June 10, 2025 - PageLarge

Posted on June 10, 2025 by admin

Komatsu Hydraulic Mining Excavator PC4000 Repair Service Manuals

Service repair manual for Komatsu Hydraulic Mining Excavator PC4000E-6, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Mining Excavator PC4000E-6 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

GZEBM08165-0 – Hydraulic Mining Excavator PC4000E-6 (Serial Number 08165 and up) Shop Manual.pdf
NOTE: “40 Troubleshooting & 50 Disassembly and Assembly” is BLANK, NO CONTENTS!

PRODUCT DETAILS:
Total Pages: 832 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
COVER…….1
00 Foreword …….3
Introduction…….5
Safety…….10
01 Specification…….31
Specification PC4000…….33
10 Structure, Function…….41
CONTENTS…….43
SAFETY…….45
ENVIRONMENT PROTECTION…….47
FOREWORD…….48
1. MAIN ASSEMBLY GROUPS…….59
1.0 General Layout…….60
1.1 Superstructure…….63
1.1.1 Machine House…….65
1.1.2 Hydraulic Oil Reservoir…….67
1.1.3 Hydraulic Oil Cooler…….69
1.1.4 Fuel Tank…….71
1.1.5 Counter weight…….73
1.1.6 Cab Support…….75
1.1.7 Operator’s Cab…….77
1.1.8 Control Blocks…….79
1.1.9 Swing Gears…….81
1.2 Undercarriage…….83
1.3 Attachment…….85
1.3.1 Backhoe Attachment (BHA)…….85
1.3.2 Front Shovel Attachment (FSA)…….88
2. DRIVE…….89
2.0 Prime Drive Assembly…….91
2.1 Flexible coupling…….93
2.2 Pump Distributor Gearbox (PTO)…….95
2.3 Pump spline shaft lubrication…….97
2.4 PTO Lubrication and Cooling…….99
2.5 PTO Lubrication and cooling…….101
2.6 Hydraulic pumps…….104
3. Hydraulic Oil Reservoir…….105
General lay out…….105
3.1 Main oil tank, location of switches, sensors etc……..109
3.2 Suction oil tank with strainers…….111
3.3 Return oil collector tube with strainer…….113
3.4 Back pressure valve…….115
3.5 Transfer pump (Optional Equipment)…….117
3.5.1 Evacuation of the suction oil reservoir…….121
3.5.2 Evacuation of the return oil collector pipes and cooler circuit…….125
3.5.3 Evacuation of the back-pressure valve pipe…….127
3.6 Return and Leak Oil Filter…….129
3.7 Breather filter…….131
4. HYDRAULIC OIL COOLING…….133
4.1 General…….135
4.2 Function of the hydraulic oil cooling circuit…….137
4.3 Adjustment of the Back Pressure Valve…….139
4.4 Fan drive (Two stage cooler fan RPM control)…….141
4.5 Pressure relief valves and solenoid valve…….143
4.6 Fixed Displacement Pump, with variable setting…….147
4.7 Adjustment of the cooler fan drive speed…….149
5. CONTROLLING…….155
5.0 General lay out…….157
5.1 Control and filter panel location of components…….159
5.2 Pilot Pressure Supply and Adjustments…….163
5.3 Remote control valves arrangement…….169
5.4 Function principle of the Electro-Hydraulic- Proportional Control…….171
5.5 Potentiometer Control (Lever, Joy Stick)…….175
5.6 Potentiometer Control (Pedal)…….177
5.7 Proportional Amplifier Module, Type A…….179
5.8 Proportional Amplifier Module, Type B…….181
5.9 Ramp Time Module…….183
5.10 Adjustments of Amplifier Modules (General)…….185
5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)…….187
5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)…….191
5.13 Adjusting the Ramp Time Module…….195
6. COMPONENTS…….203
6.1 Hydraulic…….203
6.1.1 Main Control Blocks and High Pressure Filter…….205
6.1.2 Main Control Blocks and High Pressure Filter…….207
6.1.3 Distributor Manifold – Location of restrictor blocks and anti cavitation valves…….209
6.1.4 Distributor Manifold – Location of restrictor blocks and anti cavitation valves…….211
6.1.5 Single Control Blocks (Floating) for Stick and Boom…….213
6.1.6 Restrictor Block with Pressure Relief Valve…….215
6.1.7 Anti Cavitation Valve Block…….217
6.1.8 Remote control valves…….219
6.1.9 Directional Solenoid Valves (Three positions / 4-ways)…….221
6.1.10 Proportional Solenoid Valve…….223
6.1.11 High Pressure Filter…….225
6.1.12 Control Blocks and Valves…….227
6.1.13 Travel Brake Valve…….239
6.1.14 Pressure Reducing Valve…….241
6.1.15 Directional Solenoid Valves (Two positions / 4-ways)…….243
6.1.16 Pressure Increasing Valve…….245
6.1.17 Hydraulic Cylinder…….247
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION…….249
7.0 Main hydraulic pumps and pump regulation system…….251
7.1 Main Pumps…….259
7.2 Electronic Pump Regulation System…….289
7.2.1 Electronic load limiting control…….289
7.2.2 Electronic Power Module EPM…….291
7.2.2 Electronic Signal Rectifier ESR…….293
7.2.2 Electronic Signal Rectifier ESR…….295
7.2.2 Microcontroller MC7…….297
7.2.3 Checks and adjustments Microcontroller MC7…….299
7.3 Hydraulic Constant Regulation System…….345
7.6 Energy Efficiency…….349
8. OPERATING HYDRAULICS…….355
8.0 General…….357
8.1 Hydraulic for the attachment cylinder FSA and BHA…….361
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA…….363
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” BHA…….365
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA…….367
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” BHA…….369
8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA…….371
8.1.3 Electric / Hydraulic flowchart “ Stick extending ” BHA…….373
8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA…….375
8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” BHA…….377
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA…….379
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” BHA…….381
8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” FSA…….383
8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” BHA…….385
8.1.7 Electric / Hydraulic flowchart “ Clam opening ” FSA…….387
8.1.8 Electric / Hydraulic flowchart “ Clam closing ” FSA…….389
8.1.9 Checks and adjustments of the Main Relief Valves (MRV)…….391
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV)…….395
8.1.11 Checks and adjustments of the lowering speed…….439
8.2 Hydraulic for the swing circuit…….459
8.2.1 Swing Circuit…….461
8.2.2 Swing Motor…….465
8.2.3 Swing Gear Box…….469
8.2.4 Swing Parking Brake (Gear house Brake)…….471
8.2.5 Swing Brake Valve…….473
8.2.6 Electric / Hydraulic flowchart “Swing Left”…….477
8.2.7 Electric / Hydraulic flowchart “Swing Right”…….479
8.2.8 Checks and adjustments for the swing circuit…….481
8.2.9 Function check for hydraulic swing brake…….487
8.2.10 Function check for the swing parking brake…….489
8.3 Hydraulic for the swing circuit…….491
8.3.1 Travel Circuit…….493
8.3.2 Travel Motor…….497
8.3.3 Rotary Distributor…….499
8.3.4 Travel gear…….501
8.3.5 Travel parking brake (Gear house brake)…….503
8.3.6 Travel Brake Valve…….505
8.3.7 Electric / Hydraulic flowchart “ Traveling forward ”…….507
8.3.8 Electric / Hydraulic flowchart “ Traveling backward ”…….509
8.3.9 Checks and adjustments for the travel circuit…….511
8.3.10 Function check for the travel parking brake…….513
9. HYDRAULIC TRACK TENSIONING SYSTEM…….515
9.0 General…….517
9.1 Functional description…….519
9.2 Pressure Increasing Valve…….523
9.3 Tensioning cylinder…….525
9.4 Adjustments / Checks…….527
9.5 Functional Test…….533
10. ACCESS LADDER HYDRAULICALLY OPERATED…….535
General…….537
10.1 Function of hydraulically operated access ladder…….539
10.2 Adjustments / Checks…….543
11. CABLE DRUM…….545
General…….547
11.1 Components…….549
11.2 Function…….551
11.2.1 Controlling of the drive motor…….551
11.2.2 Travel motion control…….553
11.3 Checks and Adjustments…….555
11.4 Description and operating instruction for cam switch 5S4 and 5S6…….557
12. HINTS FOR READING THE HYDRAULIC DIAGRAM…….559
General…….561
12.1 Symbols…….563
12.2 Legend for the circuit diagram…….575
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM…….583
13.1 Designation of electrical devices…….585
13.2 Symbols…….587
13.3 General information…….591
13.4 Reading a Circuit Diagram…….595
14 ELECTRONIC CONTROL SYSTEM (ECS)…….599
14.1 General Design of the ECS System…….601
14.1.1 Input and Output of the PLC…….603
14.1.2 Task…….603
14.1.3 PLC DIGSY…….605
14.1.4 Definitions; Symbols and Abbreviations…….607
14.2 How to Proceed due Maintenance and Installation…….613
14.2.1 Meaning of the Status LED’s…….617
14.2.2 Short Circuit Marker -LED “MK”…….621
14.2.3 Diagnostic for Temperature-Module “ANM”…….623
14.3 Front Connector Arrangement…….625
14.3.1 Front Connector Arrangement, BIM Module…….625
14.3.2 Front Connector Arrangement, ANM-Module…….629
14.3.3 Ground connection of the Control Unit…….633
14.3.4 Interface-connection COM SK / SP…….635
14.4 Power supply…….637
14.4.1 Operation Voltages +24 V…….637
14.4.2 Safety Precautions for Faultfinding…….639
14.4.3 CPU Voltage Range…….641
14.5 Function explanations with electrical diagram…….643
14.5.1 General…….643
14.5.2 Pressure Measuring (Hydraulic System)…….645
14.5.3 Temperature Measuring and trouble shooting…….647
14.5.4 Temperature – Resistance Chart PT100…….651
14.6 Hints for reading the functional flow charts…….653
14.6.1 General…….653
14.6.2 Example: Monitoring the X1-pressure for pump control…….655
Lubrication System…….657
General Function…….659
Function of a lubrication cycle…….661
Oscillation Cylinder and Control Block…….665
Adjustments…….667
One line system…….669
Electrical function…….673
Capacitive analog sensor for lubricant level monitoring…….677
Adjustments…….679
Function Pinion type (dummy wheel) system…….683
Capacitive analog sensor for lubricant level monitoring…….691
Hydraulically driven “Power Master III” lube pump…….697
Trouble shooting…….699
Lubricant Injector (metering valve)…….701
End-line switch…….707
In-line filter…….709
Vent valve…….711
14.7.1.3 MTC-FIRMWARE AND SOFTWARE…….713
14.7.1.4 VIEW ONTO THE MTC UNIT AND ITS CONNECTORS…….714
14.8 GLOBAL LAYOUT OF THE INTERNAL CAN BUS…….716
14.8.1 GENERAL INFORMATION ABOUT A CAN BUS SYSTEM…….716
14.8.1.1 GENERAL CAN BUS DESCRIPTION…….717
14.8.1.2 CAN BUS TROUBLESHOOTING…….717
14.8.1.3 CAN BUS WIRING…….718
14.8.1.4 CAN BUS END RESISTOR…….720
14.9 THE NODES IN THE CAN BUS SYSTEM…….722
14.9.1 GLOBAL LAYOUT…….722
14.9.2 INTRODUCTION…….723
14.9.2.1 ICN-V FEATURES…….724
14.9.2.2 ICN-D FEATURES…….725
14.9.3 NODE DIP-SWITCHES…….726
14.9.4 NODE BOX…….727
14.9.5 NODE LOCATIONS ON THE MACHINE…….728
14.9.5.1 NODE & LOCATION CHART…….729
14.9.5.2 EXEMPLARY VIEW ONTO LOCATION 11 (CAB BASE)…….730
15. AUTOMATIC LUBRICATION SYSTEMS…….733
15.1 Introduction…….777
15.2 Central Lubrication System (CLS)…….778
15.3 Lubrication Pump Station (SLS)…….784
15.3.1 Hydraulically driven Lube Pump…….790
15.3.2 Vent Valve…….792
15.3.3 End of Line Switch…….794
15.3.4 In-Line Filter…….796
15.3.5 Lubricant Level Sensor…….798
15.3.6 Lubricant Pressure Sensor…….799
15.3.7 Lubricant Injector…….800
15.3.8 Lubrication pinion…….805
15.4 Operating and Controlling…….807
15.4.1 Operating Flow, Electrical Flow…….808
15.5 Adjustments…….812
15.5.1 Pump Speed and Working Pressure…….813
15.5.2 Injectors…….816
15.5.3 End of Line Switch Setting CLS…….818
15.5.4 End of Line Switch Setting SLS…….820
15.6 Troubleshooting…….822
15.7 Commissioning…….826
15.7.1 Commissioning of the CLS…….826
15.7.2 Fine Adjustment…….827
15.7.3 Commissioning of the SLS…….827
40 Troubleshooting…….831
50 Disassembly and Assembly…….832

Komatsu Hydraulic Mining Excavator PC4000 Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 10, 2025 by admin

Komatsu Hydraulic Mining Shovel PC4000 Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Mining Shovel PC4000, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Mining Shovel PC4000 Shop workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SMPC4000-8199 – Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008152 – Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008155 – Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008170 – Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008172 – Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
CEAWDPC4000 – Hydraulic Mining Shovel PC4000 General Assembly Procedure Manual (Z21854).pdf
FAMPC4000-05 – Hydraulic Mining Shovel PC4000 General Assembly Procedure.pdf
FAMPC4000-08205 – Hydraulic Mining Shovel PC4000-6 Field Assembly Manual.pdf
GZEAM08189 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
GZEAM08218-0 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OM-PC4000-8224 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008152 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008155 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008170 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008172 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
RRPC4000-6 – Hydraulic Mining Shovel PC4000-6 Remove & Replace Procedures.pdf

PRODUCT DETAILS:
Total Pages: 10,121 pages
File Format: PDF
Language: English

MAIN SECTIONS
CEAWDPC4000 – Hydraulic Mining Shovel PC4000 General Assembly Procedure Manual (Z21854)…2
COVER…2
GENERAL CONTENT…4
1. OVERVIEWS…6
1.1 OVERVIEW SUPERSTRUCTURE…6
1.2 OVERVIEW ENGINE HOUSE…8
2. GENERAL…10
2.1 DELIVERY OF THE EXCAVATOR…10
2.2 ASSEMBLING OF THE EXCAVATOR…10
2.3 TRANSPORTATION AND LIFTING…12
2.4 MANPOWER/ASSEMBLY TIME…14
2.5 ASSEMBLY SITE REQUIREMENTS…16
2.6 SPACE AND PLACING REQUIREMENTS…18
2.7 PREPARATION FOR ASSEMBLY…18
2.8 BASIC MEASUREMENTS AND WEIGHTS…20
2.9 TRANSPORT DIMENSIONS AND WEIGHTS…22
3. ASSEMBLY SEQUENCE…24
3.1 ASSEMBLY OF UNDERCARRIAGE…26
3.2 ASSEMBLY OF SUPERSTRUCTURE ONTO THE UNDERCARRIAGE…30
3.3 ASSEMBLY OF ENGINE HOUSE…32
3.4 MOUNTING OF BOOM…34
3.5 MOUNTING OF HYDRAULIC OIL TANK…36
3.6 MOUNTING OF HYDRAULIC OIL COOLER…38
3.7 MOUNTING OF FUEL TANK…40
3.8 MOUNTING OF HYDRAULIC ACCESS LADDER…42
3.9 MOUNTING OF CAB BASE…44
3.10 MOUNTING OF COUNTERWEIGHT…46
3.11 MOUNTING OF HANDRAILS, STEPS AND GRATINGS…48
3.12 MOUNTING OF CAB WITH SUPPORT FRAME…50
3.13 MOUNTING OF BUCKET CYLINDERS…52
3.14 FILLING UP HYDRAULIC TANK AND FUEL TANK…52
3.15 MOUNTING OF STICK…54
3.16 PRE-CHECKS PRIOR TO START-UP…54
3.17 MOUNTING OF STICK CYLINDERS TO THE STICK…56
3.18 ASSEMBLY OF BULLCLAM BUCKET TO THE STICK…58
3.19 MOUNTING OF THE PIN SEALS…62
3.20 CONNECTION OF THE CABLE HARNESSES TO THE TERMINAL RAILS IN THE SWITCH BOX "X2"…64
3.21 PUTTING THE CENTRAL LUBRICATION SYSTEM INTO OPERATION…66
3.22 STANDARD APPLICATION TORQUE CHART…68
FAMPC4000-05 – Hydraulic Mining Shovel PC4000 General Assembly Procedure…72
COVER…72
GENERAL CONTENT…74
1. Overviews…76
1.1 Overview Superstructure (Z22586)…76
1.2 Overview Engine House (Z21446)…78
2. General…80
2.1 Delivery of the Excavator…80
2.2 Assembling of the Excavator…80
2.3 Transportation and Lifting…82
2.4 Manpower / Assembly Time…84
2.5 Assembly Site Requirements…86
2.6 Space and Placing Requirements…90
2.7 Preparation for Assembly…90
2.8 Basic Measurements (Z23038)…92
2.9 Transport Dimensions and Weights (as example)…92
3. Assembly Sequence…94
3.1. Assembly of Undercarriage (Z21859)…94
3.1.1. Mounting of travel gear breather filters (Z21860)…96
3.1.2 Track tensioning system (Z23037)…98
3.2. Assembly of Superstructure onto the Undercarriage (Z23863)…100
3.3 Assembly of engine house (Z21863)…102
3.4 Mounting of Boom (Z21864)…104
3.5. Mounting of Hydraulic Oil Tank (Z23039)…106
3.6. Mounting of Hydraulic Oil Cooler (Z21866)…108
3.7. Mounting of Fuel Tank (Z21867)…110
3.8 Mounting of hydraulic access ladder (Z21871)…112
3.9. Mounting of Cab Base (Z21868)…114
3.10 Mounting of Counterweight (Z21869)…116
3.11 Mounting of Handrails, Steps and Gratings (Z23033)…118
3.12 Mounting of Cable transfer to the Operators Cab (Z22937)…120
3.13 Mounting of Cab with Support Frame (Z22938; Z22939)…124
3.13.1 Mounting of the Cab air cleaner (Cab support to Cab) (Z22940)…126
3.14 Mounting of Bucket Cylinders (Z21873)…128
3.15 Mounting of Stick (Bullclam bucket) (Z21874)…130
3.15.1 Mounting of Stick (Backhoe attachment) (Z23034)…132
3.16 Filling up hydraulic oil tank (Z21585)…134
3.17 Bleed air from all hydraulic pumps and check the Oil Level in all four Main Pump Housings (Z21693; Z22513)…136
3.18 Filling up fuel tank…138
3.19 Pre-checks for initial Start-up…140
3.20 Mounting of stick cylinders to the stick (Z21875)…144
3.21 Assembly of Bullclam Bucket to the Stick (Z21876)…146
3.22 Mounting of the Pin Seals (Z22042)…150
3.22.1 Mounting of the Pin Seals (Backhoe) (Z23035)…152
3.23 Connection of the cable harnesses to the terminal rails in the switch box "X2" (Z21879)…154
3.24 Putting the Central Lubrication System into operation (Z21880)…158
3.25 Metric standard thread…160
FAMPC4000-08205 – Hydraulic Mining Shovel PC4000-6 Field Assembly Manual…166
2 SAFETY…174
2.1 SAFETY INFORMATION…175
2.2 OVERVIEW…176
2.2.1 NORMAL OPERATIONS…176
2.2.2 REGULAR MAINTENANCE…176
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR…176
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR…176
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB…177
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR…178
2.4.1 UNDERSTANDING THE MACHINE…178
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR…178
2.4.3 PREPARATIONS FOR SAFE OPERATION…178
2.4.4 FIRE PREVENTION…180
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…182
2.4.6 BURN PREVENTION…184
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…184
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…185
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)…186
2.4.10 PRECAUTIONS AT JOBSITE…187
2.4.11 STARTING ENGINE…192
2.4.12 OPERATION…193
2.5 PRECAUTION FOR MAINTENANCE…199
2.5.1 GENERAL PRECAUTIONS…199
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…207
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID…208
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS…212
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM…212
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS…212
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…212
2.7 SPECIAL SAFETY EQUIPMENT…213
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB…214
2.7.2 OBJECT HANDLING…214
2.7.3 LIGHTING…214
2.7.4 WARNING BEACON…214
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…214
2.8 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLY…222
2.8.1 WHEN ASSEMBLING THE EXCAVATOR…222
2.8.2 WHEN DISASSEMBLING THE EXCAVATOR…222
2.8.3 WHEN TRANSPORTING THE DISASSEMBLED EXCAVATOR…223
3 GENERAL…224
3.1 GENERAL…225
3.1.1 DELIVERY OF THE EXCAVATOR…225
3.1.2 ASSEMBLING THE EXCAVATOR…225
3.1.3 LIFTING AND TRANSPORTATION…225
3.1.4 PACKING LIST OF A TYPICAL FACE SHOVEL MACHINE…226
3.1.5 PACKING LIST OF A TYPICAL BACKHOE MACHINE…227
3.1.6 ELECTRICAL ENERGY…228
3.1.7 ELECTROMAGNETIC COMPATIBILITY (EMC)…228
3.1.8 MONITORING SYSTEM OF THE MACHINE…228
3.2 ASSEMBLY SITE REQUIREMENTS…229
3.2.1 CONFIGURATION OF COMPONENTS ON ERECTION SITE (EXAMPLE)…229
3.2.2 REQUIRED CRANES…231
3.2.3 MANPOWER / ASSEMBLY TIME…231
3.2.4 TOOLS AND EQUIPMENT FOR ASSEMBLY…232
3.2.5 STANDARD APPLICATION TORQUE CHART…235
3.2.6 PREPARATIONS FOR ASSEMBLY…238
3.2.7 BASIC DIMENSIONS…239
3.3 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES…240
4 ASSEMBLY SEQUENCE…242
4.1 ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES…243
4.1.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY…244
4.2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES…245
4.2.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY…246
4.3 ASSEMBLY OF UNDERCARRIAGE…247
4.3.1 ASSEMBLY OF TRACKS…248
4.3.2 ATTACH CARBODY TO SIDE FRAME…249
4.3.3 DETERMINING THE TIGHTENING TORQUE…256
4.3.4 SPECIAL HYDRAULIC TORQUE WRENCH…260
4.3.5 CLOSING THE TRACKS…261
4.3.6 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS…262
4.3.7 MOUNTING OF TRAVEL GEAR PROTECTION…265
4.3.8 MOUNTING OF TRAVEL MOTOR PROTECTION HOOD…267
4.3.9 HYDRAULIC TRACK TENSIONING SYSTEM…269
4.4 MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE…271
4.5 ASSEMBLY OF MACHINERY HOUSE ROOF…275
4.5.1 MOUNTING OF THE EXHAUST SYSTEM…277
4.5.2 MOUNTING OF THE AIR INTAKE SYSTEM…280
4.6 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM…283
4.7 MOUNTING OF BATTERY BOX AND HYDRAULIC ACCESS LADDER…285
4.8 CONNECTING ENGINE OIL RESERVE SYSTEM…291
4.9 PRE-ASSEMBLY OF FACE SHOVEL BOOM…295
4.9.1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM…299
4.9.2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS…301
4.9.3 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM…303
4.9.4 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME…307
4.10 PRE-ASSEMBLY OF BACKHOE BOOM…309
4.10.1 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM…311
4.10.2 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME…315
4.11 MOUNTING OF COUNTERWEIGHT…317
4.12 MOUNTING OF THE FUEL TANK…319
4.12.1 CONNECTING FUEL SYSTEM HOSE LINES…321
4.13 ATTACHING THE CAB BASE…325
4.13.1 MAKING OF ELECTRICAL CABLE CONNECTIONS…327
4.13.2 CONNECT CAB HEATER HOSES TO CAB BASE…329
4.14 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE…331
4.14.1 CONNECTING THE AIR CONDITIONER HOSES OF THE CAB…333
4.14.2 INSTALL ORBCOMM ANTENNA…335
4.15 CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE AND SUPERSTRUCTURE…337
4.15.1 CONNECTING HIGH PRESSURE LINES OF THE MAIN PUMPS…339
4.16 ATTACHING THE HYDRAULIC OIL RESERVOIR…341
4.17 ATTACHING THE HYDRAULIC OIL COOLER…343
4.17.1 CONNECTING THE HYDRAULIC HOSE LINES OF THE OIL COOLER CIRCUIT…345
4.17.2 CONNECTING THE HOSE LINES OF OIL COOLER FAN MOTORS…347
4.17.3 CONNECTING THE HOSE LINES OF PTO OIL COOLING CIRCUIT…349
4.17.4 CONNECTING THE RETURN OIL HOSE LINE OF RADIATOR FAN MOTOR…351
4.17.5 CONNECTING THE HOSE LINES FROM RETURN OIL MANIFOLD TO BACK-PRESSURE PIPE…353
4.18 CONNECTING SWING GEAR HYDRAULIC LINES…355
4.18.1 CONNECTING THE RETURN AND LEAKAGE OIL HOSE LINES…356
4.18.2 CONNECTING THE SWING BRAKE PRESSURE HOSES AND PILOT OIL HOSES…357
4.19 CONNECTING THE RETURN AND PRESSURE OIL HOSES FROM VALVE BLOCK…359
4.20 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP…365
4.21 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT…367
4.21.1 CONNECTING THE PILOT OIL LINE, RETURN OIL LINE AND LEAKAGE OIL LINE TO THE ROTARY JOINT…369
4.22 ATTACHING THE HANDRAILS, CATWALKS AND STEPS…371
4.23 MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES…373
4.24 CENTRAL REFILLING SYSTEM…377
4.24.1 CONNECTING THE REFILLING LINES…378
4.25 CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS…383
4.26 MOUNTING THE CAN-NODE BOXES ONTO THE MACHINERY HOUSE ROOF…385
4.26.1 CONNECTING THE CABLES TO THE CAN-NODES…386
4.27 PRE-CHECKS PRIOR TO INITIAL START UP…387
4.28 FILLING AND BLEEDING THE HYDRAULIC SYSTEM…389
4.28.1 FILLING THE HYDRAULIC SYSTEM…390
4.28.2 BLEEDING THE HYDRAULIC SYSTEM…391
4.28.3 BLEEDING THE GEAR PUMP FOR PTO GEAR LUBRICATION…394
4.29 ASSEMBLY FACE SHOVEL ATTACHMENT…395
4.29.1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM…396
4.29.2 ATTACHING THE STICK TO THE BOOM…398
4.29.3 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM…399
4.29.4 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS…399
4.29.5 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS…402
4.29.6 CONNECTING HOSE LINES FROM STICK TO BUCKET CYLINDERS…404
4.29.7 CONNECTING STICK CYLINDERS TO THE STICK…405
4.30 BLEEDING HYDRAULIC CIRCUITS…407
4.30.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT…408
4.30.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT…408
4.30.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT…410
4.30.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER…411
4.30.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS…411
4.30.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS…412
4.31 ATTACHING FACE SHOVEL TO THE STICK…413
4.31.1 ATTACHING BUCKET BACK WALL TO THE STICK…414
4.31.2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM CYLINDERS…416
4.31.3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL…418
4.31.4 CONNECTING GREASE LINES OF THE FACE SHOVEL ATTACHMENT…420
4.31.5 CONNECTING GREASE LINES ON THE BUCKET…422
4.31.6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS…422
4.32 ASSEMBLY BACKHOE ATTACHMENT…423
4.32.1 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM…424
4.32.2 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS…425
4.32.3 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS…426
4.32.4 ATTACHING THE STICK TO THE BOOM…428
4.32.5 CONNECTING HOSE LINES FROM BOOM TO BUCKET CYLINDERS…432
4.33 BLEEDING HYDRAULIC CIRCUITS…433
4.33.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT…434
4.33.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT…434
4.33.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT…436
4.33.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER…437
4.33.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS…437
4.33.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS…438
4.34 ATTACHING BACKHOE BUCKET TO THE STICK…439
4.34.1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT…444
4.35 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS…445
5 FINAL CHECKS AND ADJUSTMENTS…446
5.0.1 COMMISSIONING CHECK LIST…448
5.0.2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS…448
5.0.3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE…450
5.0.4 PRESSURE COMPENSATION OF SEALED COMPONENTS…450
5.0.5 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE…451
5.0.6 COMMISSIONING OF THE AIR CONDITIONING…469
5.1 PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC MANUAL…473
5.1.1 VISUAL INSPECTION…474
5.1.2 TRAVELLING INSTRUCTIONS…474
5.2 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING…475
6 DISASSEMBLY OF THE MACHINE…476
6.0.1 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES…477
6.0.2 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE…478
6.0.3 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES…479
6.0.4 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE…480
6.0.5 DISPOSAL OF WASTE MATERIAL…481
GZEAM08189 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual…501
COVER…501
1. INTRODUCTION…503
1.1 CONTENTS OF THE BINDER…504
1.2 DIVISION OF THE BINDER…505
1.3 DESIGNATED USE OF THE SHOVEL…506
1.4 DELIVERY OF THE SHOVEL…507
1.5 EXPLANATION OF ABBREVIATIONS…508
1.6 TABLE OF CONTENTS…509
2. SAFETY…515
2.1 SAFETY INSTRUCTIONS…516
2.1.1 WARNINGS AND SYMBOLS…516
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC MINING SHOVEL…516
2.1.3 ORGANIZATIONAL MEASURES…517
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…519
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…520
2.1.6 WARNING OF SPECIAL DANGERS…523
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…525
2.1.8 SPECIAL SAFETY EQUIPMENT…525
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…529
3. OPERATION…537
3.1 FOREWORD…538
3.2 CONSTRUCTION OF THE SHOVEL…539
3.2.1 OVERALL VIEW…539
3.2.2 SUPERSTRUCTURE…540
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…550
3.2.4 EMERGENCY ESCAPE LADDER…554
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…556
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…558
3.2.7 UNDERCARRIAGE…569
3.2.8 WORKING ATTACHMENT…570
3.2.9 DIESEL ENGINE TYPE SDA 16V160…572
3.2.10 ENGINE OIL MANAGEMENT SYSTEM…574
3.3 OPERATOR’S CAB – CONTROLS…578
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…578
3.3.2 SAFETY CIRCUIT FOR CONTROLS…579
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…582
3.3.4 SAFETY CIRCUIT FOR CONTROLS…583
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK…585
3.3.6 OPERATOR’S CONSOLE…587
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS…595
3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER…597
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR…598
3.4.1 SEQUENCE OF DISPLAYS…599
3.4.2 OPENING SCREEN…599
3.4.3 MAIN GAUGE SCREENS 1 TO 3…600
3.4.4 FUEL CONSUMPTION SCREEN…607
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR…608
3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE…608
3.4.7 MAINTENANCE MONITOR…609
3.4.8 SETTINGS FOR OPERATOR…610
3.4.9 AUTOMATIC MESSAGES…615
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM…619
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES…629
3.5 CAMERA SYSTEM WITH MONITORS…632
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS…633
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…640
3.6.1 AUXILIARY HEATER FOR OPERATOR’S CAB…645
3.7 POWER HOUSE…646
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…647
3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES…649
3.7.3 CENTRAL CONTROL AND FILTER PANEL…651
3.8 ELECTRICAL EQUIPMENT IN CAB BASE…654
3.8.1 STANDARD COMPONENTS IN CAB BASE…655
3.8.2 SWITCH BOARD (X2) IN CAB BASE…657
3.8.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE…667
3.9 CHECKS BEFORE STARTING THE ENGINE…674
3.10 STARTING THE ENGINE…680
3.10.1 STARTING PROCEDURE…683
3.10.2 ENGINE WARM-UP…691
3.10.3 HYDRAULIC OIL WARM-UP…691
3.11 MOVING THE SHOVEL…693
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS…693
3.11.2 TRAVELLING INSTRUCTIONS…696
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…697
3.12.1 SLEWING THE SUPERSTRUCTURE…697
3.12.2 BRAKING THE SUPERSTRUCTURE…699
3.12.3 SLEW PARKING BRAKE…700
3.13 WORKING WITH THE ATTACHMENT…702
3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM…702
3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM…703
3.13.3 BOTTOM DUMP BUCKET…704
3.13.4 DROP BALL OPERATION…705
3.13.5 COMBINED OPERATION CYCLES…708
3.14 WORKING INSTRUCTIONS…710
3.14.1 STABILITY OF THE SHOVEL…710
3.14.2 SHOVEL OPERATION…710
3.15 PARKING THE SHOVEL…713
3.16 STOPPING THE ENGINE…714
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…717
3.17 OPERATION OF THE LUBRICATION SYSTEM…718
3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”…718
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”…720
3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS…722
3.18.1 HIGH LEVEL ALARM ”FIRE”…727
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…727
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS…727
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S…729
