5), then fit the "thread protector" PN 409 329 40.

Fig. 5-35

Fig. 5-36 z

Base the cylinder(s) to be removed with blocks between cylinder and stick (Fig. 5-37, Pos. 1).

z

Connect the stick to a crane (Fig. 5-37, arrows).

z

Support the steering rods (Fig. 5-37, Pos. 4).

z

Using a crane, support the bucket link rod (Fig. 5-37, Pos. 3) if both or the left cylinder needs to be removed.

z

Pull the pin (Fig. 5-37, Pos. 2) out completely to clear both cylinders moving rods. WARNING


NOTE: If removing the right-hand cylinder only, pull the pin (Fig. 5-37, Pos. 2) out just enough to clear the cylinder moving rod. 5 - 38

Fig. 5-37

Attachment

Backhoe

NOTE: Pull the pin (Fig. 5-36, Pos. 5) out by using two puller bolts at the threaded holes (Fig. 5-38, Pos. 1).

Fig. 5-38 z


z

At low idle, retract the bucket cylinder(s) to be removed.

z


z

Tie the moving rod to the cylinder body with a wire rope (Fig. 5-39).

Fig. 5-39 z




5 - 39

Backhoe

z

Attachment

Disconnect the main hydraulic hoses from the cylinder(s).


Using a crane, sling the cylinder (Fig. 5-40, Pos. 1) to be removed. Ease the load of the pin (Fig. 5-40, Pos. 2) by lifting the cylinder lightly.

Fig. 5-40 z

Remove the two bolts (Fig. 5-41, Pos. 2), washers, and the shackle (Fig. 5-41, Pos. 3) securing the pin (Fig. 5-41, Pos. 4).

z

Remove the pin (Fig. 5-41, Pos. 4) connecting the cylinder (Fig. 5-41, Pos. 1) to the stick. Remove the two seals (Fig. 5-41, Pos. 5). WARNING


z

Remove the cylinder using a crane. Lower the cylinder to the ground and place it in an appropriate position. DANGER


NOTE: If required, disconnect the other bucket cylinder from the stick and remove it using the same procedure as above. 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 - 40

Fig. 5-41

Attachment

Backhoe

5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket cylinder: 2330 kg each Pin cylinder/stick: 71 kg Pin cylinder/steering rods: 711 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Prior to assembly all bushes must be inspected and replaced as required! Put the appropriate grease in every bush on assembly! z

Flush out and clean all the pipes and connecting blocks.

5 - 41

Backhoe

Attachment

z

On the stick at the bucket cylinder mounting hole, clean the mating surfaces and put appropriate grease on both sides of two new seals (Fig. 5-42, Pos. 5) and position them on both sides of the bush.

z

Using a crane, support and position the replacement bucket cylinder (Fig. 5-42, Pos. 1). DANGER


z

Install the pin (Fig. 5-42, Pos. 4). CAUTION

Never put hands into the holes when aligning the cylinder to the stick.

z

Install the shackle (Fig. 5-42, Pos. 3), the two washers, and the bolts (Fig. 5-42, Pos. 2) to secure the pin (Fig. 5-42, Pos. 4).

z

Connect the main hydraulic hoses to the bucket cylinder(s).



z


z

Perform the bleeding procedure for the replacement bucket cylinder(s). Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


z


z


z


z


z


5 - 42

Fig. 5-42

Attachment

5.1.4

Backhoe

BUCKET LINK ROD AND STEERING RODS

5.1.4.1 REMOVAL OF THE BUCKET LINK ROD Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 1805 kg Steering rod: 1128 kg Pin steering rod/bucket link rod: 711 kg Pin bucket/bucket link rod: 514 kg

Dogman/rigger

WARNING z


z


z


z

Park the machine on the prepared flat ground area and position the bucket on the ground as shown in Fig. 5-43, with the bucket cylinders not fully retracted.


Base the stick on an appropriate stand (Fig. 5-43, Pos. 1).

z

Base the bucket cylinders with appropriate blocks (Fig. 5-43, Pos. 2).

z


z

Relieve the pressure in the bucket cylinders only. refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Disconnect the grease feed lines from the bucket link rod.

Fig. 5-43

5 - 43

Backhoe

Attachment

z

Sling the bucket link rod (Fig. 5-44, Pos. 1) and both steering rods (Fig. 5-44, Pos. 2).

z

Remove the pin (Fig. 5-44, Pos. 3) at the bucket cylinders, refer to section 5.1.3.3 on page 5-36. WARNING


z


z

At low idle, carefully lift the boom a little bit to clear the link rod.

z

Remove the pin (Fig. 5-44, Pos. 3) at the bucket, refer to section 5.1.3.1 on page 5-32. WARNING


z

Remove the bucket link rod (Fig. 5-44, Pos. 1) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the bucket link rod, make sure that nobody steps below the lifted weight.

5 - 44

Fig. 5-44

Attachment

Backhoe

5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 1805 kg Steering rod: 1128 kg Pin steering rod/bucket link rod: 711 kg Pin bucket/bucket link rod: 514 kg

Dogman/rigger


WARNING z


z


NOTE: Always discard used seals and install new seals! Prior to assembly all bushes must be inspected and replaced as required! Put the appropriate grease in every bush on assembly! z


5 - 45

Backhoe

Attachment

5.1.4.3 REMOVAL OF THE STEERING RODS Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Blind plugs: BUZ 25-S, PN 371 867 99 and ROV 25-PS, PN 508 033 98 Bucket link rod: 1805 kg Steering rod: 1128 kg Pin steering rod/bucket link rod: 711 kg Pin steering rod/stick: 426 kg

Dogman/rigger

WARNING z


z


z


z

Park the machine on the prepared flat ground area and position the bucket on the ground as shown in Fig. 5-45, with the bucket cylinders not fully retracted.


Base the stick on an appropriate stand (Fig. 5-45, Pos. 1).

z

Base the bucket cylinder with appropriate blocks (Fig. 5-45, Pos. 2).

z


z

Relieve the pressure in the bucket cylinders only. refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Disconnect the grease feed line from the left side steering rod.

5 - 46

Fig. 5-45

Attachment

z

Backhoe

Sling the bucket link rod (Fig. 5-46, Pos. 1) and the steering rod (Fig. 5-46, Pos. 2) to be removed.

NOTE: If removing the left-hand steering rod only, sling both steering rods. z

Remove the pin (Fig. 5-46, Pos. 3) at the bucket cylinders, refer to section 5.1.3.3 on page 5-36. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling. Fig. 5-46 NOTE: If removing the right-hand steering rod only, pull the pin out just enough to clear the steering rod. If removing the left-hand steering rod or both steering rods, pull out the pin completely to clear both steering rods. z

Remove the pin (Fig. 5-46, Pos. 4 and Fig. 5-47, Pos. 5) as follows: z

Remove the seal fixing rings (Fig. 5-47, Pos. 1) located on both sides between the steering rod (Fig. 5-47, Pos. 6) and the stick (Fig. 5-47, Pos. 7).

z

Remove the bolt (Fig. 5-47, Pos. 2) and undo the lock (Fig. 5-47, Pos. 3)

z

Remove the nut-cap (Fig. 5-47, Pos. 4) from the pin (Fig. 5-47, Pos. 5), then fit the "thread protector" PN 409 329 40.

z

Pull the pin (Fig. 5-47, Pos. 5) out completely to clear both steering rods. Fig. 5-47 WARNING


5 - 47

Backhoe

Attachment

NOTE: Pull the pin (Fig. 5-47, Pos. 5) out by using two puller bolts at the threaded holes (Fig. 5-48, Pos. 1). If removing the right-hand steering rod only, pull the pin out just enough to clear the steering rod (Fig. 5-47, Pos. 6).

Fig. 5-48 z

Remove the steering rod(s) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the steering rod, make sure that nobody steps below the lifted weight.

5 - 48

Attachment

Backhoe

5.1.4.4 REPLACEMENT OF THE STEERING RODS Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 1805 kg Steering rod: 1128 kg Pin steering rod/bucket link rod: 711 kg Pin steering rod/stick: 426 kg

Dogman/rigger


WARNING z


z


NOTE: Always discard used seals and install new seals! Prior to assembly all bushes must be inspected and replaced as required! Put the appropriate grease in every bush on assembly! z


5 - 49

Backhoe

5.1.5

Attachment

GROUND ENGAGING TOOLS (GET)

As ground engaging tools (Fig. 5-49, Pos. 1) the ESCO POSILOK Tooth System is used.

Fig. 5-49

5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET Special tools:

POSILOK Pin removal tool PN 795 502 73 Hensley Pin removal tool (ask local dealer)


ESCO POSILOK Tooth System S95 Hensley Tooth System (XS342 series) Forklift Point (tooth): 92 kg (Hensley), 95 kg (ESCO) Tooth (center) adapter: 201 kg (Hensley), 193 kg (ESCO) Corner adapter: 402 kg (Hensley), 402 kg (ESCO) Shroud: 182 kg (Hensley), 144 kg (ESCO) Wear cap: 53 kg (Hensley), 45 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.

5 - 50

Attachment

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.

Backhoe



z

For removing and installing the ESCO Tooth System, refer to PARTS & SERVICE BULLETIN No. "AH03510".

z

Remove and install the Hensley Tooth System accordingly to PARTS & SERVICE BULLETIN No. "AH03510", Hensley uses basically the similar system.

NOTE: Use a forklift to remove and install the GET.

5 - 51

Backhoe

5.1.6

Attachment

HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT

5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES

Fig. 5-50 Arc hoses, removal and installation 5 - 52

Attachment

Backhoe


Hose clamp

(2)

Clamp line

(3)

Clamp line

(4)

Manifold

(5)

Hydraulic tube

(6)

Hydraulic hose

(7)

Bolt

(8)

O-ring

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Blind plugs (per hose, depending on type): 2 x SAE A1 1/2-6000, PN 506 581 98 2 x SAE B1 1/2-6000, PN 506 526 98 or 2 x SAE A2-6000, PN 506 582 98; 2 x SAE B2-6000, PN 506 527 98 Boom arc hose (2"): 40 kg Boom arc hose (1 1/2"): 26 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the attachment.

z


z

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended and the stick cylinders in fully retracted position (Fig. 5-51).

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. 5-51 5 - 53

Backhoe

Fig. 5-52 Arc hoses, removal and installation

5 - 54

Attachment

Attachment

Backhoe

z


z


z

Open the hose clamps (Fig. 5-52, Pos. 1) and clear the hydraulic hose (Fig. 5-52, Pos. 6) to be removed from the clamp lines (Fig. 5-52, Pos. 2 and 3). WARNING



z

Sling the hydraulic hose (Fig. 5-52, Pos. 6) to be removed.

z

Remove the bolts (Fig. 5-52, Pos. 7) and disconnect the SAE-flanges from the manifold (Fig. 5-52, Pos. 4) and from the hydraulic tube (Fig. 5-52, Pos. 5) 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. 5-52, 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 BULLETIN No. "AH06524".

z


z


z

Check hydraulic oil level again and add oil if required. 5 - 55

Backhoe

Attachment

5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES

Fig. 5-53 Hoses of the boom cylinders, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

O-ring

(4)

Bolt

(5)

Ring

(6)

Boom cylinder

(7)

Hydraulic tube

5 - 56

Attachment

Backhoe

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Blind plugs (per hose): 2 x SAE A2-6000, PN 506 582 98; 2 x SAE B2-6000, PN 506 527 98 Boom cylinder hose: 20.4 kg

Dogman/rigger


WARNING z


z


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. 5-54 z


z


z

Open the hose clamps (Fig. 5-52, Pos. 1) and clear the hydraulic hose (Fig. 5-52, Pos. 6) to be removed from the clamp lines (Fig. 5-52, Pos. 2 and 3).

5 - 57

Backhoe

Attachment

Fig. 5-55 Hoses of the boom cylinders, 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 - 58

Attachment

Backhoe


z

Sling the hydraulic hose (Fig. 5-55, Pos. 1 or 2) to be removed.

z

Remove the bolts (Fig. 5-55, Pos. 4) and disconnect the SAE-flanges at the boom cylinder (Fig. 5-55, Pos. 6) and the hydraulic tube (Fig. 5-55, Pos. 7) 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. 5-55, Pos. 3) and the rings (Fig. 5-55, Pos. 5) at the SAE-flange connections. z

Substitute all other boom cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the boom cylinder(s). Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


z


z

Check hydraulic oil level again and add oil if required.

5 - 59

Backhoe

Attachment

5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES

Fig. 5-56 Hoses of the stick cylinders, removal and installation (1)

Bolt

(2)

O-ring

(3)

Ring

(4)

Hydraulic hose

(5)

Hydraulic hose

(6)

Hydraulic cylinder

5 - 60

Attachment

Backhoe

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Blind plugs (per hose): 2 x SAE A2-6000, PN 506 582 98; 2 x SAE B2-6000, PN 506 527 98 Stick cylinder hose: 24.4 kg

Dogman/rigger


WARNING z


z


z


z




z


5 - 61

Backhoe

Attachment

Fig. 5-58 Hoses of the stick cylinders, 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.


z


5 - 62

Attachment

z

Backhoe

Remove the bolts (Fig. 5-58, Pos. 1) and disconnect the SAE-flanges at the stick cylinder and the hydraulic tube at the boom.



z

Replace the stick cylinder hoses by new ones and carry out installation in reverse order to removal.


Substitute all other stick cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the stick cylinder(s). Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


z


z


5 - 63

Backhoe

5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES

Fig. 5-59 Hoses of the bucket cylinders, removal and installation

5 - 64

Attachment

Attachment

Backhoe


Hydraulic hose

(2)

Bolt

(3)

O-ring

(4)

Ring

(5)

Hydraulic tube

(6)

Hose clamp

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Blind plugs (per hose): 2 x SAE A2-6000, PN 506 582 98; 2 x SAE B2-6000, PN 506 527 98 Bucket cylinder hose: 27.2 kg

Dogman/rigger


WARNING z


z


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. 5-60

5 - 65

Backhoe

Fig. 5-61 Hoses of the bucket cylinders, removal and installation

5 - 66

Attachment

Attachment

Backhoe

z


z




z

Remove the hose clamp (Fig. 5-61, Pos. 6) from the hydraulic hose to be removed.

z


z

Remove the bolts (Fig. 5-61, Pos. 2) and disconnect the SAE-flanges from the bucket cylinder and the hydraulic tube (Fig. 5-61, Pos. 5) at the boom.



z

Replace the bucket cylinder hoses by new ones and carry out installation in reverse order to removal.


Substitute all other bucket cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the bucket cylinder(s). Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


z


z


5 - 67

Backhoe

Attachment


5 - 68

Attachment

5.2

Faceshovel

FACESHOVEL

Fig. 5-62 Faceshovel attachment overview (1)

Bullclam bucket (clam)

(2)

Bullclam bucket (wall)

(3)

Stick

(4)

Boom

(5)

Bucket cylinder

(6)

Boom cylinder

(7)

Stick cylinder

5 - 69

Faceshovel

5.2.1

Attachment

BOOM

5.2.1.1 REMOVAL OF THE BOOM

Fig. 5-63 Boom removal (1)

Boom

(2)

Pin

(3)

Shackle

(4)

Bolt

(5)

Shackle

(6)

Bolt

(7)

Pin

(8)

Chain hoist

5 - 70

Attachment

Faceshovel

Special tools:

Installation tool, PN 909 543 40 Installation tool, PN 923 828 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform 2 x Crane 4 x Chain hoist Oil drain pan Blind plugs: 8 x SAE A2-6000, PN 506 582 98; 8 x SAE B2-6000, PN 506 527 98 6 x SAE A1 1/2-6000, PN 506 581 98 6 x SAE B1 1/2-6000, PN 506 526 98 BUZ 25-S, PN 371 867 99 and ROV 25-PS, PN 508 033 98 Boom with attached stick and boom cylinders: 34,600 kg Pin boom/superstructure: 194 kg Pin boom cylinder/superstructure: 100 kg Dogman/rigger Crane operators trained in dual crane lift

WARNING z


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. 5-64).



z


z

Remove the stick, refer to section 5.2.2 on page 5-88.

Fig. 5-64

NOTE: Leave the stick cylinders retracted and fixed to the boom. Secure them under the boom using chain hoists. It is recommended to use the installation tools PN 909 543 40.

5 - 71

Faceshovel

Attachment

Fig. 5-65 Boom removal z

Tie the moving rods to the stick cylinder bodies with a wire rope (refer to Fig. 5-39).

z

Disconnect the grease feeding lines leading to the boom.

z

Fix the boom cylinders at the boom using chain hoists (Fig. 5-65, Pos. 8).

NOTE: It is recommended to use the installation tools PN 923 828 40 z

Attach the boom to two cranes. WARNING

Make sure that the crane operators are trained in dual crane lift.

5 - 72

Attachment

Faceshovel

z

Remove the bolts (Fig. 5-65, Pos. 6) and the shackles (Fig. 5-65, Pos. 5) securing the pins (Fig. 5-65, Pos. 7).

z

Remove the pins (Fig. 5-65, Pos. 7) attaching the boom cylinders to the superstructure. Note the seals. WARNING


z


z

At low idle, retract the boom cylinders.

z

Tie the moving rods to the boom cylinder body with a wire rope (refer to Fig. 5-39).

z


z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM". DANGER


z

Disconnect all hydraulic lines leading to the boom, refer to section 5.2.5.1 on page 5-126.


Remove the bolts (Fig. 5-65, Pos. 4) and the shackles (Fig. 5-65, Pos. 3) securing the pins (Fig. 5-65, Pos. 2).

z

Remove the pins (Fig. 5-65, Pos. 2) attaching the boom to the superstructure. WARNING


5 - 73

Faceshovel

z

Attachment

Remove the boom with attached stick cylinders and boom cylinders using two cranes. Place it on appropriate blocks. 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 5.2.1.3 on page 5-80 and remove the boom cylinders from the boom.

z

Remove the pins of the stick cylinders, refer to section 5.2.2.3 on page 5-94 and remove the stick cylinders from the boom.

z

Remove all provided parts and hydraulic pipings from the boom.

5 - 74

Attachment

Faceshovel

5.2.1.2 REPLACEMENT OF THE BOOM Special tools:

Installation tool, PN 909 543 40 Installation tool, PN 923 828 40


Safety harness in conformity with DIN EN 361 2 x Crane 4 x Chain hoist Mobile elevator working platform Boom with attached stick and boom cylinders: 34,600 kg Pin boom/superstructure: 194 kg Pin boom cylinder/superstructure: 100 kg Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-66, Pos. 3) and install new seals! Insert new bushes (Fig. 5-66, Pos. 2) into the boom (Fig. 5-66, Pos. 1) if required! Put the appropriate grease in every bush (Fig. 5-66, Pos. 2) on assembly!

Fig. 5-66 z

Install all provided parts and hydraulic pipings to the boom.

NOTE: Tie the moving rods to the new cylinder body with a wire rope (refer to Fig. 5-39). z

Install the boom cylinders to the boom in reverse order to removal, refer to section 5.1.1.4 on page 5-15.

z

Install the stick cylinders to the boom in reverse order to removal, refer to section 5.1.2.4 on page 5-29.

NOTE: Make sure the hydraulic hoses are already connected to the cylinders at this state.

5 - 75

Faceshovel

Attachment

Fig. 5-67 FSA boom installation z

Fix the cylinders at the boom using chain hoists (Fig. 5-67, Pos. 8). It is recommended to use the installation tools PN 923 828 40 and PN 909 543 40.

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. 5-67, 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.

5 - 76

Attachment

Faceshovel

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. 5-67, Pos. 1) with the superstructure. DANGER


z

Insert the two pins (Fig. 5-67, Pos. 2).

z

Install the shackles (Fig. 5-67, Pos. 3), and bolts (Fig. 5-67, Pos. 4) to secure the pins (Fig. 5-67, Pos. 2).

z

Connect the hydraulic lines for the boom cylinders, leading to the boom, refer to section 5.2.5.1 on page 5-126.

WARNING Do not open the plugged hydraulic ports for the cylinders when the wire ropes are removed, because the cylinder rods may start sliding by their own mass. First connect the hydraulic line, then remove the wire ropes.

z

Remove the wire ropes from the boom cylinders.

z

Perform the bleeding procedure for the boom cylinders. Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


NOTE: Lower the boom cylinder and align the cylinder to the superstructure using the chain hoist (Fig. 5-67, Pos. 8). z

Extend the boom cylinder at low idle as needed to align cylinder and superstructure. DANGER


z

Insert the pin (Fig. 5-67, Pos. 7).

z


z

Install the shackle (Fig. 5-67, Pos. 5) and the bolt (Fig. 5-67, Pos. 6) to secure the pin (Fig. 5-67, Pos. 7).

5 - 77

Faceshovel

Attachment

z

Fix the other boom cylinder using the same procedure as above.

z

Connect the hydraulic lines for the stick cylinders, leading to the boom, refer to section 5.2.5.1 on page 5-126. WARNING

Don not open the plugged hydraulic ports for the cylinders when the wire ropes are removed, because the cylinder rods may start sliding by their own mass. First connect the hydraulic line, then remove the wire ropes.

z

Remove the wire ropes from the stick cylinders.

z

Perform the bleeding procedure for the stick cylinders. Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


z


z


z


z


z


5 - 78

Attachment

Faceshovel


5 - 79

Faceshovel

5.2.1.3 REMOVAL OF THE BOOM CYLINDERS

Fig. 5-68 Boom cylinder, removal and installation

5 - 80

Attachment

Attachment

Faceshovel


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 wit SAE-flange

(13)

Bolt

(14)

Bush

(15)

Bush

(16)

Pin

(17)

Superstructure

(18)

Shackle

(19)

Bolt

Special tools:

Installation tool, PN 923 828 40


Safety harness in conformity with DIN EN 361 Crane Chain hoist Forklift 6 t Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Blind plugs (per cylinder): 2 x SAE A2-6000, PN 506 582 98; 2 x SAE B2-6000, PN 506 527 98 Boom cylinder: 3521 kg Pin boom cylinder/superstructure: 100 kg Pin boom cylinder/boom: 150 kg

Dogman/rigger

5 - 81

Faceshovel

Attachment

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. 5-69).



z


z

Disconnect the grease feeding lines from the boom cylinder(s) to be removed.

z

Install the installation tool PN 923 828 40 at the boom cylinder’s moving rod side.

z

Sling the lower end of the boom cylinder (Fig. 5-70, Pos. 1) by means of the installation tool and fix it to the boom (Fig. 5-70, Pos. 2) using a chain hoist.

z

Remove the bolt (Fig. 5-70, Pos. 3) and the shackle (Fig. 5-63, Pos. 4) securing the pin (Fig. 5-70, Pos. 5).

z

Remove the pin (Fig. 5-70, Pos. 5) attaching the boom cylinders to the superstructure. Note the seals. WARNING


z


z

At low idle, fully retract the boom cylinder.

z


z

Tie the moving rods to the boom cylinder body with a wire rope (refer to Fig. 5-39).

5 - 82

Fig. 5-69

Fig. 5-70

Attachment

Faceshovel

z


z

Lower the boom cylinder with the chain hoist until the cylinder is in vertical position. WARNING



z

Disconnect the hydraulic hoses from the boom cylinder, refer to section 5.1.6.2 on page 5-56.