3.18.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER…731
3.19 TRANSFER PUMP FOR HYDRAULIC OIL…732
3.19.1 OPERATING THE TRANSFER PUMP…733
3.19.2 FUNCTIONS OF THE TRANSFER PUMP…735
3.20 CENTRAL REFILLING SYSTEM…738
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…739
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM…741
3.20.3 RECEIVER PANEL WITH MONITOR BOX…743
3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB…749
3.21 WORK ON THE LOADER ATTACHMENT…752
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL…753
3.22.1 DISASSEMBLING OF THE SHOVEL…753
3.22.2 TRANSPORTATION AND LIFTING…753
3.23 RETRIEVAL PROCEDURE…754
3.24 SHOVEL STORAGE…755
3.24.1 PREPARING FOR STORAGE…755
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD…756
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD…756
3.24.4 PREPARING FOR OPERATION…757
3.25 TROUBLE SHOOTING…758
3.25.1 ENGINE…758
3.25.2 HYDRAULIC SYSTEM…759
3.25.3 FINAL DRIVES AND SWING MACHINERY…760
3.25.4 CRAWLER TRACKS…760
4. MAINTENANCE…761
4.1 FOREWORD…762
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE…763
4.3 FLUIDS AND LUBRICANTS…765
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…765
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…766
4.4 FILLING CAPACITIES…768
4.5 STANDARD TORQUE LIST…769
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…770
4.6.1 INITIAL SERVICING…770
4.6.2 PERIODIC SERVICING INTERVALS…770
4.6.3 PERIODIC SERVICING SCHEDULE…771
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES…776
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…777
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM…781
4.6.7 MAINTENANCE OF THE ENGINE…783
4.7 WHEN NECESSARY…784
4.7.1 ENGINE AIR CLEANER SERVICE…785
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…789
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS…791
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…795
4.8 EVERY 10 OPERATING HOURS OR DAILY…796
4.8.1 WALK-AROUND INSPECTION…797
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…807
4.8.3 RADIATOR – CHECK COOLANT LEVEL…809
4.8.4 TRACK GROUPS – CLEAN…809
4.8.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER…811
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…812
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…813
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S" – CHECK OIL L…817
4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…819
4.9.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN" – CHECK OIL LEVELS…821
4.9.5 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…823
4.9.6 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL…825
4.9.7 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…827
4.9.8 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…829
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…830
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…831
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…833
4.10.3 SIGNAL HORN COMPRESSOR – LUBRICATE…833
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…833
4.10.5 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…833
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…835
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…839
4.10.8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…843
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL…845
4.11 EVERY 500 OPERATING HOURS OR MONTHLY…846
4.11.1 BATTERIES – CHECK FLUID LEVEL…847
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL…849
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL…851
4.11.4 FUEL TANK – DRAIN CONDENSATION…853
4.11.5 CRAWLER TRACK – INSPECTION…855
4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION…861
4.11.7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION…863
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…864
4.12.1 HIGH STRENGTH BOLT CONNECTIONS…865
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…913
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…927
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…929
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS…931
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…933
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…935
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…937
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…938
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…939
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…951
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…952
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…953
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S"- CHANGE OIL…961
4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL…965
4.14.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN"- CHANGE OIL…967
4.14.5 FINAL DRIVE HOUSINGS – CHANGE OIL…971
4.14.6 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…973
4.15 FIRE PREVENTION…974
4.16 WELD REPAIRS…976
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…979
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…981
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…983
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…984
GZEAM08218-0 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual…991
1 FOREWORD…993
1.1 BEFORE READING THIS MANUAL…994
1.2 DIRECTIONS OF THE MACHINE…995
1.3 SPECIFICATION AND SERIAL PLATE…996
1.3.1 PRODUCT IDENTIFICATION NUMBER…996
1.4 DIVISION OF THE BINDER…997
1.5 DESIGNATED USE OF THE SHOVEL…998
1.6 DELIVERY OF THE SHOVEL…999
1.6.1 SPARE PARTS…999
1.6.2 SERVICE…999
1.7 EXPLANATION OF ABBREVIATIONS…1000
1.8 CONTENTS…1001
2 SAFETY…1007
2.1 SAFETY INFORMATION…1008
2.2 OVERVIEW…1009
2.2.1 NORMAL OPERATIONS…1009
2.2.2 REGULAR MAINTENANCE…1009
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR…1009
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR…1009
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB…1010
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR…1011
2.4.1 UNDERSTANDING THE MACHINE…1011
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR…1011
2.4.2.1 ENSURING SAFE OPERATION…1011
2.4.3 PREPARATIONS FOR SAFE OPERATION…1011
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT…1011
2.4.3.2 INSPECTING THE MACHINE…1011
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT…1012
2.4.3.4 KEEP MACHINE CLEAN…1012
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT…1012
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…1013
2.4.3.7 IF A PROBLEM IS FOUND…1013
2.4.4 FIRE PREVENTION…1013
2.4.4.1 PRECAUTIONS TO PREVENT FIRE…1013
2.4.4.2 ACTION IF FIRE OCCURS…1014
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…1015
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…1015
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…1015
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE…1015
2.4.5.3 NO PEOPLE ON THE ATTACHMENT…1015
2.4.5.4 WORKING IN HIGH PLACES…1015
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK…1016
2.4.5.6 LEAVING THE MACHINE…1016
2.4.6 BURN PREVENTION…1017
2.4.6.1 Hot coolant…1017
2.4.6.2 Hot oil…1017
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…1017
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…1018
2.4.8.1 UNAUTHORIZED MODIFICATION…1018
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…1018
2.4.9 PRECAUTIONS AT JOBSITE…1020
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT…1021
2.4.9.2 CAMERA SYSTEM WITH MONITORS…1021
2.4.9.3 ENSURE GOOD VISIBILITY…1021
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS…1021
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS…1022
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…1022
2.4.9.7 WORKING ON LOOSE GROUND…1023
2.4.9.8 GAS, DUST, STEAM AND SMOKE…1023
2.4.9.9 VENTILATION OF ENCLOSED AREAS…1024
2.4.10 STARTING ENGINE…1025
2.4.10.1 WARNING TAG…1025
2.4.10.2 CHECKS BEFORE STARTING ENGINE…1025
2.4.10.3 PRECAUTION WHEN STARTING ENGINE…1025
2.4.10.4 PRECAUTION IN COLD AREAS…1026
2.4.11 OPERATION…1026
2.4.11.1 CHECKS BEFORE OPERATION…1026
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE…1027
2.4.11.3 PRECAUTIONS WHEN travelling…1028
2.4.11.4 TRAVELLING ON SLOPES…1029
2.4.11.5 OPERATIONS ON SLOPES…1030
2.4.11.6 PROHIBITED OPERATIONS…1030
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES…1031
2.4.11.8 PARKING THE MACHINE…1031
2.4.11.9 TRANSPORTATION…1031
2.5 PRECAUTION FOR MAINTENANCE…1032
2.5.1 GENERAL PRECAUTIONS…1032
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…1033
2.5.1.2 STOP ENGINE FOR MAINTENANCE…1034
2.5.1.3 WARNING TAG…1035
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…1036
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS…1036
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING…1037
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…1037
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT…1038
2.5.1.9 NOISE…1038
2.5.1.10 WHEN USING A HAMMER…1038
2.5.1.11 PROPER TOOLS…1039
2.5.1.12 ACCUMULATOR…1039
2.5.1.13 PERSONNEL…1039
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…1040
2.5.2.1 PRECAUTION WHEN WELDING…1040
2.5.2.2 BATTERY HANDLING…1040
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID…1041
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE…1041
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…1042
2.5.3.3 REPLACEMENT OF HOSE LINES…1042
2.5.3.4 INSPECTION OF HOSE LINES…1042
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1043
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE…1043
2.5.3.7 AIR CONDITIONING MAINTENANCE…1043
2.5.3.8 COMPRESSED AIR…1044
2.5.3.9 WASTE MATERIALS…1044
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS…1045
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM…1045
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS…1045
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…1045
2.7 SPECIAL SAFETY EQUIPMENT…1046
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB…1047
2.7.2 OBJECT HANDLING…1047
2.7.3 LIGHTING…1047
2.7.4 WARNING BEACON…1047
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…1047
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…1047
2.7.5.2 INSTRUCTIONS FOR USE…1049
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL…1051
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),…1051
2.7.5.5 INSTRUCTIONS FOR USE…1053
2.8 SAFETY WARNING SIGNS…1055
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS…1056
3 OPERATION…1069
3.1 FOREWORD…1070
3.2 CONSTRUCTION OF THE SHOVEL…1071
3.2.1 OVERALL VIEW…1071
3.2.2 SUPERSTRUCTURE…1072
3.2.2.1 Machinery House…1076
3.2.2.2 Main Hydraulic Oil Reservoir…1078
3.2.2.3 Hydraulic Oil Cooler…1079
3.2.2.4 Fuel Tank…1080
3.2.2.5 Counterweight…1081
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…1082
3.2.3.1 Operating the hydraulic Access Ladder…1083
3.2.4 EMERGENCY ESCAPE LADDER…1086
3.2.5 BOOM ACCESS LADDER AND WALKWAY…1088
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…1090
3.2.6.1 Emergency Engine Shutdown System actuated from Ground Man (special equipment)…1091
3.2.6.2 Operator Warning System (special equipment)…1091
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…1092
3.2.7.1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual…1097
3.2.7.2 Operator’s Seat Adjustment…1099
3.2.7.3 Co-driver’s Seat and Refrigerator Box…1100
3.2.8 UNDERCARRIAGE…1101
3.2.9 WORKING ATTACHMENT…1102
3.2.9.1 Loader attachment with bottom dump bucket…1102
3.2.9.2 Loader attachment with backhoe bucket…1103
3.2.10 DIESEL ENGINE TYPE SDA 16V160E-2…1104
3.2.11 ENGINE OIL MANAGEMENT SYSTEM…1106
3.2.11.1 Oil Burning System "Centinel" combined with Oil Supply System "Reserve"…1108
3.2.11.2 Eliminator Engine Oil Filtration System…1109
3.3 OPERATOR’S CAB – CONTROLS…1110
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…1110
3.3.1.1 HYDRAULIC CONTROL SYSTEM…1111
3.3.2 SAFETY CIRCUIT FOR CONTROLS…1111
3.3.2.1 EURO Control Pattern…1113
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…1114
3.3.3.1 HYDRAULIC CONTROL SYSTEM…1115
3.3.4 SAFETY CIRCUIT FOR CONTROLS…1115
3.3.4.1 EURO Control Pattern…1117
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK…1117
3.3.6 OPERATOR’S CONSOLE…1119
3.3.6.1 Switch Board…1121
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS…1127
3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER…1129
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR (KOMTRAX PLUS)…1130
3.4.1 SEQUENCE OF DISPLAYS…1131
3.4.2 OPENING SCREEN…1131
3.4.3 MAIN GAUGE SCREENS 1 TO 3…1132
3.4.3.1 Main Gauge Screen 1…1133
3.4.3.2 Main Gauge Screen 2…1135
3.4.3.3 Main Gauge Screen 3…1135
3.4.3.4 Color Definition…1137
3.4.3.5 Automatic Shutdown of the Machine…1137
3.4.4 FUEL CONSUMPTION SCREEN…1139
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR…1140
3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE…1140
3.4.7 MAINTENANCE MONITOR…1141
3.4.7.1 Maintenance confirmation through Service Personnel…1141
3.4.8 SETTINGS FOR OPERATOR…1142
3.4.8.1 Settings for Operator…1143
3.4.8.2 User ID Screen…1143
3.4.8.3 Reset Truck Counter 1…1143
3.4.8.4 Screen Adjustment…1144
3.4.8.5 Date Adjustment Screen…1146
3.4.8.6 Clock Adjustment Screen…1146
3.4.8.7 Language Selection Screen…1146
3.4.9 AUTOMATIC MESSAGES…1147
3.4.9.1 Automatic Messages…1148
3.4.9.2 Automatic Messages…1149
3.4.9.3 Automatic Messages…1150
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM…1151
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES…1163
3.5 CAMERA SYSTEM WITH MONITORS…1166
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS…1167
3.5.1.1 Operating the Monitors…1169
3.5.1.2 Ajustments of the Monitor…1169
3.5.1.3 Arrangement of the Cameras…1173
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…1174
3.6.1 Digital Display…1174
3.6.2 AUXILIARY HEATER FOR OPERATOR’S CAB…1179
3.7 POWER HOUSE…1180
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…1181
3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES…1183
3.7.3 CENTRAL CONTROL AND FILTER PANEL…1185
3.8 ELECTRICAL EQUIPMENT IN CAB BASE…1186
3.8.1 STANDARD COMPONENTS IN CAB BASE…1187
3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE…1191
3.8.2.1 Checking diagnostic fault codes of the engine electronic controlled fuel system QUANTUM and of the engine monitoring system CENSE…1193
3.8.3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS…1195
3.8.4 BINARY FAULT CODE LIST…1202
3.8.4.1 Combination Message 308 Trouble Can-Bus or Can Hardware…1204
3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS…1204
3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE…1207
3.9 CHECKS BEFORE STARTING THE ENGINE…1214
3.9.0.1 Coolant Level…1217
3.9.0.2 Machinery House Doors…1219
3.9.0.3 Operator’s Seat Adjustment…1219
3.10 STARTING THE ENGINE…1220
3.10.1 STARTING PROCEDURE…1223
3.10.2 ENGINE WARM-UP…1231
3.10.3 HYDRAULIC OIL WARM-UP…1231
3.10.4 JUMP START WITH BOOSTER BATTERIES…1231
3.11 MOVING THE SHOVEL…1233
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS…1233
3.11.1.1 TRAVEL ALARM / BACK-UP ALARM…1235
3.11.2 TRAVELLING INSTRUCTIONS…1235
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…1236
3.12.1 SLEWING THE SUPERSTRUCTURE…1236
3.12.1.1 MACHINES WITH "EURO" CONTROL…1236
3.12.1.2 MACHINES WITH "KMG" CONTROL…1237
3.12.2 BRAKING THE SUPERSTRUCTURE…1237
3.12.3 SLEW PARKING BRAKE…1238
3.12.3.1 Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System…1239
3.12.3.2 IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE…1239
3.13 WORKING WITH THE ATTACHMENT…1240
3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM…1240
3.13.1.1 Backhoe…1240
3.13.1.2 FACE SHOVEL…1240
3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM…1241
3.13.2.1 Backhoe…1241
3.13.2.2 FACE SHOVEL…1241
3.13.3 BOTTOM DUMP BUCKET…1242
3.13.3.1 Operating the bucket clam…1242
3.13.3.2 OPERATING THE BUCKET CLAM…1242
3.13.4 DROP BALL OPERATION…1243
3.13.4.1 SAFETY INSTRUCTIONS…1243
3.13.4.2 SAFETY DEVICES (SPECIAL EQUIPMENT)…1245
3.13.4.3 WORKING HINTS…1245
3.13.5 COMBINED OPERATION CYCLES…1246
3.14 WORKING INSTRUCTIONS…1248
3.14.1 STABILITY OF THE SHOVEL…1248
3.14.2 SHOVEL OPERATION…1248
3.15 PARKING THE SHOVEL…1251
3.15.0.1 CLEANING THE TRACK GROUPS…1251
3.16 STOPPING THE ENGINE…1252
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…1255
3.17 OPERATION OF THE LUBRICATION SYSTEM…1256
3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”…1256
3.17.1.1 Manual actuation of the central lubrication system…1256
3.17.1.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM…1257
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”…1257
3.17.2.1 Manual actuation of the swing circle lubrication system…1258
3.17.2.2 SWING CIRCLE LUBRICATION SYSTEM ”SLS”…1259
3.17.2.3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM…1259
3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS…1260
3.18.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS…1261
3.18.1 HIGH LEVEL ALARM ”FIRE”…1265
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…1265
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS…1265
3.18.3.1 MANUAL ACTUATION…1265
3.18.3.2 AUTOMATIC ACTUATION…1265
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS…1267
3.18.5 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF…1269
3.19 TRANSFER PUMP FOR HYDRAULIC OIL…1270
3.19.1 OPERATING THE TRANSFER PUMP…1271
3.19.2 FUNCTIONS OF THE TRANSFER PUMP…1273
3.20 CENTRAL REFILLING SYSTEM…1276
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…1277
3.20.1.1 Operation of the hydraulic Service Arm…1277
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM…1279
3.20.3 RECEIVER PANEL WITH MONITOR BOX…1281
3.20.3.1 Refilling Procedure…1283
3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM…1285
3.20.4.1 Refilling the Grease Containers of the Automatic Lubrication Systems…1287
3.21 WORK ON THE LOADER ATTACHMENT…1288
3.21.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS…1288
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL…1289
3.22.1 DISASSEMBLING OF THE SHOVEL…1289
3.22.2 TRANSPORTATION AND LIFTING…1289
3.23 RETRIEVAL PROCEDURE…1290
3.24 SHOVEL STORAGE…1291
3.24.0.1 GENERAL…1291
3.24.1 PREPARING FOR STORAGE…1291
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD…1291
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD…1291
3.24.4 PREPARING FOR OPERATION…1292
3.25 TROUBLE SHOOTING…1293
3.25.0.1 GENERAL…1293
3.25.1 ENGINE…1293
3.25.2 HYDRAULIC SYSTEM…1294
3.25.3 FINAL DRIVES AND SWING MACHINERY…1295
3.25.4 CRAWLER TRACKS…1295
4 MAINTENANCE…1297
4.1 FOREWORD…1298
4.1.0.1 DEFINITIONS…1298
4.1.0.2 GENERAL RECOMMENDATIONS…1298
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE…1299
4.3 FLUIDS AND LUBRICANTS…1300
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…1300
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…1301
4.4 FILLING CAPACITIES…1303
4.5 STANDARD TORQUE LIST…1304
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…1305
4.6.1 INITIAL SERVICING…1305
4.6.1.1 AFTER THE FIRST 250 OPERATING HOURS…1305
4.6.1.2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS…1305
4.6.2 PERIODIC SERVICING INTERVALS…1305
4.6.3 PERIODIC SERVICING SCHEDULE…1306
4.6.3.1 Lubrication Chart…1310
4.7 SAFETY CRITICAL PARTS…1312
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES…1312
4.7.2 INSPECTION OF HOSE LINES…1312
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS…1312
4.8 EXTENDED SERVICE INTERVALS…1315
4.8.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM…1315
4.8.1.1 Servicing Intervals…1319
4.8.2 MAINTENANCE OF THE ENGINE…1319
4.9 ENGINE FUEL FILTER LOCATION…1320
4.9.1 fuel line connections on the engine…1321
4.10 WHEN NECESSARY…1322
4.10.1 ENGINE AIR CLEANER SERVICE…1323
4.10.1.1 General Service Tips…1325
4.10.2 SWING CIRCLE TOOTHING LUBRICATION…1327
4.10.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS…1329
4.10.3.1 CLEAN OR REPLACE FILTER ELEMENTS…1331
4.10.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…1333
4.11 EVERY 10 OPERATING HOURS OR DAILY…1334
4.11.1 WALK-AROUND INSPECTION…1335
4.11.1.1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION…1339
4.11.1.2 CHECK GREASE INJECTORS…1341
4.11.1.3 CORRECTIVE ACTIONS…1341
4.11.1.4 CHECK GREASE INJECTORS…1343
4.11.2 AIR CLEANER – CLEAN PRE-CLEANER…1345
4.11.2.1 Clean dust cups of pre-cleaners…1345
4.11.3 RADIATOR – CHECK COOLANT LEVEL…1347
4.11.4 TRACK GROUPS – CLEAN…1347
4.11.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER…1349
4.11.6 BOOM – CHECK LADDER AND WALKWAY…1351
4.12 EVERY 50 OPERATING HOURS OR WEEKLY…1352
4.12.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…1353
4.12.1.1 Swing gears manufactured by "L&S"…1353
4.12.1.2 Swing gears manufactured by SIEBENHAAR…1355
4.12.1.3 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S" – CHECK OIL LEVELS…1357
4.12.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN" – CHECK OIL LEVELS…1361
4.12.2 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL…1365
4.12.2.1 CHECK OIL LEVEL OF PTO GEAR…1365
4.12.2.2 CHECK OIL LEVEL OF OIL COLLECTOR RESERVOIR (4)…1365
4.12.3 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…1367
4.12.4 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…1369
4.13 EVERY 250 OPERATING HOURS OR MONTHLY…1370
4.13.1 AIR CONDITIONING…1371
4.13.2 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…1371
4.13.3 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL…1375
4.13.4 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…1377
4.13.5 SIGNAL HORN COMPRESSOR – LUBRICATE…1377
4.13.6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…1377
4.13.7 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…1377
4.13.8 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…1379
4.13.9 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…1383
4.13.9.1 Clean and inspect filter element (2) as follows:…1383
4.13.9.2 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT (Heavy duty version, special equipment)…1385
4.13.9.3 Clean pre-cleaner dust bowl…1385
4.13.9.4 Clean and inspect main filter element…1385
4.13.10 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…1387
4.14 EVERY 500 OPERATING HOURS OR MONTHLY…1388
4.14.1 BATTERIES – CHECK FLUID LEVEL…1389
4.14.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL…1391
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL…1393
4.14.3.1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS…1393
4.14.4 FUEL TANK – DRAIN CONDENSATION…1395
4.14.4.1 DRAIN CONDENSATION AS FOLLOWS…1395
4.14.5 CRAWLER TRACK – INSPECTION…1397
4.14.5.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS…1397
4.14.5.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS…1399
4.14.5.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS…1401
4.14.5.4 Bleeding the System…1401
4.14.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION…1403
4.14.7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION…1405
4.15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…1406
4.15.1 HIGH STRENGTH BOLT CONNECTIONS…1407
4.15.2 HYDRAULIC SYSTEM – FILTER SERVICE…1457
4.15.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…1471
4.15.3.1 Oil drain plugs, illustration…1471
4.15.3.2 PTO (PUMP DISTRIBUTOR GEAR)…1471
4.15.3.3 SWING GEARS AND TRAVEL GEARS…1471
4.15.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…1473
4.15.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS…1475
4.15.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…1477
4.15.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…1479
4.16 EVERY 2000 OPERATING HOURS OR YEARLY…1480
4.16.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…1481
4.16.2 FILLING THE HYDRAULIC SYSTEM…1491
4.16.3 BLEEDING THE HYDRAULIC SYSTEM…1493
4.16.4 GEAR PUMP FOR PTO GEAR LUBRICATION…1495
4.16.5 EMERGENCY ESCAPE LADDER – INSPECTION…1497
4.17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…1498
4.17.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…1499
4.17.1.1 Swing gears manufactured by "L&S"…1499
4.17.1.2 "SWING GEARS MANUFACTURED BY “SIEBENHAAR”…1503
4.17.1.3 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S"- CHANGE OIL…1507
4.17.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN"- CHANGE OIL…1513
4.17.2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…1519
4.18 FIRE PREVENTION…1520
4.18.1 PRECAUTIONS…1521
4.19 WELD REPAIRS…1522
4.19.1 GENERAL PROTECTIVE MEASURES…1523
4.19.1.1 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL…1523
4.19.1.2 COUNTERWEIGHT…1523
4.19.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…1525
4.19.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…1527
4.19.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…1529
4.19.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…1531
OM-PC4000-8224 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual…1539
1 FOREWORD…1541
1.1 BEFORE READING THIS MANUAL…1542
1.2 DIRECTIONS OF THE MACHINE…1543
1.3 SPECIFICATION AND SERIAL PLATE…1544
1.3.1 PRODUCT IDENTIFICATION NUMBER…1544
1.4 DIVISION OF THE BINDER…1545
1.5 DESIGNATED USE OF THE SHOVEL…1546
1.6 DELIVERY OF THE SHOVEL…1547
1.6.1 SPARE PARTS…1547
1.6.2 SERVICE…1547
1.7 EXPLANATION OF ABBREVIATIONS…1548
1.8 CONTENTS…1549
2 SAFETY…1555
2.1 SAFETY INFORMATION…1556
2.2 OVERVIEW…1557
2.2.1 NORMAL OPERATIONS…1557
2.2.2 REGULAR MAINTENANCE…1557
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR…1557
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR…1557
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB…1558
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR…1559
2.4.1 UNDERSTANDING THE MACHINE…1559
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR…1559
2.4.2.1 ENSURING SAFE OPERATION…1559
2.4.3 PREPARATIONS FOR SAFE OPERATION…1559
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT…1559
2.4.3.2 INSPECTING THE MACHINE…1559
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT…1560
2.4.3.4 KEEP MACHINE CLEAN…1560
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT…1560
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…1561
2.4.3.7 IF A PROBLEM IS FOUND…1561
2.4.4 FIRE PREVENTION…1561
2.4.4.1 PRECAUTIONS TO PREVENT FIRE…1561
2.4.4.2 ACTION IF FIRE OCCURS…1562
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…1563
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…1563
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…1563
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE…1563
2.4.5.3 NO PEOPLE ON THE ATTACHMENT…1563
2.4.5.4 WORKING IN HIGH PLACES…1563
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK…1564
2.4.5.6 LEAVING THE MACHINE…1564
2.4.6 BURN PREVENTION…1565
2.4.6.1 Hot coolant…1565
2.4.6.2 Hot oil…1565
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…1565
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…1566
2.4.8.1 UNAUTHORIZED MODIFICATION…1566
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…1566
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)…1567
2.4.10 PRECAUTIONS AT JOBSITE…1568
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT…1569
2.4.10.2 CAMERA SYSTEM WITH MONITORS…1569
2.4.10.3 ENSURE GOOD VISIBILITY…1569
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS…1569
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS…1570
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…1570
2.4.10.7 WORKING ON LOOSE GROUND…1571
2.4.10.8 GAS, DUST, STEAM AND SMOKE…1571
2.4.10.9 VENTILATION OF ENCLOSED AREAS…1572
2.4.11 STARTING ENGINE…1573
2.4.11.1 WARNING TAG…1573
2.4.11.2 CHECKS BEFORE STARTING ENGINE…1573
2.4.11.3 PRECAUTION WHEN STARTING ENGINE…1573
2.4.11.4 PRECAUTION IN COLD AREAS…1574
2.4.12 OPERATION…1574
2.4.12.1 CHECKS BEFORE OPERATION…1574
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE…1575
2.4.12.3 PRECAUTIONS WHEN travelling…1576
2.4.12.4 TRAVELLING ON SLOPES…1577
2.4.12.5 OPERATIONS ON SLOPES…1578
2.4.12.6 PROHIBITED OPERATIONS…1578
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES…1579
2.4.12.8 PARKING THE MACHINE…1579
2.4.12.9 TRANSPORTATION…1579
2.5 PRECAUTION FOR MAINTENANCE…1580
2.5.1 GENERAL PRECAUTIONS…1580
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…1581
2.5.1.2 STOP ENGINE FOR MAINTENANCE…1582
2.5.1.3 WARNING TAG…1583
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…1584
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS…1584
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING…1585
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…1585
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT…1586
2.5.1.9 NOISE…1586
2.5.1.10 WHEN USING A HAMMER…1586
2.5.1.11 PROPER TOOLS…1587
2.5.1.12 ACCUMULATOR…1587
2.5.1.13 PERSONNEL…1587
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…1588
2.5.2.1 PRECAUTION WHEN WELDING…1588
2.5.2.2 BATTERY HANDLING…1588
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID…1589
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE…1589
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…1590
2.5.3.3 REPLACEMENT OF HOSE LINES…1590
2.5.3.4 INSPECTION OF HOSE LINES…1590
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1591
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE…1591
2.5.3.7 AIR CONDITIONING MAINTENANCE…1591
2.5.3.8 COMPRESSED AIR…1592
2.5.3.9 WASTE MATERIALS…1592
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS…1593
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM…1593
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS…1593
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…1593
2.7 SPECIAL SAFETY EQUIPMENT…1594
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB…1595
2.7.2 OBJECT HANDLING…1595
2.7.3 LIGHTING…1595
2.7.4 WARNING BEACON…1595
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…1595
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…1595