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

Change the installation tool PN 923 828 40 to the upper end of the boom cylinder.

z

Support the boom cylinder by means of the installation tool using the forks of the forklift.

z

Remove the bolts (Fig. 5-71, Pos. 1), the cover (Fig. 5-71, Pos. 2), and the ring (Fig. 5-71, Pos. 3).

z

Remove the pin (Fig. 5-71, Pos. 4) with the catches (Fig. 5-71, Pos. 5) as well as the seals (Fig. 5-72, Pos. 2) at the boom cylinder. WARNING


Fig. 5-71

5 - 83

Faceshovel

Attachment

z

Remove the boom cylinder using the forklift.

z

Sling the boom cylinder and place it on the ground using a crane. 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


5 - 84

Attachment

Faceshovel

5.2.1.4 REPLACEMENT OF THE BOOM CYLINDERS Special tools:



Safety harness in conformity with DIN EN 361 Chain hoist Crane Forklift 6 t Mobile elevator working platform (telescopic or articulated boom lift) Boom cylinder: 3521 kg Pin boom cylinder/superstructure: 100 kg Pin boom cylinder/boom: 150 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-72, Pos. 2) and install new seals! Insert new bushes (Fig. 5-72, Pos. 3) into the boom cylinder (Fig. 5-72, Pos. 1) if required! Put the appropriate grease in every bush on assembly!

Fig. 5-72 z

If required, install the pipe work, the connecting blocks, and the seals at the cylinder(s).

z

Install the installation tool PN 923 828 40 at the upper end of the new boom cylinder.

z

Sling the boom cylinder and place it on the forklift in a vertical position so that the upper end of the cylinder is at the top and that the cylinder is supported by means of the installation tool.

5 - 85

Faceshovel

Attachment

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 upper end of the boom cylinder with the superstructure using the forklift. DANGER


z

Insert the pin (Fig. 5-73, Pos. 4) with the catches (Fig. 5-73, Pos. 5) and mount the seals (Fig. 5-72, Pos. 2) at the boom cylinder.

z

Install the ring (Fig. 5-73, Pos. 3), the cover (Fig. 5-73, Pos. 2), and the bolts (Fig. 5-73, Pos. 1).

z

Connect the hydraulic lines to the boom cylinder, refer to section 5.1.6.2 on page 5-56. WARNING

Do not open the plugged hydraulic ports at the cylinder when the wire ropes are removed, because the cylinder rod starts sliding by its own mass. First connect the hydraulic line, then remove the wire ropes.


Remove the wire ropes from the boom cylinders.

z

Perform the bleeding procedure for the boom cylinder. Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


z

Change the installation tool PN 923 828 40 to the moving rod side of the boom cylinder.

5 - 86

Fig. 5-73

Attachment

Faceshovel

z

Sling the boom cylinder at the moving rod side by means of the installation tool using a chain hoist. Fix the chain hoist to the boom.

z


z

Hoist the boom cylinder and align the cylinder and the superstructure using the chain hoist.

NOTE: Extract the boom cylinder at low idle as needed to align the cylinder and the superstructure. DANGER Never put hands into the holes when aligning the boom to the superstructure.

z


z

Insert the pin (Fig. 5-74, Pos. 5).

z

Install the shackle (Fig. 5-74, Pos. 4), and the bolt (Fig. 5-74, Pos. 3) to secure the pin (Fig. 5-74, Pos. 5).

z


z


z


z


z


z


Fig. 5-74

5 - 87

Faceshovel

5.2.2

Attachment

STICK

5.2.2.1 REMOVAL OF THE STICK

Fig. 5-75 Stick, removal and installation

5 - 88

Attachment

Faceshovel


Boom

(2)

Stick

(3)

Bush

(4)

Seal ring

(5)

Catch

(6)

Pin

(7)

Ring

(8)

Cover

(9)

Bolt

(10)

Seal

(11)

Seal

(12)

Flange bush

(13)

Bush

(14)

Pin

(15)

Shackle

(16)

Bolt

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Blind plugs: 2 x SAE A2-6000, PN 506 582 98; 2 x SAE B2-6000, PN 506 527 98 4 x SAE A1 1/2-6000, PN 506 581 98 4 x SAE B1 1/2-6000, PN 506 526 98 BUZ 25-S, PN 371 867 99 and ROV 25-PS, PN 508 033 98 Stick: 14,350 kg Pin stick/boom: 197 kg Pin stick cylinder/stick: 58 kg

Dogman/rigger

WARNING z


z


5 - 89

Faceshovel

Attachment

z


z




z

Remove the bull clam bucket, refer to section 5.2.3.1 on page 5-102.

z

Hook up both stick cylinders (Fig. 5-77, Pos. 1) using chain hoists (Fig. 5-77, Pos. 2).

z


z

Remove the pin (Fig. 5-77, Pos. 3).

Fig. 5-76

WARNING Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling.

NOTE: Note the seals (Fig. 5-77, Pos. 5) when removing the pin. z

Check the bushes (Fig. 5-77, Pos. 6) and replace if required.

z

Remove all grease feeding lines from the stick.

z


z

At low idle, retract the stick cylinders (Fig. 5-77, Pos. 1).

z


z


5 - 90

Fig. 5-77

Attachment

Faceshovel


z

Disconnect all hydraulic hoses from the stick leading to the boom, 5.2.5, refer to section 5.2.5.3 on page 5-134.

z

Sling the stick (Fig. 5-78, Pos. 1) and lift it using a crane.

z

Remove the bolts (Fig. 5-78, Pos. 2), the covers (Fig. 5-78, Pos. 3), and the rings (Fig. 5-78, Pos. 4).

z

Remove the pins (Fig. 5-78, Pos. 6) with the catches (Fig. 5-78, Pos. 5). WARNING

Sling the pins as soon as it is 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. 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 hydraulic pipings from the stick (Fig. 5-78, Pos. 1).

Fig. 5-78

5 - 91

Faceshovel

Attachment

5.2.2.2 REPLACEMENT OF THE STICK Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Stick: 14,350 kg Pin stick/boom: 197 kg Pin stick cylinder/stick: 58 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-79, Pos. 3) and install new seals! Insert new bushes (Fig. 5-79, Pos. 2) into the stick (Fig. 5-79, Pos. 1) if required! Put the appropriate grease in every bush (Fig. 5-79, Pos. 2) on assembly!

Fig. 5-79

5 - 92

Attachment

Faceshovel

z

Install all provided parts and hydraulic pipings to the stick (Fig. 5-80, Pos. 1).

z

Sling the stick (Fig. 5-80, 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. 5-80, Pos. 6) attaching the stick (Fig. 5-80, Pos. 1) to the boom.

z

Install the catches (Fig. 5-80, Pos. 5), the rings (Fig. 5-80, Pos. 4), the covers (Fig. 5-80, Pos. 3), and the bolts (Fig. 5-80, Pos. 2) to secure the pins (Fig. 5-80, Pos. 6).

z

Bring the stick to the position shown in Fig. 5-81 using the crane.

z


z

At low idle, extract the stick cylinders (Fig. 5-81, Pos. 1) to align the stick cylinders with the stick horizontally. Use the chain hoists (Fig. 5-81, Pos. 2) to align the stick cylinders with the stick vertically.

Fig. 5-80

DANGER Never put hands into the holes when aligning the stick cylinders to the stick.

z

Put the appropriate grease in the bushes (Fig. 5-81, Pos. 6) and install the pins (Fig. 5-81, Pos. 3) with new seals (Fig. 5-81, Pos. 5).

z

Install the shackle (Fig. 5-81, Pos. 4) and the bolts (Fig. 5-81, Pos. 7) to secure the pin (Fig. 5-81, Pos. 3).

Fig. 5-81

5 - 93

Faceshovel

z


z


z


z


z


z


5.2.2.3 REMOVAL OF THE STICK CYLINDERS

Fig. 5-82 Stick cylinder, removal and installation

5 - 94

Attachment

Attachment

Faceshovel


Stick cylinder

(2)

Boom

(3)

Stick

(4)

Seal

(5)

O-ring

(6)

Connecting block

(7)

Pipe

(8)

Pin

(9)

Hydraulic hose

(10)

Seal

(11)

Bush

(12)

Bolt

(13)

Catch

(14)

Pin

(15)

Catch

(16)

Bolt

Special tools:



Safety harness in conformity with DIN EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Forklift 5 t Oil drain pan Blind plugs (per cylinder): SAE A2-6000, PN 506 582 98; SAE B2-6000, PN 506 527 98 SAE A1 1/2-6000, PN 506 581 98; SAE B1 1/2-6000, PN 506 526 98 Stick cylinder: 2400 kg each Pin stick cylinder/boom: 50 kg Pin stick cylinder/stick: 58 kg

Dogman/rigger

WARNING z


z


5 - 95

Faceshovel

Attachment

z


z




z


z

Remove the boom cylinder on the side of the machine on which the stick cylinder needs to be removed, refer to section 5.1.1.3 on page 5-10.

z

Remove the grease feeding lines from the stick cylinder(s) to be removed.

z

Hook up the stick cylinder(s) (Fig. 5-84, Pos. 1) to be removed using chain hoists.

Fig. 5-83

NOTE: It is recommended to use the installation tool PN 909 543 40. z

Pull out the pin connecting the stick cylinder moving rod to the stick, refer to section 5.2.2.1 on page 5-88. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling when it is pulled out completely.

NOTE: Pull out the pin just far enough to clear the moving rod of the cylinder to be removed. Only pull out the pin completely, if both cylinders need to be removed. z


z

At low idle retract the stick cylinder(s) (Fig. 5-84, Pos. 1).

z


z


z


5 - 96

Fig. 5-84

Attachment

Faceshovel



z

Disconnect the hydraulic hoses from the stick cylinder, refer to section 5.2.5.4 on page 5-138.


Support the stick cylinder using the forks of a forklift.

z

Remove the bolts (Fig. 5-85, Pos. 1) and the catch (Fig. 5-85, Pos. 2), securing the pin (Fig. 5-85, Pos. 3).

z

Pull out the pin (Fig. 5-85, Pos. 3) just far enough to clear the cylinder to be removed. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling when it is pulled out completely.

NOTE: Only pull out the pin completely, if both cylinders need to be removed. Note the seals (Fig. 5-85, Pos. 4) when removing the pin. Fig. 5-85 z

Check bush (Fig. 5-85, Pos. 5) and replace if required.

5 - 97

Faceshovel

Attachment

z

Remove the stick cylinder using the forklift.

z

Sling stick cylinder and place it on the ground using a crane. 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


5 - 98

Attachment

Faceshovel

5.2.2.4 REPLACEMENT OF THE STICK CYLINDERS Special tools:



Safety harness in conformity with DIN EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Forklift 5 t Stick cylinder: 2400 kg each Pin stick cylinder/boom: 50 kg Pin stick cylinder/stick: 58 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Insert new bushes into the stick cylinder if required! Put the appropriate grease in every bush on assembly! z

If required, install the pipe work, the connecting blocks, and the seals at the cylinder(s).

z

Sling stick cylinder and place it in mounting position horizontally on the forks of a forklift using a crane. 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.

5 - 99

Faceshovel

z

Attachment

Align the stick cylinder to the boom using the forklift. DANGER

Never put hands into the holes when aligning the stick cylinders to the stick.

z

Insert the pin (Fig. 5-86, Pos. 3) and the seals (Fig. 5-86, Pos. 4).

z

Install the catch (Fig. 5-86, Pos. 2) and the bolts (Fig. 5-86, Pos. 1) to secure the pin (Fig. 5-86, Pos. 3).

Fig. 5-86 z

Hook up the stick cylinder (Fig. 5-87, Pos. 1) using a chain hoist.

NOTE: It is recommended to use the installation tool PN 909 543 40. z

Connect the hydraulic hoses to the stick cylinder, refer to section 5.2.5.4 on page 5-138. hier

z

Install the pin connecting the stick cylinder with the stick, refer to section 5.1.2.2 on page 5-22.

Fig. 5-87 z


z


z


z


z


z


5 - 100

Attachment

Faceshovel


5 - 101

Faceshovel

5.2.3

Attachment

BULLCLAM BUCKET

5.2.3.1 REMOVAL OF THE BULL CLAM BUCKET

Fig. 5-88 Bullclam bucket, removal and installation

5 - 102

Attachment

Faceshovel


Bullclam bucket

(2)

Bush

(3)

Seal

(4)

Pin

(5)

Axle stirrup

(6)

Catch

(7)

Shackle

(8)

Bolt

(9)

Bush

(10)

Pin

(11)

Axle stirrup

(12)

Catch

(13)

Shackle

(14)

Bolt

(15)

Bucket cylinder

Special tools:

n/a


Crane Oil drain pan Blind plugs: 2 x SAE A1 1/4-6000, PN 506 520 98 2 x SAE B1 1/4-6000, PN 506 525 98 2 x BUZ 12-L, PN 371 854 99 and 2 x ROV 12-PL, PN 513 547 98 Bucket (without lip): 24,275 kg Pin bucket cylinder/bucket: 125 kg Pin bucket/stick: 180 kg

Dogman/rigger

5 - 103

Faceshovel

Attachment

z


z




z


z

Disconnect the grease feeding lines leading to the bucket. WARNING



z

Disconnect the hydraulic hoses from the clam cylinder distributor blocks, refer to section 5.2.5.6 on page 5-146.


5 - 104

Fig. 5-89

Attachment

z

Faceshovel

Remove the seal fixing rings (Fig. 5-90, Pos. 1) from the pin (Fig. 5-90, Pos. 4) located on both sides of the cylinder respectively the stick (Fig. 5-90, Pos. 3).

NOTE: Always use new seals (Fig. 5-90, Pos. 2).

Fig. 5-90 z

Remove the cover (Fig. 5-91, Pos. 2) from the bucket (Fig. 5-91, Pos. 1) to access the pin.

Fig. 5-91

5 - 105

Faceshovel

Fig. 5-92 Bullclam bucket removal z

Sling the bucket cylinders (Fig. 5-92, Pos. 15) to prevent them from swinging when the pins (Fig. 5-92, Pos. 10) are removed.

z

Remove the bolts (Fig. 5-92, Pos. 14) with washers and the shackle (Fig. 5-92, Pos. 13).

z

Pull out the pin (Fig. 5-92, Pos. 10) just enough to remove the axle stirrups (Fig. 5-92, Pos. 11) from the catches (Fig. 5-92, Pos. 12).

NOTE: The catches (Fig. 5-92, Pos. 12) are welded to the bucket (Fig. 5-92, Pos. 1).

5 - 106

Attachment

Attachment

z

Faceshovel

Pull out the pin (Fig. 5-92, Pos. 10) completely to clear the bucket cylinder (Fig. 5-92, Pos. 15). Remove the seals (Fig. 5-90, Pos. 2) when removing the pin. WARNING


z

Remove the bolts (Fig. 5-92, Pos. 8) with washers and the shackle (Fig. 5-92, Pos. 7).

z

Pull out the pins (Fig. 5-92, Pos. 4) just enough to remove the axle stirrups (Fig. 5-92, Pos. 5) from the catches (Fig. 5-92, Pos. 6).

NOTE: The catches (Fig. 5-92, Pos. 6) are welded to the bucket. z

Pull out the pins (Fig. 5-92, Pos. 4) completely and remove the seals (Fig. 5-92, Pos. 3). Also remove the bushes (Fig. 5-90, Pos. 2) when removing the pins.

NOTE: It is recommended to weld an angle steel (Fig. 5-93, Pos. 1) between the pin bearings (Fig. 5-93, Pos. 2) at the bucket’s backside to hold the pins (Fig. 5-93, Pos. 3). WARNING For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIR".

Fig. 5-93 z

Check bushes (Fig. 5-92, Pos. 2 and 9) for wear or damage and replace if required.

z


z

At low idle, lift the boom and move the excavator away.

z


5 - 107

Faceshovel

Attachment

5.2.3.2 REPLACEMENT OF THE BULL CLAM BUCKET Special tools:

n/a


n/a Bucket (without lip): 24,275 kg Pin bucket cylinder/bucket: 125 kg Pin bucket/stick: 180 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.3 on page 2-29. NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-90, Pos. 2) and install new seals! Insert new bushes into the stick if required! Put the appropriate grease in every bush (Fig. 5-92, Pos. 2 and 9) on assembly! z


NOTE: Perform the bleeding procedure for the clam cylinder. Refer to PARTS & SERVICE BULLETIN No. "AH06524". z


z


z


z


z


5 - 108

Attachment

Faceshovel


5 - 109

Faceshovel

5.2.3.3 REMOVAL OF THE BUCKET CYLINDERS

Fig. 5-94 Bucket cylinders, removal and installation

5 - 110

Attachment

Attachment

Faceshovel


Bucket cylinder

(2)

Stick

(3)

Boom

(4)

Axle stirrup

(5)

Pin

(6)

Ring

(7)

Cover

(8)

Bolt

(9)

Bullclam bucket

(10)

Bush

(11)

Seal fixing ring

(12)

Seal

(13)

Catch

(14)

Shackle

(15)

O-ring

(16)

SAE-flange

Special tools:



Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Forklift 5 t Oil drain pan Blind plugs (per cylinder): SAE A1 1/2-6000, PN 506 581 98; SAE B1 1/2-6000, PN 506 526 98 SAE A2-6000, PN 506 582 98; SAE B2-6000, PN 506 527 98 Bucket cylinder: 2730 kg Pin bucket cylinder/boom: 108 kg Pin bucket cylinder/bucket: 125 kg

Dogman/rigger

WARNING z


z


5 - 111

Faceshovel

Attachment

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. 5-95), 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 909 348 40 at the moving rod side of the bucket cylinder.

z

Support the bucket cylinder by means of the installation tool using the forks of a forklift.

z

Remove the bolts (Fig. 5-96, Pos. 1), the cover (Fig. 5-96, Pos. 2), and the ring (Fig. 5-96, Pos. 3).

z

Remove the pin (Fig. 5-96, Pos. 4) with the catches (Fig. 5-96, Pos. 5) as well as the seals at the bucket cylinder.

Fig. 5-95

WARNING Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling.

Fig. 5-96 z


z

At low idle, fully retract the bucket cylinder.

z


z

Tie the moving rods to the bucket cylinder body with a wire rope (refer to Fig. 5-39).

z


5 - 112

Attachment

Faceshovel



z

Disconnect the hydraulic hoses from the bucket cylinder, refer to section 5.2.5.5 on page 5-142.


Remove the seal fixing rings (Fig. 5-97, Pos. 1) from the pin (Fig. 5-97, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-97, Pos. 3).

NOTE: Always use new seals (Fig. 5-97, Pos. 2). z

Remove the pin connecting the bucket cylinder to the bucket, refer to section 5.2.3.1 on page 5-102.

Fig. 5-97 z

Remove the bucket cylinder using the forklift.

z

Sling the bucket cylinder and place it on the ground using a crane. 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.

5 - 113

Faceshovel

Attachment

5.2.3.4 REPLACEMENT OF THE BUCKET CYLINDERS Special tools:



Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Forklift 5 t Bucket cylinder: 2730 kg Pin bucket cylinder/boom: 108 kg Pin bucket cylinder/bucket: 125 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-98, Pos. 2) and install new seals! Insert new bushes (Fig. 5-98, Pos. 3) into the bucket cylinder (Fig. 5-98, Pos. 1) if required! Put the appropriate grease in every bush on assembly! z

Install the installation tool, PN 909 348 40 at the moving rod side of the new bucket cylinder. Fig. 5-98

z

Sling the bucket cylinder and place it on the forklift using a crane. 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.

NOTE: Place the cylinder on the forklift in a vertical position by means of the installation tool with the moving rod facing up.

5 - 114

Attachment

z

Faceshovel

Align the bucket cylinder with the bucket. DANGER

Never put hands into the holes when aligning the cylinder to the bucket.

z

Insert the pin (Fig. 5-99, Pos. 1) and the seals (Fig. 5-100, Pos. 2). Secure the pin with the axle stirrups (Fig. 5-99, Pos. 2) in the catches (Fig. 5-99, Pos. 3).

z

Install the shackle (Fig. 5-99, Pos. 4) and insert the bolts (Fig. 5-99, Pos. 5) with washers.

Fig. 5-99 z

Install the seal fixing rings (Fig. 5-100, Pos. 1) at the pin (Fig. 5-100, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-100, Pos. 3) to fix the seals (Fig. 5-100, Pos. 2).

z

Remove the wire ropes from the cylinder.

z

Connect the hydraulic lines to the bucket cylinder, refer to section 5.2.5.5 on page 5-142.


Perform the bleeding procedure for the bucket cylinder. Refer to PARTS & SERVICE BULLETIN No. "AH06524". Fig. 5-100

z


z

At low idle, extract the bucket cylinder and align the moving rod with the boom. DANGER

Never put hands into the holes when aligning the bucket cylinder to the boom.

5 - 115

Faceshovel

z

Insert the pin (Fig. 5-101, Pos. 4) with the catches (Fig. 5-101, Pos. 5) and mount the seals (Fig. 5-98, Pos. 2) at the bucket cylinder.

z

Install the ring (Fig. 5-101, Pos. 3), the cover (Fig. 5-101, Pos. 2), and the bolts (Fig. 5-101, Pos. 1).

z


z


Attachment

Fig. 5-101 z


z


z


z


z


z


5 - 116

Attachment

Faceshovel


5 - 117

Faceshovel

Attachment

5.2.3.5 REMOVAL OF THE CLAM CYLINDERS

Fig. 5-102 Clam cylinders, removal and installation (1)

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

5 - 118

Attachment

Faceshovel

Special tools:

n/a


Crane Blind plugs (per cylinder): 2 x SAE A1 1/4-6000, PN 506 520 98 2 x SAE B1 1/4-6000, PN 506 525 98 Clam cylinder: 585 kg Upper pin: 30 kg Lower pin: 40 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. 5-103).



z


z

Support the clam cylinder at the front side and from below with appropriate blocks (Fig. 5-104, arrows) to fix it in its position.

z

Disconnect the grease feeding lines from the clam cylinder.

Fig. 5-103

Fig. 5-104

5 - 119

Faceshovel

z

Attachment

Remove the bolts (Fig. 5-105, Pos. 1) and the cover (Fig. 5105, Pos. 2) to access the pin connecting the clam cylinder to the clam.

Fig. 5-105 z

Remove the bolts (Fig. 5-106, Pos. 6) and the cover (Fig. 5106, Pos. 5).

z

Pull out the pin (Fig. 5-106, Pos. 4) to clear the clam cylinder (Fig. 5-106, Pos. 2) from the clam (Fig. 5-106, Pos. 1). Remove the seals (Fig. 5-106, Pos. 3).

Fig. 5-106 z


z

At low idle, fully retract the clam cylinder. WARNING

Both clam cylinders are connected to the same hydraulic line, so when the cleared cylinder is fully retracted, the clam will open. Do not open the clam.

z


z

Tie the moving rods to the clam cylinder body with a wire rope (refer to Fig. 5-39).

z


5 - 120

Attachment

Faceshovel



z

Disconnect the hydraulic hoses (Fig. 5-107, Pos. 1) from the clam cylinder.

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 (Fig. 5-107, Pos. 2).

Fig. 5-107 z

Remove the bolt (Fig. 5-108, Pos. 1) and the plate (Fig. 5108, Pos. 2).

z

Pull out the pin (Fig. 5-108, Pos. 3) using pulling bolts.

z

Sling the clam cylinder and remove it 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.

Fig. 5-108

5 - 121

Faceshovel

Attachment

5.2.3.6 REPLACEMENT OF THE CLAM CYLINDERS Special tools:

n/a


Crane Clam cylinder: 585 kg Upper pin: 30 kg Lower pin: 40 kg

Dogman/rigger


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-109, Pos. 2) and install new seals! Insert new bushes (Fig. 5-109, Pos. 1) into the clam cylinder if required! Put the appropriate grease in every bush on assembly!

Fig. 5-109 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 at the front side and from below with appropriate blocks (Fig. 5-110, arrows) to fix it in its position. Fig. 5-110

5 - 122

Attachment

Faceshovel

z

Insert the pin (Fig. 5-111, Pos. 3) and install the seals. Fix the pin with the plate (Fig. 5-111, Pos. 2).

z

Secure the plate with the bolt (Fig. 5-111, Pos. 1).

Fig. 5-111

z

Connect the hydraulic hoses (Fig. 5-112, Pos. 1) to the clam cylinder.

NOTE: Use new O-rings (Fig. 5-112, Pos. 2) at the SAE-flange connections. z

Remove the wire ropes from the cylinder.

z


z

Perform the bleeding procedure for the clam cylinder. Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z

At low idle, extract the clam cylinder and align the cylinder moving rod with the clam.

Fig. 5-112

DANGER Never put hands into the holes when aligning the clam cylinder to the clam.

z

Insert the pin (Fig. 5-113, Pos. 4) connecting clam cylinder (Fig. 5-113, Pos. 2) and clam (Fig. 5-113, Pos. 1) and install the seals (Fig. 5-113, Pos. 3).

z

Install the cover (Fig. 5-113, Pos. 5) and the bolts (Fig. 5-113, Pos. 6).

z


z


z


z


z


z


Fig. 5-113

5 - 123

Faceshovel

5.2.4

Attachment

GROUND ENGAGING TOOLS (GET)

As ground engaging tools (Fig. 5-114, Pos. 1), the ESCO POSILOK Tooth System is used.

Fig. 5-114

5.2.4.1 REMOVAL AND REPLACEMENT OF THE GET Special tools:

POSILOK Pin removal tool PN 795 502 73 Hensley Pin removal tool (ask local dealer)


ESCO POSILOK Tooth System S110 Hensley Tooth System (ask local dealer) Forklift Point (tooth): * kg (Hensley), 48 kg (ESCO) Tooth (center) adapter: * kg (Hensley), 287 kg (ESCO) Corner adapter: * kg (Hensley), 674 kg (ESCO) Shroud: * kg (Hensley), 163 kg (ESCO) Wear caps: * kg (Hensley), 30 kg (ESCO) NOTE: * ask local dealer

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.

5 - 124

Attachment

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.

Faceshovel



z

For removing and installing the ESCO Tooth System, refer to PARTS & SERVICE BULLETIN No. "AH03510".

z

Remove and install the Hensley Tooth System accordingly to PARTS & SERVICE BULLETIN No. "AH03510", Hensley uses basically the similar system.

NOTE: Use a forklift to remove and install the GET.

5 - 125

Faceshovel

5.2.5

Attachment

HYDRAULIC HOSES AT THE FACESHOVEL ATTACHMENT

5.2.5.1 SUBSTITUTE THE BOOM ARC HOSES

Fig. 5-115 Boom arc hoses, removal and installation 5 - 126

Attachment

Faceshovel


Hose clamp

(2)

Clamp line

(3)

Clamp line

(4)

Manifold

(5)

Hydraulic tube

(6)

Hydraulic hose

(7)

Bolt

(8)

O-ring

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Blind plugs (per hose, depending on type): 2 x SAE A1 1/2-6000, PN 506 581 98 2 x SAE B1 1/2-6000, PN 506 526 98 or 2 x SAE A2-6000, PN 506 582 98; 2 x SAE B2-6000, PN 506 527 98 Boom arc hose (2"): 40 kg Boom arc hose (1 1/2"): 26 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the 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. 5-116).

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. 5-116 5 - 127

Faceshovel

Fig. 5-117 Boom arc hoses, removal and installation

5 - 128

Attachment

Attachment

Faceshovel

z


z


z

Open the hose clamps (Fig. 5-117, Pos. 1) and clear the hydraulic hose (Fig. 5-117, Pos. 6) to be removed from the clamp lines (Fig. 5-117, Pos. 2 and 3). WARNING



z


z

Remove the bolts (Fig. 5-117, Pos. 7) and disconnect the SAE-flanges from the manifold (Fig. 5-117, Pos. 4) and from the hydraulic tube (Fig. 5-117, Pos. 5) at the boom.



z

Replace the boom arc hoses by new ones and carry out installation in reverse order to removal.


Substitute the other boom arc hoses if required, using the same procedure.

z

Perform the bleeding procedure for all cylinders. Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


z


z

Check hydraulic oil level again and add oil if required. 5 - 129

Faceshovel

5.2.5.2 SUBSTITUTE THE BOOM CYLINDER HOSES

Fig. 5-118 Boom cylinder hoses, removal and installation

5 - 130

Attachment

Attachment

Faceshovel


Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Boom cylinder

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Blind plugs (per hose): 2 x SAE A2-6000, PN 506 582 98; 2 x SAE B2-6000, PN 506 527 98 Boom cylinder hose: 27 kg max.

Dogman/rigger


WARNING z


z


z


z



5 - 131

Faceshovel

Fig. 5-120 Boom cylinder hoses, removal and installation

5 - 132

Attachment

Attachment

Faceshovel

z


z




z


z

Remove the bolts (Fig. 5-120, Pos. 3) and disconnect the SAE-flanges from the boom cylinder (Fig. 5-120, 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.


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 BULLETIN No. "AH06524".

z


z


z


5 - 133

Faceshovel

5.2.5.3 SUBSTITUTE THE STICK ARC HOSES

Fig. 5-121 Stick arc hoses, removal and installation

5 - 134

Attachment

Attachment

Faceshovel


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 DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Blind plugs (per hose, depending on type): SAE A2-6000, PN 506 582 98; SAE B2-6000, PN 506 527 98 or SAE A1 1/2-6000, PN 506 581 98; SAE B1 1/2-6000, PN 506 526 98 Stick arc hose (2"): 28 kg Stick arc hose (1 1/2"): 26 kg

Dogman/rigger


WARNING z


z


z


z



5 - 135

Faceshovel

Fig. 5-123 Stick arc hoses, removal and installation

5 - 136

Attachment

Attachment

Faceshovel

z


z


z

Remove the hose clamp lines (Fig. 5-123, Pos. 2).

z

Sling the hydraulic hose (Fig. 5-123, Pos. 1) to be removed. WARNING



z

Remove the bolts (Fig. 5-123, Pos. 3) and disconnect the SAE-flanges from the hydraulic tubes (Fig. 5-123, Pos. 6).



z

Replace the stick arc hoses by new ones and carry out installation in reverse order to removal.


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 BULLETIN No. "AH06524".

z


z


z


5 - 137

Faceshovel

Attachment

5.2.5.4 SUBSTITUTE THE STICK CYLINDER HOSES

Fig. 5-124 Stick cylinder hoses, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

5 - 138

Attachment

Faceshovel

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Forklift Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Blind plugs (per hose, depending on type): SAE A2-6000, PN 506 582 98; SAE B2-6000, PN 506 527 98 or SAE A1 1/2-6000, PN 506 581 98; SAE B1 1/2-6000, PN 506 526 98 Stick cylinder hose (2"): 27 kg Stick cylinder hose (1 1/2"): 17.6

Dogman/rigger


WARNING z


z


z


z



z


Fig. 5-125


5 - 139

Faceshovel

Fig. 5-126 Stick cylinder hoses, removal and installation

5 - 140

Attachment

Attachment

z

Faceshovel

Sling the hydraulic hose (Fig. 5-126, Pos. 1 or 2) to be removed using a forklift. WARNING



z

Remove the bolts (Fig. 5-126, 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 BULLETIN No. "AH06524".

z


z


z


5 - 141

Faceshovel

Attachment

5.2.5.5 SUBSTITUTE THE BUCKET CYLINDER HOSES

Fig. 5-127 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)

Hose clamp

5 - 142

Attachment

Faceshovel

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Blind plugs (per hose, depending on type): SAE A2-6000, PN 506 582 98; SAE B2-6000, PN 506 527 98 or SAE A1 1/2-6000, PN 506 581 98; SAE B1 1/2-6000, PN 506 526 98 Bucket cylinder hose (2"): 27 kg Bucket cylinder hose (1 1/2"): 19.2 kg

Dogman/rigger


WARNING z


z


z


z




z


z

Remove the hose clamp (Fig. 5-127, Pos. 8).

NOTE: The hose clamp (Fig. 5-127, Pos. 8) must only be removed when substituting the bucket cylinder hose (Fig. 5-127, Pos. 2) on the moving rod side of the bucket cylinder (Fig. 5-127, Pos. 7).

5 - 143

Faceshovel

Attachment

Fig. 5-129 Bucket cylinder hoses, removal and installation z

Sling the hydraulic hose (Fig. 5-129, Pos. 1 or 2) to be removed. WARNING


5 - 144

Attachment

Faceshovel


z

Remove the bolts (Fig. 5-129, Pos. 3) and disconnect the SAE-flanges. z

Remove the intermediate flange (Fig. 5-129, Pos. 6) from the cylinder when removing the bucket cylinder hose (Fig. 5-129, Pos. 2) on the moving rod side of the bucket cylinder (Fig. 5-129, Pos. 7).



z

Replace the bucket cylinder hoses by new ones and carry out installation in reverse order to removal.


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 BULLETIN No. "AH06524".

z


z


z


5 - 145

Faceshovel

5.2.5.6 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. 5-130 Clam cylinder hoses at stick, removal and installation

5 - 146

Attachment

Attachment

Faceshovel


Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

Special tools:

n/a


Forklift Oil drain pan Blind plugs (per hose): 2 x SAE A1 1/4-6000, PN 506 520 98 2 x SAE B1 1/4-6000, PN 506 525 98 Clam cylinder hose: 24.6 kg

Dogman/rigger


z


z




z


z


5 - 147

Faceshovel

Fig. 5-132 Clam cylinder hoses at stick, removal and installation

5 - 148

Attachment

Attachment

Faceshovel



z

Remove the bolts (Fig. 5-132, 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 page 150.

z

Perform the bleeding procedure for the clam cylinders. Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


z


z


5 - 149

Faceshovel

Substitute the clam cylinder hoses at the cylinders

Fig. 5-133 Clam cylinder hoses, removal and installation

5 - 150

Attachment

Attachment

Faceshovel


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 Blind plugs (per hose): 2 x SAE A1 1/4-6000, PN 506 520 98 2 x SAE B1 1/4-6000, PN 506 525 98 Clam cylinder hose (depending on length): 9...11 kg

Dogman/rigger


z

Prepare an area of flat ground large enough to accommodate the machine.

z




z


5 - 151

Faceshovel

Attachment

Fig. 5-135 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 - 152

Attachment

Faceshovel


z

Remove the bolts (Fig. 5-135, Pos. 5) and disconnect the SAE-flanges from the distributor block (Fig. 5-135, Pos. 7) and from the clam cylinder (Fig. 5-135, Pos. 8).


Replace the hydraulic hoses (Fig. 5-135, Pos. 1 to 4).

z

Replace the clam cylinder hoses by a new ones and carry out installation in reverse order to removal.


Perform the bleeding procedure for the clam cylinder(s). Refer to PARTS & SERVICE BULLETIN No. "AH06524".

z


z


z


5 - 153

Metering valves (grease injectors) at the attachment

Attachment

5.3

METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT

5.3.1

REMOVAL OF THE METERING VALVES (GREASE INJECTORS)

Special tools:

n/a


Safety harness in conformity with DIN 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, boom, and mobile elevator working platform.

z




Fig. 5-136

NOTE: It is described how to remove the metering valves at the boom, the other metering valves at the attachment are removed analogously. z

Disconnect all grease feeding lines (Fig. 5-137, Pos. 2) from the metering valve assemblies (Fig. 5-137, Pos. 6).

z

Remove the union (Fig. 5-137, Pos. 3) from the metering valve assembly (Fig. 5-137, Pos. 6).

NOTE: Separate the metering valve assemblies (Fig. 5-137, Pos. 6) at the union (Fig. 5-137, Pos. 4). z

Remove the nuts (Fig. 5-137, Pos. 5) and remove the metering valve assemblies (Fig. 5-137, Pos. 6) from the boom (Fig. 5-137, Pos. 1).

Fig. 5-137 5 - 154

Attachment

z

Metering valves (grease injectors) at the attachment

Remove the adapter bolt (Fig. 5-138, Pos. 2) and remove the valve housing (Fig. 5-138, Pos. 1) from the metering valve assembly (Fig. 5-138, Pos. 4).

Fig. 5-138

5.3.2

REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS)

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Mobile elevator working platform

WARNING z


z

The work requires the use of men safety cages on elevator working platforms.

z


z

Use new seals (Fig. 5-138, Pos. 3) at the valve housing (Fig. 5-138, Pos. 1).

z

Check metering valves at the attachment for proper operation, refer to the Operation & Maintenance Manual, chapter 4, section "WALK AROUND INSPECTION".

5 - 155

Cylinder bypass test

5.4

Attachment

CYLINDER BYPASS TEST

Special tools:

n/a Safety harness in conformity with DIN EN 361 Mobile elevator working platform Infrared thermometer Oil drain pan Blind plugs (size depends on cylinder flange size) SAE B1 1/4-6000, PN 506 525 98 SAE B1 1/2-6000, PN 506 526 98 SAE B2-6000, PN 506 527 98


Hydraulic hose with 1 1/4", 1 1/2" or 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. 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 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 - 156

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.

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 to the piston rod side of the cylinder. Put the open end of the hose into an oil pan.

z

De-isolate the machine according to local regulations. WARNING

Make sure that nobody is at close range of the hydraulic hose’s open end when extracting the cylinder.

z

At low idle, slowly extract the hydraulic cylinder.

NOTE: The oil inside the cylinder will flow out of the hydraulic hose 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 extract the cylinder.

If the cylinder has an internal leakage, some oil will continously flow out of the hydraulic hose 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.

5 - 157


Attachment


5 - 158

Appendix

6 APPENDIX

6 -1

Fuel and Lubricants

6.1

Appendix

FUEL AND LUBRICANTS Lubrication Point

Lubricant

Engine Oil Coolant Fuel

Hydraulic System

Travel gears, Final drives and Swing gears Brake housings and Motor adapter housings of Travel gears and Swing gears *3)

PTO (Pump distributor gear)

Fan bearing housings of Radiator and Hydraulic oil cooler

Ambient Temperature [°C]

Quality Grades DIN/API

Refer to Engine Operation and Maintenance Manual for Specifications. - 25 to + 15

22

-15 to + 25

32

-10 to + 30

46

- 5 to + 35

68

+ 5 to + 50

100

Hydraulic oil HLP

- 40 to + 10

HLP T32

DIN 51524. T.2 - HLP

Gear oil CLP *2)

-15 to + 50

CLP 220

DIN 51517 3 - CLP

Hydraulic oil HLP or HLPD with ZINC anti-wear additives *1)

Engine oil

DIN-51524 T.2 - HLP

SAE 10 all

HLP 22 or HLP 32

Hydraulic oil HLP

- 40 to + 10

HLP T32

DIN 51524. T.2 - HLP

Gear oil CLP *2)

-15 to + 50

CLP 150

DIN 51517 3 - CLP

Gear oil CLP

all

CLP 150

or Hydraulic oil

NOTE: *1) DO NOT mix zinc-free hydraulic oils with hydraulic oils containing Zinc. DO NOT mix mineral hydraulic oils with synthetic hydraulic oils. Mixing the above oils will reduce anti wear properties and oxidation stability of the oil. The oil filters in the hydraulic system will clog quickly. *2) Refer to the chart -gear oils- in the binder containing volume 2 for the released gear oil qualities and viscosity grades. *3) Brake housings of swing gears manufactured by L&S have no separate oil compartment, as brake discs are lubricated by splash oil from the gear box.

6 -2

Viscosity Grades

DIN 51524T.2 - HLP

DIN 51517 3 - CLP

Appendix

Point of lubrication Grease fittings (manual lubrication) Central lubrication system Swing circle teeth (manual lubrication) Swing circle pinion lubrication system

Fuel and Lubricants

Ambient temperature °C

Lubricant

Viscosity grades

Quality grades DIN/API

Multi-purpose grease "MPG"

Refer to the lubricant chart in the binder containing volume 2 for the recommended multi-purpose greases. The part numbers of recommended multi-purpose greases are listed in the parts catalogue.

Adhesive lubricant

Refer to PARTS & SERVICE NEWS No. "AH00519" for the recommended adhesive lubricants. The part numbers of the recommended adhesive lubricants are listed in the parts catalogue.

Track rollers, carrier rollers and guide wheels

Gear oil "CLP" or "API"

all

CLP 220 SAE 90

DIN 51517 3 CLP or API GL 5

Flexible coupling

Engine oil "API"

all

SAE 15W-40

API CD+SF

Air conditioning system Refrigerant compressor

Refrigerant Special oil. See warning below.

R 134a The air conditioning is prepared for refrigerant "R134a" only. See warning below.

WARNING The air conditioning may only be filled with refrigerant "R134a" by authorized service specialists only. DO NOT use refrigerant "R12", otherwise serious damage to system components could occur. The lubrication oil for the refrigerant compressor must be compatible with "R134a" refrigerant.

WARNING The lubricating instructions in this book refer to the recommended grade specifications. Damages caused by using lubricants other than specified are not covered by the manufacturer’s warranty.

6 -3

Filling Capacities

6.2

Appendix

FILLING CAPACITIES Units or system

Liters (approximate)

Engine cooling system

475.0

Engine oil pan

290.0

Engine oil reserve tank (special equipment)

580.0 (457.0 at refill)

Fuel tank

6400.0


3900.0

Hydraulic system

5900.0

Flexible coupling between engine and PTO PTO (pump distributor gear) Pump drive shaft housings on PTO Swing gear (manufacturer L&S) each Motor adapter housing Swing gear (manufacturer Siebenhaar)

1.3 150.0 *1) 42.0 0.6 60.0

Motor adapter housing

0.6

Brake housing

*1)

Travel gears, each

155.0

Motor adapter housing

0.6

Brake housing

0.5

Drive shaft housing, final drives (each)

145

Track rollers, each

2.4

Guide wheels, each

2.9

Support rollers, each

4.0

Fan bearing housing of radiator

*2)

Fan bearing housing of hydraulic oil cooler fan

*2)

Water tank for hand wash sink in operator’s cab

50.0

Water tank for windshield washer system

7.0

NOTE: Capacities listed above are approximate values. For proper checking use level plugs, dipsticks, and inspection openings, provided for this purpose. *1) Fill up to level gauge marking *2) Fill up to lower edge of level plug opening.

6 -4

Appendix

Filling Capacities


6 -5

Tools List

Appendix

6.3

TOOLS LIST

6.3.1

USED SPECIAL TOOLS (OVERVIEW)

Component

Swing circle mounting

Part number

Part name

Q‘ty

Nature of work, remarks

PN 376 762 40

Gauge device for test bolts M36

1

PN 376 792 40 Part of PN 376 762 40

Measuring jaw

1

PN 389 815 40 Part of PN 376 762 40

Measuring bolt

8

PN 376 76340 Part of PN 376 762 40

Test block

1

PN 921 159 40

Safety unit for changing track rollers

1

Removal and installation of the track rollers and guide wheel assembly

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

Installation of the swing circle. Assembly of superstructure onto undercarriage

Track rollers

Pressure accumulators of the track tensioning system

PN 409 329 40

Thread protector

1

Removal and installation of the bucket BHA Removal and installation of the bucket cylinders BHA Removal and installation of the steering rods BHA Removal and installation of the stick BHA

PN 909 348 40

Installation tool

1

Removal and installation of the bucket cylinders FSA

PN 909 543 40

Installation tool

1

Removal and installation of the stick cylinders FSA

PN 923 828 40

Installation tool

1

Removal and installation of the boom cylinders FSA

PN 793 502 73

POSILOK pin removal tool

1

Removal and installation of the GET

Attachment

GET

6 -6

Appendix

Component

Tools List

Part number

Part name

Q‘ty

PN 793 376 73

Hydraulic torque wrench

1

PN 793 374 73

Wrench socket with supporting bar

PN 793 375 73

Electro-hydraulic pump set

PN 928 476 40

Measuring device

Sprocket

locally made (refer to PARTS & SERVICE BULLETIN No. "AH05511")

Assembly tool for dual-cone seals

1

Installation of new dual-cone seals

Hydraulic system (general)

PN 232 315 40

Hydraulic testing kit

1

Measurements of hydraulic pressures

PN 793 788 730

Rotational speed infrared probe DS03s

1

Measurements of rotation fan speed

PN 232 521 40

65 mm hexagon impact socket wrench (1 1/2")

1

PN 232 615 40

Hydraulic torque wrench (7800 Nm)

1

PN 795 922 73


1

PN 232 264 40

55 mm hexagon impact socket wrench (1")

1

PN 232 615 40


1

PN 795 922 73


1

PN 232 265 40

46 mm hexagon impact socket wrench (1")

1

PN 232 615 40


1

PN 795 922 73


1

Car body/crawler carrier

Nature of work, remarks

Removal and installation of the car body/crawler carrier

Installation of the crawler carriers

Radiator fan assembly Radiator fan drive pump Hydraulic cooler fan drive pump Hydraulic cooler fan assembly

Counterweight

Superstructure

Fuel tank

Removal and installation of the counterweight

Removal and installation of the superstructure

Removal and installation of the fuel tank

6 -7

Tools List

Appendix


6 -8

Appendix

6.3.2

Tools List

KOMATSU TOOLS CATALOGUE

6 -9

Tools List

Appendix


6 - 10

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008

Werkzeuge und Zubehör Tools and Accessories Outils et Accessoires Herramientas y Accesorios

Werkzeug Tools

991-1010 Seite6 Seite Page folgt Seite continued

1 2

ßß

ET-Nr.

Gegenstand

Inhalt, Content,

Part-No.