2.7.5.2 INSTRUCTIONS FOR USE…1597
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL…1599
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),…1599
2.7.5.5 INSTRUCTIONS FOR USE…1601
2.8 SAFETY WARNING SIGNS…1603
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS…1604
3 OPERATION…1617
3.1 FOREWORD…1618
3.2 CONSTRUCTION OF THE SHOVEL…1619
3.2.1 OVERALL VIEW…1619
3.2.2 SUPERSTRUCTURE…1620
3.2.2.1 Machinery House…1624
3.2.2.2 Main Hydraulic Oil Reservoir…1626
3.2.2.3 Hydraulic Oil Cooler…1627
3.2.2.4 Fuel Tank…1628
3.2.2.5 Counterweight…1629
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…1630
3.2.3.1 Operating the hydraulic Access Ladder…1631
3.2.4 EMERGENCY ESCAPE LADDER…1634
3.2.5 BOOM ACCESS LADDER AND WALKWAY…1636
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…1638
3.2.6.1 Emergency Engine Shutdown System actuated from Ground Man (special equipment)…1639
3.2.6.2 Operator Warning System (special equipment)…1639
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…1640
3.2.7.1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual…1645
3.2.7.2 Operator’s Seat Adjustment…1647
3.2.7.3 Co-driver’s Seat and Refrigerator Box…1648
3.2.8 UNDERCARRIAGE…1649
3.2.9 WORKING ATTACHMENT…1650
3.2.9.1 Loader attachment with bottom dump bucket…1650
3.2.9.2 Loader attachment with backhoe bucket…1651
3.2.10 DIESEL ENGINE TYPE SDA 16V160E-2…1652
3.2.11 ENGINE OIL MANAGEMENT SYSTEM…1654
3.2.11.1 Oil Burning System "Centinel" combined with Oil Supply System "Reserve"…1656
3.2.11.2 Eliminator Engine Oil Filtration System…1657
3.3 OPERATOR’S CAB – CONTROLS…1658
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…1658
3.3.1.1 HYDRAULIC CONTROL SYSTEM…1659
3.3.2 SAFETY CIRCUIT FOR CONTROLS…1659
3.3.2.1 EURO Control Pattern…1661
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…1662
3.3.3.1 HYDRAULIC CONTROL SYSTEM…1663
3.3.4 SAFETY CIRCUIT FOR CONTROLS…1663
3.3.4.1 EURO Control Pattern…1665
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK…1665
3.3.6 OPERATOR’S CONSOLE…1667
3.3.6.1 Switch Board…1669
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS…1675
3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER…1677
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR (KOMTRAX PLUS)…1678
3.4.1 SEQUENCE OF DISPLAYS…1679
3.4.2 OPENING SCREEN…1679
3.4.3 MAIN GAUGE SCREENS 1 TO 3…1680
3.4.3.1 Main Gauge Screen 1…1681
3.4.3.2 Main Gauge Screen 2…1683
3.4.3.3 Main Gauge Screen 3…1683
3.4.3.4 Color Definition…1685
3.4.3.5 Automatic Shutdown of the Machine…1685
3.4.4 FUEL CONSUMPTION SCREEN…1687
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR…1688
3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE…1688
3.4.7 MAINTENANCE MONITOR…1689
3.4.7.1 Maintenance confirmation through Service Personnel…1689
3.4.8 SETTINGS FOR OPERATOR…1690
3.4.8.1 Settings for Operator…1691
3.4.8.2 User ID Screen…1691
3.4.8.3 Reset Truck Counter 1…1691
3.4.8.4 Screen Adjustment…1692
3.4.8.5 Date Adjustment Screen…1694
3.4.8.6 Clock Adjustment Screen…1694
3.4.8.7 Language Selection Screen…1694
3.4.9 AUTOMATIC MESSAGES…1695
3.4.9.1 Automatic Messages…1696
3.4.9.2 Automatic Messages…1697
3.4.9.3 Automatic Messages…1698
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM…1699
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES…1711
3.5 CAMERA SYSTEM WITH MONITORS…1714
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS…1715
3.5.1.1 Operating the Monitors…1717
3.5.1.2 Ajustments of the Monitor…1717
3.5.1.3 Arrangement of the Cameras…1721
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…1722
3.6.1 Digital Display…1722
3.6.2 AUXILIARY HEATER FOR OPERATOR’S CAB…1727
3.7 POWER HOUSE…1728
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…1729
3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES…1731
3.7.3 CENTRAL CONTROL AND FILTER PANEL…1733
3.8 ELECTRICAL EQUIPMENT IN CAB BASE…1734
3.8.1 STANDARD COMPONENTS IN CAB BASE…1735
3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE…1739
3.8.2.1 Checking diagnostic fault codes of the engine electronic controlled fuel system QUANTUM and of the engine monitoring system CENSE…1741
3.8.3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS…1743
3.8.4 BINARY FAULT CODE LIST…1750
3.8.4.1 Combination Message 308 Trouble Can-Bus or Can Hardware…1752
3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS…1752
3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE…1755
3.9 CHECKS BEFORE STARTING THE ENGINE…1762
3.9.0.1 Coolant Level…1765
3.9.0.2 Machinery House Doors…1767
3.9.0.3 Operator’s Seat Adjustment…1767
3.10 STARTING THE ENGINE…1768
3.10.1 STARTING PROCEDURE…1771
3.10.2 ENGINE WARM-UP…1779
3.10.3 HYDRAULIC OIL WARM-UP…1779
3.10.4 JUMP START WITH BOOSTER BATTERIES…1779
3.11 MOVING THE SHOVEL…1781
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS…1781
3.11.1.1 TRAVEL ALARM / BACK-UP ALARM…1783
3.11.2 TRAVELLING INSTRUCTIONS…1783
3.11.2.1 TRAVELLING LONG DISTANCES…1785
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…1786
3.12.1 SLEWING THE SUPERSTRUCTURE…1786
3.12.1.1 MACHINES WITH "EURO" CONTROL…1786
3.12.1.2 MACHINES WITH "KMG" CONTROL…1787
3.12.2 BRAKING THE SUPERSTRUCTURE…1787
3.12.3 SLEW PARKING BRAKE…1788
3.12.3.1 Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System…1789
3.12.3.2 IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE…1789
3.13 WORKING WITH THE ATTACHMENT…1790
3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM…1790
3.13.1.1 Backhoe…1790
3.13.1.2 FACE SHOVEL…1790
3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM…1791
3.13.2.1 Backhoe…1791
3.13.2.2 FACE SHOVEL…1791
3.13.3 BOTTOM DUMP BUCKET…1792
3.13.3.1 Operating the bucket clam…1792
3.13.3.2 OPERATING THE BUCKET CLAM…1792
3.13.4 DROP BALL OPERATION…1793
3.13.4.1 SAFETY INSTRUCTIONS…1793
3.13.4.2 SAFETY DEVICES (SPECIAL EQUIPMENT)…1795
3.13.4.3 WORKING HINTS…1795
3.13.5 COMBINED OPERATION CYCLES…1796
3.14 WORKING INSTRUCTIONS…1798
3.14.1 STABILITY OF THE SHOVEL…1798
3.14.2 SHOVEL OPERATION…1798
3.15 PARKING THE SHOVEL…1801
3.15.0.1 CLEANING THE TRACK GROUPS…1801
3.16 STOPPING THE ENGINE…1802
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…1805
3.17 OPERATION OF THE LUBRICATION SYSTEM…1806
3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”…1806
3.17.1.1 Manual actuation of the central lubrication system…1806
3.17.1.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM…1807
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”…1807
3.17.2.1 Manual actuation of the swing circle lubrication system…1808
3.17.2.2 SWING CIRCLE LUBRICATION SYSTEM ”SLS”…1809
3.17.2.3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM…1809
3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS…1810
3.18.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS…1811
3.18.1 HIGH LEVEL ALARM ”FIRE”…1815
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…1815
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS…1815
3.18.3.1 MANUAL ACTUATION…1815
3.18.3.2 AUTOMATIC ACTUATION…1815
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS…1817
3.18.5 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF…1819
3.19 TRANSFER PUMP FOR HYDRAULIC OIL…1820
3.19.1 OPERATING THE TRANSFER PUMP…1821
3.19.2 FUNCTIONS OF THE TRANSFER PUMP…1823
3.20 CENTRAL REFILLING SYSTEM…1826
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…1827
3.20.1.1 Operation of the hydraulic Service Arm…1827
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM…1829
3.20.3 RECEIVER PANEL WITH MONITOR BOX…1831
3.20.3.1 Refilling Procedure…1833
3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM…1835
3.20.4.1 Refilling the Grease Containers of the Automatic Lubrication Systems…1837
3.21 WORK ON THE LOADER ATTACHMENT…1838
3.21.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS…1838
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL…1839
3.22.1 DISASSEMBLING OF THE SHOVEL…1839
3.22.2 TRANSPORTATION AND LIFTING…1839
3.23 RETRIEVAL PROCEDURE…1840
3.24 SHOVEL STORAGE…1841
3.24.0.1 GENERAL…1841
3.24.1 PREPARING FOR STORAGE…1841
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD…1841
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD…1841
3.24.4 PREPARING FOR OPERATION…1842
3.25 TROUBLE SHOOTING…1843
3.25.0.1 GENERAL…1843
3.25.1 ENGINE…1843
3.25.2 HYDRAULIC SYSTEM…1844
3.25.3 FINAL DRIVES AND SWING MACHINERY…1845
3.25.4 CRAWLER TRACKS…1845
4 MAINTENANCE…1847
4.1 FOREWORD…1848
4.1.0.1 DEFINITIONS…1848
4.1.0.2 GENERAL RECOMMENDATIONS…1848
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE…1849
4.3 FLUIDS AND LUBRICANTS…1850
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…1850
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…1851
4.4 FILLING CAPACITIES…1853
4.5 STANDARD TORQUE LIST…1854
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…1855
4.6.1 INITIAL SERVICING…1855
4.6.1.1 AFTER THE FIRST 250 OPERATING HOURS…1855
4.6.1.2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS…1855
4.6.2 PERIODIC SERVICING INTERVALS…1855
4.6.3 PERIODIC SERVICING SCHEDULE…1856
4.6.3.1 Lubrication Chart…1860
4.7 SAFETY CRITICAL PARTS…1862
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES…1862
4.7.2 INSPECTION OF HOSE LINES…1862
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS…1862
4.8 EXTENDED SERVICE INTERVALS…1865
4.8.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM…1865
4.8.1.1 Servicing Intervals…1869
4.8.2 MAINTENANCE OF THE ENGINE…1869
4.9 ENGINE FUEL FILTER LOCATION…1870
4.9.1 fuel line connections on the engine…1871
4.10 WHEN NECESSARY…1872
4.10.1 ENGINE AIR CLEANER SERVICE…1873
4.10.1.1 General Service Tips…1875
4.10.2 SWING CIRCLE TOOTHING LUBRICATION…1877
4.10.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS…1879
4.10.3.1 CLEAN OR REPLACE FILTER ELEMENTS…1881
4.10.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…1883
4.11 EVERY 10 OPERATING HOURS OR DAILY…1884
4.11.1 WALK-AROUND INSPECTION…1885
4.11.1.1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION…1889
4.11.1.2 CHECK GREASE INJECTORS…1891
4.11.1.3 CORRECTIVE ACTIONS…1891
4.11.1.4 CHECK GREASE INJECTORS…1893
4.11.2 AIR CLEANER – CLEAN PRE-CLEANER…1895
4.11.2.1 Clean dust cups of pre-cleaners…1895
4.11.3 RADIATOR – CHECK COOLANT LEVEL…1897
4.11.4 TRACK GROUPS – CLEAN…1897
4.11.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER…1899
4.11.6 BOOM – CHECK LADDER AND WALKWAY…1901
4.12 EVERY 50 OPERATING HOURS OR WEEKLY…1902
4.12.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…1903
4.12.1.1 Swing gears manufactured by "L&S"…1903
4.12.1.2 Swing gears manufactured by SIEBENHAAR…1905
4.12.1.3 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S" – CHECK OIL LEVELS…1907
4.12.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN" – CHECK OIL LEVELS…1911
4.12.2 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL…1915
4.12.2.1 CHECK OIL LEVEL OF PTO GEAR…1915
4.12.2.2 CHECK OIL LEVEL OF OIL COLLECTOR RESERVOIR (4)…1915
4.12.3 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…1917
4.12.4 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…1919
4.13 EVERY 250 OPERATING HOURS OR MONTHLY…1920
4.13.1 AIR CONDITIONING…1921
4.13.2 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…1921
4.13.3 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL…1925
4.13.4 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…1927
4.13.5 SIGNAL HORN COMPRESSOR – LUBRICATE…1927
4.13.6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…1927
4.13.7 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…1927
4.13.8 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…1929
4.13.9 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…1933
4.13.9.1 Clean and inspect filter element (2) as follows:…1933
4.13.9.2 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT (Heavy duty version, special equipment)…1935
4.13.9.3 Clean pre-cleaner dust bowl…1935
4.13.9.4 Clean and inspect main filter element…1935
4.13.10 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…1937
4.14 EVERY 500 OPERATING HOURS OR MONTHLY…1938
4.14.1 BATTERIES – CHECK FLUID LEVEL…1939
4.14.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL…1941
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL…1943
4.14.3.1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS…1943
4.14.4 FUEL TANK – DRAIN CONDENSATION…1945
4.14.4.1 DRAIN CONDENSATION AS FOLLOWS…1945
4.14.5 CRAWLER TRACK – INSPECTION…1947
4.14.5.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS…1947
4.14.5.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS…1949
4.14.5.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS…1951
4.14.5.4 Bleeding the System…1951
4.14.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION…1953
4.14.7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION…1955
4.15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…1956
4.15.1 HIGH STRENGTH BOLT CONNECTIONS…1957
4.15.2 HYDRAULIC SYSTEM – FILTER SERVICE…2007
4.15.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…2021
4.15.3.1 Oil drain plugs, illustration…2021
4.15.3.2 PTO (PUMP DISTRIBUTOR GEAR)…2021
4.15.3.3 SWING GEARS AND TRAVEL GEARS…2021
4.15.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…2023
4.15.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS…2025
4.15.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…2027
4.15.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…2029
4.16 EVERY 2000 OPERATING HOURS OR YEARLY…2030
4.16.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…2031
4.16.2 FILLING THE HYDRAULIC SYSTEM…2041
4.16.3 BLEEDING THE HYDRAULIC SYSTEM…2043
4.16.4 GEAR PUMP FOR PTO GEAR LUBRICATION…2045
4.16.5 EMERGENCY ESCAPE LADDER – INSPECTION…2047
4.17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…2048
4.17.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…2049
4.17.1.1 Swing gears manufactured by "L&S"…2049
4.17.1.2 "SWING GEARS MANUFACTURED BY “SIEBENHAAR”…2053
4.17.1.3 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S"- CHANGE OIL…2057
4.17.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN"- CHANGE OIL…2063
4.17.2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…2069
4.18 FIRE PREVENTION…2070
4.18.1 PRECAUTIONS…2071
4.19 WELD REPAIRS…2072
4.19.1 GENERAL PROTECTIVE MEASURES…2073
4.19.1.1 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL…2073
4.19.1.2 COUNTERWEIGHT…2073
4.19.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…2075
4.19.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…2077
4.19.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…2079
4.19.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…2081
OMPC40008152 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual…2089
COVER…2089
1. INTRODUCTION…2091
1.1 CONTENTS OF THE BINDER…2092
1.2 DIVISION OF THE BINDER…2093
1.3 DESIGNATED USE OF THE EXCAVATOR…2094
1.4 DELIVERY OF THE EXCAVATOR…2095
1.5 EXPLANATION OF ABBREVATIONS…2096
1.6 TABLE OF CONTENTS…2097
2. SAFETY…2103
2.1 SAFETY INSTRUCTIONS…2104
2.1.1 WARNINGS AND SYMBOLS…2104
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC EXCAVATOR…2104
2.1.3 ORGANIZATIONAL MEASURES…2105
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…2107
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…2108
2.1.6 WARNING OF SPECIAL DANGERS…2111
2.1.7 TRANSPORTING AND TOWING – RECOMMISSIONING…2113
2.1.8 SPECIAL SAFETY EQUIPMENT…2113
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…2117
3. OPERATION…2125
3.1 FOREWORD…2126
3.2 CONSTRUCTION OF THE EXCAVATOR…2127
3.2.1 OVERALL VIEW…2127
3.2.2 SUPERSTRUCTURE…2128
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…2136
3.2.4 EMERGENCY ESCAPE LADDER…2140
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN AND OPERATOR WARNING SYSTEM…2142
3.2.6 OPERATOR'S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…2144
3.2.7 UNDERCARRIAGE…2151
3.2.8 WORKING ATTACHMENT…2152
3.2.9 DIESEL ENGINE TYPE SDA 16V160…2154
3.3 OPERATOR'S CAB – CONTROLS…2160
3.3.1 HYDRAULIC CONTROL SYSTEM…2161
3.3.2 SAFETY CIRCUIT FOR CONTROLS…2161
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR…2172
3.4.1 INITIALIZATION SCREEN NO. 0.0…2172
3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1…2172
3.4.3 STANDARD MONITOR 1 (NO. 1.2)…2173
3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM…2187
3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES…2199
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…2202
3.5.1 A – HEATING…2202
3.5.2 B – COOLING…2203
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…2203
3.6 POWER HOUSE…2204
3.6.1 EMERGENY SHUTDOWN SWITCHES AND BATTERY MAIN SWITCHES…2205
3.6.2 CENTRAL CONTROL AND FILTER PANEL…2207
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…2208
3.7.1 SWITCH BOARD (X2) IN CAB BASE…2211
3.8 CHECKS BEFORE STARTING THE ENGINE…2220
3.9 STARTING THE ENGINE…2226
3.9.1 STARTING PROCEDURE…2229
3.9.2 ENGINE WARM-UP…2233
3.9.3 HYDRAULIC OIL WARM-UP…2233
3.10 MOVING THE EXCAVATOR…2235
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS…2235
3.10.2 TRAVELLING INSTRUCTIONS…2238
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE…2239
3.11.1 SLEWING THE SUPERSTRUCTURE…2239
3.11.2 BRAKING THE SUPERSTRUCTURE…2241
3.11.3 SLEW PARKING BRAKE…2242
3.12 WORKING WITH THE ATTACHMENT…2244
3.12.1 MACHINES EQUIPPED WITH "EURO" CONTROL SYSTEM…2244
3.12.2 MACHINES EQUIPPED WITH "KMG" CONTROL SYSTEM…2245
3.12.3 BOTTOM DUMP BUCKET…2246
3.12.4 DROP BALL OPERATION…2247
3.12.5 COMBINED OPERATION CYCLES…2250
3.13 WORKING INSTRUCTIONS…2252
3.13.1 STABILITY OF THE EXCAVATOR…2252
3.12.2 EXCAVATOR OPERATION…2252
3.14 PARKING THE EXCAVATOR…2255
3.15 STOPPING THE ENGINE…2256
3.16 OPERATION OF THE LUBRICATION SYSTEM…2260
3.16.1 CENTRAL LUBRICATION SYSTEM "CLS"…2260
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM "SLS"…2262
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM…2264
3.17.1 HIGH LEVEL ALARM "FIRE"…2267
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…2267
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM…2267
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM…2269
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF…2271
3.18 CENTRAL REFILLING SYSTEM…2272
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…2273
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM…2275
3.18.3 RECEIVER PANEL WITH MONITOR BOX…2277
3.18.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM…2283
3.19 WORK ON THE LOADER ATTACHMENT…2286
3.20 TRANSPORTATION AND LIFTING OF THE EXCAVATOR…2287
3.20.1 DISASSEMBLING OF THE EXCAVATOR…2287
3.20.2 TRANSPORTATION AND LIFTING…2287
3.21 RETRIEVAL PROCEDURE…2288
3.22 EXCAVATOR STORAGE…2289
3.22.1 PREPARING FOR STORAGE…2289
3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD…2290
3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD…2290
3.22.4 PREPARING FOR OPERATION…2291
3.23 TROUBLE SHOOTING…2292
3.23.1 ENGINE…2292
3.23.2 HYDRAULIC SYSTEM…2293
3.23.3 FINAL DRIVES AND SWING MACHINERY…2294
3.23.4 CRAWLER TRACKS…2294
4. MAINTENANCE…2295
4.1 FOREWORD…2296
4.2 PRECAUTIONS FOR MAINTENANCE…2297
4.3 FUEL AND LUBRICANTS…2299
4.4 FILLING CAPACITIES…2301
4.5 STANDARD TORQUE LIST…2302
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…2303
4.6.1 INITIAL SERVICING…2303
4.6.2 PERIODIC SERVICING INTERVALS…2303
4.6.3 PERIODIC SERVICING SCHEDULE…2304
4.6.4 EXTENDED SERVICE INTERVALS OF ENGINE OIL RESERVE SYSTEM…2311
4.6.5 MAINTENANCE OF THE ENGINE…2311
4.7 WHEN NECESSARY…2312
4.7.1 ENGINE AIR CLEANER SERVICE…2313
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…2317
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS…2319
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…2323
4.8 EVERY 10 OPERATING HOURS OR DAILY…2324
4.8.1 VISUAL INSPECTIONS…2325
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…2335
4.8.3 RADIATOR – CHECK COOLANT LEVEL…2337
4.8.4 TRACK GROUPS – CLEAN…2337
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…2338
4.9.1 SWING MACHINERY, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…2339
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…2345
4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…2347
4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL…2349
4.9.5 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…2351
4.9.6 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…2353
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…2354
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…2355
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…2357
4.10.3 SIGNAL HORN COMPRESSOR – LUBRICATE…2357
4.10.4 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK OIL LEVEL…2357
4.10.5 RADIATOR FAN BEARING – CHECK OIL LEVEL…2357
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…2359
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…2363
4.11 EVERY 500 OPERATING HOURS OR MONTHLY…2364
4.11.1 BATTERIES – CHECK FLUID LEVEL…2365
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL…2367
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL…2369
4.11.4 FUEL TANK – DRAIN CONDENSATION…2371
4.11.5 CRAWLER TRACK – INSPECTION…2373
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…2378
4.12.1 HIGH STRENGTH BOLT CONNECTIONS…2379
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…2421
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…2433
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…2435
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS…2437
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…2439
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…2440
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…2441
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…2453
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…2454
4.14.1 SWING MACHINERY, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…2455
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…2465
4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL…2469
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…2471
4.15 FIRE PREVENTION…2472
4.16 REPAIR WELDINGS…2474
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…2477
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…2479
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…2481
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE…2481
OMPC40008155 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual…2483
COVER…2483
1. INTRODUCTION…2485
1.1 CONTENTS OF THE BINDER…2486
1.2 DIVISION OF THE BINDER…2487
1.3 DESIGNATED USE OF THE SHOVEL…2488
1.4 DELIVERY OF THE SHOVEL…2489
1.5 EXPLANATION OF ABBREVATIONS…2490
1.6 TABLE OF CONTENTS…2491
2. SAFETY…2497
2.1 SAFETY INSTRUCTIONS…2498
2.1.1 WARNINGS AND SYMBOLS…2498
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC MINING SHOVEL…2498
2.1.3 ORGANIZATIONAL MEASURES…2499
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…2501
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…2502
2.1.6 WARNING OF SPECIAL DANGERS…2505
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…2507
2.1.8 SPECIAL SAFETY EQUIPMENT…2507
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…2511
3. OPERATION…2519
3.1 FOREWORD…2520
3.2 CONSTRUCTION OF THE SHOVEL…2521
3.2.1 OVERALL VIEW…2521
3.2.2 SUPERSTRUCTURE…2522
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…2530
3.2.4 EMERGENCY ESCAPE LADDER…2534
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN AND OPERATOR WARNING SYSTEM…2536
3.2.6 OPERATOR’S CAB…2538
3.2.7 UNDERCARRIAGE…2545
3.2.8 WORKING ATTACHMENT…2546
3.2.9 DIESEL ENGINE TYPE SDA 16V160…2548
3.2.10 ENGINE OIL MANAGEMENT SYSTEM…2550
3.3 OPERATOR’S CAB – CONTROLS…2554
3.3.1 HYDRAULIC CONTROL SYSTEM…2555
3.3.2 SAFETY CIRCUIT FOR CONTROLS…2555
3.3.3 CONTROL PANEL…2559
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR…2566
3.4.1 INITIALIZATION SCREEN NO. 0.0…2566
3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1…2566
3.4.3 STANDARD MONITOR 1 (NO. 1.2)…2567
3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM…2581
3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES…2593
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…2596
3.5.1 A – HEATING…2596
3.5.2 B – COOLING…2597
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…2597
3.6 POWER HOUSE…2598
3.6.1 EMERGENCY SHUTDOWN SWITCHES AND BATTERY MAIN SWITCHES…2599
3.6.2 CENTRAL CONTROL AND FILTER PANEL…2601
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…2602
3.7.1 STANDARD COMPONENTS IN CAB BASE…2603
3.7.2 SWITCH BOARD (X2) IN CAB BASE…2605
3.7.3 COMPONENTS OF ELECTRICAL PRE-HEATING SYSTEM LOCATED IN THE CAB BASE…2613
3.8 CHECKS BEFORE STARTING THE ENGINE…2618
3.9 STARTING THE ENGINE…2624
3.9.1 STARTING PROCEDURE…2627
3.9.2 ENGINE WARM-UP…2631
3.9.3 HYDRAULIC OIL WARM-UP…2631
3.10 MOVING THE SHOVEL…2633
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS…2633
3.10.2 TRAVELLING INSTRUCTIONS…2636
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE…2637
3.11.1 SLEWING THE SUPERSTRUCTURE…2637
3.11.2 BRAKING THE SUPERSTRUCTURE…2639
3.11.3 SLEW PARKING BRAKE…2640
3.12 WORKING WITH THE ATTACHMENT…2642
3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM…2642
3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM…2643
3.12.3 BOTTOM DUMP BUCKET…2644
3.12.4 DROP BALL OPERATION…2645
3.12.5 COMBINED OPERATION CYCLES…2648
3.13 WORKING INSTRUCTIONS…2650
3.13.1 STABILITY OF THE SHOVEL…2650
3.13.2 SHOVEL OPERATION…2650
3.14 PARKING THE SHOVEL…2653
3.15 STOPPING THE ENGINE…2654
3.16 OPERATION OF THE LUBRICATION SYSTEM…2658
3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”…2658
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”…2660
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM…2662
3.17.1 HIGH LEVEL ALARM ”FIRE”…2665
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…2665
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM…2665
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S…2667
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER…2669
3.18 CENTRAL REFILLING SYSTEM…2670
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…2671
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM…2673
3.18.3 RECEIVER PANEL WITH MONITOR BOX…2675
3.18.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB…2681
3.19 WORK ON THE LOADER ATTACHMENT…2684
3.20 TRANSPORTATION AND LIFTING OF THE SHOVEL…2685
3.20.1 DISASSEMBLING OF THE SHOVEL…2685
3.20.2 TRANSPORTATION AND LIFTING…2685
3.21 RETRIEVAL PROCEDURE…2686
3.22 SHOVEL STORAGE…2687
3.22.1 PREPARING FOR STORAGE…2687
3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD…2688
3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD…2688
3.22.4 PREPARING FOR OPERATION…2689
3.23 TROUBLE SHOOTING…2690
3.23.1 ENGINE…2690
3.23.2 HYDRAULIC SYSTEM…2691
3.23.3 FINAL DRIVES AND SWING MACHINERY…2692
3.23.4 CRAWLER TRACKS…2692
4. MAINTENANCE…2693
4.1 FOREWORD…2694
4.2 PRECAUTIONS FOR MAINTENANCE…2695
4.3 FUEL AND LUBRICANTS…2697
4.4 FILLING CAPACITIES…2699
4.5 STANDARD TORQUE LIST…2700
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…2701
4.6.1 INITIAL SERVICING…2701
4.6.2 PERIODIC SERVICING INTERVALS…2701
4.6.3 PERIODIC SERVICING SCHEDULE…2702
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM…2709
4.6.5 MAINTENANCE OF THE ENGINE…2711
4.7 WHEN NECESSARY…2712
4.7.1 ENGINE AIR CLEANER SERVICE…2713
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…2717
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS…2719
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…2723
4.8 EVERY 10 OPERATING HOURS OR DAILY…2724
4.8.1 WALK-AROUND INSPECTION…2725
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…2735
4.8.3 RADIATOR – CHECK COOLANT LEVEL…2737
4.8.4 TRACK GROUPS – CLEAN…2737
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…2738
4.9.1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…2739
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…2743
4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…2745
4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL…2747
4.9.5 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…2749
4.9.6 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…2751
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…2752
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…2753
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…2755
4.10.3 SIGNAL HORN COMPRESSOR – LUBRICATE…2755
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…2755
4.10.5 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…2755
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…2757
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…2761
4.10.8 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL…2763
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL…2765
4.11 EVERY 500 OPERATING HOURS OR MONTHLY…2766
4.11.1 BATTERIES – CHECK FLUID LEVEL…2767
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL…2769
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL…2771
4.11.4 FUEL TANK – DRAIN CONDENSATION…2773
4.11.5 CRAWLER TRACK – INSPECTION…2775
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…2780
4.12.1 HIGH STRENGTH BOLT CONNECTIONS…2781
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…2821
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…2833
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…2835
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS…2837
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…2839
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…2840
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…2841
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…2853
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…2854
4.14.1 SWING MACHINERY AND MOTOR ADAPTER HOUSING – CHANGE OIL…2855
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…2863
4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL…2867