Description

Stand 07.06.2008 232 556 40

Gabelringschlüssel, 1 Satz, 6-46 Combination wrenches, 1 set, 6-46 Gabelringschlüssel, einzeln Combination wrenches, single

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 6 SW 7 SW 7 SW 8 SW 9 SW 10 SW 11 SW 12 SW 13 SW 14 SW 15 SW 17 SW 19 SW 22 SW 24 SW 27 SW 30 SW 32 SW 36 SW 41 SW 46

232 558 40

Gabelringschlüssel, 1 Satz, 1/4” - 1 1/4” Combination wrenches, 1 set, 1/4” - 1 1/4” Gabelringschlüssel, einzeln Combination wrenches, single

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

Werkzeug Tools

SW 1/4” SW 5/16” SW 3/8” SW 7/16” SW 1/2” SW 9/16” SW 5/8” SW 11/16” SW 3/4” SW 13/16” SW 7/8” SW 15/16” SW 1” SW 11/16” SW 11/8” SW 11/4”


2 3

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008 Spezial-Ringschlüssel – offen Special Ring wrench – open

232 305 40 232 306 40 232 307 40 232 308 40

SW 41 SW 46 SW 50 SW 60

232 559 40

Doppelgabelschlüssel, 1 Satz, 6-55 Double ended open wrenches, 1 set, 6-55 Doppelgabelschlüssel, einzeln Double ended open wrenches, single

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 6 x 7 SW 8 x 9 SW 10 x 11 SW 12 x 13 SW 14 x 15 SW 16 x 17 SW 18 x 19 SW 20 x 22 SW 21 x 23 SW 24 x 27 SW 25 x 28 SW 30 x 32 SW 36 x 41 SW 50 x 55

232 560 40

Einfachgabelschlüssel, 1 Satz, 41-85 Single ended open wrenches, 1 set, 41-85 Einfachgabelschlüssel, einzeln Single ended open wrenches, single

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

Werkzeug Tools

SW 41 SW 46 SW 50 SW 55 SW 60 SW 65 SW 70 SW 75 SW 80 SW 85


3 4

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008 232 561 40

Hakenschlüssel, 1 Satz, 120-300 Hook wrenches, 1 set, 120-300 Hakenschlüssel, einzeln Hook wrenches, single

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 Knarre Push pull ratchet

232 337 40 232 047 40 232 562 40 232 563 40

1/4” 1/2” 3/4” 1” Umschaltknarre 1” x 660 mm (26”) Reversible ratchet

232 380 40 232 218 40

3/4” x 620 mm 1” x 660 mm (26”) Drehmomentschlüssel Torque wrench

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

Griff mit Gleitstück Sliding t & tommy bar 232 339 40 232 050 40 232 303 40 232 219 40

Werkzeug Tools

1/4” 1/2” x 290 mm (12”) 3/4” x 500 mm (20”) 1” x 640 mm (25”)


4 5

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008 Kardangelenk Universal joint 232 051 40

1/2”

232 564 40

Steckschlüsseleinsatz, 1/4”, 1 Satz, 4-13 Socket wrench, 1 set, 4-13 Steckschlüsseleinsatz, 1/4”, einzeln Socket wrench, single

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 4 SW 4,5 SW 5 SW 5,5 SW 6 SW 7 SW 8 SW 9 SW 10 SW 11 SW 13

232 565 40


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 9 SW 10 SW 11 SW 12 SW 13 SW 14 SW 15 SW 17 SW 19 SW 21 SW 24 SW 27 SW 30 SW 32

232 566 40

Steckschlüsseleinsatz, 1/2”, 1 Satz, 3/8” - 1 1/4” Socket wrench, 1 set, 3/8” - 1 1/4” Steckschlüsseleinsatz, 1/2”, einzeln

Werkzeug Tools


5 6

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008

Socket wrench, single 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 3/8” SW 13/32” SW 7/16” SW 1/2” SW 9/16” SW 19/32” SW 5/8” SW 11/16” SW 3/4” SW 25/32” SW 13/16” SW 7/8” SW 15/16” SW 1” SW 1 1/16” SW 1 1/8” SW 1 3/16” SW 1 1/4”

232 567 40


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

SW 22 SW 24 SW 27 SW 30 SW 32 SW 36 SW 38 SW 41 SW 46 SW 50

232 568 40

Steckschlüsseleinsatz, 1”, 1 Satz, 36-80 Socket wrench, 1 set, 36-80 Steckschlüsseleinsatz, 1”, einzeln Socket wrench, single

232 223 40 232 224 40 232 225 40 232 226 40 232 227 40 232 228 40 232 229 40 232 230 40

Werkzeug Tools

SW 36 SW 41 SW 46 SW 50 SW 55 SW 60 SW 65 SW 70


6 7

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008 232 231 40 232 232 40

SW 75 SW 80

232 569 40

Steckschlüsseleinsatz für Schmiernippel Fettspannzylinder 1/2”, lang SW 27 Extra deep socket wrench to lubricate nipple of grease cylinder

232 570 40

Schraubendrehereinsatz Inbus, 1/2”, 1 Satz, 5-17 Screwdriver socket Hexagon, 1 set, 5-17 Schraubendrehereinsatz Inbus, 1/2”, einzeln Screwdriver socket Hexagon, single

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 5 SW 6 SW 7 SW 8 SW 9 SW 10 SW 12 SW 14 SW 17

232 571 40

Schraubendrehereinsatz Inbus, 1/2”, 1 Satz, 3/16-5/8 Screwdriver socket Hexagon, 1 set, 3/16-5/8 Schraubendrehereinsatz Inbus, 1/2”, einzeln Screwdriver socket Hexagon, single

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

SW 3/16” SW 7/32” SW 1/4” SW 9/32” SW 5/16” SW 3/8” SW 1/2” SW 9/16” SW 5/8”

232 572 40

Schraubendrehereinsatz Inbus, 1/2”, 1 Satz, 5-14 Screwdriver socket Hexagon, 1 set, 5-14 Schraubendrehereinsatz Inbus, 1/2”, einzeln Screwdriver socket Hexagon, single

232 341 40

Werkzeug Tools

SW 5 x 180 mm


7 8

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008 232 342 40 232 343 40 232 344 40 232 345 40 232 346 40

SW 6 x 90 mm SW 8 x 120 mm SW 10 x 140 mm SW 12 x 140 mm SW 14 x 140 mm Schraubendrehereinsatz Inbus, 3/4”, Screwdriver socket Hexagon, 3/4”

232 347 40 232 348 40 232 349 40 232 350 40

SW 14 SW 17 SW 19 SW 22 Schraubendrehereinsatz Inbus, 1”, Screwdriver socket Hexagon ,1”

232 351 40 232 352 40 232 353 40

SW 19 SW 22 SW 24 Schraubendrehereinsatz für innen Torx Screwdriver socket for inside

232 597 40 232 598 40 232 599 40 232 600 40 232 601 40 232 602 40 232 603 40

SW 4 – 5 SW 4,5 – 5 SW 4,5 – 5 – 6 SW 6 – 7 SW 7 – 8 SW 8 – 10 SW 10 Steckschlüssel-Einsatz für außen Torx Socket wrench for outside

232 604 40 232 605 40 232 606 40 232 607 40 232 608 40 232 609 40 232 610 40

Werkzeug Tools

SW 4 SW 5 SW 6 SW 6 – 7 SW 8 SW 10 SW 12


8 9

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008 Reduzierstück Reducer 232 573 40 232 096 40 232 574 40

1 – 3/4 3/4 – 1/2 1 1/2 – 1 Vergrößerung Expansion

232 575 40 232 576 40 232 577 40

1/2 – 3/4 3/4 – 1 1 – 1 1/2

232 146 40

Bandschlüssel (Kraftstoff-Wasserfilter) Strap wrench, fuel-water filter

232 511 40

Kraftvervielfältiger 0 – 2.700 Antrieb 3/4” Untersetzung 1 : 5 Torque multiplier

Elektroschrauber Electric torque wrench

232 611 40 232 612 40

Werkzeug Tools

600 – 2.800 1600 – 7.000


9 10

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008 Hydraulikschrauber Hydraulic torque wrench

232 614 40 232 615 40

0 – 4500 0 – 7800 Elektro-hydraulisches Pumpenaggregat, 220 Volt/800 bar Electro hydraulic pump aggregate

232 613 40

5 bar

232 269 40 232 366 40 232 367 40 232 097 40 795 922 73

SW 75 SW 80 SW 85 3 – 15 mkp 30 – 150 Nm Hydraulikaggregat Electro-hydraulic pump set

793 374 73

Kraftschrauber für Seitenträgermontage Servo screw driver for sidemember assembly

793 376 73

Kraftschrauber-Aggregat Servo screw driver assembly

Werkzeug Tools


10 11

ET-Nr.

Gegenstand

Part-No.

Description

Stand 07.06.2008 232 578 40

Kraftschraubereinsatz 1”, 1 Satz , 36-65 Hexagon impact socket wrench, 1 set, 36-65 Kraftschraubereinsatz 1”, einzeln Hexagon impact socket wrench, single

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 36 SW 38 SW 41 SW 46 SW 50 SW 55 SW 60 SW 65 Kraftschraubereinsatz 1 1/2” Hexagon impact socket wrench

232 517 40 232 518 40 232 519 40 232 520 40 232 521 40

SW 46 SW 50 SW 55 SW 60 SW 65 Kraftschraubereinsatz 2 1/2” Hexagon impact socket wrench

795 923 73

Hochdruckschlauch DN6 x 10000 High pressure hose

Werkzeug Tools


11 12

ßß Inhalt, Content,

ET-Nr.

Gegenstand

Part-No.

Description

232 139 40

Wasserpumpenzange 250 mm lang Multigrip pliers

232 140 40

Grip-Zange 250 mm lang Grip pliers

232 141 40

Storchschnabelzange, gerade 200 mm lang Telephone pliers, straight

232 142 40

Storchschnabelzange, abgewinkelt 200 mm lang Telephone pliers, angled

232 143 40

Abisolierzange 160 mm lang Stripping pliers

232 663 40

Abisolier- und Schneidewerkzeug Stripax mit PVC- Isolation bis 6mm², 20mm Stripping- and cutting tool Stripax with PVC-isolation to 6mm², 20mm

232 401 40

Seitenschneider isoliert bis 1000 Volt, 190 mm Side cutter insulated

232 400 40

Kombinationszange isoliert bis 1000 Volt, 185 mm Universal pliers insulated

232 147 40

Eckrohrzange mit Rolle 350 mm lang Pipe wrench

232 404 40

Flachzange, isoliert bis 1000 Volt, 185 mm Flat pliers, insulated

Werkzeug

Schlagwerkzeuge

Tools

Percussion tools

991-1010 Blatt 3 Seite Page folgt Seite continued

12 13

ET-Nr.

Gegenstand

Part-No.

Description

232 405 40

Rundzange, isoliert bis 1000 Volt, 185 mm Round pliers, insulated Sicherungsringzange, gerade für Außenringe Safety circlip pliers (outer) straight pattern

232 150 40 232 151 40 232 152 40

19 – 60 Ø 53091-Bez. Nr.130 A2 40 – 100 Ø 53091-Bez. Nr. 140 A3 85 – 140 Ø 53091-Bez. Nr. 150 A4 Sicherungsringzange, gewinkelt für Außenringe Safety circlip pliers (outer) angled pattern

232 156 40 232 157 40 232 158 40

19 – 60 Ø 53091-Bez. Nr. 180 A21 430 – 100 Ø 53091-Bez. Nr. 190 A31 85 – 140 Ø 53091-Bez. Nr. 200 A41 Sicherungsringzange, gerade für Innenringe Safety circlip pliers (inner) straight pattern

232 159 40 232 160 40 232 161 40

19 – 60 Ø 53091-Bez. Nr. 030 J2 30 – 100 Ø 85 – 130 Ø Sicherungsringzange, gewinkelt für Innenringe Safety circlip pliers (inner) angled pattern

232 153 40 232 154 40 232 155 40 232 281 40

19 – 60 Ø 53091-Bez. Nr. 080 J21 31 – 100 Ø 85 – 140 Ø 53091-Bez. Nr. 100 J41 Seeger-Zange, gerade für Außenringe 122 – 300 mm Ø Circlip pliers (outer) straight pattern

232 282 40

Seeger-Zange, gewinkelt für Außenringe 122 – 300 mm Ø Circlip pliers (outer) angled pattern

232 283 40

Seeger-Zange, gerade für Innenringe 122 – 300 mm Ø Circlip pliers (inner) straight pattern

232 284 40

Seeger-Zange, gewinkelt für Innenringe 122 – 300 mm Ø

Werkzeug

Schlagwerkzeuge

Tools

Percussion tools


13 14

ET-Nr.

Gegenstand

Part-No.

Description

Circlip pliers (inner) angled pattern 232 662 40

Crimp-Set PZ4 PZ 4, Abisolierwerkzeug STRIPAX, Crimpbereich 0,5 4,0 mm² Crimp-set PZ 4 PZ 4, stripping tool Stripax, Crimpregion 0,5-4,0 mm²

232 661 40

Crimp-Zange PZ 4 Crimpbereich 0,5-4mm² Crimp-pliers PZ 4 Crimpregion 0,5-4mm²

793 729 73

Crimp-Zange HDT 48-00 Crimp-pliers HDT 48-00

232 209 40

Anpresszange im Kasten mit Kabelschuhsortiment Cable lugs, assortment with crimping pliers in metal box

Werkzeug

Schlagwerkzeuge

Tools

Percussion tools


14 15


ET-Nr.

Gegenstand

Part-No.

Description

Handhammer Hammer 232 129 40 232 130 40 232 131 40

300 g. 500 g. 1000 g.

232 310 40

Vorschlaghammer 5 kg Sledge hammer

232 579 40

Plastikhammer 450 g Plastic hammer

Flachmeißel Flat chisel 232 135 40 232 136 40

16 x 165 mm 19 x 180 mm

232 137 40

Kreuzmeißel 6 x 165 mm Cape chisel

232 138 40

Körner 4 x 130 mm Center punch Durchtreiber Drift Punch

232 132 40 232 133 40 232 134 40

5 x 150 mm 6 x 160 mm 8 x 180 mm Splintentreiber Splint pin driver

232 099 40 232 100 40 232 101 40 232 102 40 232 103 40 232 104 40

3 Ø mm 4 Ø mm 5 Ø mm 6 Ø mm 8 Ø mm 10 Ø mm

Werkzeug

Metallbearbeitung

Tools

Metalwork tools


15 16


ET-Nr.

Gegenstand

Part-No.

Description

232 122 40

Metallbügelsäge mit Sägeblatt Hack saw with blade

232 123 40

Dreikanthohlschaber 250 mm lang Three square scraper (hollow)

232 124 40

Flachschaber 250 mm lang Flat scraper Verstellbares Wendeisen für Gewindebohrer Adjustable tap wrench for taps

232 164 40 232 165 40 232 235 40

Gr. 1 M 1 – 10 Gr. 4 M 10 – 27 Gr. 6 M 20 – 42

232 624 40

Gewindebohrersatz = 3 Stück Tap set = 3 pieces Gewindebohrersatz, einzeln Tap set, single

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

232 625 40

Gewindebohrersatz = 2 Stück Tap set = 2 pieces

Werkzeug

Schraubendreher

Tools

Screwdrivers


16 17

ET-Nr.

Gegenstand

Part-No.

Description

Gewindebohrersatz, einzeln Tap set, single 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” Gewindefeile Thread restorer

232 162 40 232 163 40

Whitw. Metr. Schneideisenhalter für Schneideisen Stock for round die

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” Schneideisen

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

Round die 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

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

Werkzeug

Schraubendreher

Tools

Screwdrivers


17 18

ET-Nr.

Gegenstand

Part-No.

Description

232 258 40 232 251 40 232 252 40 232 253 40 232 254 40

M 24 x 1,5 R 1/8” R 1/4” R 3/8” R 1/2”

Werkzeug

Schraubendreher

Tools

Screwdrivers


18 19


ET-Nr.

Gegenstand

Part-No.

Description

Schraubendreher für Schlitzschrauben Screwdriver for slotted screws 232 120 40 232 121 40

11 x 300 mm 13 x 390 mm Schraubendreher, isoliert bis 1000 Volt Screwdriver, insulated

232 391 40 232 392 40 232 393 40 232 394 40 232 395 40

2,5 X 75 mm 3,5 x 100 mm 4 x 100 mm 5,5 x 125 mm 6,5 x 150 mm Kreuzschlitzschraubendreher, isoliert bis 1000 Volt Screwdriver, insulated

232 397 40 232 398 40 232 399 40

Gr. 0 Gr. 1 Gr. 2

232 208 40

Schraubenausdrehersatz mit Spiralbohrern zum Entfernen beschädigter oder abgebrochener Schrauben Screw extractor kit with spiral drills to remove damaged or broken screws

232 581 40

Sechskantschraubendreher, 1 Satz, 2 – 36 Allen head wrench “L” type, 1 set, 2 – 36 Sechskantschraubendreher, einzeln Allen head wrench “L” type, single

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

SW 2 SW 2,5 SW 3 SW 4 SW 5 SW 6 SW 7 SW 8 SW 9 SW 10 SW 12 SW 14 SW 17 SW 19

Werkzeug

Meßwerkzeuge

Tools

Measuring instruments


19 20

ET-Nr.

Gegenstand

Part-No.

Description

232 080 40 232 081 40 232 082 40 232 354 40 232 355 40 232 356 40

SW 22 SW 24 SW 27 SW 30 SW 32 SW 36 Sechskantschraubendreher Allen head wrench “L” type

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

SW 3/16” SW 7/32” SW 1/4” SW 5/16” SW 3/8” SW 1/2” SW 9/16” SW 5/8” SW 3/4” Sechskantschraubendreher L-Form mit Kugelkopf Allen head wrench “L” type with spherical head

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 2 SW 3 SW 4 SW 5 SW 6 SW 8 SW 10 SW 12

Werkzeug

Meßwerkzeuge

Tools

Measuring instruments


20 21


ET-Nr.

Gegenstand

Part-No.

Description

232 194 40

Lochtaster 200 mm lang Inside caliper

232 195 40

Dickentaster 200 mm lang Outside caliper

232 107 40

Taschenschiebelehre 200 mm lang Slide caliper rule

232 108 40

Rollbandmaß 2000 mm lang Measuring tape

232 590 40

Stahlmaß 1000 mm lang Steel measuring tape

232 109 40

Fühlerlehrenset Feeler gauge set

232 110 40

Gewindeschablone für Metr./Whitw. Screw pitch gauge for metric and whitworth threads

232 315 40

Hydraulik Mini-Meß-Box bestehend aus: 1 Manometer 0 – 25 bar, 1 Manometer 0 – 60 bar, 1 Manometer 0 – 400 bar, 2 Mini-Meß-Schläuche und diverse Anschlüsse Hydraulic testing kit consisting of: 1 pressure gauge 0 – 25 bar, 1 pressure gauge 0 – 60 bar, 1 pressure gauge 0 – 400 bar, 2 instrument hoses, misc. adapters

Werkzeug

Sonstiges

Tools

Others


21 22

ET-Nr.

Gegenstand

Part-No.

Description

232 591 40

Hydraulik Mini-Meß-Box bestehend aus: 2 Manometer 0 – 400 bar, 2 Meßschläuche je 3 m, 1 Meßschlauch 5 m, diverse Anschlüsse Hydraulic testing kit consisting of: 2 pressure gauges 0 – 400 bar, 2 instrument hoses 3 m each, 1 hose 5 m, misc. adapters


Kontrollblock/Logik-Testmanometer PC3000-8000/6 Control element/logical testmanometer 79453773

Digitalmessuhr Artikel-Nr: 32042001 0-12,5mm

Messkabel MK S für die Verbindung zu Druck-, Temperatur- und Volumenstärkesensoren Measuring cable MK S for connection to pressure-, temperatureand volume flow rate sensors 232 664 40

Fluke Multimeter Art Nr.120 552-62 Fa. Conrad Fluke multimeter

232 619 40

Autorange Digital-Multimeter incl. Sicherungssatz und Temperatursensor F 207 Autorange digital multimeter F 207 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 m?? – 40 M? ? 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 ? Spannungsversorgung: 1 x 9 V Block-Batterie Fluke 187 Art Nr. 120408-62 Fa.Conrad

Werkzeug

Sonstiges

Tools

Others


22 23

ET-Nr.

Gegenstand

Part-No.

Description

793 780 73

Tragbares Messgerät „Multi-System 5050” mit ISDS Hand-held measuring unit „Multi-System 5050“ with ISDS

793 787 73

Messturbine RE4 Messbereich: 16,0 bis 600l/min Measuring turbine RE4 Measuring range: 16,0 to 600l/min

232 670 40

SUBITO Innenmessgerät 280-510 mm im Etui ohne Uhr SUBITO Internal analyser280-510 mm in box without clock

232 384 40

Volumenstrommeßgerät incl. Zubehör Flow meter incl. accessories

232 593 40

Stoßimpulsmessgerät Shock pulse measuring instrument

ßß

232 665 40

Inhalt, Content,

Infrarot-Thermometer 112-1001-A Fa. Conrad Infrared thermometer

793 788 73

Temperaturmeßgerät mit Temperaturfühler Electric thermometer Rotational speed infrared probe DS03, Measuring range : 1 to 9999min-1

694 944

Infrarotdrehzahlmesser DS03 Messbereich: 1 bis 999min-1

232 671 40

SUBITO Messtiefenverlängerung Rohr Ø 18mm, 2000mm lang

Werkzeug

Sonstiges

Tools

Others


23 24

ET-Nr.

Gegenstand

Part-No.

Description

SUBITO Measuring depth elongation Pipe Ø 18mm, 2000mm lg. 232 620 40

Berührungsloser Drehzahlmesser (digital) Manual non-contact revolution counter (digital) DT 2234 Braun GmbH

232 496 40

Kabelset für ET-Nr. 23232340 (s.o.) Cable set for part-no. 23232340

Einzeln Manometer ab 100 Ø plus Zubehör Separate manometer from 100 Ø plus equipment

770 466 73 769 150 73 770 464 73 770 465 75 761 520 73

Füll- und Prüfvorrichtung für Kolben-, Membran- und Blasenspeicher 0 – 100 bar (mit Druckminderer) Filling and testing device for piston, diaphragm and accumulators reservoirs (with pressure reducing valve)

Werkzeug

Sonstiges

Tools

Others


24 25

ET-Nr.

Gegenstand

Part-No.

Description

232 382 40

Füll- und Prüfvorrichtung für Kolben- und Membranspeicher 0 – 100 bar 0 – 250 bar Filling and testing device for piston and diaphragm and accumulators reservoirs

Gewindereduzierung (Manometer) Threaded reduction (Pressure gauge) 232 506 40 232 507 40 232 508 40 796 726 73

R 1/4” R 3/8” R 1/2” Bodem PC-Software

796 439 73

Konverter Converter

796 440 73

USB Kabel USB extension

796 441 73

UMG Diagnose Software (CD) UMG Diagnostic software (CD)

796 443 73

Kabel Set Cable set Inhalt:

Content:

Kabel VL3 Kabel VL12 Kabel VL10 Kabel VL9a

Cable VL3 Cable VL12 Cable VL10 Cable VL9a

Werkzeug

Sonstiges

Tools

Others


25 26

ET-Nr.

Gegenstand

Part-No.

Description

Kabel VL9b

232 385 40

Cable VL9b

Spannungsprüfer 25 kV Voltage tester 25 kV

232 386 40

Universal-Erdungs- und Kurzschließvorrichtung Ø 95/35 mm2 Universal grounding short-circuiting device

232 387 40

Isolationsmesser . . . . . 500 V Insulation tester

232 388 40

Drehfeldrichtungsanzeiger 100 . . . 600 V Phase-sequence indicator Elektronischer einpoliger Spannungsprüfer Electronical unipolar voltage meter

232 389 40 232 390 40

5 – 10 kV 3 – 6 kV

232 594 40

Stoßimpulsaufnehmer Shock pulse transducer

232 595 40

Stoßimpulsaufnehmer Shock pulse transducer

Werkzeug

Sonstiges

Tools

Others


26 27

ET-Nr.

Gegenstand

Part-No.

Description

232 596 40

Kopfhörer zum Stoßimpulsmeßgerät Head receiver for shock pulse measuring instrument

873 570 40

Datenübertragung Fettanzeige Speicher ETM, ECS, 1 Satz Data transfer, grease, memory, 1 set

766 138 73

Systemdiagnose Schmieranlage Systems diagnostics, lubrication system

793 639 73

Lösewerkzeug für Doppelstockklemmen Unscrew tool for doublestockclamps

966 225

Testset Rißprüfung, bestehend aus: Crack detection testing kit, consisting of:

966 229

Permanentmagnet Permanent magnet

966 226

Magnetpulver Magnetic powder

966 227

Untergrund Contrasting agent

966 228

Reiniger Cleaner

Werkzeug

Sonstiges

Tools

Others


27 28

ET-Nr.

Gegenstand

Part-No.

Description

232 621 40

Sprechfunkanlage Cordless Headphone Intercom

Werkzeug

Sonstiges

Tools

Others


28 29


ET-Nr.

Gegenstand

Part-No.

Description

232 623 40

Vacuumpumpe + Adapter Vacuum pump + adaptor

Abzieher, Spannweite/Spanntiefe Wheel puller, gripping width/depth range

232 300 40

120mm/100mm

232 301 40

200mm/150mm

232 302 40

350mm/200mm

???

400mm/420mm

232 287 40

Handhebelfettpresse mit Anschlüssen 400 Bar Grease gun, hand-lever type, w/couplings

232 288 40

Montagewanne Fitters tub

232 000 40

Werkzeugkasten, 5-teilig 420 x 200 x 210 mm Tool box, 5 parts

232 299 40

Brechstange mit Klaue und Spitze 1000 mm lang Pinch bar w/pointed and claw ends

976 382 73

Universalschmierfett Fettkartusche, 400 g Multi purpose grease

Werkzeug Tools


29 30

ET-Nr.

Gegenstand

Part-No.

Description

232 542 40

Öl-Analyse Oil analysis

232 622 40

Pumpe zur Entnahme der Ölprobe Suction pump

Hubzug mit Gelenkkette Flat-link chain hoist

232 368 40 232 289 40 ??? 324460 40

Tragkraft 0,75 t Tragkraft 1,5 t Tragkraft 3,0 t Drahtseilgehänge 5 t Cable suspension

792 005 73

Kantenschoner Edge protector

792 006 73

Werkzeug Tools


30 31

ET-Nr.

Gegenstand

Part-No.

Description

232 616 40

4-Strang-Kette WM 1401 4-hook chain WMH S6 A = 1500 m/m

232 617 40

Nylon Hebegurt AL 4, Breite 75 mm, Länge 3500 mm

Nylon lifting belt, width 75 mm, length 3500 mm 1500 kg 232 618 40

Nylon Hebegurt, AL 5, Breite 25 mm, Länge 1500 mm Nylon liftig belt, width 25 mm, length 1500 mm 1000 kg Ringschrauben Lifting bolt

313 500 99 313 501 99 313 502 99 313 503 99 313 504 99 313 505 99 313 510 99 313 506 99 313 507 99 313 508 99 313 514 99 313 527 99

M8 M 10 M 12 M 16 M 20 M 24 M 27 M 30 M 36 M 42 M 48 M 56 Bolzenpresse, komplett für Traktorenlaufwerk Pin-driving press, complete set

232 313 40

Werkzeug Tools

100 t für alle Bagger bis H 121


31 32

ET-Nr.

Gegenstand

Part-No.

Description

232 381 40 232 626 40

150 t für alle Bagger bis H 185 Montage-Buchsensatz für Zylinder-Reparatur. Bei Bestellung der Werkzeuge unbedingt Ident-Nr. von Zylinder angeben. Mounting bushing set for cylinder repair. When tools are ordered, please always state identification number of the cylinder.

999 860 73

5-Finger-Handschuhe mit Strickbund, gefüttert Glove

999 861 73

Gummi- Handschuhe, Größe F3 und F4 Rubber gloves

999 925 73

Arbeits -Handschuhe, Schweinsleder mit Futter Working gloves, pork leather w/lining

950 642

Kanister 10 l (Kunststoff) Tank 10 l

Werkzeug Tools


32 33

ET-Nr.

Gegenstand

Part-No.

Description

950 643

Kanister 25 l (Kunststoff) Tank 25 l

Werkzeug Tools


33 34


ET-Nr.

Gegenstand

Part-No.

Description

Druckanzeiger Pressure gauge 793 361 73 793 362 73 793 363 73

0-25 bar (1pc.) 0-60 bar (1 pc.) 0-400 bar (2pcs.)

232 501 40

Verbindung Druckanzeiger (4Stück) Pressure gauge connection (4pcs.)

Messschlauch Measuring pipe

792 283 73 792 284 73

Werkzeug Tools

3200mm lg (2pcs.) 5000mm lg (1pc.)


34 35


ET-Nr.

Gegenstand

Part-No.

Description

232 285 40

Drehmomentschlüssel mit Skala DSG-5S Messbereich: 300-750Nm Torque wrench with scale DSG-5S measuring region: 300-750Nm

232 477 40

Drehmomentschlüssel mit Skala DSG-6S Messbereich: 500-1300Nm Torque wrench with s cale DSG-6S measuring region: 500-1300Nm

232 478 40

Drehmomentschlüssel mit Skala DSG-7S Messbereich: 800-2000Nm Torque wrench with scale DSG-7S measuring region: 800-2000Nm

232 681 40

Einsteck-Winkelstück 28/5-3/4 x 70 Inserting- angle

232 682 40

Einsteck-Winkelstück 28/6-7; 1” x 70 Inserting-angle

232 683 40

Satz Kombinationswinkel Combination angle set

793 781 73

Stromversorgungseinheit, 230VAC/24VDC/340mA Plug-in power supply unit, 230VAC/24VDC/340mA

793 782 73

Transportbox (Aluminium) Transport case 1 (aluminium box)

793 784 73

Transportbox für Multi-System 5050 Carrier bag for Multi-System 5050

793 783 73

793 786 73

Druckumwandler WechselbatterieHT-PD für Multi-System 5050 Signalstärke: 0 bis 20mA; Messbereich: 0 bis 60 bar Alternating battery for Multi-System 5050 Pressure transducer HAT-PD Signal output: 0 to20 mA; measuring range: 0 to 60 bar Druckumwandler HT-PD Signalstärke: 0 bis 20mA; Messbereich: 0 bis 600 bar Pressure transducer HT-PD Signal output: 0 to 20mA; measuring range: 0 to 600 bar

Farben Colours


35 36

ET-Nr.

Gegenstand

Part-No.

Description

793 791 73

Spannungsadaptor 1-Kanal Messbereich: 0 bis +/- 48VDC Voltage adaptor 1-channel Measuring range: 0 to +/- 48 VDC

793 789 73

Magnethalter für DS03 Magnetic holder for DS03

793 790 73

Reserveset Reflexionsfolien (50 Stück) Spare set of reflective foils (50 pieces)

793 793 73 793 794 73 793 795 73 793 796 73

Länge 2,5m: Länge: 5m Länge: 10m Datenübertragungskabel USB Data communication cable USB

232 666 40

Druckluft-Schlagschrauber (Bosch) Pneumatic percussion drill

232 667 40

Druckluft-Schlagschrauber (Bosch) Pneumatic percussion drill

232 668 40

Bügelmessschrauben Messbereich: 0-150mm Micrometer gauge Measuring region: 0-150mm

232 669 40

Bügelmessschrauben Messbereich: 150-300 Micrometer gauge Measuring region: 150-300mm

ßß

232 574 40

Inhalt, Content,

Reduzierstück 1 ½ -1 Reducer

232 577 40

Vergrößerungsstück 1 ½-1 Extension piece

23268440

Farben Colours

Vibrotip – Paket ”Trend”


36 37

ßß ß ß Inhalt, Inhalt, Content, Content,

ET-Nr.

Gegenstand

Part-No.

Description

23268640 23268540

Maschienen-Analysator und Datensammler Bohrer für Vibrotip Aufnehmer mit Schnellkupplung

Farben Colours


37 38

ET-Nr.

Gegenstand

Part-No.

Description

767 566 73

Verdünner 011 0218 Haku 148 G, 10 kg Thinner

767 567 73

Grundierung zitronengelb Gehorol-Metallgrund G 80, 1 kg Priming lemon yellow

083 026

Spraydose gelb RAL 1007 400 ml Spray yellow

501 415 98

Farbe himmelblau RAL 5015 2,5 kg Paint box sky-blue

767 568 73

Farbe Schwarz RAL 9005, 1 kg Paint black

Betriebsmittel Öle & Fette Oil & Grease


38 39

ET-Nr.

Gegenstand

Part-No.

Description

767 569 73

Farbe gelb = DEMAG KOMATSU – gelb, 1 kg Paint yellow

767 570 73

Farbe grau = KOMATSU – grau, 1 kg Komatsu grey

Betriebsmittel Öle & Fette Oil & Grease


39 40

ET-Nr.

Gegenstand

Part-No.

Description

510 678 98

Haftschmierfett, 13 kg H 55 – H 485


Adhesive grease 510 679 98

Haftschmierfett, 50 kg H 55 – H 485 Adhesive grease

500 893 98

Haftschmierspray für Zahnkränze Adhesive lubrication spray for gear rims

Hilfsstoffe, Reiniger, Kleber, Dichtungsmittel Auxiliaries, cleaners, adhesives, sealing material


40 41


ET-Nr.

Gegenstand

Part-No.

Description

592 199 40

Flüssigdichtung (Epple blau, Nr. 28), 250 ml Liquid sealing agent (blue, No. 28), 250 ml

461 798 40

Klebstoff Sicomet 85, in Tuben (für Dichtung der Rollendrehverbindung, Kugeldrehverbindung) Adhesive

390 905

Teflonband Teflon tape

464 814

Isolierband 33-19 Tesa PVCd Insulating tape

515 068 40

Gleitmetall- Paste, 350 g-Dose zur Bolzenmontage bei Vielkeilverzahnungen Slide metal paste to mount bolts

515 067 40

Gleitmetall- Paste, 1kg Dose Slide metal paste

691 959

Füllflasche Startpilot Filler bottle

989 967

Ölbindemittel (Papiersäcke à 8 kg) Oil binder

999 019

Nickelspray, Metaflux 70-81 Nickel-Spray

993 528 73

Reinigungsmittel Bio Pent E für Dampfstrahler



41 42

ET-Nr.

Gegenstand

Part-No.

Description

Cleaning detergent 993 529 73

Reinigungsmittel Bio Versal für Dampfstrahler Cleaning detergent

999 926 73

Paket Putzlappen (Vliestücher) 35x35 cm, in 30 kg-Ballen 0160520 Cleaning towels Loctite Produkte Loctite Products

414 299 40

Loctite Nr. 222 E, Schraubensicherung, à 50 ml niedrigfest, bis M 36 Loctite Nr. 222 E

973 125

Loctite Nr. 241, Flüssigdichtung, 50 ml Schraubensicherung, mittelfest, bis M 12 Fluid sealing

973 130

Loctite Nr. 24333, Schraubensicherung, 50 ml mittelfest, bis M 36 Loctite No. 24333

255 242 40

Loctite Nr. 243, Schraubensicherung, 250 ml mittelfest, bis M 36 Liquid retention

170 470 40

Loctite Nr. 245, Schraubensicherung, 250 ml mittelfest, bis M 80 Adhesive

158 856 40

Loctite Nr. 27041, Schraubensicherung, 50 ml hochfest, bis M 20 Loctite No. 27041



42 43

ET-Nr.

Gegenstand

Part-No.

Description

167 644 40

Loctite Nr. 307, 50 ml Metallkleber (nur in Verbindung mit 7471) Adhesive (only in connection with 7471)

288 906 40

Loctite Nr. 330, Klebeset verbindet nahezu alle Materialien (außer Gi) Loctite Nr. 330

461 798 40

Loctite Nr. 401, 20 g, Cyanacrylat, zum Verkleben von Kn, Gummi, Pappe, Leder, Holz, u.v.m. Loctite Nr. 401 for wood, rubber etc. .

255 238 40

Loctite Nr. 511, Flüssigdichtung, niedrigfest zum Abdichten von Verschr. bis R 2”, 50 ml Fluid sealing

232 554 40

Loctite Nr. 511, 250 ml, Flüssigdichtung, niedrigfest Adhesive

083 399 40

Loctite Nr. 586, 50 ml, Flüssigdichtung, hochfest, bis R2” Loctite Nr. 586

255 239 40

Loctite Nr. 574, 50 ml Flächendichtung, Spaltgröße bis 0,5 mm Loctite 574 for surface

255 237 40

Loctite Nr. 603, hochfest, 50 ml Fügeverbindung Loctite 603



43 -

ET-Nr.

Gegenstand

Part-No.

Description

288 907 40

Loctite Nr. 706, Schnellreiniger, 400 ml Fast cleaner

321 32240

Loctite, Klebstoff- u. Dichtungsentferner 300 ml-Sprühdose Loctite

083 376 40

Loctite Nr. 7471, Aktivator, 500 ml (Zur Aushärtung von 307 und zur Beschleunigung des Aushärtevorgangs) Loctite Nr. 7471



44 45

Appendix

Tools List


6 - 11

Work instructions

Appendix

6.4

WORK INSTRUCTIONS

6.4.1

REMOVE / INSTALL THE CRAWLER CARRIER

Special tools:

Hydraulic torque wrench, PN 793 376 73 + PN 793 374 73 Electro-hydraulic pump set, PN 795 922 73

NOTE: Fig. 6-1 shows the following: (Fig. 6-1, Pos. 1) Application of the hydraulic torque wrench. (Fig. 6-1, Pos. 2) Special wrench socket with supporting bar PN 793 376 73. (Fig. 6-1, Pos. 3) Hydraulic wrench PN 793 374 73. (Fig. 6-1, Pos. 4) Electro-hydraulic pump set PN 795 922 73.

Fig. 6-1

6 - 12

Hydraulic torque wrench

Appendix

6.4.2

Work instructions

USE OF THE HYDRAULIC TORQUE WRENCH (SUPPLIER’S DOCUMENTATION)

6 - 13

Work instructions

Appendix


6 - 14

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.

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-8 Operating the Avanti and Stealth SYSTEMS Releasing “LOCKED-ON” tools. Should the tool “LOCK-ON” after the final cycle, slide the slider (or the lever on Avanti) with the pump off or in retract position. Turn the pump back on and while maintaining the pressure, cycle Avanti in the pump’s manual mode. Should Stealth “LOCK-ON”, advance pump pressure and while advancing, press down on the release button located on the sides of the ratchet link. Once you are able to press down the button without resistance, continue holding the button down and release the advance pressure on the pump. Shut off the pump, and remove the tool from the nut.

Avanti Release Procedure

Disengage lever

1)

Push lever to position A

2)

Cycle tool in manual mode, release advance button

3)

Shut pump off

4)

Remove tool and reset lever to position B

Stealth Release Procedure STEALTH

1)

Push remote to full pressure for final stroke

2)

Disengage the reaction pawl by holding the button in the direction of arrow

3)

Release the rocker switch

4)

Shut pump off

5)

Remove tool

MADE IN U. S.A.

Disengage button

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-9 Loosening Procedures Avanti and Stealth SYSTEM First, set the pump to 10,000PSI. Set the tools for the loosening mode (Refer to 3-3), assuring the reaction surface abuts squarely off a solid reaction point. Press and hold the remote control button down. Pressure will decrease as the socket begins to turn. As the cylinder extends fully, you will hear a “CLICK”. Release the remote control button and the cylinder automatically retracts, at which time you again hear a “CLICK”. Repeat this process until the fastener can be removed by hand. NOTE: If the bolt does not loosen with the above procedure, it is an indication that you may require the next larger size tool to loosen the bolt. Corroded nuts and thread galling on bolts can cause difficulty in loosening. Please consult your HYTORC bolt specialist.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp 4-1 Tool Set up and Operation When used in conjunction with the HYTORC LoaDISC Washer or Clamp, the operation is essentially the same as with the conventional nuts, but with one notable exception: THERE ARE NO REACTION FORCES TO CONSIDER OR PROVIDE FOR! The reaction forces are absorbed through the fastener assembly itself. Each individual customer order for LoaDISC or Clamps will be provided with specific installation instructions for each application. However, the following general guidelines outline correct installation procedures. 4-2 HYTORC LoaDISC Tensioning 1. Do not use grease or lubricants on LoaDISC , nut, bolt or joint face. LoaDISC is “DRY LUBE” protected. 2. Place the LoaDISC over the bolt with the flat surface firmly against joint face. 3. Install the nuts on the bolt and hand tighten snugly on both sides of assembly. 4. Set required pump pressure. 5. Place tooling to engage a nut and the LoaDISC with “TIGHTENING” side facing the operator.

-continued to the next page-

DRIVE SOCKET

HOLDING SOCKET

Soft Joint LoaDISC

Reusable LoaDISC

Hard Joint LoaDISC

Limited Clearance

HEX NUT

DISC WASHER THREADED SEGMENT

LoaDISC

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-2 HYTORC LoaDISC Tensioning 6. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until tool “STALLS OUT” 7. Should tool rotate during initial pressurizing: A. Insure both socket and sleeve are fully engaged. B. Insure that joint faces are free from grease and oil. *Also refer to the trouble shooting section (4-4) LoaDISC Driver Installation for Tensioning LOCK-RING 'NEUTRAL' POSITION

PLACE DRIVER NUT/LoaDisc

ROTATE 'CW' BY HAND, TO SNUG LoaDisc TO FLANGE

LoaDisc LOCK-GROOVE

NOTE:

ROTATE DRIVER ASSEMBLY 'CCW' DIRECTION FOR TIGHTEN MODE

TIGHTEN 'CCW' DIRECTION

LOOSEN 'CW' DIRECTION

1

2

3

* DO NOT GRAB A SWIVEL DURING OPERATION! * DO NOT PLACE TOOL HOUSING * TO ABUT AGAINST STATIONARY OBJECTS * DO NOT STAND UNDERNEATH OR CLOSE TO TOOL * DO NOT RE-USE SINGLE-TIME USE LoaDISC

VERIFY ROTATE LOCK-RING

LOCK-RING ENGAGE LoaDisc LOCK-GROOVE

4

5

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-3 HYTORC LoaDISC De-tensioning 1. Set pump to maximum pressure. 2. Place tooling to disengage the nut and the LoaDISC with “LOOSENING” side facing the operator. 3. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until the nut is loose. 4. Should tool rotate during initial pressurizing: A. Insure both socket and sleeve are fully engaged. B. Insure that joint faces are free from grease and oil. *Also refer to the trouble shooting section (4-4)

ROTATE DRIVER ASSEMBLY 'CW' DIRECTION FOR LOOSEN MODE

LoaDISC Driver Installation for De-tensioning

VERIFY ROTATE LOCK-RING

3

4

5

Releasing “LOCKED-ON” tools. (Refer to 3-8 for Avanti and Stealth) Should the tool “LOCK-ON” after the final cycle, slide the slider with the pump off or in retract position. Turn the pump back on and while maintaining the pressure, cycle XXI in the pump’s manual mode. the pump. Shut off the pump, and remove the tool from the nut. XXI Release Procedure HYT RC

1)

Push slide cover up to position A

2)

Cycle tool in manual mode, release advance button

3)

Shut pump off

4)

Remove tool and reset slide cover to position B

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-4 HYTORC LoaDISC Lubrication Instruction & Trouble Shooting STEP 1:

Make sure all threads and surfaces are free of dirt or grit.

STEP 2:

Apply spray lube TS801 moly spray to nut per procedure indicated below. Allow spray lube to dry (spray lube is shipped with LoaDISC order). Refer to the Dry-lube container label for a drying time. Do Not Apply Lube to LoaDISC

STEP 3:

Clean and dry protruding stud threads and nut seat surfaces.

STEP 4:

Install LoaDISC with flat side against joint, turn till snug.

STEP 5:

Install lubricated hex nut on top of LoaDISC , snug against top surface of LoaDISC .

LoaDISC Application of Spray TS801

NOTE: *Allow sufficient time for spray to dry before use. Hex nut can be reused, if re-lubricated per illustration. NO NOT REUSE ONE TIME USE LoaDISC

HYTORC LoaDISC Trouble Shooting SYMPTOM Driver does not lock

CAUSE Lock ring misaligned with LoaDISC

SOLUTION Check for excessive stud protrusion Check that holding socket is flush to flange surface

LoaDISC groove damaged

Replace LoaDISC

Missing or damage lock-ring

Replace lock-ring

LoaDISC not snug against

flange surface

Tighten LoaDISC to flange surface with driver assembly (CW direction)

Driver un-locks during verification

Worn lock-ring

Replace lock-ring

Driver un-locks during use

Lock-ring rotated in wrong direction

Rotate Holding socket and lock-ring •CCW toward ‘T’ for Tighten •CW toward ‘L’ for Loosen

Driver does not un-lock after torque procedure

Stud driven up into bottom of drive socket

Check for excessive stud extension.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-5 HYTORC Clamp Installation - Tensioning The HYTORC Clamp is provided with lubrication and is shipped ready for use. For re-lubrication, please refer to lubrication Instructions. (4-6) 1. Thread the Clamp down on the stud, turn the Puller Sleeve to contact the flange, contacting the flange or the spot face firmly. The Clamp should fit easily onto the spot face. 2. The Puller Sleeve, when properly installed, should protrude no more than 1/16 (15mm) past the top of the Nut (outside sleeve). If the Puller Sleeve is raised beyond 1/16”, hold the Puller Sleeve or the Bridge by hand and turn the Nut counter-clockwise (loosen direction) until the Puller Sleeve protrudes no more than 1/16” past the top of the Nut. After adjusting the Nut, turn the entire Clamp assembly down to contact the flange or the spot face firmly. 3. Before using XXI tool on the Clamp, make sure the tool and the drive member are set properly. The castellated drive and the splined reaction member should stick out on the right side for tensioning. Cycle the tool and the drive a few times to ensure that the tool is properly operating. Repeat this step only when you change the tool or the drive. 4. Refer to the load chart supplied with the Clamp and set the pump pressure to achieve the desired load. Do not engage drive on the Clamp while setting the pump pressure. Turn the pressure regulator counter-clockwise to set it below the target pressure. While holding the advanced button on the remote control, slowly turn the pressure regulator clock wise to increase the pressure to the desired value. Ensure the pressure value is set properly by holding the advanced button. 5 Before applying the tool and the drive, engage the splined reaction member to the Puller Sleeve first. Then engage the castellated drive to the castellated section of the Nut. Turn the drive manually until both castellation are fully engaged. IMPORTANT: If the castellated teeth do not fully engage, the Puller Sleeve is sticking up too far or stud protrusion is more than maximum value. Refer back to Step 3. Then reposition the Puller Sleeve and check stud protrusion. 6 Apply the pump pressure to tension the Clamp, until the target pressure is reached. To ensure that the proper tension has been applied to the stud, allow the tool to fully retract then advance to the target pressure a final time. 7 Repeat 5 & 6 until all bolts are fully tensioned.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-6 HYTORC Clamp Installation - Detensioning 1. Before using XXI or Avanti tool on the Clamp, make sure the tool and the drive member are set properly. The castellated drive and the splined reaction member should stick out on the left side for detensioning. Cycle the tool and the drive a few times to ensure that the tool is properly operating. Repeat this step only when you change the tool or the drive. 2. Detensioning, in general, requires higher pump pressure. Refer to the load chart and set the pump pressure slightly higher than the value used for tensioning. Turn the pressure regulator counter clockwise to set it below the target pressure. While holding the advanced button on the remote control, slowly turn the pressure regulator clockwise to increase the pressure to the desired value. Ensure the pressure value is set properly by holding the advanced button. 3. Remove drive from tool, engage the splined reaction member to the Puller Sleeve first. Then engage the castellated drive to the castellated section of the Nut. Turn the drive manually until both castellation are fully engaged. Place tool on drive with “LOOSEN” side facing the operator. Install drive retainer. 4. Apply the pump pressure to detension the Clamp, until it can be turned by hand. 5. Repeat 3 & 4 until all bolts are fully tensioned. On applications that require two or three passes to tension, it is advised to detension the last few bolts in two passes. If corrosion makes it impossible for the Clamp to be turned by hand even after detensioning, use the hex/spine adaptor. To use the hex/spline adaptor, insert the male spline of the adaptor into the female spline of the Puller Sleeve. Place a wrench over the hex of the adaptor and rotate the Sleeve off the bolt.