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…2869
4.15 FIRE PREVENTION…2870
4.16 REPAIR WELDINGS…2872
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…2875
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…2877
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…2879
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE…2880
OMPC40008170 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual…2881
COVER…2881
1. INTRODUCTION…2883
1.1 CONTENTS OF THE BINDER…2884
1.2 DIVISION OF THE BINDER…2885
1.3 DESIGNATED USE OF THE SHOVEL…2886
1.4 DELIVERY OF THE SHOVEL…2887
1.5 EXPLANATION OF ABBREVIATIONS…2888
1.6 TABLE OF CONTENTS…2889
2. SAFETY…2895
2.1 SAFETY INSTRUCTIONS…2896
2.1.1 WARNINGS AND SYMBOLS…2896
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC MINING SHOVEL…2896
2.1.3 ORGANIZATIONAL MEASURES…2897
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…2899
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…2900
2.1.6 WARNING OF SPECIAL DANGERS…2903
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…2905
2.1.8 SPECIAL SAFETY EQUIPMENT…2905
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…2909
3. OPERATION…2917
3.1 FOREWORD…2918
3.2 CONSTRUCTION OF THE SHOVEL…2919
3.2.1 OVERALL VIEW…2919
3.2.2 SUPERSTRUCTURE…2920
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…2930
3.2.4 EMERGENCY ESCAPE LADDER…2934
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…2936
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…2938
3.2.7 UNDERCARRIAGE…2949
3.2.8 WORKING ATTACHMENT…2950
3.2.9 DIESEL ENGINE TYPE SDA 16V160…2952
3.2.10 ENGINE OIL MANAGEMENT SYSTEM…2954
3.3 OPERATOR’S CAB – CONTROLS…2958
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…2958
3.3.2 SAFETY CIRCUIT FOR CONTROLS…2959
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…2962
3.3.4 SAFETY CIRCUIT FOR CONTROLS…2963
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK…2965
3.3.6 OPERATOR’S CONSOLE…2967
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING…2973
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR…2976
3.4.1 INITIALIZATION SCREEN NO. 0.0…2976
3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1…2976
3.4.3 STANDARD MONITOR 1 (NO. 1.2)…2977
3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM…2991
3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES…3000
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…3002
3.5.1 A – HEATING…3003
3.5.2 B – COOLING…3003
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…3003
3.5.4 AUXILIARY HEATER FOR OPERATOR’S CAB…3005
3.6 POWER HOUSE…3006
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…3007
3.6.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES…3009
3.6.3 CENTRAL CONTROL AND FILTER PANEL…3011
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…3014
3.7.1 STANDARD COMPONENTS IN CAB BASE…3015
3.7.2 SWITCH BOARD (X2) IN CAB BASE…3017
3.7.3 COMPONENTS OF ELECTRICAL PRE-HEATING SYSTEM LOCATED IN THE CAB BASE…3027
3.8 CHECKS BEFORE STARTING THE ENGINE…3034
3.9 STARTING THE ENGINE…3040
3.9.1 STARTING PROCEDURE…3043
3.9.2 ENGINE WARM-UP…3047
3.9.3 HYDRAULIC OIL WARM-UP…3047
3.10 MOVING THE SHOVEL…3049
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS…3049
3.10.2 TRAVELLING INSTRUCTIONS…3052
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE…3053
3.11.1 SLEWING THE SUPERSTRUCTURE…3053
3.11.2 BRAKING THE SUPERSTRUCTURE…3055
3.11.3 SLEW PARKING BRAKE…3056
3.12 WORKING WITH THE ATTACHMENT…3058
3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM…3058
3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM…3059
3.12.3 BOTTOM DUMP BUCKET…3060
3.12.4 DROP BALL OPERATION…3061
3.12.5 COMBINED OPERATION CYCLES…3064
3.13 WORKING INSTRUCTIONS…3066
3.13.1 STABILITY OF THE SHOVEL…3066
3.13.2 SHOVEL OPERATION…3066
3.14 PARKING THE SHOVEL…3069
3.15 STOPPING THE ENGINE…3070
3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…3073
3.16 OPERATION OF THE LUBRICATION SYSTEM…3074
3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”…3074
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”…3076
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM…3078
3.17.1 HIGH LEVEL ALARM ”FIRE”…3081
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…3081
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM…3081
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S…3083
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER…3085
3.18 TRANSFER PUMP FOR HYDRAULIC OIL…3086
3.18.1 OPERATING THE TRANSFER PUMP…3087
3.18.2 FUNCTIONS OF THE TRANSFER PUMP…3089
3.19 CENTRAL REFILLING SYSTEM…3092
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…3093
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM…3095
3.19.3 RECEIVER PANEL WITH MONITOR BOX…3097
3.19.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB…3103
3.20 WORK ON THE LOADER ATTACHMENT…3106
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL…3107
3.21.1 DISASSEMBLING OF THE SHOVEL…3107
3.21.2 TRANSPORTATION AND LIFTING…3107
3.22 RETRIEVAL PROCEDURE…3108
3.23 SHOVEL STORAGE…3109
3.23.1 PREPARING FOR STORAGE…3109
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD…3110
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD…3110
3.23.4 PREPARING FOR OPERATION…3111
3.24 TROUBLE SHOOTING…3112
3.24.1 ENGINE…3112
3.24.2 HYDRAULIC SYSTEM…3113
3.24.3 FINAL DRIVES AND SWING MACHINERY…3114
3.24.4 CRAWLER TRACKS…3114
4. MAINTENANCE…3115
4.1 FOREWORD…3116
4.2 PRECAUTIONS FOR MAINTENANCE…3117
4.3 FUEL AND LUBRICANTS…3119
4.4 FILLING CAPACITIES…3121
4.5 STANDARD TORQUE LIST…3122
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…3123
4.6.1 INITIAL SERVICING…3123
4.6.2 PERIODIC SERVICING INTERVALS…3123
4.6.3 PERIODIC SERVICING SCHEDULE…3124
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM…3131
4.6.5 MAINTENANCE OF THE ENGINE…3133
4.7 WHEN NECESSARY…3134
4.7.1 ENGINE AIR CLEANER SERVICE…3135
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…3139
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS…3141
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…3145
4.8 EVERY 10 OPERATING HOURS OR DAILY…3146
4.8.1 WALK-AROUND INSPECTION…3147
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…3157
4.8.3 RADIATOR – CHECK COOLANT LEVEL…3159
4.8.4 TRACK GROUPS – CLEAN…3159
4.8.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER…3161
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…3162
4.9.1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…3163
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…3167
4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…3169
4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL…3171
4.9.5 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…3173
4.9.6 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…3175
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…3176
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…3177
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…3179
4.10.3 SIGNAL HORN COMPRESSOR – LUBRICATE…3179
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…3179
4.10.5 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…3179
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…3181
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…3185
4.10.8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…3187
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL…3189
4.11 EVERY 500 OPERATING HOURS OR MONTHLY…3190
4.11.1 BATTERIES – CHECK FLUID LEVEL…3191
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL…3193
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL…3195
4.11.4 FUEL TANK – DRAIN CONDENSATION…3197
4.11.5 CRAWLER TRACK – INSPECTION…3199
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…3204
4.12.1 HIGH STRENGTH BOLT CONNECTIONS…3205
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…3247
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…3259
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…3261
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS…3263
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…3265
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…3267
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…3269
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…3270
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…3271
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…3283
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…3284
4.14.1 SWING MACHINERY AND MOTOR ADAPTER HOUSING – CHANGE OIL…3285
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…3293
4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL…3297
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…3299
4.15 FIRE PREVENTION…3300
4.16 WELD REPAIRS…3302
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…3305
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…3307
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…3309
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…3310
OMPC40008172 – Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual…3317
COVER…3317
1. INTRODUCTION…3319
1.1 CONTENTS OF THE BINDER…3320
1.2 DIVISION OF THE BINDER…3321
1.3 DESIGNATED USE OF THE SHOVEL…3322
1.4 DELIVERY OF THE SHOVEL…3323
1.5 EXPLANATION OF ABBREVIATIONS…3324
1.6 TABLE OF CONTENTS…3325
2. SAFETY…3331
2.1 SAFETY INSTRUCTIONS…3332
2.1.1 WARNINGS AND SYMBOLS…3332
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC MINING SHOVEL…3332
2.1.3 ORGANIZATIONAL MEASURES…3333
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…3335
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…3336
2.1.6 WARNING OF SPECIAL DANGERS…3339
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…3341
2.1.8 SPECIAL SAFETY EQUIPMENT…3341
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…3345
3. OPERATION…3353
3.1 FOREWORD…3354
3.2 CONSTRUCTION OF THE SHOVEL…3355
3.2.1 OVERALL VIEW…3355
3.2.2 SUPERSTRUCTURE…3356
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…3366
3.2.4 EMERGENCY ESCAPE LADDER…3370
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…3372
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…3374
3.2.7 UNDERCARRIAGE…3385
3.2.8 WORKING ATTACHMENT…3386
3.2.9 DIESEL ENGINE TYPE SDA 16V160…3388
3.2.10 ENGINE OIL MANAGEMENT SYSTEM…3390
3.3 OPERATOR’S CAB – CONTROLS…3394
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…3394
3.3.2 SAFETY CIRCUIT FOR CONTROLS…3395
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…3398
3.3.4 SAFETY CIRCUIT FOR CONTROLS…3399
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK…3401
3.3.6 OPERATOR’S CONSOLE…3403
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING…3409
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR…3412
3.4.1 INITIALIZATION SCREEN NO. 0.0…3412
3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1…3412
3.4.3 STANDARD MONITOR 1 (NO. 1.2)…3413
3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM…3427
3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES…3436
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…3438
3.5.1 A – HEATING…3439
3.5.2 B – COOLING…3439
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…3439
3.5.4 AUXILIARY HEATER FOR OPERATOR’S CAB…3441
3.6 POWER HOUSE…3442
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…3443
3.6.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES…3445
3.6.3 CENTRAL CONTROL AND FILTER PANEL…3447
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…3450
3.7.1 STANDARD COMPONENTS IN CAB BASE…3451
3.7.2 SWITCH BOARD (X2) IN CAB BASE…3453
3.7.3 COMPONENTS OF ELECTRICAL PRE-HEATING SYSTEM LOCATED IN THE CAB BASE…3463
3.8 CHECKS BEFORE STARTING THE ENGINE…3470
3.9 STARTING THE ENGINE…3476
3.9.1 STARTING PROCEDURE…3479
3.9.2 ENGINE WARM-UP…3483
3.9.3 HYDRAULIC OIL WARM-UP…3483
3.10 MOVING THE SHOVEL…3485
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS…3485
3.10.2 TRAVELLING INSTRUCTIONS…3488
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE…3489
3.11.1 SLEWING THE SUPERSTRUCTURE…3489
3.11.2 BRAKING THE SUPERSTRUCTURE…3491
3.11.3 SLEW PARKING BRAKE…3492
3.12 WORKING WITH THE ATTACHMENT…3494
3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM…3494
3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM…3495
3.12.3 BOTTOM DUMP BUCKET…3496
3.12.4 DROP BALL OPERATION…3497
3.12.5 COMBINED OPERATION CYCLES…3500
3.13 WORKING INSTRUCTIONS…3502
3.13.1 STABILITY OF THE SHOVEL…3502
3.13.2 SHOVEL OPERATION…3502
3.14 PARKING THE SHOVEL…3505
3.15 STOPPING THE ENGINE…3506
3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…3509
3.16 OPERATION OF THE LUBRICATION SYSTEM…3510
3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”…3510
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”…3512
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM…3514
3.17.1 HIGH LEVEL ALARM ”FIRE”…3517
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…3517
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM…3517
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S…3519
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER…3521
3.18 TRANSFER PUMP FOR HYDRAULIC OIL…3522
3.18.1 OPERATING THE TRANSFER PUMP…3523
3.18.2 FUNCTIONS OF THE TRANSFER PUMP…3525
3.19 CENTRAL REFILLING SYSTEM…3528
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…3529
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM…3531
3.19.3 RECEIVER PANEL WITH MONITOR BOX…3533
3.19.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB…3539
3.20 WORK ON THE LOADER ATTACHMENT…3542
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL…3543
3.21.1 DISASSEMBLING OF THE SHOVEL…3543
3.21.2 TRANSPORTATION AND LIFTING…3543
3.22 RETRIEVAL PROCEDURE…3544
3.23 SHOVEL STORAGE…3545
3.23.1 PREPARING FOR STORAGE…3545
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD…3546
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD…3546
3.23.4 PREPARING FOR OPERATION…3547
3.24 TROUBLE SHOOTING…3548
3.24.1 ENGINE…3548
3.24.2 HYDRAULIC SYSTEM…3549
3.24.3 FINAL DRIVES AND SWING MACHINERY…3550
3.24.4 CRAWLER TRACKS…3550
4. MAINTENANCE…3551
4.1 FOREWORD…3552
4.2 PRECAUTIONS FOR MAINTENANCE…3553
4.3 FUEL AND LUBRICANTS…3555
4.4 FILLING CAPACITIES…3557
4.5 STANDARD TORQUE LIST…3558
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…3559
4.6.1 INITIAL SERVICING…3559
4.6.2 PERIODIC SERVICING INTERVALS…3559
4.6.3 PERIODIC SERVICING SCHEDULE…3560
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM…3567
4.6.5 MAINTENANCE OF THE ENGINE…3569
4.7 WHEN NECESSARY…3570
4.7.1 ENGINE AIR CLEANER SERVICE…3571
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…3575
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS…3577
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…3581
4.8 EVERY 10 OPERATING HOURS OR DAILY…3582
4.8.1 WALK-AROUND INSPECTION…3583
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…3593
4.8.3 RADIATOR – CHECK COOLANT LEVEL…3595
4.8.4 TRACK GROUPS – CLEAN…3595
4.8.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER…3597
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…3598
4.9.1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…3599
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…3603
4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…3605
4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL…3607
4.9.5 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…3609
4.9.6 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…3611
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…3612
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…3613
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…3615
4.10.3 SIGNAL HORN COMPRESSOR – LUBRICATE…3615
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…3615
4.10.5 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…3615
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…3617
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…3621
4.10.8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…3623
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL…3625
4.11 EVERY 500 OPERATING HOURS OR MONTHLY…3626
4.11.1 BATTERIES – CHECK FLUID LEVEL…3627
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL…3629
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL…3631
4.11.4 FUEL TANK – DRAIN CONDENSATION…3633
4.11.5 CRAWLER TRACK – INSPECTION…3635
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…3640
4.12.1 HIGH STRENGTH BOLT CONNECTIONS…3641
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…3683
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…3695
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…3697
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS…3699
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…3701
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…3703
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…3705
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…3706
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…3707
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…3719
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…3720
4.14.1 SWING MACHINERY AND MOTOR ADAPTER HOUSING – CHANGE OIL…3721
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…3729
4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL…3733
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…3735
4.15 FIRE PREVENTION…3736
4.16 WELD REPAIRS…3738
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…3741
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…3743
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…3745
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…3746
RRPC4000-6 – Hydraulic Mining Shovel PC4000-6 Remove & Replace Procedures…3753
1 Introduction…3765
1.1 Contents of the binder…3766
1.2 Foreword…3767
1.2.1 Service…3768
2 Safety…3769
2.1 Safety Instructions…3770
2.1.1 Method of using this manual…3770
2.1.2 General precautions…3772
2.1.3 Preparations for work…3773
2.1.4 Precautions during work…3774
2.1.5 WARNING OF SPECIAL DANGERS…3776
2.1.5.1 ELECTRICal ENERGY…3776
2.1.5.2 GAS, DUST, STEAM AND SMOKE…3777
2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT…3778
2.1.5.4 NOISE…3778
2.1.5.5 Heat…3779
2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES…3779
2.1.5.7 Height…3779
2.1.6 SPECIAL SAFETY EQUIPMENT…3781
2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…3781
2.1.6.2 INSTRUCTIONS FOR USE…3783
2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS…3785
2.1.6.4 INSTRUCTIONS FOR USE…3787
2.2 Lifting Gears…3788
2.2.1 Wire ropes…3788
2.2.2 Sling accessory…3790
2.2.3 Weight tables…3791
2.2.3.1 Superstructure…3791
2.2.3.2 Undercarriage…3793
2.2.3.3 Backhoe AttachmenT (BHA)…3794
2.2.3.4 Faceshovel Attachment (FSA)…3795
2.3 Torque charts according to DIN…3797
2.3.1 Metric standard thread…3797
2.3.2 Metric fine thread…3798
2.3.3 Cummins motor torques – metric…3799
2.3.4 Cummins motor torques – U.S. Customary…3799
2.3.5 Flange connections…3800
2.4 Conversation table…3801
2.4.1 Method of using the conversation table…3801
2.4.2 Millimeter – Inch & Kilogram – Pound…3802
2.4.3 Liter – U.S. Gallon & Liter – U.K. Gallon…3803
2.4.4 KGm – ft.lb…3804
2.4.5 bar – PSI / PSI – bar…3805
2.4.6 Basic Values in Ohm according to DIN 43 76…3806
2.4.7 Temperature…3807
2.5 Explanation of abbreviations…3808
3 Superstructure…3809
3.1 Diesel Engine…3810
3.1.1 Removal of the Diesel engine…3810
3.1.2 Replacement of the Diesel engine…3817
3.1.3 Engine torque support and engine/PTO mounts…3820
3.1.3.1 Flexible mounts…3821
3.1.3.2 Torque support…3823
3.1.4 Alternator…3824
3.1.4.1 Removal of the alternator…3824
3.1.4.2 Replacement of the alternator…3825
3.1.5 Batteries…3826
3.1.5.1 Removal of the batteries…3826
3.1.5.2 Replacement of the batteries…3828
3.1.6 Radiator fan…3830
3.1.6.1 Removal of the radiator fan assembly…3831
3.1.6.2 Replacement of the radiator fan assembly…3835
3.1.6.3 Removal of the radiator fan…3837
3.1.6.4 Replacement of the radiator fan…3837
3.1.6.5 Removal of the radiator fan drive pump…3838
3.1.6.6 Replacement of the radiator fan drive pump…3840
3.1.7 Radiators…3841
3.1.7.1 Removal of the Radiator assembly…3841
3.1.7.2 Replacement of the radiator assembly…3845
3.1.8 Fuel cooler…3846
3.1.8.1 Removal of the fuel cooler…3846
3.1.8.2 Replacement of the fuel cooler…3848
3.1.9 Starter system…3849
3.1.9.1 Removal of the starter motor…3849
3.1.9.2 Replacement of the starter motor…3849
3.1.10 Geislinger coupling…3850
3.1.10.1 Removal of the Geislinger coupling…3851
3.1.10.2 Replacement of the Geislinger coupling…3853
3.2 PTO…3854
3.2.1 Main pumps…3854
3.2.1.1 Preparatory works for main pump removal…3855
3.2.1.2 Removal of Main Pump 1…3858
3.2.1.3 Replacement of main pump 1…3859
3.2.1.4 Removal of Main Pump 2…3861
3.2.1.5 Replacement of main pump 2…3863
3.2.1.6 Removal of Main Pump 3…3865
3.2.1.7 Replacement of main pump 3…3867
3.2.1.8 Removal of Main Pump 4…3868
3.2.1.9 Replacement of main pump 4…3870
3.2.2 PTO oil circulation pump (auxiliary pump)…3871
3.2.2.1 Removal of the oil circulation pump (auxiliary pump)…3871
3.2.2.2 Replacement of the oil circulation pump (auxiliary pump)…3873
3.2.3 Pump distributor gearbox (PTO)…3874
3.2.3.1 Removal of the Pump distributor gearbox (PTO)…3876
3.2.3.2 Replacement of the Pump distributor gearbox (PTO)…3879
3.3 Hydraulics…3880
3.3.1 Hydraulic cooler fan Drive Pump…3880
3.3.1.1 Removal of the hydraulic cooler fan drive pump…3880
3.3.1.2 Replacement of the hydraulic cooler fan drive pump…3883
3.3.2 Hydraulic Cooler Fan Assembly…3884
3.3.2.1 Removal of hydraulic cooler fan assembly…3884
3.3.2.2 Replacement of hydraulic cooler fan assembly…3887
3.3.2.3 Removal of hydraulic cooler Fan and motor…3888
3.3.2.4 Replacement of hydraulic cooler Fan and motor…3890
3.3.3 Hydraulic Oil Coolers…3892
3.3.3.1 Removal of the hydraulic oil coolers…3894
3.3.3.2 Replacement of the hydraulic oil coolers…3898
3.3.3.3 Removal of the hydraulic oil cooler frame…3900
3.3.3.4 Replacement of the hydraulic oil cooler frame…3905
3.3.4 Main Relief Valves (MRV)…3906
3.3.4.1 Removal of the MRV…3906
3.3.4.2 Replacement of the MRV…3907
3.3.5 pilot oil pump (Gear pump)…3908
3.3.5.1 Removal of the pilot oil pump)…3908
3.3.5.2 Replacement of the pilot oil pump…3910
3.3.6 Main Gate Valve…3910
3.3.6.1 Removal of the main gate valve…3911
3.3.6.2 Replacement of the main gate valve…3912
3.3.7 Hydraulic Oil Reservoir…3914
3.3.7.1 Removal of the hydraulic oil reservoir…3916
3.3.7.2 Replacement of the hydraulic oil reservoir…3923
3.3.8 Main Control Valve Blocks…3925
3.3.8.1 Removal of the main control valve blocks…3934
3.3.8.2 Replacement of the main control valve blocks…3938
3.3.9 Service line Relief Valves (SRV)…3939
3.3.9.1 Removal of SRV on main Control valve block…3939
3.3.9.2 Replacement of SRV on main control valve blocks…3942
3.3.10 Anti-cavitation Valves (ACV)…3944
3.3.10.1 Removal of ACV on Manifold…3945
3.3.10.2 Replacement of ACV on Manifold…3950
3.3.10.3 Removal of ACV on main control valve blocks…3951
3.3.10.4 Replacement of ACV on main control valve blocks…3953
3.3.11 Throttle check valves…3954
3.3.11.1 Removal of throttle check valves…3956
3.3.11.2 Replacement of throttle check valves…3959
3.3.12 manifold…3960
3.3.12.1 Removal of the manifold…3960
3.3.12.2 Replacement of the manifold…3962
3.3.12.3 Removal of the Diffuser on the Manifold (FSA only)…3963
3.3.12.4 Replacement of Diffuser on Manifold (FSA only)…3965
3.4 Slew Drive…3967
3.4.1 Slew Gear…3968
3.4.1.1 Removal of the slew gear…3969
3.4.1.2 Replacement of the slew gear…3971
3.4.2 Swing Motor…3974
3.4.2.1 Removal of the swing motor…3975
3.4.2.2 Replacement of the swing motor…3978
3.4.3 Slew parking brake…3981
3.4.3.1 Removal/Disassembly of the slew parking brake…3983
3.4.3.2 Replacement/assembly of the slew parking brake…3986
3.4.4 Dynamic Slew Brake…3988
3.4.4.1 Removal of the slew brake valve…3991
3.4.4.2 Replacement of the slew brake valve…3993
3.4.5 Swing circle lubrication pinion (dummy wheel)…3994
3.4.5.1 Removal of the lubrication pinion assembly…3996
3.4.5.2 Replacement of the lubrication pinion assembly…3998
3.5 Lubrication pumps…3999
3.5.1 Removal of the Lubrication pump…3999
3.5.2 Replacement of the lubricating pump…4001
3.6 Pump controller MC7…4002
3.6.1 Removal of the pump controller MC7…4002
3.6.2 Replacement of the pump controller MC7…4003
3.7 Operator’s Cab…4004
3.7.1 Removal of the operator’s cab…4007
3.7.2 Replacement of the operator’s cab…4012
3.7.3 Cab-mounts…4013
3.7.3.1 Removal of the cab-mounts…4013
3.7.3.2 replacement of the cab-mounts…4015
3.7.4 FRONT WINDOW…4016
3.7.4.1 Removal of the Front window…4016
3.7.4.2 Replacement of the front window…4017
3.7.5 Operator’s seat…4018
3.7.5.1 Removal of the operator’s seat…4018
3.7.5.2 Replacement of the operator’s seat…4019
3.7.6 VHMS…4020
3.7.6.1 Removal of the VHMS-Controller…4020
3.7.6.2 Replacement of the VHMS-Controller…4021
3.7.7 Access Ladder…4022
3.7.7.1 Removal of the access Ladder…4025
3.7.7.2 Replacement of the access ladder…4027
3.7.7.3 Removal of the access ladder cylinder…4029
3.7.7.4 Replacement of the access ladder cylinder…4031
3.7.8 Removal of the cab base…4032
3.7.9 Replacement of the cab base…4034
3.8 Counterweight…4036
3.8.1 Removal of the counterweight…4037
3.8.2 Replacement of the counterweight…4039
3.9 Superstructure Lifting…4040
3.9.1 Remove the Superstructure from the Undercarriage…4040
3.9.2 Install the Superstructure onto the undercarriage…4043
3.10 Fuel Tank…4046
3.10.1 Removal of the Fuel tank…4047
3.10.2 Replacement of the Fuel tank…4050
4 Undercarriage…4053
4.1 Travel System…4054
4.1.1 Track group…4054
4.1.1.1 Changing of the track group…4054
4.1.2 Sprocket…4058
4.1.2.1 Removal of the sprocket…4058
4.1.2.2 Replacement of the sprocket…4062
4.1.3 Guide wheels…4064
4.1.3.1 Removal of the guide wheel assembly…4064
4.1.3.2 Replacement of the guide wheel assembly…4065
4.1.4 Track tensioning accumulators…4066
4.1.4.1 Removal of the low pressure accumulators…4066
4.1.4.2 Replacement of the low pressure accumulators…4068
4.1.4.3 Removal of the high pressure accumulators…4069
4.1.4.4 Replacement of the high pressure accumulators…4070
4.1.5 Track tension valve block…4071
4.1.5.1 Removal of the track tensioning valve block…4071
4.1.5.2 Replacement of the track tensioning valve block…4072
4.1.6 Hydraulic hoses of the track tensioning system…4073
4.1.6.1 Substitute the hydraulic hoses…4073
4.1.7 Travel brake valve block (overspeed valve)…4076
4.1.7.1 Removal of the travel brake valve block…4077
4.1.7.2 Replacement of the travel brake valve block…4079
4.1.8 Track tensioning cylinders…4080
4.1.8.1 Removal of the track tensioning cylinders…4080
4.1.8.2 Replacement of the track tensioning cylinders…4081
4.1.9 Travel motor…4082
4.1.9.1 Removal of the travel motors…4082
4.1.9.2 Replacement of the travel motors…4084
4.1.10 travel parking brake…4086
4.1.10.1 Removal/disassembly of the travel parking brake…4089
4.1.10.2 Replacement/assembly of the travel parking brake…4092
4.1.11 Travel gearbox…4094
4.1.11.1 Removal of the travel gearbox…4095
4.1.11.2 Replacement of the travel gearbox…4097
4.1.12 Carrier roller…4098
4.1.12.1 Removal of the carrier roller assembly…4098
4.1.12.2 Replacement of the carrier roller assembly…4100
4.1.13 Track roller…4101
4.1.13.1 Removal of the Track roller assembly…4101
4.1.13.2 Replacement of the Track roller assembly…4103
4.2 Car body…4104
4.2.1 Removal of the car bodY (previous type with mounting pins)…4104
4.2.2 Replacement of the car bodY (previous type with mounting pins)…4108
4.2.3 Removal OF the car Body (NEW type with bolted connection)…4112
4.2.4 Replacement of the car body (NEW type with bolted connection)…4117
4.2.4.1 Tightening torque for the crawler carrier mounting bolts…4122
4.2.5 Rotary joint…4126
4.2.5.1 Removal of the rotary joint…4128
4.2.5.2 Replacement of the rotary joint…4131
4.2.6 swing circle…4132
4.2.6.1 Removal of the swing circle…4134
4.2.6.2 Replacement of the swing circle…4136
5 Attachment…4141
5.1 Backhoe…4142
5.1.1 Boom…4144
5.1.1.1 Removal of the Boom…4144
5.1.1.2 Replacement of the boom…4148
5.1.1.3 Removal of boom cylinders…4150
5.1.1.4 Replacement of boom cylinders…4155
5.1.2 Stick…4158
5.1.2.1 Removal of the Stick…4158
5.1.2.2 Replacement of Stick…4162
5.1.2.3 Removal of Stick Cylinders…4164
5.1.2.4 Replacement of Stick cylinders…4169
5.1.3 Bucket…4172
5.1.3.1 Removal of the bucket…4172
5.1.3.2 Replacement of the bucket…4175
5.1.3.3 Removal of Bucket Cylinders…4176
5.1.3.4 Replacement of Bucket Cylinders…4181
5.1.4 Bucket link rod and steering rods…4183
5.1.4.1 Removal of the bucket link rod…4183
5.1.4.2 Replacement of the bucket link rod…4185
5.1.4.3 Removal of the steering rods…4186
5.1.4.4 Replacement of the steering rods…4189
5.1.5 Ground engaging tools (GET)…4190
5.1.5.1 Removal and replacement of the GET…4190
5.1.6 Hydraulic hoses at the backhoe attachment…4192
5.1.6.1 Substitute the boom arc hoses…4192
5.1.6.2 Substitute the boom cylinder hoses…4196
5.1.6.3 Substitute the stick cylinder hoses…4200
5.1.6.4 Substitute the bucket cylinder hoses…4204
5.2 Faceshovel…4209
5.2.1 Boom…4210
5.2.1.1 Removal of the boom…4210
5.2.1.2 Replacement of the boom…4215
5.2.1.3 Removal of the boom cylinders…4220
5.2.1.4 Replacement of the boom cylinders…4225
5.2.2 Stick…4228
5.2.2.1 Removal of the stick…4228
5.2.2.2 Replacement of the stick…4232
5.2.2.3 Removal of the stick cylinders…4234
5.2.2.4 Replacement of the stick cylinders…4239
5.2.3 Bullclam bucket…4242
5.2.3.1 Removal of the bull clam bucket…4242
5.2.3.2 Replacement of the bull clam bucket…4248
5.2.3.3 Removal of the bucket cylinders…4250
5.2.3.4 Replacement of the bucket cylinders…4254
5.2.3.5 Removal of the clam cylinders…4258
5.2.3.6 Replacement of the clam cylinders…4262