NOTE: Before reusing the Clamps, it is imperative that the Clamps are properly cleaned and re lubricated to prolong their life. Refer to the lubrication instruction on the next page.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-7 HYTORC Clamp Lubrication Instruction The Clamp Lubrication Instructions: (Use a clean stiff bristle brush) STEP 1:

Make sure all threads and splines are free of dirt or grit. Generously grease internal threads on the Jack-up Sleeve with a brush to get full coverage to the thread root.

STEP 2:

Generously grease external threads on the Puller Sleeve with a brush to get full coverage to the thread root.

STEP 3:

Grip the bottom splined section and internal threads of the Jack-up Sleeve into the Jack-up Sleeve as the arrow indicates. Leave the bottom splined section sticking out the bottom.

STEP 4:

Turn the assembled parts upside-down. Spread excess grease around to coat bottom surface of the Jack-up Sleeve and splines. Apply grease on the splines if coating is thin.

STEP 5:

Apply grease to internal splines on the Washer to get full coverage to the spline root. Coat top surface of the Washer.

STEP 6:

Slide the Washer to the assembled Sleeves as the arrow indicates. When the Puller Sleeve and the Washer are in contact, the Puller Sleeve and the Washer bottoms should be flush with each other. Rotate the Jack-up Sleeve while holding the Washer to achieve this desired condition.

SECTION V OPERATION – HYTORC Power Packs 5-1 HYOTRC Power Packs General Information All HYTORC Power Packs operate at a pressure range from 500 to 10,000 PSI and are fully adjustable. They have been engineered and designed for portability and high flow for increased speed. Before using your HYTORC Power Pack, check the following points: • • • • •

Is the reservoir filled with oil? Where is the closest electrical outlet at the job site? (Electric pump only) Is there enough air pressure (100 PSI) and flow (50 CFM) at the job site? (Air units only) Is the gauge mounted and rated for 10,000 PSI Is the oil filler plug securely in place?

The Power Packs maximum working pressure is 10,000 PSI (700 kg/cm2, 690 Bar) Make sure all hydraulic equipment and accessories are rated for 10,000 PSI operating pressure. 5-2 Hydraulic Connections When making a connection with quick connect couplings, make sure the couplings are fully engaged. Threaded connectors such as fittings, gauges etc. must be clean and securely tightened and leak free. CAUTION: Loose or improperly threaded couplers can be potentially dangerous if pressurized. Severe over tightening can cause premature thread failure. Knurled sleeve on couplers need to be only hand tight. Never grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury. Do not subject the hose to potential hazard such as sharp surfaces, extreme heat or heavy impact. Do not allow the hose to kink and twist. Inspect the hose for wear before each usage. 5-3 Prior to Use Do not use a power or extension cord that is damaged or has exposed wiring. All single phase motors come equipped with a three prong grounding type plug to fit the proper grounded type electrical outlet. Do not use a two prong ungrounded extension cord as the pump’s grounded type electrical outlet. Compare motor nameplate against power availability to prevent motor burnout or dangerous electrical overloading. *For electric cord extension, refer to below chart 0-25 Foot Extension 26-50 Foot Extension 51-75 Foot Extension 76-100 Foot Extension

Use size 12 gauge cord Use size 10 gauge cord Use size 8 gauge cord Use size 6 gauge cord

Check hydraulic oil level to prevent possible pump burnout. Look at oil fill level on the oil sight gauge. The oil level should be approximately 2” from the top of the reservoir plate-with motor off. Add HYTORC oil as necessary. Air Pump Oil Sight Gauge

*Do not mix different grades of oil.

Electric Pump Oil Sight Gauge

SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-3 Prior to Use -ContinuedMake sure all desired gauge, valve, hose and quick coupler connections are tight and secure. The gauge permits the operator to monitor the load on the wrench. *Calibrated gauges are available for most application. Before starting your HYTORC pump, connect your hydraulic hoses to both the pump and torque wrench. (Refer to 3-2) 5-4 Operation Electric Pump Push the rocker switch on the hand control pendant in the OFF position. Then, depress and release the safety button. NOTE: The safety button is an added feature designed to prevent premature starting and should only be depressed by the tool operator. Safety Button

Push the rocker switch to advance position and release it. This will start your pump and place it in the retract position. Your HYTORC electric pump has been designed with an auto shut off system. The pump will shut off after approximately 20 seconds of non-cycling. This will prevent overheating or unnecessary wear and results in longer life of your pump. To restart the pump, depress the safety button again.

OFF Retract/Neutral Advance

Rocker Switch

5-5 Operation Air Pump Before connecting air supply line to the Air Filter Lubricator, make sure the Air Flow Lever is in the OFF position. Then connect air supply line. Open the Air Flow Lever. Check the PSI reading on the Air Pressure Gauge. It should be at 100 psi. Depress the Air Adjustment Knob to increase psi reading. Air Adjustment Knob Air Flow Lever Adjust lubricator to approximately one drop per Lubricator Adjust Minute. *Before operating your HYTORC air pump, check for air leaks on the air hoses/tubing. Air Pressure gauge

SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-5 Operation Air Pump To start the pump, depress the advance button and release it. This will put the tool in the retract mode. To advance the tool, depress the advance button and hold it down. When you are done, depress the stop button and the motor will stop. NOTE: The pump is still pressurized. To release the air pressure from the pump, put the Air Flow Lever in the OFF position, then depress the advance button on the air remote control. This will purge the air in the motor. Now it is safe to disconnect your air supply line.

Advance Button Stop Button

5-6 Operation of automatic pump Before operating automatic pump, the cable line attached to each hose must be connected securely with the appropriate receptacle on the pump manifold and the receptacle on the tool.

Securely connect

NOTE: Connect only the number of tools used on the application to the pump.

Set pump pressure to achieve desired torque value. (refer to 3-5 and 3-6)

SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-7 Starting with automatic operation MANUAL MODE For manual operation, depress the Mode [M] 3-position rocker switch to the ‘MANUAL’ position. Hold down the Control [C] rocker switch in the ‘RUN’ position to advance the tool(s). The switch will toggle to the ‘NEUTRAL’ position when released, retracting the tool(s). Depress the Control [C] switch to the ‘OFF’ position to turn off the system. AUTOMATIC MODE

CONTROL SWITCH

PERSS FOR RUN (TOOL ADVANCE) RELEASE (TOOL RETRACT) (NEUTRAL)

PRESS FOR PUMP OFF

Initialize Computer: To operate the automatic system, the computer has to recognize how many tools are attached to the system. To accomplish this, attach the required number of tools to both hydraulic and electric lines. Then cycle system in manual mode for at least one full cycle.

PRESS FOR TIGHTENING NEUTRAL LOOSENING PRESS FOR MANUAL

MODE SWITCH AUTOMATIC TIGHTENING MODE Initialize the computer (see above). Without shutting pump off, push Mode switch [M] into ‘TIGHTENING’ position. Press and hold control switch [C] in ‘RUN’ position. As long as the run switch is held depressed, the pump will function in automatic tightening mode. The tool(s) will continue to cycle until the preset torque Is achieved. Allow sufficient time to be sure that the tool(s) have stopped rotating before releasing the run switch. The pump motor will automatically shut off after 20 seconds, allowing the tool(s) to return to the retract position. The ‘OFF’ position on the Control switch turns off the system. AUTOMATIC LOOSENING MODE Initialize the computer (see above). Without shutting pump off, push Mode switch [M] into ‘LOOSENING’ position. Press and hold control switch [C] in ‘RUN’ position. As long as the run switch is held depressed, the pump will function in automatic loosening mode. The tool(s) will continue to cycle until the Control switch is released. Cycle tool(s) until nuts are free and can be removed by hand. Release the Control switch and depress the Control switch to the ‘OFF’ position to complete the loosening cycle.

Appendix

6.5

Service Bulletins

SERVICE BULLETINS

Overview: SB-No.

Subject

AH00511d

Installation procedure for the swing circle / Slew Ring (SR)

AH00514

Track group - Hints for sprocket exchange

AH00519c

Adhesive lubricants for the Slew Ring Gear

AH01512

Setup - procedure of the VHMS Integrated Tool Soft

AH01521a

Diesel engine suspension

AH01531A

Hydraulic accumulators - testing and refilling

AH02513b

Testing wear and tear of swing circle bearing

AH02521

Track group – wear measurement

AH03506b

Hydraulic oil cooler and water cooler fan bearings

AH03509a

Slew gear GFB 174 E 9017 (Part No. 917 915 40)

AH03510

ESCO bucket tooth system

AH03526a

Downloading of VHMS Data from VHMS memory to a connected PC/Laptop

AH03538

Replacing of the VHMS - Controller on PC4000-6

AH04518a

Welding procedure for welded counterweight

AH05510

Bearing flushing of the A4VS variable displacement axial piston pump

AH05511

Dual cone seal ring mouting

AH05546

Automatic lubrication system - Vent valve (PN 769 879 73)

AH06524

Hydraulic cylinder

AH06530

Relieving of the track chain tension

6 - 15

Service Bulletins

Appendix


6 - 16

Appendix

6.5.1

Service Bulletins

AH00511D Installation procedure for the swing circle / Slew Ring (SR)

6 - 17

Service Bulletins

Appendix


6 - 18

COMPONENT CODE:

2500

REF NO.

AH00511d

PARTS & SERVICE NEWS

DATE

March 22, 2006 Page 1 of 20

This PARTS & SERVICE NEWS supersedes the previous issue No. AH00511c which should be discarded. SUBJECT:

Installation procedure for the swing circle / Slew Ring (SR)

PURPOSE:

Correct installation and adjustments

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 40 864 187 40 379 129 40 864 187 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

AH00511d

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.

AH00511d

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 eye bolts 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.

AH00511d

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 is protected from the direct sunlight.

Legend ID = Inner diameter slewring OD = Outer diameter slewring Π = 3.14 P = Maximum Deviation (deflection)

P=

OD – ID 2

: 100 x 0.2 *

* 0.2 = Constant Example: OD = 4000 mm ID = 3600 mm

W

P = 4000 – 3600 : 100 x 0.2

2 P = 200 : 100 x 0.2 P = 0.4 mm

• If the measured value exceeds the calculated value P the surface has to be remachined.

AH00511d

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.

AH00511d

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, 8 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 8 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 8 tightening torque's. For the exactly procedure refer to the following pages.

AH00511d

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 190

10.9

46 mm

0.55 ±0.015 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

H 655S PC8000 (to 12036) PC8000 (12037 up)

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

• Note down the tightening values in Nm, ft. lbf. resp. bar. • Repeat this procedure with all 8 test bolts. • Add all 8 tightening values and than divide by 8. • Torque bolts to the calculated value.

AH00511d

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.

AH00511d

Page 9 of 20

)

• When replacing the swing circle all fastening bolts must also be replaced.

The 8 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.

AH00511d

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. Type

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

864 187 40

H685SX (12030)

16.3

864 187 40

H 685SP

14.0

379 129 40

H 455S / PC5500 H 485S H 655S PC8000 ( - 12036) PC8000 (12037 - )

AH00511d

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 punchmarked 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.

AH00511d

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 back lash 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.

AH00511d

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 2 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 4 dimensions are noted in the table. 8. If necessary adjust the backlash by displacement of the SR. For the correct back lash refer to chart above. 9. Hints for the 3 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

Play – nominal value

gear 1

refer to table

gear 2

at page 10

Tooth 1 Tooth 2 Tooth 3 Tooth 4

gear 3

AH00511d

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.

Part no.: 864 501 40

AH00511d

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 back lash 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.

AH00511d

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 8 test bolts (4) of the connection SR / carbody. Determine the required torque with these 8 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.

AH00511d

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.

AH00511d

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, brush, 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.

AH00511d

Page 19 of 20

)

• 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

Molub-Alloy 936 SF Heavy Castrol Industrie TRIBOL

Molub-Alloy 958 SF 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

BEL RAY Molub Gear Tac 6895 Molub Gear Tac 6894 / 6899 ESSO

Dynagear Extra Ceplattyn KG 10 ECO (Biodegradable)

FUCHS LUBRITECH

Ceplattyn KG 10 LT URETHYN HGO *1)

MOLYBOND

TSG Heavy Malleus GL 500

SHELL

Malleus GL 400 Malleus GL 25

TEXACO

*1)

*2)

Crater 2X Fluid *2)

The URETHYN HGO 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.

AH00511d

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 replace 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.

AH00511d

Appendix

6.5.2

Service Bulletins

AH00514 Track group - Hints for sprocket exchange

6 - 19

Service Bulletins

Appendix


6 - 20


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

Appendix

6.5.3

Service Bulletins

AH00519 Adhesive lubricants for the Slew Ring Gear

6 - 21

Service Bulletins

Appendix


6 - 22


COMPONENT CODE:

2500

REF NO.

AH00519c

DATE

June 23, 2006 Page 1 of 4

This PARTS & SERVICE NEWS supercedes the previous issue AH00519b 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, brush, spray tin. Automatically tooth lubrication systems provides the upper most protection because of the continuously uninterrupted lubrication, permanent checks are not required.

AH00519c

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.

AH00519c

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 Molub-Alloy 936 SF Heavy Castrol Industrie GmbH

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

BEL RAY Molub Gear Tac 6895 Molub Gear Tac 6894 / 6899 ESSO

Dynagear Extra Ceplattyn KG 10 ECO (Biodegradable)

FUCHS LUBRITECH

Ceplattyn KG 10 HMF URETHYN HGO *1)

MOLYBOND

TSG Heavy Malleus GL 500

SHELL

Malleus GL 400 Malleus GL 25

TEXACO *1)

*2)

Crater 2X Fluid *2)

The URETHYN HGO 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.

AH00519c

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.

AH00519c

Appendix

6.5.4

Service Bulletins

AH01512 Setup - procedure of the VHMS Integrated Tool Soft

6 - 23

Service Bulletins

Appendix


6 - 24


COMPONENT CODE:

DB20

REF NO.

AH01512

DATE

05182001 Page 1 of 8

SUBJECT:

Setup – procedure of the VHMS Integrated Tool Soft

PURPOSE:

Presentation of the VHSM – System for PC4000-6

APPLICATION:

PC4000-6

FAILURE CODE:

DB20Z9

DESCRIPTION: This Bulletin shows the installation procedure of the VHMS* - software on your PC /Laptop. 1.

Preparation Before proceeding the setup, exit from ALL other applications that are currently running. Also, exit from the resident programs such as Virus Buster, if possible. Then prepare the VHMS Integrated Tool Soft Setup Disk 1 to 6.

2.

Insert the Setup Disk 1. (1) Click on the “Start” button on your Desktop and select “Settings”; (2) Click on “Control panel”; (3) Double click on “Software”; (4) Click on “Install”; (5) Click on “Next”; (6) Click on “Finish” to proceed the “Setup.exe” on drive A:\.

.

• Setup can be proceeded up to ten times. The following message will appear at the eleventh time, and the setup will not be proceeded further.

* VHMS – Vehicle Health Monitoring System

AH01512

Page 2 of 8

3.

“Welcome” screen is displayed.

Click on Next: 4.

Continue with the setup program.

“Choose Destination Location” screen is displayed

Click on Next:

Decide the destination folder, and continue with the setup.

AH01512

Page 3 of 8

5.

“Choose Destination Location” screen is displayed.

Click on Next:

6.

Decide the destination folder of VHMS data, and continue with the setup program.

“Select Program Folder” screen is displayed.

Click on Next:

Decide the program folder, and continue with the setup program.

AH01512

Page 4 of 8

7.

“Setup Needs The Next Disk” screen is displayed. The following instruction screen will appear when the Disk 2, 3, 4 and 5 are required accordingly.

(If you see a mistake message after changing a Disk – please click: Ignore) Please click on OK: Set the next disk, and continue with the setup program.

8.

“Read Only File Detected” screen is displayed.

During installing the program, if the above screen is displayed, you need to click the “Yes” button.

AH01512

Page 5 of 8

10.

“Setup Complete” screen is displayed.

Please click on Finish:

.

Finish the setup.

• After the setup procedure, a Restart Screen for the Windows might appear. In this case, please do restart it by choosing “Yes, I will restart the computer immediately”. We cannot guarantee the performance of the program if you did not restart. In the worst case, it could result in the malfunctioned Windows.

AH01512

Page 6 of 8

Finishing of the installation In order to start up the VHMS Integrated Tools Soft System, double-click the icon of VHMS, which is displayed on the desktop of the Windows . Password Input Screen is displayed then. Followings are the descriptions of each screen. 0. Start-Up Check Screen (only appears at the first start-up after the installation) The following screen will appear at an initial start of the system. Please turn off the write-protect switch of the Setup Disk 1 and then insert the floppy disk.

Please click on OK:

If the initialization check was properly completed,

1. Password Input Screen Input the user name and the password here.

User name: Password: Please click on OK:

Input “ user “. Input “ password” Go to “2. Start Option” screen.

AH01512

Page 7 of 8

2. Start Option Screen

Click on “Tool” Select with a click: “Add Failure code defined file”. Please insert Disk 6. Input necessary setups to add or update the fault code definition file.

PC4000 -6

Model: Input Model Type: Input Minor Variation Code: Input Please click on Reference:

” PC4000”. “-6”. “LC”. - Select Floppy (A:); - Highlight the file “DOWNLOAD_TEXTS.... .CSV” with click on

DOWNLOAD_TEXTS_ENGLISH_892 201 40.CSV

Click on “Open”

AH01512

Page 8 of 8

Click on OK:

Register information that was input.

Confirmation of Registration Result Screen is displayed. If successful, Screen as shown below is displayed.

Push OK Button

Setup of the VHMS Integrated Tool Soft is completed.

Close the program with click on the cross (x) up in the right corner of the screen. Then click on the OK Button.

AH01512

Appendix

6.5.5

Service Bulletins

AH01521A Diesel engine suspension

6 - 25

Service Bulletins

Appendix


6 - 26

COMPONENT CODE:

A2

REF NO.

AH01521a


DATE

20 Sept. 2002 Page 1 of 9

This PARTS & SERVICE NEWS supersedes the previous issue No.: AH01521 dated November 2001 which should be discarded. SUBJECT:

Diesel engine suspension

PURPOSE:

Hints for checking

APPLICATION:

H 185; H 255; H 285; H 455; H 485; H 655; H 685; PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

A2T0EH

DESCRIPTION:

Diesel engines are mounted on elastic elements. With increase of life the flexible mountings will show setting effects. 1.

Inspection intervals

• Damages to the engine might arise if the bolts of the flexible mountings are not tightened correctly.

1.1 Therefore check bolts after the following intervals: • Prior to putting the machine into operation or after replacement of the flexible mountings • after the first 250 operating hours • every 1000 operating hours or every 6 month latest

1.2 The elastic engine suspension must be checked (visual check): • Every 6 month or every 1000 operation hours (check the flexible mountings for damage). 1.3

Check the fatigue of the rubber elements according to the appendix (pages 5 to 9) once a year and give the records to our service department. Take a calliper.

AH01521a

Page 2 of 9

2.

Kinds of mounts

There are two types of mounts at each location: Type A: Flexible engine mountings Type B: Flexible engine mountings with self locking nut item (3) for limiting of the flexible distance.

3.

Control measures (see also in your Operation and Maintenance Manual) (Caterpillar-Engine fig.1; Cummins/Komastu - Engine fig.2) • All tests during motor stop!

The bolts of the flexible engine mountings have to be checked as follows: 1. Tighten the bolt (2) to 880 Nm (649 lbf ft). 2. Position the nut (3) so it just touches the steel plate of the rubber mount item (6). Tighten the nut an additional ¼ turn (90°).

F

Over tightening of this nut will result in removing the required elasticity of the rubber mounts and may cause engine failure.

3. Only by Cummins Engines Check distance „C“ between torque support and stop bolt(4). With setting of the flexible engine mountings the distance „C“ increases and must be readjusted. To do this, loosen lock nut (7) and tighten stop bolt (4) until the correct distance „C“ is obtained. Tighten lock nut (7) and recheck distance (C). 4. Check all rubber metal bars (1) and all strips (6) for damage.

F

• All rubber metal bars(1), all strips(6) and all cup springs(5) should be replaced during engine overhaul.

AH01521a

Page 3 of 9 Fig. 1: For example PC8000 with Caterpillar - engine

1

2 A

A B 6

3

2

B A 3 2

M24x150

M24x150 M24x350

A

A

B

Legend: (A); (B) Two types of engine mounts (1) Rubber metal bar (2) Bolt of engine mount type (A (3) Self locking retainer nut of the engine mount type (B)) (6) Strip

3

AH01521a

Page 4 of 9 Fig. 2: For example PC4000 with Cummins/Komatsu - engine

LEGEND: (A); (B) Two types of engine mounts (C) Distance between torque support and stop bolt(4) (1) Rubber metal bar (2) Bolt of the engine mount type (A) (3) Self locking retainer nut of the engine mount type (B) (4) Stop bolt (5) Cup spring package (6) Stip (7) Lock nut

6

4

5 C

7 2 6 B

1 A

A

Lock nut tighten snugly

B 3 AH01521a

Page 5 of 9

Record of measurement - fatigue of the engine bearings Excavator model:

PC3000

Inspector:

Serial number:

Date:

Engine manufacturer:

Signature:

Measuring point

Value (X) (mm)

1 2 3 4 5 6 7 8 AH01521a

Page 6 of 9


PC4000

Inspector:

Serial number:

Date:


Signature:

Measuring point

Value (X) (mm)

1 2 3 4 5 6 7 8

AH01521a

Page 7 of 9


PC5500

Inspector:

Serial number:

Date:


Signature:

5

Measuring points PC5500

1

Pump distributer gear

Measuring point

Value (X) (mm)

1 6

2 Engine

7

2 3

3

4 5 6 7

8

4

8 AH01521a

Page 8 of 9


PC8000

Inspector:

Serial number:

Date:


Signature:

5

1

Measuring points PC 8000

6

2 Engine 7

3

Measuring point

Value (X) (mm)

1 2 3 4 5


6 7 8

4

8 AH01521a

Page 9 of 9


PC8000

Inspector:

Serial number:

Date:


Signature:

5

Measuring points PC 8000 (CAT)

1

Measuring point

Engine 6

2

7

3

Value (X) (mm)

1 2 3 4 5


6 7

8

4

8 AH01521a

Appendix

6.5.6

Service Bulletins

AH01531A Hydraulic accumulators - testing and refilling

6 - 27

Service Bulletins

Appendix


6 - 28

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

Appendix

6.5.7

Service Bulletins

AH02513B Testing wear and tear of the swing circle bearing

6 - 29

Service Bulletins

Appendix


6 - 30

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

Appendix

6.5.8

Service Bulletins

AH02521 Track group – wear measurement

6 - 31

Service Bulletins

Appendix


6 - 32

COMPONENT CODE:

75

REF NO.

AH02521

DATE

06212002


Page 1 of 6 This PARTS & SERVICE NEWS supersedes the previous issue Number 21-205b which should be discarded. SUBJECT:

Track group – wear measurement

PURPOSE:

Increasing the service life and avoiding unforeseen standstill

APPLICATION:

H 185 to PC8000

FAILURE CODE:

752DCA

DESCRIPTION: 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 06.

The measurements are described in detail and illustrated on pages 02 - 05.

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.

AH02521

Page 2 of 6 Preconditions for the measurements: 1.

Cleaning of the track group, according to the Lubrication and Maintenance Manual.

2. Track sag (A): On Machines without the hydraulic track - tensioning system.

ð ð

On Machines with 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

No specification, since self-regulating

AH02521

Page 3 of 6

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 (see illustration). • 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 of short duration, so that the track tensioning system is released to 35 bar. For the track sag refer to page 02.