5.2.4 Ground engaging tools (GET)…4264
5.2.4.1 Removal and replacement of the GET…4264
5.2.5 Hydraulic hoses at the Faceshovel attachment…4266
5.2.5.1 Substitute the boom arc hoses…4266
5.2.5.2 Substitute the boom cylinder hoses…4270
5.2.5.3 Substitute the stick arc hoses…4274
5.2.5.4 Substitute the stick cylinder hoses…4278
5.2.5.5 Substitute the bucket cylinder hoses…4282
5.2.5.6 Substitute the clam cylinder hoses…4286
5.3 Metering valves (grease injectors) at the attachment…4294
5.3.1 Removal of the metering valves (grease injectors)…4294
5.3.2 Replacement of the metering valves (grease injectors)…4295
5.4 Cylinder bypass test…4296
6 Appendix…4299
6.1 Fuel and Lubricants…4300
6.2 Filling Capacities…4302
6.3 Tools List…4304
6.3.1 Used special tools (Overview)…4304
6.3.2 KOMATSU tools catalogue…4307
6.4 Work instructions…4354
6.4.1 Remove / install the crawler carrier…4354
6.4.2 Use of the hydraulic torque wrench (supplier’s documentation)…4355
6.5 Service Bulletins…4383
6.5.1 AH00511d…4385
6.5.2 AH00514…4407
6.5.3 AH00519…4421
6.5.4 AH01512…4427
6.5.5 AH01521a…4437
6.5.6 AH01531A…4449
6.5.7 AH02513b…4461
6.5.8 AH02521…4467
6.5.9 AH03506B…4475
6.5.10 AH03509a…4483
6.5.11 AH03510…4511
6.5.12 AH03526a…4531
6.5.13 AH03538…4535
6.5.14 AH04518…4563
6.5.15 AH05510…4567
6.5.16 AH05511…4571
6.5.17 AH05546…4577
6.5.18 AH06524…4581
6.5.19 AH06530…4585
SMPC4000-8199 – Hydraulic Mining Shovel PC4000-6 Shop Manual…4589
1 Foreword…4591
1.1 Purpose of this THIS MANUAL…4592
1.2 Contents of thE Shop Manual…4593
1.2.1 Contacting the Service…4593
1.2.2 Guarantee…4593
1.3 DIVISION OF THE Shop Manual…4594
00_SAFETY.pdf…0
2 SAFETY…4597
2.1 SAFETY INFORMATION…4598
2.2 OVERVIEW…4599
2.2.1 NORMAL OPERATIONS…4599
2.2.2 REGULAR MAINTENANCE…4599
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR…4599
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR…4599
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB…4600
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR…4601
2.4.1 UNDERSTANDING THE MACHINE…4601
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR…4601
2.4.2.1 ENSURING SAFE OPERATION…4601
2.4.3 PREPARATIONS FOR SAFE OPERATION…4601
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT…4601
2.4.3.2 INSPECTING THE MACHINE…4601
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT…4602
2.4.3.4 KEEP MACHINE CLEAN…4602
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT…4602
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…4603
2.4.3.7 IF A PROBLEM IS FOUND…4603
2.4.4 FIRE PREVENTION…4603
2.4.4.1 PRECAUTIONS TO PREVENT FIRE…4603
2.4.4.2 ACTION IF FIRE OCCURS…4604
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…4605
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…4605
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…4605
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE…4605
2.4.5.3 NO PEOPLE ON THE ATTACHMENT…4605
2.4.5.4 WORKING IN HIGH PLACES…4605
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK…4606
2.4.5.6 LEAVING THE MACHINE…4606
2.4.6 BURN PREVENTION…4607
2.4.6.1 Hot coolant…4607
2.4.6.2 Hot oil…4607
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…4607
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4608
2.4.8.1 UNAUTHORIZED MODIFICATION…4608
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4608
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)…4609
2.4.10 PRECAUTIONS AT JOBSITE…4610
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT…4611
2.4.10.2 CAMERA SYSTEM WITH MONITORS…4611
2.4.10.3 ENSURE GOOD VISIBILITY…4611
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS…4611
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS…4612
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…4612
2.4.10.7 WORKING ON LOOSE GROUND…4613
2.4.10.8 GAS, DUST, STEAM AND SMOKE…4613
2.4.10.9 VENTILATION OF ENCLOSED AREAS…4614
2.4.11 STARTING ENGINE…4615
2.4.11.1 WARNING TAG…4615
2.4.11.2 CHECKS BEFORE STARTING ENGINE…4615
2.4.11.3 PRECAUTION WHEN STARTING ENGINE…4615
2.4.11.4 PRECAUTION IN COLD AREAS…4616
2.4.12 OPERATION…4616
2.4.12.1 CHECKS BEFORE OPERATION…4616
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE…4617
2.4.12.3 PRECAUTIONS WHEN travelling…4618
2.4.12.4 TRAVELLING ON SLOPES…4619
2.4.12.5 OPERATIONS ON SLOPES…4620
2.4.12.6 PROHIBITED OPERATIONS…4620
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES…4621
2.4.12.8 PARKING THE MACHINE…4621
2.4.12.9 TRANSPORTATION…4621
2.5 PRECAUTION FOR MAINTENANCE…4622
2.5.1 GENERAL PRECAUTIONS…4622
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…4623
2.5.1.2 STOP ENGINE FOR MAINTENANCE…4624
2.5.1.3 WARNING TAG…4625
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…4626
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS…4626
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING…4627
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…4627
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT…4628
2.5.1.9 NOISE…4628
2.5.1.10 WHEN USING A HAMMER…4628
2.5.1.11 PROPER TOOLS…4629
2.5.1.12 ACCUMULATOR…4629
2.5.1.13 PERSONNEL…4629
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4630
2.5.2.1 PRECAUTION WHEN WELDING…4630
2.5.2.2 BATTERY HANDLING…4630
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID…4631
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE…4631
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…4632
2.5.3.3 REPLACEMENT OF HOSE LINES…4632
2.5.3.4 INSPECTION OF HOSE LINES…4632
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…4633
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE…4633
2.5.3.7 AIR CONDITIONING MAINTENANCE…4633
2.5.3.8 COMPRESSED AIR…4634
2.5.3.9 WASTE MATERIALS…4634
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS…4635
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM…4635
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS…4635
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…4635
2.7 SPECIAL SAFETY EQUIPMENT…4636
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB…4637
2.7.2 OBJECT HANDLING…4637
2.7.3 LIGHTING…4637
2.7.4 WARNING BEACON…4637
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…4637
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…4637
2.7.5.2 INSTRUCTIONS FOR USE…4639
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL…4641
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),…4641
2.7.5.5 INSTRUCTIONS FOR USE…4643
START PAGE Safety 00.pdf…0
00 Safety…4595
01_SPECIFICATIONS.pdf…0
START PAGE Specifications 01.pdf…0
01 SPECIFICATION…4645
10_STRUCTURE, FUNCTION.pdf…0
I. INTRODUCTION…4667
I.I Contents of the Binder…4668
I.II Foreword…4669
SERVICE…4669
I.III RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS…4670
Operation…4670
Maintenance and repair…4670
I.IV Explanation of Abbrevations…4671
I.V Diagrams and Illustrations in this manual…4672
Wiring Diagrams & Hydraulic Diagrams…4672
Illustrations & technical drawings…4672
II. …4675
CONTENTS…4676
Overview…4677
NORMAL OPERATIONS…4677
REGULAR MAINTENANCE…4677
TROUBLESHOOTING, ADJUSTMENTS AND REPAIR…4677
ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR…4677
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR…4678
PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR…4678
ENSURING SAFE OPERATION…4678
UNDERSTANDING THE MACHINE…4678
PREPARATIONS FOR SAFE OPERATION…4678
PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT…4678
INSPECTING THE MACHINE…4678
WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT…4679
KEEP MACHINE CLEAN…4679
PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT…4679
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…4680
IF A PROBLEM IS FOUND…4680
FIRE PREVENTION…4680
ACTION IF FIRE OCCURS…4680
PRECAUTIONS TO PREVENT FIRE…4681
PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…4682
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…4682
NO JUMPING ON OR OFF THE MACHINE…4682
NO PEOPLE ON THE ATTACHMENT…4682
LEAVING OPERATOR’S SEAT WITH LOCK…4682
LEAVING THE MACHINE…4683
BURN PREVENTION…4683
PRECAUTIONS WHEN CLEANING CAB GLASS…4683
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4684
UNAUTHORIZED MODIFICATION…4684
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4684
PRECAUTIONS AT JOBSITE…4685
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS…4685
WORKING ON LOOSE GROUND…4685
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…4686
Camera System with Monitors…4689
CHECKING SIGNS AND SIGNALMAN’S SIGNALS…4689
GAS, DUST, STEAM AND SMOKE…4690
VENTILATION OF ENCLOSED AREAS…4690
EMERGENCY EXIT FROM OPERATOR’S CAB…4690
STARTING ENGINE…4691
WARNING TAG…4691
PRECAUTION WHEN STARTING ENGINE…4692
PRECAUTION IN COLD AREAS…4692
OPERATION…4692
CHECKS BEFORE OPERATION…4692
PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE…4693
PRECAUTIONS WHEN travelling…4694
TRAVELLING ON SLOPES…4694
OPERATIONS ON SLOPES…4695
PROHIBITED OPERATIONS…4696
TRAVELLING ON FROZEN OR SNOW COVERED SURFACES…4696
PARKING THE MACHINE…4697
TRANSPORTATION…4697
PRECAUTION FOR MAINTENANCE…4698
STOP ENGINE FOR MAINTENANCE…4699
WARNING TAG…4700
KEEP WORKPLACE CLEAN AND TIDY…4701
APPOINT LEADER WHEN WORKING WITH OTHERS…4701
TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING…4701
INSTALLING, REMOVING OR STORING ATTACHMENTS…4701
PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT…4702
NOISE…4702
WHEN USING A HAMMER…4702
PROPER TOOLS…4703
ACCUMULATOR…4703
PERSONNEL…4703
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4704
PRECAUTION WHEN WELDING…4704
BATTERY HANDLING…4704
PRECAUTIONS WITH HIGH PRESSURE OIL…4705
PRECAUTIONS WITH HIGH FUEL PRESSURE…4705
HANDLING HIGH PRESSURES HOSES OR PIPES…4705
REPLACEMENT OF HOSE LINES…4705
INSPECTION OF HOSE LINES…4706
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…4706
PRECAUTIONS FOR HIGH VOLTAGE…4708
SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…4708
WASTE MATERIALS…4708
AIR CONDITIONING MAINTENANCE…4709
COMPRESSED AIR…4709
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS…4710
INSPECTION OF THE HYDRAULIC SYSTEM…4710
TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS…4710
AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…4711
SPECIAL SAFETY EQUIPMENT…4712
FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB…4713
OBJECT HANDLING…4713
LIGHTING…4713
WARNING BEACON…4713
SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…4713
SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…4714
INSTRUCTIONS FOR USE…4717
PRIOR TO USING THE HARNESS (1), THE WEARER SHALL…4719
RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1),…4719
INSTRUCTIONS FOR USE…4721
III. SPECIFICATIONS…4723
III.I Lifting Gears…4724
III.II Safety hints for sling accessory…4726
III.III Standard Tightening Torque Chart…4727
III.IV Conversion Table…4728
III.V Blind plugs…4735
III.VI Classification of threads to the nominal width…4737
III.VII Plugs and fittings according to ISO 8434-1 / DIN 2353…4738
1. MAIN ASSEMBLY GROUPS…4741
1.1 General Layout…4742
1.2 Superstructure…4744
1.3 Machine House…4746
1.4 Hydraulic Oil tank…4748
1.5 Hydraulic Oil Cooler…4750
1.6 Fuel Tank…4752
1.7 Counterweight…4754
1.8 Cab Support…4756
1.9 Operator’s Cab…4758
1.10 Control Blocks…4760
1.11 Swing machinery…4762
1.11.1 Swing Machinery L&S…4762
1.11.2 Swing Machinery SIEBENHAAR…4764
1.12 Undercarriage…4766
1.13 Backhoe Attachment (BHA)…4768
1.14 Front Shovel Attachment (FSA)…4770
2. DRIVE…4773
2.1 Prime Drive Assembly…4774
2.2 Engine and PTO Mounts…4776
2.2.1 engine Mounts…4777
2.2.2 Torque Support…4778
2.3 Geislinger Coupling…4780
2.4 Fan Drive and Radiator Assembly…4782
2.4.1 Radiator Fan Drive Speed Adjustment…4786
2.5 Pump Distributor Gearbox (PTO)…4790
2.5.1 Pump Drive Shaft Housing…4792
2.5.2 PTO Lubrication and Cooling…4794
2.5.3 Hydraulic Pumps – Location, Drive Speed and Flow Rates…4798
2.6 Air Filter…4800
3. HYDRAULIC OIL TANK…4803
3.1 General Layout…4804
3.2 Hydraulic Oil Tank, Location of the Electric Equipment…4806
3.3 Suction Oil Tank with Strainers…4808
3.4 Return Oil Collector Pipe with Strainer…4810
3.5 Back Pressure Valve…4812
3.6 Transfer Pump for hydraulic oil…4814
3.7 Return and Leak Oil Filter…4816
3.8 Breather Filter…4818
4. HYDRAULIC OIL COOLING…4821
4.1 Overall view of the hydraulic oil cooling…4822
4.2 Function of the Hydraulic Oil Cooling Circuit…4824
4.3 Adjustment of the Back Pressure Valve…4826
4.4 Fan Drive (Two Stage Cooler Fan RPM Control)…4828
4.4.1 Fixed Displacement Pump, with Variable Setting…4830
4.4.2 Pressure Relief Valve…4832
4.4.3 Solenoid Valve…4834
4.5 Adjustment of the Cooler Fan Drive Speed…4836
4.5.1 Maximum speed…4836
4.5.2 Medium speed…4839
4.5.3 Function Check of Fan Speed Control…4840
5. CONTROLLING…4843
5.1 General layout…4844
5.2 Valve cartridge block…4846
5.3 Pilot pressure supply and adjustments…4852
5.3.1 Pilot pressure control (PPC) circuit…4853
5.3.2 Checks and adjustment of pilot pressure…4856
5.3.3 Remote control valves arrangement…4858
5.4 Function of the electro hydraulic control system…4860
5.5 Hand lever (joystick) control…4864
5.6 Foot pedal control…4866
5.7 Proportional amplifier module, type A…4868
5.8 Proportional amplifier module, type B…4870
5.9 Ramp time module…4872
5.10 Adjustments of amplifier modules…4874
5.10.1 General…4875
5.10.2 Adjusting the amplifiers type A…4876
5.10.3 Adjusting the amplifiers type B…4878
5.11 Adjusting the ramp time modul…4880
6. COMPONENTS…4885
6.1 Main control blocks and high pressure filter (FSA)…4886
6.2 Main control blocks and high pressure filter (BHA)…4888
6.3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA)…4890
6.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA)…4892
6.5 Single control blocks (floating) for stick and boom (FSA)…4894
6.6 Restrictor block with pressure relief valve…4896
6.7 Anti cavitation valve block…4898
6.8 Remote control valves…4900
6.9 4/3 Directional solenoid valves…4902
6.10 Proportional solenoid valves…4904
6.11 High pressure filter…4906
6.12 Control blocks and valves…4908
6.13 Travel brake valve…4920
6.14 Pressure reducing valve…4922
6.15 4/2 Directional solenoid valves…4924
6.16 Pressure double stage valve…4926
6.17 Hydraulic cylinder…4928
6.18 Slew ring…4932
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION…4935
7.1 General…4936
7.2 Main pumps…4944
7.2.1 Location of pumps…4945
7.2.2 Pump bearing flushing / lubrication…4946
7.2.3 Operating principle…4948
7.2.4 Checks / adjustments…4964
7.3 Electronic Pump Regulation System…4972
7.3.1 Electronic Load Limiting Control – General…4973
7.3.2 Microcontroller RC4-4…4975
7.3.3 Checks and adjustments…4977
7.4 Hydraulic Constant Regulation System…4984
7.4.1 General…4985
7.4.2 X1 Pressure adjustment (constant pressure)…4986
7.5 Determination of the peak point (engine performance)…4988
7.6 Engine speed sensor (pick-up)…4990
7.6.1 General…4991
7.6.2 Engine speed sensor (pick-up) adjustment…4991
7.7 Energy Efficiency…4992
7.7.1 General…4993
7.7.2 Checks and adjustments…4994
8. OPERATING HYDRAULICS…4999
8.1 General…5000
8.1.1 Floating system…5002
8.2 Hydraulics for the attachment cylinder FSA and BHA…5004
8.2.1 Electric / hydraulic flowchart "boom raise" FSA…5004
8.2.2 Electric / hydraulic flowchart "boom raise" BHA…5006
8.2.3 Electric / hydraulic flowchart "boom lowering" FSA…5008
8.2.4 Electric / hydraulic flowchart "boom lowering" BHA…5010
8.2.5 Electric / hydraulic flowchart "stick extend" FSA…5012
8.2.6 Electric / hydraulic flowchart "stick extend" BHA…5014
8.2.7 Electric / hydraulic flowchart "stick retract" FSA…5016
8.2.8 Electric / hydraulic flowchart "stick retract" BHA…5018
8.2.9 Electric / hydraulic flowchart "bucket curl" FSA…5020
8.2.10 Electric / hydraulic flowchart "bucket curl" BHA…5022
8.2.11 Electric / hydraulic flowchart "bucket dump" FSA…5024
8.2.12 Electric / hydraulic flowchart "bucket dump" BHA…5026
8.2.13 Electric / hydraulic flowchart "clam Open" FSA…5028
8.2.14 Electric / hydraulic flowchart "clam close" FSA…5030
8.2.15 Checks and adjustments of the main relief valves (FSA)…5032
8.2.16 Checks and adjustments of the main relief valves (BHA)…5034
8.2.17 Checks and adjustments of the secondary relief valves (SRV)…5036
8.2.17.1 Boom cylinder "Piston Side" FSA + BHA…5037
8.2.17.2 Boom Cylinder "Piston Rod Side" FSA +BHA…5041
8.2.17.3 Stick Cylinder "Piston Side" FSA…5045
8.2.17.4 Stick Cylinder "Piston Side" BHA…5049
8.2.18 Stick cylinder "piston rod side" FSA…5053
8.2.18.1 Stick Cylinder "Piston Rod Side" BHA…5057
8.2.18.2 Bucket Cylinder "Piston Side" FSA…5061
8.2.18.3 Bucket Cylinder "Piston Side" BHA…5065
8.2.18.4 Bucket Cylinder "Piston Rod Side" FSA…5069
8.2.18.5 Bucket Cylinder "Piston Rod Side" BHA…5073
8.2.18.6 Clam Cylinder "Piston Rod Side" FSA…5077
8.2.18.7 Clam Cylinder "Piston Side" FSA…5079
8.2.18.8 Checks and Adjustments of the Lowering Speed…5081
8.3 Hydraulics for the swing circuit…5100
8.3.1 Swing circuit…5100
8.3.2 Swing motor…5104
8.3.3 Swing gearbox (L & S)…5106
8.3.4 Swing gearbox (Siebenhaar)…5108
8.3.5 Slew parking brake (L & S)…5110
8.3.6 Slew parking brake (Siebenhaar)…5112
8.3.7 Swing brake valve…5114
8.3.8 Electric / hydraulic flowchart "swing left"…5116
8.3.9 Electric / hydraulic flowchart "swing right"…5118
8.3.10 Checks and adjustments for the swing circuit…5120
8.3.11 Function check for the hydraulic swing brake…5126
8.3.12 Function check for the slew parking brake…5128
8.4 Hydraulics for the travel circuit…5130
8.4.1 Travel circuit…5130
8.4.2 Travel motor…5134
8.4.3 Rotary joint…5136
8.4.4 Travel gearbox (L & S)…5138
8.4.5 Travel gearbox (Zollern)…5140
8.4.6 Travel parking brake (gear house brake)…5142
8.4.7 Travel brake valve…5144
8.4.8 Electric / hydraulic flowchart “travel forward”…5146
8.4.9 Electric / hydraulic flowchart “travel backwards”…5148
8.4.10 Checks and adjustments for the travel circuit…5150
8.4.11 Function check for the travel parking brake…5152
9. HYDRAULIC TRACK TENSIONING SYSTEM…5155
9.1 General…5156
9.2 Functional description…5158
9.3 Pressure double stage valve…5160
9.4 Tensioning cylinder…5162
9.5 Adjustments / checks…5164
10. ACCESS LADDER, HYDRAULICALLY OPERATED…5167
10.1 General…5168
10.2 Function of Hydraulically Operated Access Ladder…5170
10.3 Adjustments / Checks…5174
11. CENTRAL REFILLING SYSTEM (SERVICE ARM)…5177
11.1 General…5178
11.2 Function…5180
12. HINTS FOR READING THE HYDRAULIC DIAGRAM…5183
12.1 General…5184
12.2 Hydraulic symbols…5186
12.2.1 Lines, unions…5187
12.2.2 Components, valves…5189
12.2.3 Sensors…5189
12.2.4 Valves, valve components…5190
12.2.5 Pump, motor, cylinder…5194
13. HINTS FOR READING THE ELECTRIC WIRING DIAGRAM…5199
13.1 General…5200
13.2 Reference designation of the electrical components…5201
13.2.1 Area code…5201
13.2.2 Component identifying letter…5203
13.3 Graphical symbols…5204
13.4 Drawing concept…5208
13.5 Cable marking…5218
13.6 Table of new and old component designations…5219
14. VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM…5255
14.1 General…5256
14.2 Specifications for Operators…5258
14.2.1 Sequence of Displays…5259
14.2.2 Opening Screen…5259
14.2.3 Main Gauge Screens 1 to 3…5260
14.2.4 Fuel Consumption Screen…5265
14.2.5 Failure message Screen for the Operator…5267
14.2.6 Main Gauge Screens – Changing of Time / SMR / Date…5269
14.2.7 Maintenance Monitor…5270
14.2.8 Settings for Operators…5272
14.2.9 Automatic Messages…5280
14.2.10 Tables of all Messages provided by the System…5283
14.2.10.1 Table of G-Codes…5284
14.2.10.2 Table of C-Codes – Diesel engines with emission standard TIER 2…5293
14.2.10.3 Table of C-Codes – Diesel engines with emission standard TIER 1…5300
14.2.10.4 Table of available Instruction Messages…5306
14.3 Flow Charts (1-4) VHMS Main Screens…5309
14.4 VHMS Service Level…5313
14.4.1 Explanation of the Button Symbols (Service Level)…5314
14.4.2 Service Menu Select Screen…5315
14.4.3 Real Time Menu Select Screen…5316
14.4.3.1 Real Time Menu, option: 01 Engine 1…5316
14.4.3.2 Real Time Menu, option: 02 PTO 1…5317
14.4.3.3 Real Time Menu, option: 03 Hydraulic…5318
14.4.3.4 Real Time Menu, option: 04 Slew…5319
14.4.3.5 Real Time Menu, option: 05 Electrical Equipment…5319
14.4.3.6 Real Time Menu, option: 06 Emergency Stop…5319
14.4.3.7 Real Time Menu, option: 07 Manual Switch…5320
14.4.3.8 Real Time Menu, option: 08 Central lUBE System 1…5321
14.4.3.9 Real Time Menu, option: 09 Slew Ring Gear Lube System…5321
14.4.3.10 Real Time Menu, option: 10 Windscreen Wiper…5322
14.4.3.11 Real Time Menu, option: 11 lADDER…5322
14.4.3.12 Real Time Menu, option: 12 Service Arm…5323
14.4.3.13 Real Time Menu, option: 13 Pilot Control…5324
14.4.3.14 Real Time Menu, option: 14 oTHER ITEMS…5325
14.4.3.15 Real Time Menu, option: 15 Output Signals…5326
14.4.3.16 Output Signals with deactivated MTC- Evaluation…5331
14.4.4 PM-Clinic…5332
14.4.4.1 General…5332
14.4.4.2 Power Check…5333
14.4.5 Serial/GCC No. Setting…5334
14.4.6 Memory Clear…5335
14.4.6.1 Input Memory Clear ID…5335
14.4.6.2 Memory Clear Screen…5336
14.4.7 Failure History…5337
14.4.8 Maintenance Monitor…5338
14.4.9 Snapshot…5339
14.4.10 Settings…5340
14.4.10.1 Central Lubrication System (CLS 1), screen 1/8…5340
14.4.10.2 Swing Lubrication System (SLS), screen 2/8…5341
14.4.10.3 Qmin – Qmax – Setting, screen 3/8…5342
14.4.10.4 Other Settings 1/2, screen 4/8…5342
14.4.10.5 Other Settings 2/2, screen 5/8…5344
14.4.10.6 Shutdown Bypass ON/OFF…5346
14.5 Interface-Connection VHMS-Controller…5348
14.5.1 VHMS-Controller…5349
14.6 Wiring of the VHMS-Controller…5350
14.7 Global Layout of the MTC Control System…5354
14.7.1 MTC (Master Turbo Controller)…5356
14.7.1.1 MTC-Flowchart…5356
14.7.1.2 MTC Features…5356
14.7.1.3 MTC-Firmware and Software…5357
14.7.1.4 View onto the MTC unit and its Connectors…5358
14.8 Global Layout of the Internal CAN bus…5360
14.8.1 General Information about a CAN bus System…5360
14.8.1.1 General CAN bus description…5361
14.8.1.2 CAN bus troubleshooting…5361
14.8.1.3 Can bus wiring…5362
14.8.1.4 CAN bus End Resistor…5364
14.9 The Nodes in the CAN bus System…5366
14.9.1 Global Layout…5366
14.9.2 Introduction…5367
14.9.2.1 ICN-V Features…5368
14.9.2.2 ICN-D Features…5369
14.9.3 Node DIP-Switches…5370
14.9.4 Node Box…5371
14.9.5 Node Locations on the Machine…5372
14.9.5.1 Node & Location Chart…5373
14.9.5.2 Exemplary View onto Location 11 (Cab base)…5374
15. AUTOMATIC LUBRICATION SYSTEMS…5377
15.1 General Overview CLS & SLS…5378
15.1.1 General Description…5379
15.2 Basic Function of the Lubrication Systems…5380
15.3 Central Lubrication System (CLS)…5382
15.3.1 General Information on CLS…5384
15.4 Lubrication Pump Station (SLS)…5386
15.4.1 General Information on SLS…5388
15.5 Lubrication Cycle…5389
15.5.1 Operation and Control…5389
15.5.2 Lubrication Cycle – Components…5390
15.5.3 Lubrication Cycle – Processing…5392
15.5.4 Time Segments & Switch Points of a Lubrication Cycle…5393
15.5.5 Lubrication Modes…5394
15.5.5.1 Automatic Lubrication Mode…5394
15.5.5.2 Manual Lubrication Mode…5394
15.5.5.3 VHMS Service Mode…5394
15.6 Hydraulically Driven Lube Pump…5396
15.6.1 Adjustment of Lube Pump Speed & Working Pressure…5398
15.6.1.1 Stroke Speed Adjustment…5399
15.6.1.2 Working Pressure Adjustment…5399
15.7 Lubricant Injectors…5400
15.7.1 Tightening torque for fittings at the grease incetors…5401
15.7.2 Description…5401
15.7.3 Adjustment of the Lubricant Output…5401
15.7.4 Operation Principle of Lubricant Injectors…5402
15.7.4.1 Function Description…5404
15.7.5 Connection of one or more Injectors…5405
15.8 Vent Valve…5406
15.8.1 Description…5407
15.9 End-Line Switch…5408
15.9.1 Description…5409
15.9.2 CLS End-Line Switch Adjustment…5410
15.9.3 SLS End-Line Switch Adjustment…5412
15.10 In-Line Filter…5414
15.10.1 Description…5415
15.10.2 Maintenance procedure…5415
15.11 Lubricant Level Sensor…5416
15.11.1 Description…5417
15.11.1.1 LEDs at the sonar sensor…5417
15.12 Lubrication Pinion (SLS)…5420
15.12.1 Description…5421
15.13 Commissioning…5422
15.13.1 COMMISSIONING OF THE CLS Lubrication SYSTEM…5422
15.13.2 Fine Adjustment…5423
15.13.3 COMMISSIONING OF THE SLS Lubrication SYSTEM…5424
START PAGE Structure_Function 10.pdf…0
10 STRUCTURE, FUNCTION…4655
40_TROUBLESHOOTING.pdf…0
1 SAFETY…5443
1.1 SAFETY INFORMATION…5444
1.2 OVERVIEW…5445
1.2.1 NORMAL OPERATIONS…5445
1.2.2 REGULAR MAINTENANCE…5445
1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR…5445
1.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR…5445
1.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB…5446
1.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR…5447
1.4.1 UNDERSTANDING THE MACHINE…5447
1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR…5447
1.4.2.1 ENSURING SAFE OPERATION…5447
1.4.3 PREPARATIONS FOR SAFE OPERATION…5447
1.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT…5447
1.4.3.2 INSPECTING THE MACHINE…5447
1.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT…5448
1.4.3.4 KEEP MACHINE CLEAN…5448
1.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT…5448
1.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…5449
1.4.3.7 IF A PROBLEM IS FOUND…5449
1.4.4 FIRE PREVENTION…5449
1.4.4.1 PRECAUTIONS TO PREVENT FIRE…5449
1.4.4.2 ACTION IF FIRE OCCURS…5450
1.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…5451
1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…5451
1.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…5451
1.4.5.2 NO JUMPING ON OR OFF THE MACHINE…5451
1.4.5.3 NO PEOPLE ON THE ATTACHMENT…5451
1.4.5.4 WORKING IN HIGH PLACES…5451
1.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK…5452
1.4.5.6 LEAVING THE MACHINE…5452
1.4.6 BURN PREVENTION…5453
1.4.6.1 Hot coolant…5453
1.4.6.2 Hot oil…5453
1.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…5453
1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…5454
1.4.8.1 UNAUTHORIZED MODIFICATION…5454
1.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…5454
1.4.9 PRECAUTIONS AT JOBSITE…5455
1.4.9.1 VISIBILITY FROM OPERATOR’S SEAT…5456
1.4.9.2 CAMERA SYSTEM WITH MONITORS…5456
1.4.9.3 ENSURE GOOD VISIBILITY…5456
1.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS…5456
1.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS…5457
1.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…5457
1.4.9.7 WORKING ON LOOSE GROUND…5458
1.4.9.8 GAS, DUST, STEAM AND SMOKE…5458
1.4.9.9 VENTILATION OF ENCLOSED AREAS…5459
1.4.10 STARTING ENGINE…5460
1.4.10.1 WARNING TAG…5460
1.4.10.2 CHECKS BEFORE STARTING ENGINE…5460
1.4.10.3 PRECAUTION WHEN STARTING ENGINE…5460
1.4.10.4 PRECAUTION IN COLD AREAS…5461
1.4.11 OPERATION…5461
1.4.11.1 CHECKS BEFORE OPERATION…5461
1.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE…5462
1.4.11.3 PRECAUTIONS WHEN travelling…5463
1.4.11.4 TRAVELLING ON SLOPES…5464
1.4.11.5 OPERATIONS ON SLOPES…5465
1.4.11.6 PROHIBITED OPERATIONS…5465
1.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES…5466
1.4.11.8 PARKING THE MACHINE…5466
1.4.11.9 TRANSPORTATION…5466
1.5 PRECAUTION FOR MAINTENANCE…5467
1.5.1 GENERAL PRECAUTIONS…5467
1.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…5468
1.5.1.2 STOP ENGINE FOR MAINTENANCE…5469
1.5.1.3 WARNING TAG…5470
1.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…5471
1.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS…5471
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING…5472
1.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…5472
1.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT…5473
1.5.1.9 NOISE…5473
1.5.1.10 WHEN USING A HAMMER…5473
1.5.1.11 PROPER TOOLS…5474
1.5.1.12 ACCUMULATOR…5474
1.5.1.13 PERSONNEL…5474
1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…5475
1.5.2.1 PRECAUTION WHEN WELDING…5475
1.5.2.2 BATTERY HANDLING…5475
1.5.3 PRECAUTIONS WITH HIGH PRESSURE Fluid…5476
1.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE…5476
1.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…5477
1.5.3.3 REPLACEMENT OF HOSE LINES…5477
1.5.3.4 INSPECTION OF HOSE LINES…5477
1.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…5478
1.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE…5478
1.5.3.7 AIR CONDITIONING MAINTENANCE…5478
1.5.3.8 COMPRESSED AIR…5479
1.5.3.9 WASTE MATERIALS…5479
1.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS…5480
1.6.1 INSPECTION OF THE HYDRAULIC SYSTEM…5480
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS…5480
1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…5480
1.7 SPECIAL SAFETY EQUIPMENT…5481
1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB…5482
1.7.2 OBJECT HANDLING…5482
1.7.3 LIGHTING…5482
1.7.4 WARNING BEACON…5482
1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…5482
1.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…5482
1.7.5.2 INSTRUCTIONS FOR USE…5484
1.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL…5486
1.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1)…5486
1.7.5.5 INSTRUCTIONS FOR USE…5488
2 Introduction & General Information for Troubleshooting…5489
2.1 Overview…5490
2.1.1 General advice when using troubleshooting charts…5490
2.2 General Precautions…5491
2.3 Preparations For Work…5492
2.4 Precautions During Work…5492
2.5 Precautions When Carrying Out Any Operation…5493
2.5.1 Precautions when carrying out removal work…5493
2.5.2 Precautions when carrying out installation work…5493
2.5.3 Precautions when completing the operation…5494
2.6 Fundamental Requirements for Troubleshooting…5495
2.6.1 Technical documentation…5495
2.6.2 Tools…5495
2.6.2.1 Reference Guide for Deutsch Removal Tools…5498
2.6.3 Personnel…5499
2.7 Points To Remember When Troubleshooting…5499
2.8 Sequence Of Events In Troubleshooting…5501
2.9 Checks Before Troubleshooting…5502
2.10 Handling Of Electric Equipment And Hydraulic Components…5503
2.10.1 Points to remember when handling electric equipment…5503
2.10.2 Points To Remember When Handling Hydraulic Equipment…5505
2.11 General working procedures…5508
2.11.1 Air Bleeding of Various Hydraulic Parts…5508
2.11.2 Air bleeding from the hydraulic pumps…5508
2.11.3 Air bleeding from hydraulic cylinders…5508
2.12 Cylinder bypass test…5509
2.13 Information about MTC & Nodes…5510
2.13.1 Outline of the MTC and its connector locations…5510
2.13.1.1 View onto the MTC connectors* LH & RH…5510
2.13.1.2 General description of the MTC…5510
2.13.1.3 Information about the LED indications at the MTC…5511
2.13.2 Information about the ICN-D node…5511
2.13.2.1 View onto an ICN-D node without wiring…5512
2.13.2.2 View onto the Status LEDs at the ICN-D node…5513
2.13.2.3 General information on the LED control…5513
2.13.3 Information about the ICN-V node…5515
2.13.3.1 View onto an ICN-V node…5515
2.13.3.2 View onto an open ICN-V node and its DIP-switches…5516
2.13.4 DIP switches at the ICN-D and ICN-V nodes…5517
2.14 Basics about "How to crimp"…5518
2.14.1 Stripping a wire for use with the HDT 48 crimp tool…5518
2.14.2 View onto the Deutsch crimp tool HDT 48…5518
2.14.3 Adjustment of the wire size at the Deutsch crimp tool HDT 48…5519
2.14.3.1 Wire cross section units in mm2 and AWG…5519
2.14.4 Crimping instructions (for Deutsch crimp tool HDT 48)…5520
2.15 Cable Shielding…5521
3 Mounting Locations and Connector Types…5523
3.1 Component location…5524
3.1.1 View onto the Superstructure…5524
3.1.2 Location of Engine Electrical Parts (1)…5526
3.1.3 Location of Engine Electrical Parts (2)…5528
3.1.4 Location of Hydraulic Components (1)…5529
3.1.5 Location of Hydraulic Components (2)…5531
3.1.6 Location of the Remote Control Valves…5532
3.1.7 Location of the High Pressure Sensors…5534
3.1.8 View onto the SLS and CLS Grease Barrel and the Lubrication Cycle Components…5535
3.1.9 View onto the Electrical Components in the Cab Base…5537
3.1.10 Hydraulic Oil Tank – Location of Electrical Components…5539
3.1.11 Hydraulically Operated Access Ladder…5541
3.2 Connector Types Overview…5543
4 Standard Value Table for Electrical Components…5549
5 References for Troubleshooting (CAN Bus & Node Outputs)…5561
5.1 CAN-Bus trouble or Node Output Trouble…5562
5.1.1 Trouble CAN-BUS or CAN-Hardware (G00308)…5563
5.1.2 Trouble output short-circuit (G00043)…5564
5.2 Sequence of the CAN nodes at the CAN bus…5566
5.3 Troubleshooting for Relay Monitored Node Outputs…5567
5.3.1 Relay Check…5567
G00107 – Trouble slew parking brake control 56K250a…5568
G00109 – Trouble slew parking brake control 56K250b…5568
View onto the CoDeSys HMI Visualization screen for trouble code G00107…5570
Wiring Diagram (56K250a & 56K250b) for trouble code G00107…5571
5.3.2 Output Check…5572
G00108 – Trouble slew parking brake control Output to 56K250a…5573
G00110 – Trouble slew parking brake control Output to 56K250b…5573
View onto the CoDeSys HMI Visualization screen for trouble code G00108…5575
Wiring Diagram (56K250a & 56K250b) for trouble code G00108…5576
6 Tables for Testing and Troubleshooting…5579
6.1 Index of Tables in this section…5580
6.2 Test Value Table for Temperature Sensors (PT100) g Centigrade – Volt…5581
6.3 Test Value Table for Temperature Sensors (PT100) g Centigrade – Ohm…5582
6.4 Table of Trouble Codes (G-Codes)…5583
6.5 Table of Instruction Messages…5589
6.6 Table of Binary Codes…5592
6.6.1 Table of Add-On Binary Codes for G00308…5594
6.7 Binary Output Signals on the VHMS Monitor…5595
6.8 Power Supply…5597
6.9 Cable colour identification…5598
7 Troubleshooting by Trouble Code…5599
G00001 – Trouble Shut-Off (gate) valve…5600
View onto the gap of proximity switch 40B031…5602
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR…5603
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor…5603
Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open)…5604
G00002 – Test speed 1800 1/min engine 1…5605
Wiring Diagram (11S041-1) for trouble code G00002…5606
G00003 – Trouble pump controller…5607
G00005 – Low hydraulic oil level…5611
Wiring Diagram, oil level label, and defined position of the attachment (G00005)…5613
G00007 – Trouble hydraulic oil level…5614
Wiring Diagram (40B004) and the defined position of the attachment (G00007)…5615
G00012 – Central lubrication system grease level too low…5616
G00013 – Slew ring gear lubr. system grease level too low…5616
Wiring Diagram (62B108 & 62B109) for trouble codes G00012 & G00013…5620
Wiring Diagram (junction box) for trouble codes G00012 & G00013…5621
G00020 – Trouble Shut-Off (gate) valve (Start blocked)…5622
View onto the gap of proximity switch 40B031 (G00020)…5624
Wiring Diagram (40B031) for trouble code G00020 (Main gate valve closed)…5625
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR…5626
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor…5626
G00031 – Set engine to low idle…5627
Wiring Diagram (20S030) for trouble code G00031…5628
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR…5628
G00032 – Trouble starter…5629
Wiring Diagram (Cold Start Signal) for trouble code G00032…5630
Wiring Diagram ("Engine running" signal) for trouble code G00032…5631
G00033 – Trouble VHMS-Controller…5632
G00034 – Trouble VHMS-Display…5633
G00035 – Trouble totally loss gear oil (PTO 1)…5634
View onto the location of sensor 57B175-1 at the PTO (G00035)…5636
Input signal (analog) of the PTO 1 gear oil sensor 57B175-1 on the REAL TIME MONITOR…5637
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor…5637
Wiring Diagram (57B175-1) for trouble code G00035…5638
G00039 – Actuate engine speed selector switch…5639
G00043 – Trouble output short-circuit…5640
G00048 – Trouble emergency safety circuit…5641
Wiring Diagram (11K044a) for trouble code G00048…5641
G00053 – Reset emergency safety circuit…5642
G00054 – Monitoring idle position cut off…5643
Wiring Diagram (11K032) for trouble code G00054…5644
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054)…5645
Exemplary view onto the VHMS Failure History (G00054)…5645
G00060 – Fire in the power house…5646
Wiring Diagram (fire alarm) for trouble code G00060…5648
Wiring Diagram (10B351 in the safety circuit) for G00060…5649
G00061 – Trouble monitoring, engine 1 speed too low…5650
Input signal (analog) of 51K003b-1 on the REAL TIME MONITOR (G00061)…5651
Wrong signal of the engine speed converter on the REAL TIME MONITOR (G00061)…5652
Wiring Diagram (engine speed) for trouble code G00061…5652
G00062 – Trouble monitoring, engine 1 speed too high…5653
Wiring Diagram (engine speed) for trouble code G00062…5654
G00063 – Trouble monitoring hydraulic oil temp…5655
Wiring Diagram (59B015) for trouble code G00063…5656
G00064 – Trouble monitoring hydraulic oil level…5657
Wiring Diagram (40B004) for trouble code G00064…5659
G00065 – Very low hydraulic oil level…5660
View onto the hydraulic oil level label…5660
G00066 – Trouble hydraulic oil temperature…5661
Wiring Diagram (57K506a-1 / 57K506b-1) and location for G00066…5663
Hydraulic oil temperature table…5663
G00067 – Trouble battery voltage too high…5664
Wiring Diagram (11T080) and component location for G00067…5665
G00067 – Input signal of 11T080 on the REAL TIME MONITOR…5665
G00069 – Trouble monitoring oil temperature gear (PTO 1)…5666
Input of 57B049-1 on the REAL TIME MONITOR (G00069)…5667
Gear oil temperature (PTO 1) on the Main Gauge Screen (G00069)…5667
Wiring Diagram (57B049-1) and component location for G00069…5668
G00070 – Trouble oil temperature gear (PTO 1)…5669
Location of the PTO 1 gear oil level dipstick and temperature sensor 57B049-1…5671
G00071 – Trouble gear lubrication (PTO 1)…5672
Wiring Diagram (57B017-1) for trouble code G00071…5673
G00081 – Trouble lubrication system…5674
Operation cycles of the lubrication systems…5676
Wiring Diagram (11K050) for trouble code G00081…5677
Wiring Diagram (pilot control slew & stick) for trouble code G00081…5678
G00086 – SHUTDOWN…5679
G00087 – Stop all movements for low idle…5680
G00090 – Trouble power supply…5681
G00099 – Trouble power supply…5681
Wiring Diagram (stabilized power supply) for G00090 & G00099…5682
G00091 – Pilot control cut out…5683
View onto the lock lever and the cover of 20S105 (G00091)…5684
G00092 – Emergency shut-down at access ladder…5685
G00093 – Emergency shut-down at valve block…5685
G00094 – Emergency shut-down at hydraulic control panel…5685
G00095 – Emergency shut-down in cabin…5685
Wiring Diagram (emergency switches) for G00092~G00095…5686
G00096 – Pilot control cut out…5687
Wiring Diagram (20S094) for trouble code G00096…5688
G00100 – Maintenance Safety Switch…5689
Wiring Diagram (50S058) for trouble code G00100…5690
G00102 – Switch off wiper [S/N 08199 only]…5691
G00103 – Faulty switch 20M004 [S/N 08199 only]…5692
Wiring Diagram 1 (wiper) for trouble code G00103 [S/N 08199 only]…5694
Wiring Diagram 2 (wiper) for trouble code G00103 [S/N 08199 only]…5695
G00104 – Trouble battery current…5696
Wiring Diagram (battery current) for trouble code G00104…5698
G00105 – Trouble battery charging current too low…5699
Wiring Diagram (11T080) for trouble code G00105…5700
G00107 – Trouble slew parking brake control 56K250a…5701
G00109 – Trouble slew parking brake control 56K250b…5701
View onto the CoDeSys HMI Visualization screen for trouble code G00107…5703
Wiring Diagram (56K250a & 56K250b) for trouble code G00107…5704
G00108 – Trouble slew parking brake control Output to 56K250a…5705
G00110 – Trouble slew parking brake control Output to 56K250b…5705
View onto the CoDeSys HMI Visualization screen for trouble code G00108…5707
Wiring Diagram (56K250a & 56K250b) for trouble code G00108…5708
G00111 – Trouble travel parking brake control 56K251a…5709
G00113 – Trouble travel parking brake control 56K251b…5709
G00112 – Trouble travel parking brake control Output to 56K251a…5710
G00114 – Trouble travel parking brake control Output to 56K251b…5710
G00115 – Trouble slew hydraulic brake control 56K252a…5711
G00117 – Trouble slew hydraulic brake control 56K252b…5711
G00116 – Trouble slew hydraulic brake control Output to 56K252a…5712
G00118 – Trouble slew hydraulic brake control Output to 56K252b…5712
G00140 – Trouble monitoring X1-1 pressure…5713
Wiring Diagram (57B085-1) for trouble code G00140…5715
G00141 – Trouble monitoring X2 pressure…5716
Wiring Diagram (57B086) for trouble code G00141…5718
G00147 – Trouble monitoring gear lubrication (PTO 1)…5719
Wiring Diagram (57B017-1) for trouble code G00147…5721
G00148 – Trouble monitoring fuel level…5722
Wiring Diagram (31B063) and component location for G00148…5724
G00151 – Trouble monitoring gear (PTO) oil filter 1…5725
Wiring Diagram (57B027-1) and component location for trouble code G00151…5727
G00154 – Trouble monitoring return oil filter…5728
Wiring Diagram (40B163) for trouble code G00154…5730
G00155 – Trouble monitoring leak oil filter…5731
Wiring Diagram (40B164) for trouble code G00155…5733
G00159 – Trouble monitoring breather filter…5734
Wiring Diagram (40B024) for trouble code G00159…5736
G00160 – Trouble monitoring engine air cleaner 1…5737
Wiring diagram (52B018-1 & 52B019-1) for trouble code G00160…5739
G00161 – Trouble monitoring battery voltage…5740
Wiring Diagram (11T080) for trouble code G00161…5742
G00162 – Trouble monitoring charging-/discharging current…5743
Wiring Diagram (battery charging current) for trouble code G00162…5745
G00164 – Trouble air cleaner 1…5746
View onto the engine air cleaner (G00164)…5747
G00165 – Trouble breather filter hydraulic oil tank…5748
Label showing temperature information and defined positions (G00165)…5749
G00166 – Trouble oil filter gear (PTO 1)…5750
View onto the PTO 1 gear oil filter with pressure sensor 57B027-1 (G00166)…5751
G00169 – Trouble return oil filter hydraulic oil tank…5752
G00170 – Trouble leak oil filter hydraulic oil tank…5753
G00176 – Trouble battery voltage too low…5754
Wiring Diagram (batteries) for trouble code G00176…5756
G00177 – Trouble battery charging circuit…5757
Wiring Diagram (measuring points 1-4) for trouble code G00177…5758
G00178 – Trouble battery charging current too high…5759
Wiring Diagram (51T017) for trouble code G00178…5760
G00179 – Trouble control pressure X1-1…5761
View onto the valve cartridge block (G00179)…5762
G00180 – Trouble pilot pressure X2 too low…5763
Valve cartridge block with X2 pressure sensor 57B086 & M1.2…5764
G00181 – Trouble pilot pressure X2 too high…5765
Valve cartridge block with X2 pressure sensor 57B086 & M1.2…5766
G00184 – Central lubrication system empty…5767
G00187 – Slew ring gear lubrication system empty…5767
Grease level (CLS & SLS) on the REAL TIME MONITOR…5768
G00185 – Trouble central lubrication system…5769
G00188 – Trouble slew ring gear lubrication system…5769
Allocation of vent valves and end-of-line switches…5770
Action chart for lube cycles…5771
View onto the vent valve (62Q507a/62Q509a)…5772
Wiring Diagram (80B043 & 62B046) for trouble codes G00185/G00188…5773
G00186 – Trouble central lubrication system…5774
G00189 – Trouble slew ring gear lubrication system…5774
Allocation of vent valves…5774
Action chart for lube cycles…5775
View onto the vent valve (62Q507a/62Q509a)…5776
G00207 – Engine remote oil tank 1 empty…5777
G00216 – Trouble software not compatible…5778
G00218 – Switch off all motors for running transfer pump…5780
G00220 – Trouble transfer pump motor overheated…5781
Wiring Diagram (transfer pump) for trouble code G00220…5782
G00223 – Trouble starter control 51K001a-1…5783
G00225 – Trouble starter control 51K001b-1…5783
G00224 – Trouble starter control Output to 51K001a-1…5784
G00226 – Trouble starter control Output to 51K001b-1…5784
G00231 – Trouble pilot control lever 20S019…5785
Wiring Diagram (20S019) for trouble code G00231…5786
Wiring Diagram (20S020) for trouble code G00232…5787
G00233 – Trouble pilot control 11Q045…5788
Wiring Diagram (11Q045) for trouble code G00233…5789
G00234 – Trouble pilot control 11K111a…5790
G00236 – Trouble pilot control 11K111b…5790
G00235 – Trouble pilot control Output to 11K111a…5791
G00237 – Trouble pilot control Output to 11K111b…5791
G00238 – Trouble supply by key switch 11Q044…5792
Input signal of 11Q044 on the REAL TIME MONITOR (G00238)…5792
Wiring Diagram (11Q044) for trouble code G00238…5793
G00240 – Trouble hydraulic oil temperature…5794
G00242 – Engine 1 already running…5795
G00243 – Fill up fuel tank…5795
G00245 – Engine shutdown from ground…5796
Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245)…5797
G00246 – Hydraulic oil temperature…5798
G00252 – Emergency shut-down at access ladder…5799
G00253 – Emergency shut-down at valve block…5799
G00254 – Emergency shut-down at hydraulic control panel…5799
G00255 – Emergency shut-down in cabin…5799
Wiring Diagram (emergency switches) for trouble codes G00252~G00255…5800
G00257 – Hydraulic oil temperature…5801
G00261 – Maintenance Safety Switch…5802
Wiring Diagram (50S058) for trouble code G00261…5803
G00262 – Trouble screen at hydr. cooler entry clogged…5804
40B166 and 40B165 on the REAL TIME MONITOR 03 Hydraulic (G00262)…5804
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262)…5805
Wiring Diagram (40B166 & 40B165) for trouble code G00262…5806
G00308 – Trouble CAN-Bus or CAN-Hardware…5807
G00309 – Trouble ladder up 56K253a…5810
G00311 – Trouble ladder up redundant 56K253b…5810
G00310 – Trouble ladder up Output to 56K253a…5811
G00312 – Trouble ladder up redundant Output to 56K253b…5811
G00313 – Trouble ladder down 56K254a…5812
G00315 – Trouble ladder down redundant 56K254b…5812
G00314 – Trouble ladder down Output to 56K254a…5813
G00316 – Trouble ladder down redundant Output to 56K254b…5813
G00317 – Trouble service arm up 56K255a…5814
G00319 – Trouble service arm up redundant 56K255b…5814
G00318 – Trouble service arm up Output to 56K255a…5815
G00320 – Trouble service arm up redundant Output to 56K255b…5815
G00321 – Trouble service arm down 56K256a…5816
G00323 – Trouble service arm down redundant 56K256b…5816
G00322 – Trouble service arm down Output to 56K256a…5817
G00324 – Trouble service arm down redundant Output to 56K256b…5817
G00325 – Trouble service arm Input…5818
G00326 – Trouble ladder Input…5818
G00327 – Trouble parking brake Input…5818
G00328 – Trouble start Input…5818
G00330 – Trouble pilot control 11Q111…5821
Wiring Diagram (11Q111/11K126) for trouble code G00330…5823
G00331 – Automatic after_running engine 1…5824
G00333 – Trouble battery charger relay…5825
Wiring Diagram (11Q122) for trouble code G00333…5826
G00351 – Engine 1 running…5827
G00352 – Engine 1 standstill…5827
G00417 – Communication failure PLC [MTC] <=> VHMS-controller…5828
G00420 – Connector sel error…5829
G00421 – Farm sys error…5830
G00422 – Can-net sys (J1939)…5831
G00423 – Application sys error…5832
G00425 – Settings impossible to take over into the PLC…5833
Wiring Diagram overview for G00425: VHMS monitor → VHMS controller → MTC…5834
G00491 – Communication failure MH800 <=> VHMS-Controller…5835
Wiring Diagram overview for G00491: VHMS monitor (MH801) → VHMS controller…5836
8 Troubleshooting by Symptoms…5839
8.1 Symptoms of the Engine and Related Electrical System…5840
SEL001 – Engine does not start (engine does not rotate)…5840
Wiring Diagram 1 (engine start) for trouble code SEL001…5842
Wiring Diagram 2 (engine start) for trouble code SEL001…5844
SEL002 – Engine stops while in operation…5845
View onto the fuel system water separator (SEL002)…5847
SEL003 – Engine speed is hunting during boom-up movement…5848
SEL004 – Engine does not stop…5849
SEL005 – Engine lacks output (no power)…5850
Judgment Table for SEL005…5851
SEL006 – Exhaust smoke is black…5852
Judgment Table for SEL006…5853
SEL007 – Oil consumption is excessive…5854
Judgment Table for SEL007…5855
SEL008 – Oil becomes contaminated quickly…5856
Judgment Table for SEL008…5857
SEL009 – Fuel consumption is excessive…5858
Judgment Table for SEL009…5859
SEL010 – Oil is in engine coolant…5860
Judgment Table for SEL010…5861
SEL011 – Oil level rises…5862
Judgment Table for SEL011…5863
SEL012 – Coolant temperature becomes too high (overheating)…5864
Judgment Table for SEL012…5865
8.2 Symptoms of the Hydraulic System…5866
SHY001 – All the work equipment shows lack of power or slow movement (especially the "boom up" function)…5866
SHY002 – Engine speed sharply drops or engine stalls too much…5868
SHY003 – No work equipment, travel or swing movement…5870
SHY004 – Work equipment has too much hydraulic drift…5871
SHY005 – Work equipment has big time lag…5873
SHY006 – Machine deviates during travel movement…5874
SHY007 – Hydraulic system has lack of power (Energy Efficiency)…5875
SHY008 – Machine does not swing…5877
SHY009 – Swing acceleration is poor…5878
SHY010 – Excessive overrun when stopping swing…5880
SHY011 – Floating system without function…5882
SHY012 – Abnormal noise coming from SRV or MRV…5883
SHY013 – Track tensioning system without function…5884
SHY014 – Ladder does not move, or slow movement…5885
SHY015 – Refilling arm does not move, or slow movement…5887
SHY016 – The hydraulic driven grease pump does not move…5889
SHY017 – Trouble pump bearing lubrication…5891
SHY018 – Abnormal track chain movement during digging…5892
SHY019 – Swing parking brake without function…5893
SHY020 – Travel parking brake without function…5894
8.3 Symptoms of the Mechanical System…5895
SME001 – Abnormal noise is made…5895
Judgment Table for SME001…5896
SME002 – Abnormal noise around the PTO / hydraulic pumps…5897
SME003 – Vibration is excessive (engine mountings)…5899
Judgment Table for SME003…5900
SME004 – Vibration is excessive (engine torsion)…5901
SME005 – There is a big shock when stopping swing…5902
SME006 – There is a big abnormal noise when moving/stopping swing…5903
SME007 – Fan hub bearing noise is abnormal…5905
SME008 – Abnormal noise coming from a travel gearbox…5906
SME009 – Abnormal noise coming from the work equipment (lack of grease)…5908
SME010 – Abnormal idler movement…5910
SME011 – Leak at the PTO shaft seal…5911
8.4 Symptoms of Additional Systems…5913
SAD001 – Air conditioner does not work…5913
View onto the A/C unit (SAD001)…5914
SAD002 – Air conditioner compressor clutch is burnt…5915
View onto the A/C compressor and its mounting (SAD002)…5916
SAD003 – Air conditioning system defective (pipes and hoses full of moisture)…5917
SAD004 – Travel alarm does not sound…5918
Wiring Diagram (60P140) for trouble code SAD004…5919
START PAGE Troubleshooting 40.pdf…0
40 TROUBLESHOOTING…5427
50_DISASSEMBLY AND ASSEMBLY.pdf…0
Table of Contents…5923
1 Introduction…5933
1.1 Contents of this binder…5934
1.2 Preface…5935
1.2.1 Contacting the Service…5935
1.2.2 Guarantee…5935
2 SAFETY…5937
2.1 SAFETY INFORMATION…5939
2.2 OVERVIEW…5940
2.2.1 NORMAL OPERATIONS…5940
2.2.2 REGULAR MAINTENANCE…5940
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR…5940
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR…5940
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB…5941
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR…5942
2.4.1 UNDERSTANDING THE MACHINE…5942
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR…5942
2.4.2.1 ENSURING SAFE OPERATION…5942
2.4.3 PREPARATIONS FOR SAFE OPERATION…5942
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT…5942
2.4.3.2 INSPECTING THE MACHINE…5942
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT…5943
2.4.3.4 KEEP MACHINE CLEAN…5943
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT…5943
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…5944
2.4.3.7 IF A PROBLEM IS FOUND…5944
2.4.4 FIRE PREVENTION…5944
2.4.4.1 PRECAUTIONS TO PREVENT FIRE…5944
2.4.4.2 ACTION IF FIRE OCCURS…5945
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…5946
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…5946
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…5946
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE…5946
2.4.5.3 NO PEOPLE ON THE ATTACHMENT…5946
2.4.5.4 WORKING IN HIGH PLACES…5946
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK…5947
2.4.5.6 LEAVING THE MACHINE…5947
2.4.6 BURN PREVENTION…5948
2.4.6.1 Hot coolant…5948
2.4.6.2 Hot oil…5948
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…5948
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…5949
2.4.8.1 UNAUTHORIZED MODIFICATION…5949
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…5949
2.4.9 PRECAUTIONS AT JOBSITE…5950
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT…5951
2.4.9.2 CAMERA SYSTEM WITH MONITORS…5951
2.4.9.3 ENSURE GOOD VISIBILITY…5951
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS…5951
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS…5952
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…5952
2.4.9.7 WORKING ON LOOSE GROUND…5953
2.4.9.8 GAS, DUST, STEAM AND SMOKE…5953
2.4.9.9 VENTILATION OF ENCLOSED AREAS…5954
2.4.10 STARTING ENGINE…5955
2.4.10.1 WARNING TAG…5955
2.4.10.2 CHECKS BEFORE STARTING ENGINE…5955
2.4.10.3 PRECAUTION WHEN STARTING ENGINE…5955
2.4.10.4 PRECAUTION IN COLD AREAS…5956
2.4.11 OPERATION…5956
2.4.11.1 CHECKS BEFORE OPERATION…5956
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE…5957
2.4.11.3 PRECAUTIONS WHEN travelling…5958
2.4.11.4 TRAVELLING ON SLOPES…5959
2.4.11.5 OPERATIONS ON SLOPES…5960
2.4.11.6 PROHIBITED OPERATIONS…5960
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES…5961
2.4.11.8 PARKING THE MACHINE…5961
2.4.11.9 TRANSPORTATION…5961
2.5 PRECAUTION FOR MAINTENANCE…5962
2.5.1 GENERAL PRECAUTIONS…5962
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…5963
2.5.1.2 STOP ENGINE FOR MAINTENANCE…5964
2.5.1.3 WARNING TAG…5965
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…5966
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS…5966
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING…5967
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…5967
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT…5968
2.5.1.9 NOISE…5968
2.5.1.10 WHEN USING A HAMMER…5968
2.5.1.11 PROPER TOOLS…5969
2.5.1.12 ACCUMULATOR…5969
2.5.1.13 PERSONNEL…5969
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…5970
2.5.2.1 PRECAUTION WHEN WELDING…5970
2.5.2.2 BATTERY HANDLING…5970
2.5.3 PRECAUTIONS WITH HIGH PRESSURE Fluid…5971
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE…5971
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…5972
2.5.3.3 REPLACEMENT OF HOSE LINES…5972
2.5.3.4 INSPECTION OF HOSE LINES…5972
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…5973
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE…5973
2.5.3.7 AIR CONDITIONING MAINTENANCE…5973
2.5.3.8 COMPRESSED AIR…5974
2.5.3.9 WASTE MATERIALS…5974
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS…5975
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM…5975
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS…5975
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…5975
2.7 SPECIAL SAFETY EQUIPMENT…5976
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB…5977
2.7.2 OBJECT HANDLING…5977
2.7.3 LIGHTING…5977
2.7.4 WARNING BEACON…5977
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…5977
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…5977
2.7.5.2 INSTRUCTIONS FOR USE…5979
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL…5981
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1),…5981
2.7.5.5 INSTRUCTIONS FOR USE…5983
3 Superstructure…5985
3.1 Superstructure overview…5986
3.2 Diesel engine…5988
3.2.1 Removal of the Diesel engine…5988
3.2.2 Replacement of the Diesel engine…5996
3.2.3 Engine torque support and engine/PTO mounts…5998
3.2.3.1 Flexible mounts…5999
3.2.3.2 Torque support…6001
3.2.4 Alternator…6002
3.2.4.1 Removal of the alternator…6002
3.2.4.2 Replacement of the alternator…6003
3.2.5 Starter system…6004
3.2.5.1 Removal of the starter motor…6004
3.2.5.2 Replacement of the starter motor…6005
3.2.6 Batteries…6005
3.2.6.1 Removal of the batteries…6005
3.2.6.2 Replacement of the batteries…6007
3.3 Engine radiator assembly…6008
3.3.1 Radiator fan assembly…6008
3.3.1.1 Removal of the radiator fan bearing block and motor…6009
3.3.1.2 Replacement of the radiator fan bearing block and motor…6013
3.3.1.3 Removal of the radiator fan…6015
3.3.1.4 Replacement of the radiator fan…6017
3.3.2 Radiator assembly…6018
3.3.2.1 Removal of the Radiator assembly…6018
3.3.2.2 Replacement of the radiator assembly…6023
3.3.3 Fuel cooler…6024
3.3.3.1 Removal of the fuel cooler…6024
3.3.3.2 Replacement of the fuel cooler…6026
3.4 Coupling assembly…6028
3.4.1 Geislinger coupling…6028
3.4.1.1 Removal of the Geislinger coupling…6029
3.4.1.2 Replacement of the Geislinger coupling…6033
3.5 PTO…6034
3.5.1 Overview of the PTO and the mounting of the pumps…6034
3.5.2 Main pumps…6036
3.5.2.1 Preparatory works for main pump removal…6036
3.5.2.2 Removal of main pump 1…6039
3.5.2.3 Replacement of main pump 1…6041
3.5.2.4 Removal of main pump 2…6042
3.5.2.5 Replacement of main pump 2…6044
3.5.2.6 Removal of main pump 3…6045
3.5.2.7 Replacement of main pump 3…6045
3.5.2.8 Removal of main pump 4…6045
3.5.2.9 Replacement of main pump 4…6045
3.5.3 PTO oil circulation pump (auxiliary pump)…6046
3.5.3.1 Removal of the oil circulation pump (auxiliary pump)…6046
3.5.3.2 Replacement of the oil circulation pump (auxiliary pump)…6048
3.5.4 Pilot oil pump…6049
3.5.4.1 Removal of the pilot oil pump…6049
3.5.4.2 Replacement of the pilot oil pump…6049
3.5.5 Radiator drive pump…6051
3.5.5.1 Removal of the radiator fan drive pump…6051
3.5.5.2 Replacement of the radiator fan drive pump…6053
3.5.6 Hydraulic oil cooler fan drive pump…6054
3.5.6.1 Removal of the hydraulic oil cooler fan drive pump…6054
3.5.6.2 Replacement of the hydraulic oil cooler fan drive pump…6054
3.5.7 Pump distributor gearbox (PTO)…6056
3.5.7.1 Removal of the pump distributor gearbox (PTO)…6058
3.5.7.2 Replacement of the pump distributor gearbox (PTO)…6061
3.6 Hydraulics…6062
3.6.1 Hydraulic oil cooler assembly…6062
3.6.1.1 Removal of hydraulic cooler fan…6063
3.6.1.2 Replacement of hydraulic cooler fan…6064
3.6.1.3 Removal of hydraulic cooler fan bearings and motors…6065
3.6.1.4 Replacement of hydraulic cooler fan bearings and motors…6067
3.6.1.5 Removal of the hydraulic oil coolers…6068
3.6.1.6 Replacement of the hydraulic oil coolers…6071
3.6.1.7 Removal of the hydraulic oil cooler assembly…6072
3.6.1.8 Replacement of the hydraulic oil cooler assembly…6077
3.6.2 Main gate valve…6078
3.6.2.1 Removal of the main gate valve…6078
3.6.2.2 Replacement of the main gate valve…6079
3.6.3 Hydraulic oil reservoir…6080
3.6.3.1 Removal of the hydraulic oil reservoir…6081
3.6.3.2 Replacement of the hydraulic oil reservoir…6087
3.6.4 Main control valve blocks…6090
3.6.4.1 General information…6090
3.6.4.2 Removal of the main control valve blocks…6098
3.6.4.3 Replacement of the main control valve blocks…6102
3.6.5 Main relief valves (MRV)…6103
3.6.5.1 Removal of the MRV at the main control valve blocks…6103
3.6.5.2 Replacement of the MRV at the main control valve blocks…6104
3.6.6 Service line relief valves (SRV)…6107
3.6.6.1 Removal of SRV on main control valve block…6107
3.6.6.2 Replacement of SRV on main control valve blocks…6108
3.6.7 Anti-cavitation valves (ACV)…6109
3.6.7.1 Removal of single ACV at the manifold…6111
3.6.7.2 Replacement of single ACV at the manifold…6114
3.6.7.3 Removal of ACV with attached check valve at the manifold…6115
3.6.7.4 Replacement of ACV with attached check valve at the manifold…6117
3.6.7.5 Removal of ACV on main control valve blocks…6119
3.6.7.6 Replacement of ACV on main control valve blocks…6120