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 06. Repeat measuring procedure at measuring areas L2 / R2 - L4 / R4.

AH02521

Page 4 of 6 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: Operate in low idle. • Electric motor: Operate joy-stick slightly. • Move l.h. track group forward (Sprocket rotation F = forward), until the contact area of the uppermost sprocket tooth (0) and the track-pad lug (0) is in the illustrated position, see ill. A, on page 05. • Measure gaps (X1) according to ill. A. 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 into table -circular pitch A- on page 06. • 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 lowest sprocket tooth (0) and the track-pad lug (0) is in the illustrated position, see ill. B, on page 05. • Measure gaps (X2) according to ill. B. 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 06. • Repeat the measurements at the r.h. track group.

F

• The minimum permissible X1/X2 dimension amounts 0.5mm. If this dimension is reached, an oversized sprocket has to be installed, to bring the X1/X2 dimension to the new condition. • If the dimension X becomes a negative amount (less than 0mm). the lugs of the track pads will be damaged so strongly, that a complete exchange of the track pads will be the required. Therefore, make sure that the X1/X2 dimension never falls below 0.5mm.

For the exchange of the oversize sprockets, refer to Service Bulletin AH00514.

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, see illust.. C, page 05. • Record the measuring results in the form sheet on page 06.

AH02521

Page 5 of 6

L.h. track group is illustrated

AH02521

Page 6 of 6

Machine-Type : Customer : Oversize sprocket ? : (left hand side)

Oversize sprocket ? : (right hand side)

NO

YES

NO

YES

Chain elongation:

Serial-No. : Location : ð Date of installation: ................... at operating hours: ..................... ð Date of installation: ................... at operating hours: .....................

Operating hours : Date of measurement : Part-No. of track pad :

left hand crawler track “L“

Measuring area W-dimension [mm] via 4 pins

Chain elongation:

L1

L2

L3

L4

L3

L4

right hand crawler track “R“

Measuring area W-dimension [mm] via 4 pins

L1

L2

Circular pitch: Illustration “A“

3

inside

3 points (equally distributedon the chain) 2 outside inside outside inside

3

inside

3 points (equally distributedon the chain) 1 2 outside inside outside inside

1 Sprocket side X1-dimension [mm]

outside

L.H

X1-dimension

[mm]

R.H

Illustration“B“ Sprocket side X2-dimension [mm]

outside

L.H

X2-dimension

[mm]

R.H

Wear of Track pads (Roller contact surface): Track pad

Side

No.1 No.2 No.3 No.4 No.5 No.6

L.H. L.H. L.H. R.H. R.H. R.H.

Dimension “B“ [mm]

Number of cracked track pads left hand crawler track

right hand crawler track

AH02521

Appendix

6.5.9

Service Bulletins

AH03506B Hydraulic oil cooler and water cooler fan bearings

6 - 33

Service Bulletins

Appendix


6 - 34

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

Appendix

Service Bulletins

6.5.10 AH03509A Slew gear GFB 174 E 9017 (Part No. 917 915 40)

6 - 35

Service Bulletins

Appendix


6 - 36

COMPONENT CODE:

26

REF NO.

AH03509a


DATE

22nd July 2003 Page 1 of 25

This PARTS & SERVICE NEWS supersedes the previous issue AH03509 which should be discarded. SUBJECT:

Slew gear GFB 174 E 9017 (Part No. 917 915 40)

PURPOSE:

Modification to slew gear GFB 174 E 9020 (Part No. 92432540) including exchanging the sun gear shaft

APPLICATION:

PC8000 (12037 – 39); PC5500 (15012 – 15017); PC4000 (08151); PC3000 (06194)

FAILURE CODE:

2600Z9

DESCRIPTION:

General In order to increase the lifetime of the parking brake discs the swing gear oil filling capacity should be reduced by approximately 20 liters. The new filling capacity is approx. 42 liters. The present oil level gauge on the gear can no longer be used for checking the oil level. There are two possibilities to modify the oil level checking system. For increasing the lifetime of the slew gear the sun gear shaft should be changed during the slew gear modification. Page 1. Modification Kits 2 2.

Variant (A) – Modification by replacing of the swing gear cover with the complete parking brake unit,

6

3.

Variant (B) – Modification by machining the swing gear cover. 3.1 Modification of the swing gear cover a) Dismounting b) Machining of the swing gear cover c) Reassembly

8 11 11 12 13

4.

Completion of the swing gear cover

24

5.

Oil level checking procedure

25

AH03509a

Page 2 of 25 1. 1.0

Modification Kits One new gear shaft is required for one slew gear (Part No. 757 360 73 – differences to the old sun gear shaft: refer to illustration 6) 1.1 Kits for modification of the slew gear(s) according to Variant (A) 1.1.1 PC3000-1 Part No.: 794 016 73 Pos.

Part-No.

1 15 16 17 14 18 1 20 1 2

79227073 37441299 90635240 37126599 92582540 31318499 90756840 92582940 972111 50774898

Qty. Description 1 4 4 4 4 4 1 1 1 1

Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring

Illustration 3 6 6 6 6 6 6 6 2 2

1.1.2 PC4000-6 Part No.: 794 017 73 Pos.

Part-No.

1 15 16 17 14 18 19 20 1 2

79227073 37441299 90635240 37126599 92582540 31318499 90756840 92582940 972111 50774898

Qty. Description 2 12 12 12 12 12 2 2 2 2


Illustration 3 6 6 6 6 6 6 6 2 2

(Cover plates must be adapted.)

AH03509a

Page 3 of 25 1.1.3 PC5500 Part No.: 794 018 73 Pos.

Part-No.

1 15 16 17 14 18 19 20 1 2

79227073 37441299 90635240 37126599 92582440 31318499 90756940 92582840 972111 50774898

Qty. Description 2 10 10 10 10 10 1 1 2 2


Illustration 3 6 6 6 6 6 6 6 2 2

1.1.4 PC8000 Part No.: 794 019 73 Pos.

Part-No.

1 15 16 17 14 18 19 20 1 2 1 1

79227073 37441299 90635240 37126599 92582440 31318499 90756940 92582840 972111 50774898 92583240 92583140

Qty. Description 3 14 14 14 14 14 2 2 3 3 1 1

Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring Cover plate Cover plate

Illustration 3 6 6 6 6 6 6 6 2 2 -

AH03509a

Page 4 of 25 1.2 Kits for modification of the slew gear(s) according to Variant (B) 1.2.1 PC3000-1 Part No.: 794 020 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2

37441299 90635240 37126599 92582540 31318499 90756840 92582940 33132299 79224973 972111 50774898

Qty. Description 4 4 4 4 4 1 1 1 1 3 1

Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring

Illustration 6 6 6 6 6 6 6 4 4 2 2

1.2.2 PC4000 Part No.: 794 021 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2

37441299 90635240 37126599 92582540 31318499 90756840 92582940 33132299 79224973 972111 50774898

Qty. Description 12 12 12 12 12 2 2 2 2 6 2


Illustration 6 6 6 6 6 6 6 4 4 2 2

(Cover plates must be adapted.)

AH03509a

Page 5 of 25 1.2.3 PC5500 Part No.: 794 022 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2

37441299 90635240 37126599 92582440 31318499 90756940 92582840 33132299 79224973 972111 50774898

Qty. Description 10 10 10 10 10 1 1 2 2 6 2


Illustration 6 6 6 6 6 6 6 4 4 2 2

1.2.4 PC8000 Part No.: 794 023 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2 1 1

37441299 90635240 37126599 92582440 31318499 90756940 92582840 33132299 79224973 972111 50774898 92583240 92583140

Qty. Description 14 14 14 14 14 2 2 3 3 9 3 1 1

Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring Cover plate Cover plate

Illustration 6 6 6 6 6 6 6 4 4 2 2 -

AH03509a

Page 6 of 25 2. Variant (A) – Modification by replacing of the swing gear cover with the complete parking brake unit 1. 2. 3. 4.

Prepare the swing gear cover as described on page 23. Drain the motor adapter housing (about 0.6l oil). Remove the 8 bolts (7) M16 mm at the hydraulic motor (refer to illustration 1). Remove the motor with connected hoses and place it beside or if this is not possible, disconnect the hydraulic lines and close the ports. 5. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16 from the gear box. 6. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit. 7. Replace the sun gear shaft (5) (refer to illustration 2). 8. Install the new Cover-Brake-Unit by using a new O-ring. 9. Modify the Swing gear type on the type plate old: GFB 174 E9017 to new: GFB 174 E9020 with punch marks. 10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring. 11. Fill the motor adapter housing with oil according to the Maintenance Manual. 12. Weld on the oil level gauge brackets (20) on the hydraulic oil reservoir carrier and if so planed a second one onto the machinery house wall. 13. Insert the attached oil level gauges (19)into the brackets. 14. Check the oil level in the swing gear as described on page 25.

AH03509a

Page 7 of 25

Illustration 1 Illustration 1 – before modification 1

Oil level gauge swing machinery

2

Oil filler plug swing machinery

3

Breather filter swing machinery

4

Oil level gauge motor adapter housing

5

Breather filter motor adapter housing

6

Oil drain plug

7

Motor fastening bolts

8

- Gearbox fastening bolts (quantity: 34) - Mounting screws (quantity: 8)

AH03509a

Page 8 of 25 3. Variant (B) – Modification by machining the swing gear cover 1. Drain the motor adapter housing (about 0.6l oil). 2. Remove the 8 bolts (7) M16 at the hydraulic motor (refer to illustration 1). 3. Remove the motor with connected hoses and place it beside or if this is not possible, disconnect the hydraulic lines and close the ports. 4. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16 from the gear box (refer to illustration 1). 5. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit. 6. Replace the sun gear shaft (5) (refer to illustration 2). 7. Remove the old O-ring and clean the groove. 8. Modify the swing gear cover as described on pages 11 - 22. 8. Install the modified Cover-Brake-Unit by using a new O-ring. 9. Modify the Swing gear type on the type plate old: GFB 174 E9017 Part No. 917 915 40 to new: GFB 174 E9020 Part No. 924 325 40 with punch marks. 10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring. 11. Fill the motor adapter housing with oil according to the Maintenance Manual. 12. Weld on an oil level gauge bracket (20) on the hydraulic oil reservoir carrier and if so planed a second one onto the machinery house wall. 13. Insert the attached oil level gauges (19)into the brackets. 14. Check the oil level in the swing gear as described on page 24.

AH03509a

Page 9 of 25 Illustration 2 – Overview before modification 1

3

4 5

2

AH03509a

Page 10 of 25 Illustration 3 – Cover with brake (partly)

1

Pressure connection (M18x1.5) – max 60 bar

AH03509a

Page 11 of 25 3.1 Modification of the swing gear cover a) Dismounting 1. Remove the old oil level gauge assy. (390) and close the opening with a plug (99). 2. Remove the both snap rings (508; 549). 3. Loosen the 8 socket head cap screws (519). 4. Remove the bearing ring (503) by using of 2 eyebolts (M 16). 5. Before reinstallation apply the piston (116) with pressure (max. 60 bar) (see also illustration 4), otherwise the 2 screws (316)are prestressed (springloaded). 6. Remove the 2 socket head cap screws (316). Remove the piston (116). 6. Dismount the 10 Inner discs (505); the 11 outer discs (506) and the 10 sinus rings (551). 7. Remove the drive shaft (130). 501 8. Remove the disc (504). 99 501 390 316 551 505 503 506 504

130 549

508

116

519 Illustration 4

AH03509a

Page 12 of 25 b) Machining of the swing gear cover (501 – disc housing) 1. Mill at the swing gear cover six areas as shown. 2. Drill 6 holes in the milled areas and tap 1 ¼ inch. Illustration 5

45°

45°

R31.5 30

30°

+0.5

30°

Ø524 Ø660 R 1.6 30

G 5/4 AH03509a

Page 13 of 25

AH03509a

Page 14 of 25 c) Reassembly 3. Install the new disc (504) as shown.

4. Reinstall the drive shaft (130) with the ball bearing (51353298).

AH03509a

Page 15 of 25

5. Install the new discs. At first an outer disc (grease it with oil), then an inner disc and then a sinus ring ... and so on.

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Page 16 of 25

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Page 17 of 25

AH03509a

Page 18 of 25 Before installation supply the piston (116) with pressure (max. 60 bar). Do not forget to exchange the O-ring.

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Page 19 of 25

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Page 20 of 25

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Page 21 of 25

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Page 22 of 25

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Page 23 of 25

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Page 24 of 25 4. Completion of the swing gear cover 1. Remove plugs* (A3) from the swing gear cover. * numbers depends on type of the excavator 2. Install the oil level gauge tubes (14; 15; 16; 17) as shown in the illustration 6. 3. Close the tubes with plugs M24 (18).

20

19

Illustration 6

A3 – Plug 14 – Oil level gauge tube 15 – Socket 16 – Cutting ring 17 – Union nut 18 – Plug 19 – Oil level gauge 20 – Oil level gauge bracket AH03509a

Page 25 of 25 5. Oil level checking procedure (engine at standstill) The design of the swing gear requires four or five locations for oil level checking. The correct oil level is below the upper planetary stage. To reach this level between the planetary gears it is necessary to find out at which of the four, five or six tubes the oil level gauge can be insert to the stop.

Proceed as follow: 1. Take out oil level gauge (19) from bracket (20). 2. Remove plug (18) from one tube (14) and insert gauge (19). If the gauge can not be moved in to the stop use the next tube (14). Repeat this procedure until the gauge can be inserted to the stop. 3. The oil level should be between the MIN and MAX marking on the gauge. Add oil if necessary. 4. Remove oil level gauge from the tube and insert into bracket (20). 5. Close the tubes with the plugs (18).

• Do not leave the gauge (19) in the tube (14). If the gauge is left in the tube the swing gear and the gauge will be damaged when the swing gear operates.

AH03509a

Appendix

Service Bulletins

6.5.11 AH03510 ESCO bucket tooth system

6 - 37

Service Bulletins

Appendix


6 - 38

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

Appendix

Service Bulletins

6.5.12 AH03526A Downloading of VHMS Data from VHMS memory to a connected PC/Laptop

6 - 39

Service Bulletins

Appendix


6 - 40

COMPONENT CODE:

DB

REF NO.

AH03526a


DATE


This PARTS & SERVICE NEWS supersedes the previous issue AH03526 which should be discarded. SUBJECT:

Downloading of VHMS Data from VHMS memory to a connected PC/Laptop

PURPOSE:

Introduction of the VHSM – System for PC4000-6

APPLICATION:

PC4000-6 with VHMS - system

FAILURE CODE:

DB20Z9

DESCRIPTION: To carry out the data transfer from VHMS – system memory to a PC/Laptop, the necessary soft-/ hardware can be ordered individually. For machines up to Serial No. 08155: No 01 02

Designation Data transfer cable VHMS Technical analysis tool box (Download software + instruction manual)

Part No. 913 273 40 792 504 73

For machines up Serial No. 08156: No 01 02

Designation Data transfer cable VHMS Technical analysis tool box (Download software + instruction manual)

For price and delivery time contact:

Part No. 894 580 40 792 504 73

Komatsu Mining Germany Parts and Service Department 8152 Dinglerstr. 1 66440 Bierbach Germany

AH03526a

Appendix

Service Bulletins

6.5.13 AH03538 Replacing of the VHMS - Controller on PC4000-6

6 - 41

Service Bulletins

Appendix


6 - 42


COMPONENT CODE:

DA

REF NO.

AH03538

DATE

December 4, 2003 Page 1 of 26

SUBJECT:

Replacing of the VHMS – Controller on PC4000-6

PURPOSE:

To expound on the steps for replacing the existing VHMS controller with new one and the latter's setting

APPLICATION:

PC4000-6

FAILURE CODE:

DA00Z9

DESCRIPTION:

1. 2. 3. 4. 5.

Introduction Part number Precautions for Controller Replacement Appendix VHMS initial setting check sheet

1. Introduction PC4000 are equipped with a VHMS controller as part of their standard specifications. The VHMS controller is a device to control the CGC display and to record the history of machine operation. The VHMS controller is constantly powered direct by a battery and its function is to compile and record the day's operation in the VHMS memory, after the engine is switched off, while checking data consistency with the record up to the previous day. This work takes a certain amount of time, i.e. approx. 10 seconds. For this reason, cautions have to be taken in advance, when disconnecting the power to the VHMS. Such disconnection usually takes place with machines equipped with a battery isolator and a turbo-timer, when switching off the engine for emergency, right after the turbo timer has been set in operation, or when the battery terminal is disconnected immediately after switching off the starting switch, say for welding. In such case, the compilation and write-in work in the VHMS memory is interrupted, resulting in the controller program being damaged and the initial screen remaining in the CGC display unchanged. Hence be sure to provide an interval of more than 3 minutes after the engine is switched off and before disconnecting all the electric circuits. This Parts and Service News describes the procedures for you to follow when replacing the existing VHMS controller with a new one.

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Page 2 of 26

2. Part No.

3.

Part No.

Part Name

89200040

Controller

Precautions for Controller Replacement

3.1 Before starting with the replacement A. Download the VHMS data, if possible. First download the data on failure history in the existing VHMS controller that have been stored up to that moment, since they will likely be lost by the replacement. Next send them to WebCare. B

Disconnect the normal VHMS power source.

i)

Terminate the normal power supply by turning off the ignition key.

ii)

Maintain constant power supply for the controller at least for more than two minutes.

iii)

Then terminate constant power supply for the controller by disconnecting the power source.

3.2 Procedures for replacement and setting of VHMS system and actions after replacement A. Precautions for replacement: Replace the existing VHMS system with new one, taking care that no excessive force or shock is applied to the main body, the harness, etc. Relative to the VHMS connectors, disconnect CN1 first and connect it last, since it serves as a power supply cable, too.

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Page 3 of 26

B. Controller setting after replacement When a VHMS controller is replaced, data setting has to be done anew. Make correct setting, referring to the instructions on the following pages. Items to be newly set.

No. 1

Settings Operator: USER ID; Truck counter

Page 4; 5

2 3 4 5 6 7 8 9 10 11

Service: Machine model; Serial No. (Machine) Engine model; Serial No. (Engine) Maintenance Acknowledgement Central Lubrication System Swing Lubrication System Language; Operating Hours; Date Time; GMT Ref. Hydraulic Oil Viscosity; Gear Oil Viscosity Message ON/OFF; PLC-autom. ON/OFF Shut-Down ON/OFF

6; 7 8; 9 10; 11 12; 13 14; 15 16; 17 18; 19 20; 21 22; 23 24; 25

C. Disposal of replaced VHMS controller Return the replaced VHMS controller to the KMG Service Department, in accordance with its request for return of fault parts. When returning the controller, be sure to attach a tag to it, declaring that it is the VHMS controller replaced under this Parts and Service News. Also the attached form “VHMS initial setting check sheet” has to be send to KMG-Service Department.

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Page 4 of 26

4. Appendix 1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800

Fuel Level

Hyd Oil Temp

F

E

Oil Press Eng

H

L

H

L

Maint Mess Next Monitor 1

1.3 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800

1.2.3

Operator ID

1.2.4 1.2.5

Maintenance Monitor Current Messages

0.0 1.1

H

L

Coolant Eng

1.2 1.3 1.4 1.2.1 1.2.2

Operator Menu Initialization Information Machine Conditions: Monitor1 Standard monitor Monitor2 Expansion monitor Monitor3 Expansion monitor Screen Adjustment Consumption

1.2.3 Oil Temp Eng

Oil Temp PTO

H

L

L

Boardnet Volt

SETTING for Operator

H

USER ID

12345678901

Reset Truck Counter 1

16


17

Charging AMP

+

H

-

L


1.4 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 RPM 1800

Oil Level Hyd

Oil Level Eng

H

L

H

L

Gre Level CLS

Gre Level SLS H

H

L

L


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Page 5 of 26

14.1.7 Settings for Operator, Screen (No. 1.2.3)

See illust. (Z 21576)

When the button -Settings for Operator is pressed, the screen No. 1.2.3 is displayed.

)

• There are two hidden touch switches on the SETTING for Operator screen, see (1) and (2) illust. (Z 21576). These switches are used by service personnel for entering the Service Menu. To enter the Service Menu, first press the lower button (1) and then the upper button(2).

Entry of the Operator identification number (USER ID button): In the selection menu for settings (1.2.3) appears on the right side of the button ”USER ID” the actual eleven-digit Operator identification number. The use of the button ”USER ID” branches into the setting mode for the Operator identification number, see illust. (Z 21578). Without prior entry, 0 is predetermined as identification number. To distinguish Operators, it is possible to enter a eleven-digit Operator identification number. To this effect, the Clear-button puts the cursor onto the first position (left side). Data entry may be started via the number buttons. If eleven numbers were entered each further entry will be ignored. Using the Enter-button the identification number will be taken over and branched back to the selection menu (1.2.3). Resetting the Truck Counter: Press the button ”Reset Truck Counter 1” the display changes to ”YES – NO” decision screen, picture (Z 21577). When pressing the ”YES” button the counter 1 will be reset to zero. Truck counter 2 is reset in the same way.

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Page 6 of 26


Fuel Level

⇒

Hyd Oil Temp

F

H

E

L

Coolant Eng

Oil Press Eng

H

H

L

1.2.3 SETTING for Operator

2

USER ID

12345678901


16


17

L


2.0 Please Input Service ID 1

2

3

4

5

6

7

8

9

⇓

1

******

Please Input Service ID

0

Clear Enter

STO P

4.3.1 SERIAL NO. SETTING (MACHINE) MACHINE MODEL

PC4000

Variation Code

BHA

Type

-6

SERIAL No.

12345678901

MENU MACHINE

⇐

3.1 SERVICE MENU SELECT

⇓

Real Time Monitor

Failure History

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

ENGINE

AH03538

Page 7 of 26

14.2.6 Serial No. Setting (No. 4.3.1) Machine

1 2 3 4


PC4000

Variation Code

BHA

Type

-6

SERIAL No.

12345678901

MENU MACHINE

(1)

5

ENGINE

Machine model setup button: When you press this button, the model name selection menu appears.

SERIAL NO. SETTING (MACHINE) MACHINE MODEL PC4000 PC1000 PC6000 Variation Code PC2000

PC8000

Type PC3000

-6

PC10000

SERIAL No. PC4000 MENU

BHA

12345678901

MACHINE

ENGINE

SERIAL NO. SETTING (MACHINE)

(2)

Variation code setup button: When you press this button, the LBA and BHA selection menu appears.

MACHINE MODEL Variation Code LBA

PC4000 BHA

BHA

Type

-6

SERIAL No.

12345678901

MENU MACHINE

ENGINE

SERIAL NO. SETTING (MACHINE)

(3)

Type setup button: When you press this button, the type selection menu appears.

MACHINE MODEL

PC4000

Variation Code -1 -6

BHA

-2 Type-7

-6

-3 SERIAL-8No. -4

12345678901

-9

MENU -5 MACHINE

ENGINE

SERIAL No. SETTING

(4)

Serial number setup switch: Press this switch to set the serial number.

1

2

3

Please input SERIAL No.

4

5

6

12345678901

7

8

9

0

Clear Enter

EXIT

(5)

Engine serial number setup switch: Press this switch to change the display to the engine serial number setup screen.

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Page 8 of 26


Fuel Level

⇒

Hyd Oil Temp

F

H

E

L

Coolant Eng

Oil Press Eng

H

H

L


2

USER ID

12345678901


16


17

L



2

3

4

5

6

7

8

9

⇓

1

******


0

Clear Enter

STO P


PC4000

Variation Code

BHA

Type

-6

SERIAL No.

12345678901

MENU MACHINE

⇐


⇓

Real Time Monitor

Failure History

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

ENGINE

AH03538

Page 9 of 26

14.2.6 Serial No. Setting (No. 4.3.2) Machine

1 2

4.3.2 SERIAL NO. SETTING (ENGINE) ENGINE MODEL

QSK60

#1 S/N

12345678901

MENU MACHINE

(1)

3

ENGINE

Engine model setup button: When you press this button, selectable engine models are displayed. Select a desired one.

SERIAL NO. SETTING (ENGINE) ENGINE MODEL QSK60

QSK60

#1 S/N

12345678901

MENU MACHINE

(2)

ENGINE

Serial number setup button: Press this button and then set the serial number in the screen below. SERIAL No. SETTING 1

2

3

Please input SERIAL No.

4

5

6

12345678901

7

8

9

0

Clear Enter

EXIT

(3)

Machine serial number setup switch: Press this switch to change the display to the machine serial number setup screen.

AH03538

Page 10 of 26


Fuel Level F

E

⇒

Hyd Oil Temp H

L

Coolant Eng

Oil Press Eng

H

L

H


2

USER ID

12345678901


16


17

L



2

3

4

5

6

7

8

9

⇓

1

******


0

Clear Enter

STO P

4.5 MAINTENANCE MONITOR

⇐


⇓

h

Real Time Monitor

Failure History

h

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

250h Maintenance

-2

500h Maintenance

248

1000h Maintenance

748

2000h Maintenance

1748

h

3000h Maintenance

2748

h

h

MENU

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Page 11 of 26

14.2.8

Maintenance Monitor (No. 4.5 – 4.5.1) Maintenance Acknowledgement

Maintenance confirmation through Service Personnel Maintenance indicated with yellow or red background color should be confirmed through Service Personnel in the Service Menu subsequent to the execution of the maintenance. With the confirmation the actual value maintenance number is increased by 1. Thus, the length of the maintenance cycle is added to the display value and the gray color will appear in the maintenance display. The button in the Service Menu used for maintenance confirmation then turns gray instead of yellow and is then without any function. The confirmation of the maintenance is then stored. Example: 250h Maintenance is required (yellow), service meter reading is 252 Hours.

When you select the yellow button, again, it changes to blue and starts blinking. MAINTENANCE MONITOR

When you press the blinking button the following screen appears. MAINTENANCE MONITOR

250h Maintenance

-2

h

500h Maintenance

248

h

1000h Maintenance

748

h

2000h Maintenance

1748

h

3000h Maintenance

2748

h

⇒

MENU

MENU

If the display color changes from yellow to grey, also the "MAINT" color button changes to grey blinking

-2

h

500h Maintenance

248

h

1000h Maintenance

748

h

2000h Maintenance

1748

h

3000h Maintenance

2748

h

⇓

When you press the YES button, the changes back to grey and stops

MAINTENANCE MONITOR

MAINTENANCE MONITOR

250h Maintenance

248

h

500h Maintenance

248

h

1000h Maintenance

748

h

2000h Maintenance

1748

h

3000h Maintenance

2748

h

MENU

250h Maintenance

⇐

-2

h

248 Really Reset 250h Maintenance? 500h Maintenance

h

1000h Maintenance

748

h

2000h Maintenance YES

NO 1748

h

3000h Maintenance

2748

h

MENU

⇓

Date 31.08.01 Time 23:59 25 °C 252.1 h Tr1 Tr2 12 15 1/min 1800

250h Maintenance

Fuel Level

Hyd Oil Temp

F

E

H

L

Coolant Eng

Oil Press Eng

H

L

H

L


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Page 12 of 26


Fuel Level

⇒

Hyd Oil Temp

F

H

E

L

Coolant Eng


Oil Press Eng

H

H

L

2

USER ID

12345678901


16


17

L



2

3

4

5

6

7

8

9

⇓

1

******


0

Clear Enter

STO P

4.8.1

3.1

CLS SETTINGS Pause Time

60

min

Monitoring Time

3

min

Press. Relief Time

10

min

Lub. Cycle Counter

32000

Times

⇐

SERVICE MENU SELECT

⇓

Real Time Monitor

Failure History

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

MENU

AH03538

Page 13 of 26

14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Central Lubrication System CLS Only an integer can be entered as a numerical value. Decimal numbers cannot be entered.

(No. 4.8.1) CLS SETTINGS

Set CLS Pause Time

Pause (10 - 60)

60

min

Monitor. (1 – 20)

3

min

Relief (10 – 15)

10

min

Lub. Cycle Counter

32000

Times

⇒

MENU

1

2

3

4

5

6

7

8

9

0

Please input CLS Pause Time 60 min

Clear Enter

EXIT

Pause Time setting button:

Enter the time depending on the operating conditions. Only values between 10 and 60 minutes can be entered.

CLS SETTINGS

Set CLS Monitoring Time

Pause (10 - 60)

60

min

Monitor. (1 – 20)

3

min

Relief (10 – 15)

10

min

Lub. Cycle Counter

32000

Times

⇒

1

2

3

4

5

6

7

8

9

0

MENU

Please input CLS Monitoring Time 3 min

Clear Enter

EXIT

Monitoring Time setting button:


CLS SETTINGS

Set CLS Press. Relief Time

Pause (10 - 60)

60

min

Monitor. (1 – 20)

3

min

Relief (10 – 15)

10

min

Lub. Cycle Counter

32000

Times

⇒

MENU

1

2

3

Please input CLS Press. Relief Time

4

5

6

10

7

8

9

0

min

Clear Enter

EXIT

Pressure Relief setting button:

Enter the time depending on the operating conditions. Only values between 10 and 15 minutes can be

entered. CLS SETTINGS

Set CLS Lub. Cycle Counter

Pause (10 - 60)

60

min

Monitor. (1 – 20)

3

min

Relief (10 – 15)

10

min

Lub. Cycle Counter

32000

Times

MENU

Lub. Cycle Counter setting button:

⇒

1

2

3

Please input CLS Lub. Cycle Counter

4

5

6

32000

7

8

9

0

Times

Clear Enter

EXIT

It is recommendable to keep the counter reading over the live time of the machine. If necessary enter the number of the last download.

AH03538

Page 14 of 26


Fuel Level

⇒

Hyd Oil Temp

F

H

E

L

Coolant Eng


Oil Press Eng

H

H

L

2

USER ID

12345678901


16


17

L



2

3

4

5

6

7

8

9

⇓

1

******


0

Clear Enter

STO P

4.8.1

3.1


60

min

Monitoring Time

3

min

Press. Relief Time

10

min

Lub. Cycle Counter

32000

MENU

4.8.2

⇓

Times

⇐

SERVICE MENU SELECT

⇓

Real Time Monitor

Failure History

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

1X

SLS SETTINGS

Pause Time

10

min

Monitoring Time

2

min

Press. Relief Time

10

min

Lub. Cycle Counter

32000

Times

MENU

AH03538

Page 15 of 26

14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Swing Lubrication System SLS Only an integer can be entered as a numerical value. Decimal numbers cannot be entered.

(No. 4.8.2) SLS SETTINGS

Set SLS Pause Time

Pause (10 - 20)

10

min

Monitor. (1 – 20)

2

min

Relief (10 – 15)

10

min

Lub. Cycle Counter

32000

Times

⇒

MENU

1

2

3

4

5

6

7

8

9

0

Please input SLS Pause Time 10 min

Clear Enter

EXIT

Pause Time setting button:


SLS SETTINGS

Set SLS Monitoring Time

Pause (10 - 20)

10

min

Monitor. (1 – 20)

2

min

Relief (10 – 15)

10

min

Lub. Cycle Counter

32000

Times

⇒

1

2

3

4

5

6

7

8

9

0

MENU

Please input SLS Monitoring Time 2 min

Clear Enter

EXIT

Monitoring Time setting button:


SLS SETTINGS

Set SLS Press. Relief Time

Pause (10 - 20)

10

min

Monitor. (1 – 20)

2

min

Relief (10 – 15)

10

min

Lub. Cycle Counter

32000

Times

⇒

MENU

1

2

3

Please input SLS Press. Relief Time

4

5

6

10

7

8

9

0

min

Clear Enter

EXIT

Pressure Relief setting button:


SLS SETTINGS

Set SLS Lub. Cycle Counter

Pause (10 - 20)

10

min

Monitor. (1 – 20)

2

min

Relief (10 – 15)

10

min

Lub. Cycle Counter

32000

Times

MENU

Lub. Cycle Counter setting button:

⇒

1

2

3

Please input SLS Lub. Cycle Counter

4

5

6

32000

7

8

9

0

Times

Clear Enter

EXIT

It is recommendable to keep the counter reading over the live time of the machine. If necessary enter the number of the last download.

AH03538

Page 16 of 26


Fuel Level

⇒

Hyd Oil Temp

F

H

E

L

Coolant Eng


Oil Press Eng

H

H

L

2

USER ID

12345678901


16


17

L



2

3

4

5

6

7

8

9

⇓

1

******


0

Clear Enter

STO P

4.8.1

3.1


60

min

Monitoring Time

3

min

Press. Relief Time

10

min

Lub. Cycle Counter

32000

MENU

4.8.3

⇓

Times

⇐

SERVICE MENU SELECT

⇓

Real Time Monitor

Failure History

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

2X

OTHER SETTINGS (1/2) Language

English

Operating hours

650.2

Date

2001

Time

16 : 16

GMT Ref. MENU

3

19

8.5 Summer

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Page 17 of 26

14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Other Settings 1/2 (No. 4.8.3) OTHER SETTINGS (1/2) Language Operating hours

OTHER SETTINGS (1/2)

English 650.2

Date

2001

Time

16 : 16

GMT Ref.

3

19

⇒

Operating German hours

8.5

MENU

English

Language English

2001

Time

16 : 16

MENU

Summer

3

19

8.5

GMT Ref.

Language selector button:

650.2

Date

Summer

When the language menu appears, select a desired language.

The CGC is reset on a software basis. The screen disappears and then the software is restarted from the opening screen.

OTHER SETTINGS (1/2) Language Operating hours

Operating Hours SETTING

English 650.2

Date

2001

Time

16 : 16

GMT Ref.

3

19

⇒

8.5

MENU

1

2

3

4

5

6

7

8

9

0 Summer

SMR setting button:

Please input operating hours 650 .0 hour

Clear Enter

EXIT

Only an integer can be entered as a numerical value. Decimal numbers cannot be entered.

Set the service meter only while the engine is stopped.



Language

English

Operating hours

650.2

Date

2001

Time

16 : 16

GMT Ref. MENU

3

19

8.5

⇒

Language

English

Operating hours

650.2

Date Year Time Month GMT DayRef.

Summer

DATE SETTING

MENU

2001

3

19

16 : 16

⇒

8.5

1

2

3

Please input year

4

5

6

2001

7

8

9

0 Summer

Clear Enter

⇓

EXIT


For all DATE SETTINGS, i.e. Year Month and Day it is necessary to confirm the new settings by using the SET button.

Language Operating hours

English 650.2

Date

2001

3

Time

16 : 16

19 SET

GMT Ref. MENU

8.5 Summer

AH03538

Page 18 of 26


Fuel Level

⇒

Hyd Oil Temp

F

H

E

L

Coolant Eng


Oil Press Eng

H

H

L

2

USER ID

12345678901


16


17

L



2

3

4

5

6

7

8

9

⇓

1

******


0

Clear Enter

STO P

4.8.1

3.1


60

min

Monitoring Time

3

min

Press. Relief Time

10

min

Lub. Cycle Counter

32000

MENU

4.8.3

⇓

Times

⇐

SERVICE MENU SELECT

⇓

Real Time Monitor

Failure History

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

2X


English

Operating hours

650.2

Date

2001

Time

16 : 16

GMT Ref. MENU

3

19

8.5 Summer

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Page 19 of 26

14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Other Settings 1/2 (No. 4.8.3) OTHER SETTINGS (1/2)


TIME SETTING

Language

English

Language

English

Operating hours

650.2

Operating hours

650.2

Date

2001

Time

16 : 16

GMT Ref.

3

19

8.5

MENU

⇒

Summer

Date

2001

3

Time Hour

16 : 16

19

8.5

GMT Ref. Minute MENU

⇒

Summer

1

2

3

Please input hour

4

5

6

16

7

8

9

0

Clear Enter

EXIT

⇓


For all TIME SETTINGS, i.e. Hour and Minute it is necessary to confirm the new settings by using the SET button.

Language Operating hours

English 650.2

Date

2001

3

Time

16 : 16

19 SET

GMT Ref. MENU


English 650.2

Date

2001

Time

16 : 16

3

19

⇒

8.5

MENU

Summer

Time difference entry button:

2

3

4

5

6

7

8

9

0

.5

-

Please input GMT Reference 8.5

Clear Enter

To set the local time difference (from the international standard time) in the VHMS controller, press the GMT Ref.-button and then enter time with the combination of the numeric keypad and the 0.5h setting.


Language

English

Operating hours

650.2

MENU

1

EXIT


Date

2001

Time

16 : 16

GMT Ref.

Summer

DATE GMT Reference

Operating hours

GMT Ref.

8.5

3

Language

19

8.5

⇒

Operating hours

Summer time setup switch:

MENU

650.2

Date

2001

Time

17 : 16

GMT Ref. Summer

English

3

19

8.5 Summer

When pressed, a check mark appears and the time increases by 1 hour.

AH03538

Page 20 of 26


Fuel Level

⇒

Hyd Oil Temp

F

H

E

L

Coolant Eng


Oil Press Eng

H

H

L

2

USER ID

12345678901


16


17

L



2

3

4

5

6

7

8

9

⇓

1

******


0

Clear Enter

STO P

4.8.1

3.1


60

min

Monitoring Time

3

min

Press. Relief Time

10

min

Lub. Cycle Counter

32000

MENU

4.8.4

⇓

Times

⇐

SERVICE MENU SELECT

⇓

Real Time Monitor

Failure History

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

3X

OTHER SETTINGS (2/2) Oil viscosity hydraulic

VG46

Oil viscosity gear

CLP150

Message ON/OFF

ON

PLC-autom.ON/OFF

ON

MENU

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Page 21 of 26

14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Other Settings 2/2 (No. 4.8.4) OTHER SETTINGS (2/2) Oil viscosity hydraulic

VG46

⇒

OTHER SETTINGS (2) Oil viscosity hydraulic

VG46

Oil viscosity gear

CLP150

VG22 7 13 Oil viscosity gear VG32 8 14

Message ON/OFF

ON

Message ON/OFF VG46 9 15

-- ON

--

PLC-autom.ON/OFF

ON

VG68 10 16 PLC-autom.ON/OFF

--

--

VG100 MENU

MENU6

Hydraulic oil selector button: now

19 -CLP150 ---

ON

11

17

--

--

12

18

--

--

⇒


VG22

Oil viscosity gear

CLP150

Message ON/OFF

ON

PLC-autom.ON/OFF

ON

MENU

When the selection menu appears, The selected hydraulic oil is select the required hydraulic oil.


displayed. OTHER SETTINGS (2/2)

OTHER SETTINGS (2)

Oil viscosity hydraulic

VG46

Oil viscosity gear

CLP150

Message ON/OFF

ON

CLP150 Message ON/OFF--

PLC-autom.ON/OFF

ON

PLC-autom.ON/OFF

⇒

MENU

PTO - gear oil selector button:

Oil viscosity hydraulic Oil viscosity gear T32 75W-140

MENU

⇒


VG46

Oil viscosity gear

T32

ON

Message ON/OFF

ON

ON

PLC-autom.ON/OFF

ON

VG46 CLP150 --

MENU

When the selection menu appears, The selected gear oil is now select the required gear oil. displayed.

Select the required oil out of the table from the specific flowchart.

AH03538

Page 22 of 26


Fuel Level

⇒

Hyd Oil Temp

F

H

E

L

Coolant Eng


Oil Press Eng

H

H

L

2

USER ID

12345678901


16


17

L



2

3

4

5

6

7

8

9

⇓

1

******


0

Clear Enter

STO P

4.8.1

3.1


60

min

Monitoring Time

3

min

Press. Relief Time

10

min

Lub. Cycle Counter

32000

MENU

4.8.4

⇓

Times

⇐

SERVICE MENU SELECT

⇓

Real Time Monitor

Failure History

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

3X


VG46

Oil viscosity gear

CLP150

Message ON/OFF

ON

PLC-autom.ON/OFF

ON

MENU

AH03538

Page 23 of 26

14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Other Settings 2/2 (No. 4.8.4) OTHER SETTINGS (2/2)



VG46


VG46

Oil viscosity gear

CLP150

Oil viscosity gear

CLP150

Message ON/OFF

ON

Message ON/OFF

OFF

PLC-autom.ON/OFF

ON

PLC-autom.ON/OFF

ON

⇒

MENU

MENU

Message ON/OFF selector button:

When pressed the display changes from ON to OFF or vice versa.

Messages ON/OFF With the button "Messages ON/OFF" is shut down only the automatic display of actual messages for service purposes. In this case, setting works are not interrupted by accidentally occurred messages and the memory will not be filled with messages caused by testing operations. Control and monitoring functions remain active. Each operation of the button "Messages ON/OFF" is saved in the service memory, invisible for the operator. OTHER SETTINGS (2/2)



VG46


VG46

Oil viscosity gear

CLP150

Oil viscosity gear

CLP150

Message ON/OFF

ON

Message ON/OFF

OFF

PLC-autom.ON/OFF

ON

PLC-autom.ON/OFF

ON

⇒

MENU

MENU

PLC-autom. ON/OFF selector button:

When pressed the display changes from ON to OFF or vice versa.

PLC-autom. ON/OFF. With the button "PLC-autom. ON/OFF" it is possible to shut down all control and monitoring functions of the PLC. The PLC does not evaluate any entry signals and does not change any exit signals. With the menu pictures 5.10.1 "REAL TIME MONITOR (OUTPUT SIGNALS) (1)" up to 5.10.6 "REAL TIME MONITOR (OUTPUT SIGNALS) (6)" it is then possible to shut on and off any exit for service purposes without any interference. Each operation of the button "PLC-autom. ON/OFF" is saved in the service memory, invisible for the operator.

Example: 5.10.1 REAL TIME MONITOR (OUTPUT SIGNALS) (1) ACOUSTIC SIGNAL

H22

0

0/1

CLS PUMP

K29

0

0/1

SLS PUMP

K36

0

0/1

RPM SHIFTING

K45

0

0/1

EXIT

W

⇒

Output Signal 0/1 selector button: When pressed the display changes from0 to 1 and the

REAL TIME MONITOR (OUTPUT SIGNALS) (1) ACOUSTIC SIGNAL

H22

1

0/1

CLS PUMP

K29

0

0/1

SLS PUMP

K36

0

0/1

RPM SHIFTING

K45

0

0/1

EXIT

• With the function PLC-AUTOM. (evaluation)switched OFF all monitoring and control functions of the PLC are inoperative.

AH03538

Page 24 of 26


Fuel Level

⇒

Hyd Oil Temp

F

H

E

L

Coolant Eng


Oil Press Eng

H

H

L

2

USER ID

12345678901


16


17

L



2

3

4

5

6

7

8

9

⇓

1

******


0

Clear Enter

STO P

4.8.1

3.1


60

min

Monitoring Time

3

min

Press. Relief Time

10

min

Lub. Cycle Counter MENU

32000

⇓

⇐

Times

SERVICE MENU SELECT

⇓

Real Time Monitor

Failure History

PM-Clinic

Maintenance

Serial No. Setting

Snapshot

Memory Clear

Setting

4X – 9X

4.8.5 - 4.8.10

SHUT-DOWN ON/OFF (1) Shut-Off (gate) valve

ON

Reserve 11

ON

Reserve 10

ON

Hydraulic oil level

ON

MENU

AH03538

Page 25 of 26

14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Shut Down ON / OFF (No. 4.8.5 - 4.8.10) For purposes of initial start-up and repair each Shutdown may be closed down individually. The shutdown remains without any time limit. With the operation of the button the logical state of the respective Flag in the interface changes to the PLC. With the Flag set, the PLC will not activate the shutdown. However, there will result a shutdown message. Each operation of the button is saved in the service memory invisible for the operator. Example: 4.8.5

⇒


ON

Reserve 11

ON

Reserve 10

ON

Hydraulic oil level

ON


OFF

Reserve 11

ON

Reserve 10

ON

Hydraulic oil level

ON

Shut-Down ON/OFF selector button: When pressed the display changes MENU

MENU

4.8.6

4.8.7

SHUT-DOWN ON/OFF (2)

4.8.8



Reserve 9

ON

Monitoring HPF3/Chip3 (Start bl.)

ON

Trouble HPF3/Chip3 (Low idle)

ON

Shut-Off (gate) valve (Start bl.)

ON


ON


ON


ON


ON

Hydr. Oil temp. (Bucket cut off)

ON


ON


ON

Lubrication syst. (Bucket cut off)

ON

MENU

MENU

4.8.9

4.8.10 SHUT-DOWN ON/OFF (6)


MENU

MENU

Reserve 8

ON

Reserve 4

ON

Reserve 7

ON

Reserve 3

ON

Reserve 6

ON

Reserve 2

ON

Reserve 5

ON

Reserve 1

ON

MENU

AH03538

Page 26 of 26

5. VHMS initial setting check sheet In case you replace the VHMS controller, you require to conduct the VHMS controller setting. In order to avoid miss setting, please check setting item with this sheet and report it to VHMS / WebCARE support center and KMG by FAX or e-mail. This check sheet will be used when we receive the data downloaded by New VHMS controller in WebCARE, in order to check the download data if the setting has been done correctly or not. If the check sheet is not received by Komatsu, the download data will not be entered in WebCARE system.

Checking item Setting date Distributor & Branch Subsidiary Person in charge Model name Serial no. SMR (Hour meter reading) Engine Serial No. PTO Serial No. Down load date & time Before (by watch) replacement After replacement Reference No. (FC No. or Claim No.) Please send the downloads (from old VHMS controller if possible and from new VHMS controller) to the following e-mail addresses:

1. [email protected] 2. [email protected]

AH03538

Appendix

Service Bulletins

6.5.14 AH04518 Welding procedure for welded counterweight

6 - 43

Service Bulletins

Appendix


6 - 44


COMPONENT CODE:

46

REF NO.

AH04518a

DATE


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

Appendix

Service Bulletins

6.5.15 AH05510 Bearing flushing of the A4VS variable displacement axial piston pump

6 - 45

Service Bulletins

Appendix


6 - 46


COMPONENT CODE:

K1

REF NO.

AH05510

DATE

February 16, 2005 Page 1 of 1

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

Appendix

Service Bulletins

6.5.16 AH05511 Dual cone seal ring mouting

6 - 47

Service Bulletins

Appendix


6 - 48

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

Appendix

Service Bulletins

6.5.17 AH05546 Automatic lubrication system - Vent valve (PN 769 879 73)

6 - 49

Service Bulletins

Appendix


6 - 50

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

Appendix

Service Bulletins

6.5.18 AH06524 Hydraulic cylinder

6 - 51

Service Bulletins

Appendix


6 - 52

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

Appendix

Service Bulletins

6.5.19 AH06530 Relieving of the track chain tension

6 - 53

Service Bulletins

Appendix


6 - 54

COMPONENT CODE:

32

REF NO.

AH06530


DATE

July 24, 2006 Page 1 of 2

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

PC4000 GZEBM08199-1 (Completo)Mm

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