3.6.8 Throttle check valves…6122
3.6.8.1 Removal of throttle check valves…6125
3.6.8.2 Replacement of throttle check valves…6127
3.6.9 Diffuser block (FSA only)…6128
3.6.9.1 Removal of the Diffuser block at the manifold…6128
3.6.9.2 Replacement of the Diffuser block at the manifold…6129
3.6.10 Manifold…6130
3.6.10.1 Removal of the manifold…6130
3.6.10.2 Replacement of the manifold…6132
3.7 Slew system…6133
3.7.1 Slew gear…6133
3.7.1.1 Removal of the slew gear…6135
3.7.1.2 Replacement of the slew gear…6138
3.7.2 Swing motor…6140
3.7.2.1 Removal of the swing motor…6141
3.7.2.2 Replacement of the swing motor…6143
3.7.3 Slew parking brake…6144
3.7.3.1 Removal/disassembly of the slew parking brake (L&S)…6145
3.7.3.2 Replacement/assembly of the slew parking brake (L&S)…6148
3.7.3.3 Removal of the slew parking brake (siebenhaar)…6151
3.7.3.4 Replacement of the slew parking brake (Siebenhaar)…6154
3.7.4 Dynamic slew brake…6158
3.7.4.1 Removal of the slew brake valve…6161
3.7.4.2 Replacement of the slew brake valve…6163
3.7.5 Swing circle…6164
3.7.5.1 Removal of the swing circle…6165
3.7.5.2 Replacement of the swing circle…6168
3.7.6 Swing circle lubrication pinion (dummy wheel)…6172
3.7.6.1 Removal of the lubrication pinion assembly…6173
3.7.6.2 Replacement of the lubrication pinion assembly…6175
3.8 Lubrication pumps…6176
3.8.1 Removal of the lubrication pump…6176
3.8.2 Replacement of the lubricating pump…6178
3.9 Operator’s cab…6180
3.9.1 Removal of the operator’s cab…6182
3.9.2 Replacement of the operator’s cab…6188
3.9.3 Cab-mounts…6190
3.9.3.1 Removal of the cab-mounts…6190
3.9.3.2 replacement of the cab-mounts…6192
3.9.4 Front window…6194
3.9.4.1 Removal of the front window…6194
3.9.4.2 Replacement of the front window…6195
3.9.5 Operator’s seat…6196
3.9.5.1 Removal of the operator’s seat…6196
3.9.5.2 Replacement of the operator’s seat…6197
3.10 Cab base…6198
3.10.1 Removal of the cab base…6198
3.10.2 Replacement of the cab base…6201
3.10.3 Pump controller…6203
3.10.3.1 Removal of the pump controller…6203
3.10.3.2 Replacement of the pump controller…6203
3.10.4 VHMS…6204
3.10.4.1 Removal of the VHMS-controller…6204
3.10.4.2 Replacement of the VHMS-controller…6205
3.11 Access ladder…6206
3.11.1 Removal of the access ladder…6207
3.11.2 Replacement of the access ladder…6209
3.11.3 Removal of the access ladder cylinder…6211
3.11.4 Replacement of the access ladder cylinder…6213
3.12 Counterweight…6214
3.12.1 Removal of the counterweight…6215
3.12.2 Replacement of the counterweight…6217
3.13 Superstructure Lifting…6218
3.13.1 Remove the superstructure from the undercarriage…6218
3.13.2 Install the superstructure onto the undercarriage…6223
3.14 Fuel tank…6226
3.14.1 General information…6227
3.14.2 Removal of the fuel tank…6228
3.14.3 Replacement of the fuel tank…6234
4 Undercarriage…6237
4.1 Undercarriage overview…6238
4.2 Travel system…6240
4.2.1 Track group…6240
4.2.1.1 Changing of the track group…6240
4.2.2 Sprocket…6245
4.2.2.1 Removal of the sprocket…6245
4.2.2.2 Replacement of the sprocket…6250
4.2.3 Guide wheels…6252
4.2.3.1 Removal of the guide wheel assembly…6252
4.2.3.2 Replacement of the guide wheel assembly…6254
4.2.4 Track tensioning accumulators…6256
4.2.4.1 Removal of the low pressure accumulators…6256
4.2.4.2 Replacement of the low pressure accumulators…6258
4.2.4.3 Removal of the high pressure accumulators…6259
4.2.4.4 Replacement of the high pressure accumulators…6260
4.2.5 Track tension valve block…6261
4.2.5.1 Removal of the track tensioning valve block…6261
4.2.5.2 Replacement of the track tensioning valve block…6263
4.2.6 Track tensioning cylinders…6264
4.2.6.1 Removal of the track tensioning cylinders…6264
4.2.6.2 Replacement of the track tensioning cylinders…6266
4.2.7 Hydraulic hoses of the track tensioning system…6267
4.2.7.1 Precursory work…6267
4.2.7.2 Substitute the hydraulic hoses inside the car body…6269
4.2.7.3 Substitute the hydraulic hoses between car body and crawler frame…6269
4.2.7.4 Substitute the hydraulic hoses inside the crawler frame…6271
4.2.7.5 Subsequent work…6271
4.2.8 Travel brake valve block (overspeed valve)…6273
4.2.8.1 Removal of the travel brake valve block…6276
4.2.8.2 Replacement of the travel brake valve block…6277
4.2.9 Travel motors…6278
4.2.9.1 Removal of the travel motors…6278
4.2.9.2 Replacement of the travel motors…6280
4.2.10 Travel parking brake…6282
4.2.10.1 Travel parking brake overview…6282
4.2.10.2 Removal/disassembly of the travel parking brake (L&S)…6287
4.2.10.3 Replacement/assembly of the travel parking brake (L&S)…6290
4.2.10.4 Removal/disassembly of the travel parking brake (Zollern)…6293
4.2.10.5 Replacement/assembly of the travel parking brake (Zollern)…6296
4.2.11 Travel gear box…6298
4.2.11.1 Removal of the travel gear box…6299
4.2.11.2 Replacement of the travel gear box…6301
4.2.12 Carrier roller…6303
4.2.12.1 Removal of the carrier roller assembly…6303
4.2.12.2 Replacement of the carrier roller assembly…6306
4.2.13 Track roller…6307
4.2.13.1 Removal of the track roller assembly…6307
4.2.13.2 Replacement of the track roller assembly…6309
4.3 Car body…6310
4.3.1 Removal of the car body and the crawler carriers (type with mounting pins)…6310
4.3.2 Replacement of the car body and the crawler carriers (type with mounting pins)…6314
4.3.3 Removal of the car Body and the crawler carriers (type with bolted connection)…6318
4.3.4 Replacement of the car body and the crawler carriers (type with bolted connection)…6324
4.3.5 Rotary joint…6333
4.3.5.1 Removal of the rotary joint…6335
4.3.5.2 Replacement of the rotary joint…6338
5 Attachment…6341
5.1 Backhoe…6342
5.1.1 Boom…6343
5.1.1.1 Removal of the Boom…6343
5.1.1.2 Replacement of the boom…6346
5.1.1.3 Removal of the boom cylinders…6348
5.1.1.4 Replacement of the boom cylinders…6353
5.1.2 Stick…6358
5.1.2.1 Removal of the Stick…6358
5.1.2.2 Replacement of the Stick…6362
5.1.2.3 Removal of the Stick Cylinders…6364
5.1.2.4 Replacement of the Stick cylinders…6369
5.1.3 Bucket…6374
5.1.3.1 Removal of the bucket…6374
5.1.3.2 Replacement of the bucket…6377
5.1.3.3 Removal of the Bucket Cylinders…6378
5.1.3.4 Replacement of the Bucket Cylinders…6384
5.1.4 Bucket link rod and steering rods…6387
5.1.4.1 Removal of the bucket link rod…6387
5.1.4.2 Replacement of the bucket link rod…6389
5.1.4.3 Removal of the steering rods…6390
5.1.4.4 Replacement of the steering rods…6393
5.1.5 Ground engaging tools (GET)…6394
5.1.5.1 Removal and replacement of the GET…6394
5.1.6 Hydraulic hoses at the backhoe attachment…6396
5.1.6.1 Substitute the boom arc hoses…6396
5.1.6.2 Substitute the boom cylinder hoses…6402
5.1.6.3 Substitute the stick cylinder hoses…6406
5.1.6.4 Substitute the bucket cylinder hoses…6410
5.2 Faceshovel…6414
5.2.1 Using the installation tools for hydraulic cylinders…6415
5.2.2 Boom…6416
5.2.2.1 Removal of the boom…6416
5.2.2.2 Replacement of the boom…6423
5.2.2.3 Removal of the boom cylinders…6428
5.2.2.4 Replacement of the boom cylinders…6432
5.2.3 Stick…6436
5.2.3.1 Removal of the stick…6436
5.2.3.2 Replacement of the stick…6440
5.2.3.3 Removal of the stick cylinders…6444
5.2.3.4 Replacement of the stick cylinders…6448
5.2.4 Bull Clam bucket…6452
5.2.4.1 Removal of the bull clam bucket…6452
5.2.4.2 Replacement of the bull clam bucket…6458
5.2.4.3 Removal of the bucket cylinders…6460
5.2.4.4 Replacement of the bucket cylinders…6464
5.2.4.5 Removal of the clam cylinders…6468
5.2.4.6 Replacement of the clam cylinders…6472
5.2.5 Ground engaging tools (GET)…6475
5.2.5.1 Removal and replacement of the GET…6475
5.2.6 Hydraulic hoses at the Faceshovel attachment…6476
5.2.6.1 Substitute the boom arc hoses…6476
5.2.6.2 Substitute the boom cylinder hoses…6482
5.2.6.3 Substitute the stick arc hoses…6486
5.2.6.4 Substitute the stick cylinder hoses…6490
5.2.6.5 Substitute the bucket cylinder hoses…6494
5.2.6.6 Substitute the clam cylinder hoses…6498
5.3 Metering valves (grease injectors) at the attachment…6506
5.3.1 Operation test of the metering valves (grease injectors)…6507
5.3.2 Removal of the metering valves (grease injectors)…6508
5.3.3 Replacement of the metering valves (grease injectors)…6510
5.4 Cylinder bypass test…6511
6 Service Information…6513
6.1 Fluids and lubricants…6514
6.2 Filling capacities…6515
6.3 Work instructions…6516
6.3.1 Remove / install the crawler carrier…6516
6.4 Weight tables…6517
6.4.1 Superstructure…6517
6.4.2 Undercarriage…6519
6.4.3 Backhoe attachment (BHA)…6520
6.4.4 Face shovel attachment (FSA)…6521
6.5 Torque charts according to KOMATSU company standard…6522
6.5.1 Metric standard thread…6522
6.5.2 Metric fine thread…6523
6.5.3 Cummins motor torques – metric…6524
6.5.4 Cummins motor torques – U.S. customary…6524
6.5.5 Flange connections…6525
6.6 Blind plugs…6526
6.6.1 Dummy plates for SAE–flanges…6526
6.6.2 Classification of threads to the nominal width…6528
6.6.3 Plugs and fittings according to DIN 2353…6529
6.7 Conversion table…6530
6.7.1 Method of using the conversion table…6530
6.7.2 Millimeter – inch & kilogram – pound…6531
6.7.3 Liter – U.S. gallon & liter – U.K. gallon…6532
6.7.4 Nm- ft.lb…6533
6.7.5 Bar – PSI – kPa – MPa…6534
6.7.6 Basic values in Ohm according to ISO 43 76…6535
6.7.7 Temperature…6536
6.8 Tools…6537
6.8.1 Standard tool case…6537
6.8.2 Used special tools (Overview)…6539
7 Tools catalogue…6541
8 Parts & Service News…6597
8.1 List of the PARTS AND SERVICE NEWS…6598
AH00511h…6601
AH00514…6623
AH00515c…6635
AH01512…6645
AH01531…6653
AH02513…6663
AH02521…6667
AH03506…6677
AH03509…6683
AH03510…6709
AH03538…6729
AH04518…6755
AH05510…6757
AH05518…6763
AH05535…6765
AH05537…6789
AH05546…6805
AH06524…6807
AH06530…6809
AH06544…6811
AH06545…6823
AH08502…6827
AH08504…6835
AH08508…6837
AH08512…6841
AH09522…6861
AH10530…6863
9 Supplier’s documentation…7007
START PAGE Disassembly and Assembly 50.pdf…0
50 DISASSEMBLY AND ASSEMBLY…5921
SMPC40008152 – Hydraulic Mining Shovel PC4000-6 Shop Manual…7034
Cover…7034
Contents…7035
TABLE OF CONTENTS…7035
SAFETY – FOREWORD…7036
SAFETY NOTICE…7036
GENERAL PRECAUTIONS…7036
PREPARATIONS FOR WORK…7037
PRECAUTIONS DURING WORK…7037
FOREWORD…7039
HOISTING INSTRUCTIONS…7040
HOISTING…7040
WIRE ROPES…7040
STANDARD TIGHTENING TORQUE…7042
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS…7042
CONVERSION TABLE…7043
METHOD OF USING THE CONVERSION TABLE…7043
TEMPERATURE…7049
Section 1.0 – Main Assembly Groups…7050
Table of contents Section 1.0 – Main assembly groups…7050
1.0 – Main Assembly Groups – General lay out…7052
1.1 Superstructure…7054
1.1.1 Machine house…7056
1.1.2 Hydraulic Oil Reservoir…7058
1.1.3 Hydraulic Oil Cooler…7060
1.1.4 Fuel tank (Fuel reservoir)…7062
1.1.5 Counter weight…7064
1.1.6 Cab support…7066
1.1.7 Operators cab…7068
1.1.8 Control blocks…7070
1.1.9 Swing gears…7072
1.2 Under carriage…7074
1.3 Attachment…7076
1.3.1 Backhoe attachment (BHA)…7076
1.3.2 Front Shovel Attachment (FSA)…7078
Section 2.0 – Drive…7079
Table of contents Section 2.0 – Drive…7079
2.0 Prime Drive Assembly – General Lay Out…7081
2.1 Engine and PTO mounts…7083
2.2 Coupling…7087
2.3 Air Filter…7089
2.4 Fan drive and radiator assembly…7091
2.5 Radiator fan drive speed adjustment…7095
2.6 Pump distributor gearbox (PTO)…7099
2.7 Pump-spline lubrication…7101
2.8 PTO Lubrication and cooling…7103
2.9 Hydraulic pumps – location, drive speed and flow rates…7107
Section 3.0 – Hydraulic Oil Reservoir…7108
Table of contents Section 3.0 – Hydraulic Oil Reservoir…7108
3.0 Hydraulic Oil Reservoir – General Lay Out…7110
3.1 Main oil tank, location of switches, sensors etc…7112
3.2 Suction oil tank with strainers…7114
3.3 Return oil collector tube with strainer…7116
3.4 Back pressure valve…7118
3.5 Transfer pump (Optional Equipment)…7120
3.6 Return and Leak Oil Filter…7122
3.7 Breather filter…7124
Section 4.0 – Hydraulic Oil Cooling…7125
Table of contents section 4.0 – Hydraulic Oil Cooling…7125
4.1 General…7127
4.2 Function of the hydraulic oil cooling circuit…7129
4.3 Adjustment of the Back Pressure Valve…7131
4.4 Fan drive (Two stage cooler fan RPM control)…7133
4.5 Pressure relief valves and solenoid valve…7135
4.5 Fixed Displacement Pump, with variable setting…7139
Section 5.0 – Controlling…7140
Table of contents Section 5.0 – Controlling…7140
5.0 General Lay Out…7142
5.1 Control and filter panel location of components…7144
5.2 Pilot Pressure Supply and Adjustments…7148
5.3 Remote control valves arrangement…7154
5.4 Function principle of the Electro-Hydraulic- Proportional Control…7156
5.5 Potentiometer Control (Lever, Joy Stick)…7160
5.6 Potentiometer Control (Pedal)…7162
5.7 Proportional Amplifier Module, Type A…7164
5.8 Proportional Amplifier Module, Type B…7166
5.9 Ramp Time Module…7168
5.10 Adjustments of Amplifier Modules (General)…7170
5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)…7172
5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)…7176
5.13 Adjusting the Ramp Time Module…7180
Section 6.0 – Components…7185
Table of contents Section 6.0 – Components…7185
6.0 Components…7185
6.1 Hydraulic…7185
6.1.1 Main Control Blocks and High Pressure Filter FSA…7187
6.1.2 Main Control Blocks and High Pressure Filter BHA…7189
6.1.3 Distributor Manifold – Location of restrictor blocks and anti cavitation valves FSA…7191
6.1.4 Distributor Manifold – Location of restrictor blocks and anti cavitation valves BHA…7193
6.1.5 Single Control Blocks (Floating) for Stick and Boom FSA…7195
6.1.6 Restrictor Block with Pressure Relief Valve…7197
6.1.7 Anti Cavitation Valve Block…7199
6.1.8 Remote control valves…7201
6.1.9 Directional Solenoid Valves (Three positions / 4-ways)…7203
6.1.10 Proportional Solenoid Valve…7205
6.1.11 High Pressure Filter…7207
6.1.12 Control Blocks and Valves…7209
6.1.13 Travel Brake Valve…7221
6.1.14 Pressure Reducing Valve…7223
6.1.15 Directional Solenoid Valves (Two positions / 4-ways)…7225
6.1.16 Pressure Increasing Valve…7227
Section 7.0 – Main Hydraulic Pumps and Pump Regulation System…7228
Table of contents Section 7.0 – Main Hyraulic Pumps and Pump Regulation System…7228
7.0 Main hydraulic pumps and pump regulation system…7230
7.1 Main Pumps…7238
7.1.1. Location of Pumps…7238
7.1.2. Pump bearing flushing / lubrication…7240
7.1.3 Operating Principles…7242
7.1.4 Checks / Adjustments…7258
7.2 Electronic Pump Regulation System…7268
7.2.1 Electronic load limiting control – general, illustration (Z 21713)…7268
7.2.2 Microcontroller MC7, illustration (Z 21716)…7270
7.2.3 Checks and adjustments…7272
Method A…7274
X1-pressure with 24V supply to separating terminals at the X2-switch board…7274
Method B…7276
With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab)…7276
Language selection…7276
Excavator Type selection…7280
X1-Pressure (maximum current) Adjustment…7284
Method C…7288
With a laptop computer and BODEM software connected to the serial interface X13-1 (located in the operators cab)…7288
Language selection…7292
Excavator Type selection…7294
X1-Pressure (maximum current) Adjustment…7296
7.3 Hydraulic Constant Regulation System…7298
7.3.1. General…7298
7.3.2. X1-pressure adjustment (constant-pressure) , illustration (Z 22360)…7300
7.4 Determination of the Peak point (Engine performance) ,illustration (Z 22360)…7302
Section 8.0 – Operating Hydraulic…7303
Table of contents Section 8.0 – Operating Hydraulic…7303
8.0 General…7305
8.1 Table of Contents – Hydraulic for the Attachment Cylinders…7308
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA…7310
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA…7314
8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA…7318
8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA…7322
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA…7326
8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” FSA…7330
8.1.7 Electric / Hydraulic flowchart “ Clam opening ” FSA…7334
8.1.8 Electric / Hydraulic flowchart “ Clam closing ” FSA…7336
8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972)…7338
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z21973)…7342
Boom cylinder “Piston side” FSA + BHA…7342
Boom cylinder “Piston rod side” FSA +BHA…7346
Stick cylinder “Piston side” FSA…7350
Stick cylinder “Piston side” BHA…7354
Stick cylinder “Piston rod side” FSA…7358
Stick cylinder “Piston rod side” BHA…7362
Bucket cylinder “Piston side” FSA…7366
Bucket cylinder “Piston side” BHA…7370
Bucket cylinder “Piston rod side” FSA…7374
Bucket cylinder “Piston rod side” BHA…7378
Clam cylinder “Piston rod side” FSA…7382
Clam cylinder “Piston side” FSA…7384
8.1.11 Checks and adjustments of the lowering speed, illustration (Z 22033)…7386
General…7386
Boom cylinder FSA…7388
Boom cylinder BHA…7392
Stick cylinder FSA…7394
Stick cylinder BHA…7398
Bucket cylinder FSA…7400
Bucket cylinder BHA…7402
Clam cylinder BHA…7404
8.2 Table of Contents – Hydraulic for the Swing Circuit…7405
8.2.1 Swing Circuit…7407
8.2.2 Swing Motor…7411
8.2.3 Swing Gear Box…7415
8.2.4 Swing Parking Brake (Gear house Brake)…7417
8.2.5 Swing Brake Valve…7419
8.2.6 Electric / Hydraulic flowchart “Swing Left”…7423
8.2.7 Electric / Hydraulic flowchart “Swing Right”…7425
8.2.8 Swing Monitoring System, illustration (Z 21947)…7427
8.2.9 Checks and adjustments for the swing circuit…7431
8.2.10 Function check for the swing parking brake…7437
8.3 Table of Contents – Hydraulic for the Travel Circuit…7438
8.3.1 Travel Circuit…7440
8.3.2 Travel Motor…7444
8.3.3 Rotary Distributor…7446
8.3.4 Travel gear…7448
8.3.5 Travel parking brake (Gear house brake)…7450
8.3.6 Travel Brake Valve…7452
8.3.7 Electric / Hydraulic flowchart “Traveling forward”…7454
8.3.8 Electric / Hydraulic flowchart “Traveling backward”…7456
8.3.9 Checks and adjustments for the travel circuit…7458
8.3.10 Function check for the travel parking brake…7460
Section 9.0 – Hydraulic Track Tensioning System…7461
Table of contents Section 9.0 – Hydraulic Track Tensioning System…7461
9.0 General – Hydraulic Track Tensioning System…7463
9.1 Functional description…7465
9.2 Pressure Increasing Valve…7469
9.3 Tensioning cylinder…7471
9.4 Adjustments / Checks…7473
9.5 Functional Test…7477
Section 10.0 – Access Ladder Hydraulically Operated…7478
Table of contents Section 10.0 – Access Ladder Hydraulic Operated…7478
10.0 General…7480
10.1 Function of hydraulic operated access ladder illustration (Z 22495)…7482
Section 11.0 – Hydraulic Operated Refilling Arm…7485
Table of contents Section 11.0 – Hydraulic Operated Refilling Arm…7485
11.0 Hydraulic operated refilling arm – General…7487
11.1 Function of hydraulic operated refilling arm…7489
Section 12.0 – Hints For Reading The Hydraulic Circuit Diagram…7490
Table of contents Section 12 – Hints For Reading The Hydraulic Circuit Diagram…7490
12.0 General – Hints For Reading The Hydraulic Circuit Diagram…7491
Section 14.0 – VHMS / ECS-T / ETM…7642
Table of contents Section 14.0 – Vehicle Health Monitoring System…7642
14.0 General – VHMS…7644
14.1 Colored Graphic Console (CGC) for PC4000 – Specifications for Operators…7645
Table of contents section 14.1 – Colored Graphic Console (CGC) for PC4000…7645
14.1.1 Graphic Flow Chart…7647
14.1.2 Initialization Screen (No. 0.0)…7649
14.1.3 Operator Information Screen (No. 1.1)…7649
14.1.4 Monitoring Screens…7651
Standard Monitor 1 (No. 1.2)…7651
Expansion monitor 2 (No. 1.3)…7651
Expansion monitor 3 (No. 1.4)…7651
14.1.5 Brightness and Contrast Setting Screen (No. 1.2.1)…7653
14.1.6 Fuel Consumption Screen (No. 1.2.2)…7655
14.1.7 Settings for Operator, Screen (No. 1.2.3)…7657
Entry of the Operator identification number…7657
Resetting the Truck Counter…7657
14.1.8 Maintenance Monitor (No. 1.2.4)…7659
14.1.9 Failure Message (No. 1.2.5)…7663
Failure history for Operator…7663
14.1.10 Automatic Messages…7665
14.2 Colored Graphic Console (CGC) for PC4000 – Specifications for Servicemen…7666
Table of contents Section 14.2 – Colored Graphic Console (CGC) for PC4000…7666
14.2.1 Graphic Flow Chart…7668
14.2.2 Service ID Setup Screen (No. 2.0)…7670
14.2.3 Service Menu Select Screen (No. 3.1)…7672
14.2.4 Real Time Menu Select Screen (No. 4.1.1)…7674
Engine (No. 5.1.1 – No. 5.1.4)…7674
Engine (No. 5.2.1)…7676
Hydraulic (No. 5.3.1 – No. 5.3.7)…7678
Electrical Equipment (No. 5.4.1 – 5.4.2)…7680
Emergency Stop (No. 5.5.1 – No. 5.5.2)…7682
Manual Switch (No. 5.6.1 – No. 5.6.3)…7684
Central Lubrication System (No. 5.7.1 – No. 5.7.2)…7686
Swing Lubrication System (No. 5.8.1 – No. 5.8.2)…7688
Other Items (No. 5.9.1 – No. 5.9.3)…7690
Output Signals (No. 5.10.1 – No. 5.10.6)…7692
14.2.5 PM-Clinic (No. 4.2.1 + 4.2.2) General…7694
(No. 4.2.1 + 4.2.2) General…7694
(No. 4.2.3 – 4.2.5) Power Check…7696
14.2.6 Serial No. Setting (No. 4.3.1) Machine…7698
(No. 4.3.1) Machine…7698
(No. 4.3.2) Engine…7700
14.2.7 Memory Clear (No. 4.3.2) Input Memory Clear ID…7702
Entry of the identification number…7702
Memory Clear (No. 4.4.1) Memory Clear Screen…7704
14.2.8 Maintenance Monitor (No. 4.5 – 4.5.1) Maintenance Acknowledgement…7706
14.2.9 Failure History for Service (No. 4.6)…7708
14.2.10 Snapshot Trigger (No. 4.7)…7710
14.2.11 Settings (No. 4.8.1 – No. 4.8.10)…7712
Central Lubrication System CLS No. 4.8.1)…7712
Swing Lubrication System SLS No. 4.8.2)…7714
Other Settings 1/2 (No. 4.8.3)…7716
Language selector button…7716
Operating Hours…7716
Date Settings…7716
Time Settings…7718
GMT Ref…7718
Other Settings 2/2 (No. 4.8.4)…7720
Oil Viscosity Hydraulic…7720
Oil Viscosity Gear…7720
Messages ON/OFF…7722
PLC-autom. ON/OFF…7722
Shut Down ON / OFF (No. 4.8.5 – No. 4.8.10)…7724
14.4 Wiring of the Main Components…7725
Table of contents section 14.4 – Wiring of the Main Components…7725
14.4 Wiring of the main components…7727
14.4.1 Wiring of the engine…7729
14.4.2 Wiring of the VHMS Controller…7731
14.4.3 Wiring of the CGC Monitor…7735
14.4.4 Wiring of the PLC…7737
Section 15.0 – Lubrication Systems…7738
Introduction…7738
General Contents…7740
Table of Contents Chapter 1 – Hydraulically Driven Lube Pump…7741
Function – Hydraulically Driven Lube Pump Power Master III…7743
Oscillation Cylinder and Control Block, illustration Z 21174…7747
Adjustments (illustration Z21175)…7749
Table of Contents Chapter 2 – One Line System With Hydraulically Driven "Power Master III" Pump…7750
Function Central Lubrication System…7752
Electrical Function…7756
Sonar Sensor For Grease Level…7760
Adjustments…7762
End Line Pressure Switch…7762
Injectors…7764
Table of Contents Chapter 3 – Pinion Type System With Hydr. Driven "Power Master III" Pump…7765
Function Pinion type (dummy wheel) system…7767
Electrical Function (dummy wheel) system…7771
Lubricant Level Monitoring…7775
Adjustments…7777
End-Of-Line Switch Setting…7777
Injectors…7779
Table of Contents Chapter 4 – Components…7780
Hydraulically Drive Lube Pump…7782
Lubricant Injectors…7786
End-Of-Line Switch…7792
Filter…7794
Vent valve (Solenoid valve)…7796
Magnetventile Solenoid Valves – Owner's Manual…7797
Table of Content…7798
Safety Instructions…7798
Application…7799
Examples of Application…7799
Erection and Installation…7799
Operating Instructions…7799
Type Identification…7800
Troubleshooting…7801
Technical Data…7801
Electrical Data…7801
Dimensions…7802
Troubleshooting Flowcharts 898 688 40 (50 Pages)…7805
Flowcharts 898 688 40 (Page 1 of 50)…7805
Flowcharts 898 688 40 (Page 2 of 50)…7806
Flowcharts 898 688 40 (Page 3 of 50)…7807
Flowcharts 898 688 40 (Page 4 of 50)…7808
Flowcharts 898 688 40 (Page 5 of 50)…7809
Flowcharts 898 688 40 (Page 6 of 50)…7810
Flowcharts 898 688 40 (Page 7 of 50)…7811
Flowcharts 898 688 40 (Page 8 of 50)…7812
Flowcharts 898 688 40 (Page 9 of 50)…7813
Flowcharts 898 688 40 (Page 10 of 50)…7814
Flowcharts 898 688 40 (Page 11 of 50)…7815
Flowcharts 898 688 40 (Page 12 of 50)…7816
Flowcharts 898 688 40 (Page 13 of 50)…7817
Flowcharts 898 688 40 (Page 14 of 50)…7818
Flowcharts 898 688 40 (Page 15 of 50)…7819
Flowcharts 898 688 40 (Page 16 of 50)…7820
Flowcharts 898 688 40 (Page 17 of 50)…7821
Flowcharts 898 688 40 (Page 18 of 50)…7822
Flowcharts 898 688 40 (Page 19 of 50)…7823
Flowcharts 898 688 40 (Page 20 of 50)…7824
Flowcharts 898 688 40 (Page 21 of 50)…7825
Flowcharts 898 688 40 (Page 22 of 50)…7826
Flowcharts 898 688 40 (Page 23 of 50)…7827
Flowcharts 898 688 40 (Page 24 of 50)…7828
Flowcharts 898 688 40 (Page 25 of 50)…7829
Flowcharts 898 688 40 (Page 26 of 50)…7830
Flowcharts 898 688 40 (Page 27 of 50)…7831
Flowcharts 898 688 40 (Page 28 of 50)…7832
Flowcharts 898 688 40 (Page 29 of 50)…7833
Flowcharts 898 688 40 (Page 30 of 50)…7834
Flowcharts 898 688 40 (Page 31 of 50)…7835
Flowcharts 898 688 40 (Page 32 of 50)…7836
Flowcharts 898 688 40 (Page 33 of 50)…7837
Flowcharts 898 688 40 (Page 34 of 50)…7838
Flowcharts 898 688 40 (Page 35 of 50)…7839
Flowcharts 898 688 40 (Page 36 of 50)…7840
Flowcharts 898 688 40 (Page 37 of 50)…7841
Flowcharts 898 688 40 (Page 38 of 50)…7842
Flowcharts 898 688 40 (Page 39 of 50)…7843
Flowcharts 898 688 40 (Page 40 of 50)…7844
Flowcharts 898 688 40 (Page 41 of 50)…7845
Flowcharts 898 688 40 (Page 42 of 50)…7846
Flowcharts 898 688 40 (Page 43 of 50)…7847
Flowcharts 898 688 40 (Page 44 of 50)…7848
Flowcharts 898 688 40 (Page 45 of 50)…7849
Flowcharts 898 688 40 (Page 46 of 50)…7850
Flowcharts 898 688 40 (Page 47 of 50)…7851
Flowcharts 898 688 40 (Page 48 of 50)…7852
Flowcharts 898 688 40 (Page 49 of 50)…7853
Flowcharts 898 688 40 (Page 50 of 50)…7854
SMPC40008155 – Hydraulic Mining Shovel PC4000-6 Shop Manual…7855
Cover…7855
Contents…7856
TABLE OF CONTENTS…7856
SAFETY – FOREWORD…7857
SAFETY NOTICE…7857
GENERAL PRECAUTIONS…7857
PREPARATIONS FOR WORK…7858
PRECAUTIONS DURING WORK…7858
FOREWORD…7860
HOISTING INSTRUCTIONS…7861
HOISTING…7861
WIRE ROPES…7861
STANDARD TIGHTENING TORQUE…7863
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS…7863
CONVERSION TABLE…7864
METHOD OF USING THE CONVERSION TABLE…7864
TEMPERATURE…7870
Section 1.0 – Main Assembly Groups…7871
Table of contents Section 1.0 – Main assembly groups…7871
1.0 – Main Assembly Groups – General lay out…7873
1.1 Superstructure…7875
1.1.1 Machine house…7877
1.1.2 Hydraulic Oil Reservoir…7879
1.1.3 Hydraulic Oil Cooler…7881
1.1.4 Fuel tank (Fuel reservoir)…7883
1.1.5 Counter weight…7885
1.1.6 Cab support…7887
1.1.7 Operators cab…7889
1.1.8 Control blocks…7891
1.1.9 Swing gears…7893
1.2 Under carriage…7895
1.3 Attachment…7897
1.3.1 Backhoe attachment (BHA)…7897
1.3.2 Front Shovel Attachment (FSA)…7899
Section 2.0 – Drive…7900
Table of contents Section 2.0 – Drive…7900
2.0 Prime Drive Assembly – General Lay Out…7902
2.1 Engine and PTO mounts…7904
2.2 Coupling…7908
2.3 Air Filter…7910
2.4 Fan drive and radiator assembly…7912
2.5 Radiator fan drive speed adjustment…7916
2.6 Pump distributor gearbox (PTO)…7920
2.7 Pump-spline lubrication…7922
2.8 PTO Lubrication and cooling…7924
2.9 Hydraulic pumps – location, drive speed and flow rates…7928
Section 3.0 – Hydraulic Oil Reservoir…7929
Table of contents Section 3.0 – Hydraulic Oil Reservoir…7929
3.0 Hydraulic Oil Reservoir – General Lay Out…7931
3.1 Main oil tank, location of switches, sensors etc…7933
3.2 Suction oil tank with strainers…7935
3.3 Return oil collector tube with strainer…7937
3.4 Back pressure valve…7939
3.5 Transfer pump (Optional Equipment)…7941
3.6 Return and Leak Oil Filter…7943
3.7 Breather filter…7945
Section 4.0 – Hydraulic Oil Cooling…7946
Table of contents section 4.0 – Hydraulic Oil Cooling…7946
4.1 General…7948
4.2 Function of the hydraulic oil cooling circuit…7950
4.3 Adjustment of the Back Pressure Valve…7952
4.4 Fan drive (Two stage cooler fan RPM control)…7954
4.5 Pressure relief valves and solenoid valve…7956
4.5 Fixed Displacement Pump, with variable setting…7960
Section 5.0 – Controlling…7961
Table of contents Section 5.0 – Controlling…7961
5.0 General Lay Out…7963
5.1 Control and filter panel location of components…7965
5.2 Pilot Pressure Supply and Adjustments…7969
5.3 Remote control valves arrangement…7975
5.4 Function principle of the Electro-Hydraulic- Proportional Control…7977
5.5 Potentiometer Control (Lever, Joy Stick)…7981
5.6 Potentiometer Control (Pedal)…7983
5.7 Proportional Amplifier Module, Type A…7985
5.8 Proportional Amplifier Module, Type B…7987
5.9 Ramp Time Module…7989
5.10 Adjustments of Amplifier Modules (General)…7991
5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)…7993
5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)…7997
5.13 Adjusting the Ramp Time Module…8001
Section 6.0 – Components…8006
Table of contents Section 6.0 – Components…8006
6.0 Components…8006
6.1 Hydraulic…8006
6.1.1 Main Control Blocks and High Pressure Filter FSA…8008
6.1.2 Main Control Blocks and High Pressure Filter BHA…8010
6.1.3 Distributor Manifold – Location of restrictor blocks and anti cavitation valves FSA…8012
6.1.4 Distributor Manifold – Location of restrictor blocks and anti cavitation valves BHA…8014
6.1.5 Single Control Blocks (Floating) for Stick and Boom FSA…8016
6.1.6 Restrictor Block with Pressure Relief Valve…8018
6.1.7 Anti Cavitation Valve Block…8020
6.1.8 Remote control valves…8022
6.1.9 Directional Solenoid Valves (Three positions / 4-ways)…8024
6.1.10 Proportional Solenoid Valve…8026
6.1.11 High Pressure Filter…8028
6.1.12 Control Blocks and Valves…8030
6.1.13 Travel Brake Valve…8042
6.1.14 Pressure Reducing Valve…8044
6.1.15 Directional Solenoid Valves (Two positions / 4-ways)…8046
6.1.16 Pressure Increasing Valve…8048
Section 7.0 – Main Hydraulic Pumps and Pump Regulation System…8049
Table of contents Section 7.0 – Main Hyraulic Pumps and Pump Regulation System…8049
7.0 Main hydraulic pumps and pump regulation system…8051
7.1 Main Pumps…8059
7.1.1. Location of Pumps…8059
7.1.2. Pump bearing flushing / lubrication…8061
7.1.3 Operating Principles…8063
7.1.4 Checks / Adjustments…8079
7.2 Electronic Pump Regulation System…8089
7.2.1 Electronic load limiting control – general, illustration (Z 21713)…8089
7.2.2 Microcontroller MC7, illustration (Z 21716)…8091
7.2.3 Checks and adjustments…8093
Method A…8095
X1-pressure with 24V supply to separating terminals at the X2-switch board…8095
Method B…8097
With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab)…8097
Language selection…8097
Excavator Type selection…8101
X1-Pressure (maximum current) Adjustment…8105
Method C…8109
With a laptop computer and BODEM software connected to the serial interface X13-1 (located in the operators cab)…8109
Language selection…8113
Excavator Type selection…8115
X1-Pressure (maximum current) Adjustment…8117
7.3 Hydraulic Constant Regulation System…8119
7.3.1. General…8119
7.3.2. X1-pressure adjustment (constant-pressure) , illustration (Z 22360)…8121
7.4 Determination of the Peak point (Engine performance) ,illustration (Z 22360)…8123
Section 8.0 – Operating Hydraulic…8124
Table of contents Section 8.0 – Operating Hydraulic…8124
8.0 General…8126
8.1 Table of Contents – Hydraulic for the Attachment Cylinders…8129
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA…8131
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA…8135
8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA…8139
8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA…8143
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA…8147
8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” FSA…8151
8.1.7 Electric / Hydraulic flowchart “ Clam opening ” FSA…8155
8.1.8 Electric / Hydraulic flowchart “ Clam closing ” FSA…8157
8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972)…8159
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z21973)…8163
Boom cylinder “Piston side” FSA + BHA…8163
Boom cylinder “Piston rod side” FSA +BHA…8167
Stick cylinder “Piston side” FSA…8171
Stick cylinder “Piston side” BHA…8175
Stick cylinder “Piston rod side” FSA…8179
Stick cylinder “Piston rod side” BHA…8183
Bucket cylinder “Piston side” FSA…8187
Bucket cylinder “Piston side” BHA…8191
Bucket cylinder “Piston rod side” FSA…8195
Bucket cylinder “Piston rod side” BHA…8199
Clam cylinder “Piston rod side” FSA…8203
Clam cylinder “Piston side” FSA…8205
8.1.11 Checks and adjustments of the lowering speed, illustration (Z 22033)…8207
General…8207
Boom cylinder FSA…8209
Boom cylinder BHA…8213
Stick cylinder FSA…8215
Stick cylinder BHA…8219
Bucket cylinder FSA…8221
Bucket cylinder BHA…8223
Clam cylinder BHA…8225
8.2 Table of Contents – Hydraulic for the Swing Circuit…8226
8.2.1 Swing Circuit…8228
8.2.2 Swing Motor…8232
8.2.3 Swing Gear Box…8236
8.2.4 Swing Parking Brake (Gear house Brake)…8238
8.2.5 Swing Brake Valve…8240
8.2.6 Electric / Hydraulic flowchart “Swing Left”…8244
8.2.7 Electric / Hydraulic flowchart “Swing Right”…8246
8.2.8 Swing Monitoring System, illustration (Z 21947)…8248
8.2.9 Checks and adjustments for the swing circuit…8252
8.2.10 Function check for the swing parking brake…8258
8.3 Table of Contents – Hydraulic for the Travel Circuit…8259
8.3.1 Travel Circuit…8261
8.3.2 Travel Motor…8265
8.3.3 Rotary Distributor…8267
8.3.4 Travel gear…8269
8.3.5 Travel parking brake (Gear house brake)…8271
8.3.6 Travel Brake Valve…8273
8.3.7 Electric / Hydraulic flowchart “Traveling forward”…8275
8.3.8 Electric / Hydraulic flowchart “Traveling backward”…8277
8.3.9 Checks and adjustments for the travel circuit…8279
8.3.10 Function check for the travel parking brake…8281
Section 9.0 – Hydraulic Track Tensioning System…8282
Table of contents Section 9.0 – Hydraulic Track Tensioning System…8282
9.0 General – Hydraulic Track Tensioning System…8284
9.1 Functional description…8286
9.2 Pressure Increasing Valve…8290
9.3 Tensioning cylinder…8292
9.4 Adjustments / Checks…8294
9.5 Functional Test…8298
Section 10.0 – Access Ladder Hydraulically Operated…8299
Table of contents Section 10.0 – Access Ladder Hydraulic Operated…8299
10.0 General…8301
10.1 Function of hydraulic operated access ladder illustration (Z 22495)…8303
Section 11.0 – Hydraulic Operated Refilling Arm…8306
Table of contents Section 11.0 – Hydraulic Operated Refilling Arm…8306
11.0 Hydraulic operated refilling arm – General…8308
11.1 Function of hydraulic operated refilling arm…8310
Section 12.0 – Hints For Reading The Hydraulic Circuit Diagram…8311
Table of contents Section 12 – Hints For Reading The Hydraulic Circuit Diagram…8311
12.0 General – Hints For Reading The Hydraulic Circuit Diagram…8312
12.1 Legend for the circuit diagram…8313
12.2 How to read the circuit diagram…8321
Hydraulic Plans 897 969 40 – (9 Pages)…8322
Hydraulic Plan 897 969 40 (Page 1 of 9)…8322
Hydraulic Plan 897 969 40 (Page 2 of 9)…8323
Hydraulic Plan 897 969 40 (Page 3 of 9)…8324
Hydraulic Plan 897 969 40 (Page 4 of 9)…8325
Hydraulic Plan 897 969 40 (Page 5 of 9)…8326
Hydraulic Plan 897 969 40 (Page 6 of 9)…8327
Hydraulic Plan 897 969 40 (Page 7 of 9)…8328
Hydraulic Plan 897 969 40 (Page 8 of 9)…8329
Hydraulic Plan 897 969 40 (Page 9 of 9)…8330
Section 13.0 – Hints For Reading The Electric Circuit Diagram…8331
Table of contents Section 13.0 – Hints For Reading The Electric Circuit Diagram…8331
13.0 Hints For Reading The Electric Circuit Diagram…8331
13.1 Designation of electrical devices…8332
13.2 Symbols…8334
13.3 General information…8338
13.4 Reading a Circuit Diagram…8342
13.5 Component list…8346
Electrical Plans 897 844 40 (64 Pages)…8399
Electrical Plans 897 844 40 (1 of 64 Pages)…8399
Electrical Plans 897 844 40 (2 of 64 Pages)…8400
Electrical Plans 897 844 40 (3 of 64 Pages)…8401
Electrical Plans 897 844 40 (4 of 64 Pages)…8402
Electrical Plans 897 844 40 (5 of 64 Pages)…8403
Electrical Plans 897 844 40 (6 of 64 Pages)…8404
Electrical Plans 897 844 40 (7 of 64 Pages)…8405
Electrical Plans 897 844 40 (8 of 64 Pages)…8406
Electrical Plans 897 844 40 (9 of 64 Pages)…8407
Electrical Plans 897 844 40 (10 of 64 Pages)…8408
Electrical Plans 897 844 40 (11 of 64 Pages)…8409
Electrical Plans 897 844 40 (12 of 64 Pages)…8410
Electrical Plans 897 844 40 (13 of 64 Pages)…8411
Electrical Plans 897 844 40 (14 of 64 Pages)…8412
Electrical Plans 897 844 40 (15 of 64 Pages)…8413
Electrical Plans 897 844 40 (16 of 64 Pages)…8414
Electrical Plans 897 844 40 (17 of 64 Pages)…8415
Electrical Plans 897 844 40 (18 of 64 Pages)…8416
Electrical Plans 897 844 40 (19 of 64 Pages)…8417
Electrical Plans 897 844 40 (20 of 64 Pages)…8418
Electrical Plans 897 844 40 (21 of 64 Pages)…8419
Electrical Plans 897 844 40 (22 of 64 Pages)…8420
Electrical Plans 897 844 40 (23 of 64 Pages)…8421
Electrical Plans 897 844 40 (24 of 64 Pages)…8422
Electrical Plans 897 844 40 (25 of 64 Pages)…8423
Electrical Plans 897 844 40 (26 of 64 Pages)…8424
Electrical Plans 897 844 40 (27 of 64 Pages)…8425
Electrical Plans 897 844 40 (28 of 64 Pages)…8426
Electrical Plans 897 844 40 (29 of 64 Pages)…8427
Electrical Plans 897 844 40 (30 of 64 Pages)…8428
Electrical Plans 897 844 40 (31 of 64 Pages)…8429
Electrical Plans 897 844 40 (32 of 64 Pages)…8430
Electrical Plans 897 844 40 (33 of 64 Pages)…8431
Electrical Plans 897 844 40 (34 of 64 Pages)…8432
Electrical Plans 897 844 40 (35 of 64 Pages)…8433
Electrical Plans 897 844 40 (36 of 64 Pages)…8434
Electrical Plans 897 844 40 (37 of 64 Pages)…8435
Electrical Plans 897 844 40 (38 of 64 Pages)…8436
Electrical Plans 897 844 40 (39 of 64 Pages)…8437
Electrical Plans 897 844 40 (40 of 64 Pages)…8438
Electrical Plans 897 844 40 (41 of 64 Pages)…8439
Electrical Plans 897 844 40 (42 of 64 Pages)…8440
Electrical Plans 897 844 40 (43 of 64 Pages)…8441
Electrical Plans 897 844 40 (44 of 64 Pages)…8442
Electrical Plans 897 844 40 (45 of 64 Pages)…8443
Electrical Plans 897 844 40 (46 of 64 Pages)…8444
Electrical Plans 897 844 40 (47 of 64 Pages)…8445
Electrical Plans 897 844 40 (48 of 64 Pages)…8446
Electrical Plans 897 844 40 (49 of 64 Pages)…8447
Electrical Plans 897 844 40 (50 of 64 Pages)…8448
Electrical Plans 897 844 40 (51 of 64 Pages)…8449
Electrical Plans 897 844 40 (52 of 64 Pages)…8450
Electrical Plans 897 844 40 (53 of 64 Pages)…8451
Electrical Plans 897 844 40 (54 of 64 Pages)…8452
Electrical Plans 897 844 40 (55 of 64 Pages)…8453
Electrical Plans 897 844 40 (56 of 64 Pages)…8454
Electrical Plans 897 844 40 (57 of 64 Pages)…8455
Electrical Plans 897 844 40 (58 of 64 Pages)…8456
Electrical Plans 897 844 40 (59 of 64 Pages)…8457
Electrical Plans 897 844 40 (60 of 64 Pages)…8458
Electrical Plans 897 844 40 (61 of 64 Pages)…8459
Electrical Plans 897 844 40 (62 of 64 Pages)…8460
Electrical Plans 897 844 40 (63 of 64 Pages)…8461
Electrical Plans 897 844 40 (64 of 64 Pages)…8462
Section 14.0 – VHMS / ECS-T / ETM…8463
Table of contents Section 14.0 – Vehicle Health Monitoring System…8463
14.0 General – VHMS…8465
14.1 Colored Graphic Console (CGC) for PC4000 – Specifications for Operators…8466
Table of contents section 14.1 – Colored Graphic Console (CGC) for PC4000…8466
14.1.1 Graphic Flow Chart…8468
14.1.2 Initialization Screen (No. 0.0)…8470
14.1.3 Operator Information Screen (No. 1.1)…8470
14.1.4 Monitoring Screens…8472
Standard Monitor 1 (No. 1.2)…8472
Expansion monitor 2 (No. 1.3)…8472
Expansion monitor 3 (No. 1.4)…8472
14.1.5 Brightness and Contrast Setting Screen (No. 1.2.1)…8474
14.1.6 Fuel Consumption Screen (No. 1.2.2)…8476
14.1.7 Settings for Operator, Screen (No. 1.2.3)…8478
Entry of the Operator identification number…8478
Resetting the Truck Counter…8478
14.1.8 Maintenance Monitor (No. 1.2.4)…8480
14.1.9 Failure Message (No. 1.2.5)…8484
Failure history for Operator…8484
14.1.10 Automatic Messages…8486
14.2 Colored Graphic Console (CGC) for PC4000 – Specifications for Servicemen…8487
Table of contents Section 14.2 – Colored Graphic Console (CGC) for PC4000…8487
14.2.1 Graphic Flow Chart…8489
14.2.2 Service ID Setup Screen (No. 2.0)…8491
14.2.3 Service Menu Select Screen (No. 3.1)…8493
14.2.4 Real Time Menu Select Screen (No. 4.1.1)…8495
Engine (No. 5.1.1 – No. 5.1.4)…8495
Engine (No. 5.2.1)…8497
Hydraulic (No. 5.3.1 – No. 5.3.7)…8499
Electrical Equipment (No. 5.4.1 – 5.4.2)…8501
Emergency Stop (No. 5.5.1 – No. 5.5.2)…8503
Manual Switch (No. 5.6.1 – No. 5.6.3)…8505
Central Lubrication System (No. 5.7.1 – No. 5.7.2)…8507
Swing Lubrication System (No. 5.8.1 – No. 5.8.2)…8509
Other Items (No. 5.9.1 – No. 5.9.3)…8511
Output Signals (No. 5.10.1 – No. 5.10.6)…8513
14.2.5 PM-Clinic (No. 4.2.1 + 4.2.2) General…8515
(No. 4.2.1 + 4.2.2) General…8515
(No. 4.2.3 – 4.2.5) Power Check…8517
14.2.6 Serial No. Setting (No. 4.3.1) Machine…8519
(No. 4.3.1) Machine…8519
(No. 4.3.2) Engine…8521
14.2.7 Memory Clear (No. 4.3.2) Input Memory Clear ID…8523
Entry of the identification number…8523
Memory Clear (No. 4.4.1) Memory Clear Screen…8525
14.2.8 Maintenance Monitor (No. 4.5 – 4.5.1) Maintenance Acknowledgement…8527
14.2.9 Failure History for Service (No. 4.6)…8529
14.2.10 Snapshot Trigger (No. 4.7)…8531
14.2.11 Settings (No. 4.8.1 – No. 4.8.10)…8533
Central Lubrication System CLS No. 4.8.1)…8533
Swing Lubrication System SLS No. 4.8.2)…8535
Other Settings 1/2 (No. 4.8.3)…8537
Language selector button…8537
Operating Hours…8537
Date Settings…8537
Time Settings…8539
GMT Ref…8539
Other Settings 2/2 (No. 4.8.4)…8541
Oil Viscosity Hydraulic…8541
Oil Viscosity Gear…8541
Messages ON/OFF…8543
PLC-autom. ON/OFF…8543
Shut Down ON / OFF (No. 4.8.5 – No. 4.8.10)…8545
14.4 Wiring of the Main Components…8546
Table of contents section 14.4 – Wiring of the Main Components…8546
14.4 Wiring of the main components…8548
14.4.1 Wiring of the engine…8550
14.4.2 Wiring of the VHMS Controller…8552
14.4.3 Wiring of the CGC Monitor…8556
14.4.4 Wiring of the PLC…8558
Section 15.0 – Lubrication Systems…8559
Introduction…8559
General Contents…8561
Table of Contents Chapter 1 – Hydraulically Driven Lube Pump…8562
Function – Hydraulically Driven Lube Pump Power Master III…8564
Oscillation Cylinder and Control Block, illustration Z 21174…8568
Adjustments (illustration Z21175)…8570
Table of Contents Chapter 2 – One Line System With Hydraulically Driven "Power Master III" Pump…8571
Function Central Lubrication System…8573
Electrical Function…8577
Sonar Sensor For Grease Level…8581
Adjustments…8583
End Line Pressure Switch…8583
Injectors…8585
Table of Contents Chapter 3 – Pinion Type System With Hydr. Driven "Power Master III" Pump…8586
Function Pinion type (dummy wheel) system…8588
Electrical Function (dummy wheel) system…8592
Lubricant Level Monitoring…8596
Adjustments…8598
End-Of-Line Switch Setting…8598
Injectors…8600
Table of Contents Chapter 4 – Components…8601
Hydraulically Drive Lube Pump…8603
Lubricant Injectors…8607
End-Of-Line Switch…8613
Filter…8615
Vent valve (Solenoid valve)…8617
Magnetventile Solenoid Valves – Owner's Manual…8618
Table of Content…8619
Safety Instructions…8619
Application…8620
Examples of Application…8620
Erection and Installation…8620
Operating Instructions…8620
Type Identification…8621
Troubleshooting…8622
Technical Data…8622
Electrical Data…8622
Dimensions…8623
Troubleshooting Elektro Plan 897 888 40 (68 Pages)…8626
Elektroplan 897 888 40 (Page 1 of 68)…8626
Elektroplan 897 888 40 (Page 2 of 68)…8627
Elektroplan 897 888 40 (Page 3 of 68)…8628
Elektroplan 897 888 40 (Page 4 of 68)…8629
Elektroplan 897 888 40 (Page 5 of 68)…8630
Elektroplan 897 888 40 (Page 6 of 68)…8631
Elektroplan 897 888 40 (Page 7 of 68)…8632
Elektroplan 897 888 40 (Page 8 of 68)…8633
Elektroplan 897 888 40 (Page 9 of 68)…8634
Elektroplan 897 888 40 (Page 10 of 68)…8635
Elektroplan 897 888 40 (Page 11 of 68)…8636
Elektroplan 897 888 40 (Page 12 of 68)…8637
Elektroplan 897 888 40 (Page 13 of 68)…8638
Elektroplan 897 888 40 (Page 14 of 68)…8639
Elektroplan 897 888 40 (Page 15 of 68)…8640
Elektroplan 897 888 40 (Page 16 of 68)…8641
Elektroplan 897 888 40 (Page 17 of 68)…8642
Elektroplan 897 888 40 (Page 18 of 68)…8643
Elektroplan 897 888 40 (Page 19 of 68)…8644
Elektroplan 897 888 40 (Page 20 of 68)…8645
Elektroplan 897 888 40 (Page 21 of 68)…8646
Elektroplan 897 888 40 (Page 22 of 68)…8647
Elektroplan 897 888 40 (Page 23 of 68)…8648
Elektroplan 897 888 40 (Page 24 of 68)…8649
Elektroplan 897 888 40 (Page 25 of 68)…8650
Elektroplan 897 888 40 (Page 26 of 68)…8651
Elektroplan 897 888 40 (Page 27 of 68)…8652
Elektroplan 897 888 40 (Page 28 of 68)…8653
Elektroplan 897 888 40 (Page 29 of 68)…8654
Elektroplan 897 888 40 (Page 30 of 68)…8655
Elektroplan 897 888 40 (Page 31 of 68)…8656
Elektroplan 897 888 40 (Page 32 of 68)…8657
Elektroplan 897 888 40 (Page 33 of 68)…8658
Elektroplan 897 888 40 (Page 34 of 68)…8659
Elektroplan 897 888 40 (Page 35 of 68)…8660
Elektroplan 897 888 40 (Page 36 of 68)…8661
Elektroplan 897 888 40 (Page 37 of 68)…8662
Elektroplan 897 888 40 (Page 38 of 68)…8663
Elektroplan 897 888 40 (Page 39 of 68)…8664
Elektroplan 897 888 40 (Page 40 of 68)…8665
Elektroplan 897 888 40 (Page 41 of 68)…8666
Elektroplan 897 888 40 (Page 42 of 68)…8667
Elektroplan 897 888 40 (Page 43 of 68)…8668
Elektroplan 897 888 40 (Page 44 of 68)…8669
Elektroplan 897 888 40 (Page 45 of 68)…8670
Elektroplan 897 888 40 (Page 46 of 68)…8671
Elektroplan 897 888 40 (Page 47 of 68)…8672
Elektroplan 897 888 40 (Page 48 of 68)…8673
Elektroplan 897 888 40 (Page 49 of 68)…8674
Elektroplan 897 888 40 (Page 50 of 68)…8675
Elektroplan 897 888 40 (Page 51 of 68)…8676
Elektroplan 897 888 40 (Page 52 of 68)…8677
Elektroplan 897 888 40 (Page 53 of 68)…8678
Elektroplan 897 888 40 (Page 54 of 68)…8679
Elektroplan 897 888 40 (Page 55 of 68)…8680
Elektroplan 897 888 40 (Page 56 of 68)…8681
Elektroplan 897 888 40 (Page 57 of 68)…8682
Elektroplan 897 888 40 (Page 58 of 68)…8683
Elektroplan 897 888 40 (Page 59 of 68)…8684
Elektroplan 897 888 40 (Page 60 of 68)…8685
Elektroplan 897 888 40 (Page 61 of 68)…8686
Elektroplan 897 888 40 (Page 62 of 68)…8687
Elektroplan 897 888 40 (Page 63 of 68)…8688
Elektroplan 897 888 40 (Page 64 of 68)…8689
Elektroplan 897 888 40 (Page 65 of 68)…8690
Elektroplan 897 888 40 (Page 66 of 68)…8691
Elektroplan 897 888 40 (Page 67 of 68)…8692
Elektroplan 897 888 40 (Page 68 of 68)…8693
Troubleshooting Hydraulic Plan 897 893 40 (9 Pages)…8694
Hydraulikplan 897 893 40 (Page 1 of 9)…8694
Hydraulikplan 897 893 40 (Page 2 of 9)…8695
Hydraulikplan 897 893 40 (Page 3 of 9)…8696
Hydraulikplan 897 893 40 (Page 4 of 9)…8697
Hydraulikplan 897 893 40 (Page 5 of 9)…8698
Hydraulikplan 897 893 40 (Page 6 of 9)…8699
Hydraulikplan 897 893 40 (Page 7 of 9)…8700
Hydraulikplan 897 893 40 (Page 8 of 9)…8701
Hydraulikplan 897 893 40 (Page 9 of 9)…8702
Troubleshooting Flowchart 897 894 40 (51 Pages)…8703
Ablaufdiagramm Flowchart 897 894 40 (Page 1 of 51)…8703
Ablaufdiagramm Flowchart 897 894 40 (Page 2 of 51)…8704
Ablaufdiagramm Flowchart 897 894 40 (Page 3 of 51)…8705
Ablaufdiagramm Flowchart 897 894 40 (Page 4 of 51)…8706
Ablaufdiagramm Flowchart 897 894 40 (Page 5 of 51)…8707
Ablaufdiagramm Flowchart 897 894 40 (Page 6 of 51)…8708
Ablaufdiagramm Flowchart 897 894 40 (Page 7 of 51)…8709
Ablaufdiagramm Flowchart 897 894 40 (Page 8 of 51)…8710
Ablaufdiagramm Flowchart 897 894 40 (Page 9 of 51)…8711
Ablaufdiagramm Flowchart 897 894 40 (Page 10 of 51)…8712
Ablaufdiagramm Flowchart 897 894 40 (Page 11 of 51)…8713
Ablaufdiagramm Flowchart 897 894 40 (Page 12 of 51)…8714
Ablaufdiagramm Flowchart 897 894 40 (Page 13 of 51)…8715
Ablaufdiagramm Flowchart 897 894 40 (Page 14 of 51)…8716
Ablaufdiagramm Flowchart 897 894 40 (Page 15 of 51)…8717
Ablaufdiagramm Flowchart 897 894 40 (Page 16 of 51)…8718
Ablaufdiagramm Flowchart 897 894 40 (Page 17 of 51)…8719
Ablaufdiagramm Flowchart 897 894 40 (Page 18 of 51)…8720
Ablaufdiagramm Flowchart 897 894 40 (Page 19 of 51)…8721
Ablaufdiagramm Flowchart 897 894 40 (Page 20 of 51)…8722
Ablaufdiagramm Flowchart 897 894 40 (Page 21 of 51)…8723
Ablaufdiagramm Flowchart 897 894 40 (Page 22 of 51)…8724
Ablaufdiagramm Flowchart 897 894 40 (Page 23 of 51)…8725
Ablaufdiagramm Flowchart 897 894 40 (Page 24 of 51)…8726
Ablaufdiagramm Flowchart 897 894 40 (Page 25 of 51)…8727
Ablaufdiagramm Flowchart 897 894 40 (Page 26 of 51)…8728
Ablaufdiagramm Flowchart 897 894 40 (Page 27 of 51)…8729
Ablaufdiagramm Flowchart 897 894 40 (Page 28 of 51)…8730
Ablaufdiagramm Flowchart 897 894 40 (Page 29 of 51)…8731
Ablaufdiagramm Flowchart 897 894 40 (Page 30 of 51)…8732
Ablaufdiagramm Flowchart 897 894 40 (Page 31 of 51)…8733
Ablaufdiagramm Flowchart 897 894 40 (Page 32 of 51)…8734
Ablaufdiagramm Flowchart 897 894 40 (Page 33 of 51)…8735
Ablaufdiagramm Flowchart 897 894 40 (Page 34 of 51)…8736
Ablaufdiagramm Flowchart 897 894 40 (Page 35 of 51)…8737
Ablaufdiagramm Flowchart 897 894 40 (Page 36 of 51)…8738
Ablaufdiagramm Flowchart 897 894 40 (Page 37 of 51)…8739
Ablaufdiagramm Flowchart 897 894 40 (Page 38 of 51)…8740
Ablaufdiagramm Flowchart 897 894 40 (Page 39 of 51)…8741
Ablaufdiagramm Flowchart 897 894 40 (Page 40 of 51)…8742
Ablaufdiagramm Flowchart 897 894 40 (Page 41 of 51)…8743
Ablaufdiagramm Flowchart 897 894 40 (Page 42 of 51)…8744
Ablaufdiagramm Flowchart 897 894 40 (Page 43 of 51)…8745
Ablaufdiagramm Flowchart 897 894 40 (Page 44 of 51)…8746
Ablaufdiagramm Flowchart 897 894 40 (Page 45 of 51)…8747
Ablaufdiagramm Flowchart 897 894 40 (Page 46 of 51)…8748
Ablaufdiagramm Flowchart 897 894 40 (Page 47 of 51)…8749
Ablaufdiagramm Flowchart 897 894 40 (Page 48 of 51)…8750
Ablaufdiagramm Flowchart 897 894 40 (Page 49 of 51)…8751
Ablaufdiagramm Flowchart 897 894 40 (Page 50 of 51)…8752
Ablaufdiagramm Flowchart 897 894 40 (Page 51 of 51)…8753
Troubleshooting Flowcharts 898 688 40 (50 Pages)…8754
Flowcharts 898 688 40 (Page 1 of 50)…8754
Flowcharts 898 688 40 (Page 2 of 50)…8755
Flowcharts 898 688 40 (Page 3 of 50)…8756
Flowcharts 898 688 40 (Page 4 of 50)…8757
Flowcharts 898 688 40 (Page 5 of 50)…8758
Flowcharts 898 688 40 (Page 6 of 50)…8759
Flowcharts 898 688 40 (Page 7 of 50)…8760
Flowcharts 898 688 40 (Page 8 of 50)…8761
Flowcharts 898 688 40 (Page 9 of 50)…8762
Flowcharts 898 688 40 (Page 10 of 50)…8763
Flowcharts 898 688 40 (Page 11 of 50)…8764
Flowcharts 898 688 40 (Page 12 of 50)…8765
Flowcharts 898 688 40 (Page 13 of 50)…8766
Flowcharts 898 688 40 (Page 14 of 50)…8767
Flowcharts 898 688 40 (Page 15 of 50)…8768
Flowcharts 898 688 40 (Page 16 of 50)…8769
Flowcharts 898 688 40 (Page 17 of 50)…8770
Flowcharts 898 688 40 (Page 18 of 50)…8771
Flowcharts 898 688 40 (Page 19 of 50)…8772
Flowcharts 898 688 40 (Page 20 of 50)…8773
Flowcharts 898 688 40 (Page 21 of 50)…8774
Flowcharts 898 688 40 (Page 22 of 50)…8775
Flowcharts 898 688 40 (Page 23 of 50)…8776
Flowcharts 898 688 40 (Page 24 of 50)…8777
Flowcharts 898 688 40 (Page 25 of 50)…8778
Flowcharts 898 688 40 (Page 26 of 50)…8779
Flowcharts 898 688 40 (Page 27 of 50)…8780
Flowcharts 898 688 40 (Page 28 of 50)…8781
Flowcharts 898 688 40 (Page 29 of 50)…8782
Flowcharts 898 688 40 (Page 30 of 50)…8783
Flowcharts 898 688 40 (Page 31 of 50)…8784
Flowcharts 898 688 40 (Page 32 of 50)…8785
Flowcharts 898 688 40 (Page 33 of 50)…8786
Flowcharts 898 688 40 (Page 34 of 50)…8787
Flowcharts 898 688 40 (Page 35 of 50)…8788
Flowcharts 898 688 40 (Page 36 of 50)…8789
Flowcharts 898 688 40 (Page 37 of 50)…8790
Flowcharts 898 688 40 (Page 38 of 50)…8791
Flowcharts 898 688 40 (Page 39 of 50)…8792
Flowcharts 898 688 40 (Page 40 of 50)…8793
Flowcharts 898 688 40 (Page 41 of 50)…8794
Flowcharts 898 688 40 (Page 42 of 50)…8795
Flowcharts 898 688 40 (Page 43 of 50)…8796
Flowcharts 898 688 40 (Page 44 of 50)…8797
Flowcharts 898 688 40 (Page 45 of 50)…8798
Flowcharts 898 688 40 (Page 46 of 50)…8799
Flowcharts 898 688 40 (Page 47 of 50)…8800
Flowcharts 898 688 40 (Page 48 of 50)…8801
Flowcharts 898 688 40 (Page 49 of 50)…8802
Flowcharts 898 688 40 (Page 50 of 50)…8803
SMPC40008170 – Hydraulic Mining Shovel PC4000-6 Shop Manual…8804
COVER…8804
CONTENTS…8806
TABLE OF CONTENTS…8806
SAFETY…8807
FOREWARD…8810
HOISTING INSTRUCTIONS…8811
STANDARD TIGHTENING TORQUE…8813
CONVERSION TABLE…8814
1.0 MAIN ASSEMBLY GROUPS…8821
1.0 MAIN ASSEMBLY GROUPS – GENERAL LAY OUT…8823
1. GENERAL LAY OUT – LEGEND FOR ILLUSTRATION\…8823
1.1 SUPERSTRUCTURE – LEGEND FOR ILLUSTRATION…8825
1.1.1 MACHINE HOUSE – LEGEND FOR ILLUSTRATION…8827
1.1.2 HYDRAULIC OIL RESERVOIR – LEGEND FOR ILLUSTRATION…8829
1.1.3 HYDRAULIC OIL COOLER – LEGEND FOR ILLUSTRATION…8831
1.1.4 FUEL TANK (FUEL RESERVOIR) – LEGEND FOR ILLUSTRATION…8833
1.1.5 COUNTERWEIGHT – LEGEND FOR ILLUSTRATION…8835
1.1.6 CAB SUPPORT – LEGEND FOR ILLUSTRATION…8837
1.1.7 OPERATOR'S CAB – LEGEND FOR ILLUSTRATION…8839
1.1.8 CONTROL BLOCKS – LEGEND FOR ILLUSTRATION…8841
1.1.9 SWING GEARS – LEGEND FOR ILLUSTRATION…8843
1.2 UNDER CARRIAGE – LEGEND FOR ILLUSTRATION…8845
1.3 ATTACHMENT – LEGEND FOR ILLUSTRATION…8847
1.3.1 BACKHOE ATTACHMENT (BHA) – LEGEND FOR ILLUSTRATION…8847
1.3.2 FRONT SHOVEL ATTACHMENT – LEGEND FOR ILLUSTRATION…8849
2.0 PRIME DRIVE ASSEMBLY…8850
2.0 PRIME DRIVE ASSEMBLY – GENERAL LAY OUT…8850
2.0 PRIME DRIVE ASSEMBLY – LEGEND FOR ILLUSTRATION…8852
2.1 ENGINE AND PTO MOUNT…8854
2.2 COUPLING…8858
2.2 COUPLING LEGEND FOR ILLUSTRATION…8858
2.3 AIR FILTER…8860
2.3 AIR FILTER – LEGEND FOR ILLUSTRATION…8860
2.4 FAN DRIVE AND RADIATOR ASSEMBLY…8862
2.4 FAN DRIVE AND RADIATOR ASSEMBLY – LEGEND FOR ILLUSTRATION…8862
2.5 RADIATOR FAN DRIVE SPEED ADJUSTMENT…8866
2.6 PUMP DISTRIBUTOR GEARBOX (PTO)…8870
2.7 PUMP-SPLINE LUBRICATION…8872
2.8 PTO LUBRICATION AND COOLING…8874
2.8 PTO LUBRICATION AND COOLING – LEGEND OF ILLUSTRATION…8874
2.9 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES…8878
3.0 HYDRAULIC OIL RESERVOIR…8879
3.0 HYDRAULIC OIL RESERVOIR GENERAL LAYOUT…8879
3.1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS ETC…8883
3.2 SUCTION OIL TANK WITH STRAINERS…8885
3.3 RETURN OIL COLLECTOR TUBE WITH STRAINER…8887
3.4 BACK PRESSURE VALVE…8889
3.5 TRANSFER PUMP (OPTIONAL EQUIPMENT)…8891
3.6 RETURN AND LEAK OIL FILTER…8893
3.7 BREATHER FILTER…8895
4.0 HYDRAULIC OIL COOLING…8896
4.1 GENERAL…8898
4.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT…8900
4.3 ADJUSTMENT OF THE BACK PRESSURE VALVE…8902
4.4 FAN DRIVE (TWO STAGE COOLER FAN PRM CONTROL)…8904
4.5 PRESSURE RELIEF VALVES AND SOLENOID VALVE…8906
4.6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING…8910
5.0 CONTROLLING…8911
5.0 GENERAL LAYOUT – LEGEND FOR ILLUSTRATIONS…8913
5.1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS (VALVES, SWITCHES, SENSORS ETC)…8915
5.2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS…8919
5.3 REMOTE CONTROL VALVES ARRANGEMENT…8925
5.4 FUNCTION PRINCIPLEOF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL…8927
5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK)…8931
5.6 POTENTIOMETER CONTROL (PEDAL)…8933
5.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A…8935
5.8 PROPORTIONAL AMPLIFIER MODULE, TYPE B…8937
5.9 RAMP TIME MODULE…8939
5.10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)…8941
5.11 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION…8943
5.12 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION…8947
5.13 ADJUSTING THE RAMP TIME MODULE…8951
6.0 COMPONENTS…8956
6.1 HYDRAULIC…8956
6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER – FRONT SHOVEL ATTACHMENT…8958
6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACK HOE ATTACHMENT…8960
6.1.3 DISTRIBUTOR MAINFOLD – LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES – FRONT SHOVEL ATTACHMENT…8962
6.1.4 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES – BACKHOE ATTACHMENT…8964
6.1.5 SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM FRONT SHOVEL ATTACHMENT…8966
6.1.6 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE…8968
6.1.7 ANTI CAVITATION VALVE BLOCK…8970
6.1.8 REMOTE CONTROL VALVE…8972
6.1.9 DIRECTIONAL SOLENOID VALVES (THREE POSITIONS / 4-WAY)…8974
6.1.10 PROPORTIONAL SOLENOID VALVE…8976
6.1.11 HIGH PRESSURE FILTER…8978
6.1.12 CONTROL BLOCKS AND VALVES…8980
6.1.13 TRAVEL BRAKE VALVE…8992
6.1.14 PRESSURE REDUCING VALVE…8994
6.1.15 DIRECTIONAL SOLENOID VALVES (TWO POSITIONS / 4-WAYS)…8996
6.1.16 PRESSURE INCREASING VALVE…8998
7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM…8999
7.0 GENERAL LAYOUT (HYDRAULIC ONLY)…9001
7.0 GENERAL LAYOUG (PUMP REGULATION SYSTEM)…9003
7.1 MAIN PUMPS…9009
7.1.1 LOCATION OF PUMPS…9009
7.1.2 PUMP BEARING FLUSHING / LUBRICATION…9011
7.1.3 OPERATING PRINCIPLES…9013
7.1.4 CHECKS / ADJUSTMENTS…9029
7.2 ELECTRONIC PUMP REGULATION SYSTEM…9039
7.2.1 ELECTRONIC LOAD LIMITING CONTROL – GENERAL…9039
7.2.2 MICROCONTROLLER MC7…9041
7.2.3 CHECKS AND ADJUSTMENTS…9043
METHOD A X1 PRESSURE WITH 24V SUPPLY…9045
METHOD B – WITH ELECTRONIC SERVICE TOOL…9047
LANGUAGE SELECTION…9047
EXCAVATOR TYPE SELECTION…9051
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT…9055
METHOD C – WITH A LAPTOP COMPUTER…9059
STARTING THE PROGRAM…9059
LANGUAGE SELECTION…9063
EXCAVATOR TYPE SELECTION…9065
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT…9067
7.3 HYDRAULIC CONSTANT REGULATION SYSTEM…9069
7.3.1 GENERAL…9069
7.3.2 X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE)…9071
7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)…9073
8.0 OPERATING HYDRAULIC…9074
OPERATING HYDRAULIC – GENERAL…9076
8.1 HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA…9079
8.1.1 ELECTRIC/HYDRAULIC FLOWCHART "BOOM RAISING"…9081
8.1.2 ELECTRIC/HYDRAULIC FLOWCHART "BOOM LOWERING"…9085
8.1.3 ELECTRIC/HYDRAULIC FLOWCHART "STICK EXTENDING"…9089
8.1.4 ELECTRIC/HYDRAULIC FLOWCHART "STICK RETRACTING"…9093
8.1.5 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET FILLING"…9097
8.1.6 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET EMPTYING"…9101
8.1.7 ELECTRIC/HYDRAULIC FLOWCHART "CLAM OPENING"…9105
8.1.8 ELECTRIC/HYDRAULIC FLOWCHARG "CLAM CLOSING"…9107
8.1.9 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES …9109
8.1.10 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES…9113
Boom cylinder “Piston side” FSA +BHA…9115
Boom cylinder “Piston rod side” FSA +BHA…9117
Stick cylinder “Piston side” FSA…9121
Stick cylinder “Piston side” BHA…9125
Stick cylinder “Piston rod side” FSA…9129
Stick cylinder “Piston rod side” BHA…9133
Bucket cylinder “Piston side” FSA…9137
Bucket cylinder “Piston side” BHA…9141
Bucket cylinder “Piston rod side” FSA…9145
Bucket cylinder “Piston rod side” BHA…9149
Clam cylinder “Piston rod side” FSA…9153
Clam cylinder “Piston side” FSA…9155
8.1.11 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED…9157
Boom cylinder FSA…9159
Boom cylinder BHA…9163
Stick cylinder BHA…9169
Bucket cylinder FSA…9171
Bucket cylinder BHA…9173
Clam cylinder BHA…9175
8.2 HYDRAULIC FOR THE SWING CIRCUIT…9176
8.2.1 SWING CIRCUIT…9178
8.2.2 SWING MOTOR…9182
8.2.3 SWING GEAR BOX…9186
8.2.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE)…9188
8.2.5 SWING BRAKE VALVE…9190
8.2.6 ELECTRIC/HYDRAULIC FLOWCHART "SWING LEFT"…9194
8.2.7 ELECTRIC/HYDRAULIC FLOWCHART "SWING RIGHT"…9196
8.2.8 SWING MONITORING SYSTEM…9198
8.2.9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT…9202
8.2.10 FUNCTION FOR THE SWING PARKING BRAKE…9208
8.3 HYDRAULIC FOR THE SWING CIRCUIT…9209
8.3.1 TRAVEL CIRCUIT…9211
8.3.2 TRAVEL MOTOR…9215
8.3.3 ROTARY DISTRIBUTOR…9217
8.3.4 TRAVEL GEAR…9219
8.3.5 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)…9221
8.3.6 TRAVEL BRAKE VALVE…9223
8.3.7 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING FORWARD"…9225
8.3.8 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING BACKWARD"…9227
8.3.9 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT…9229
8.3.10 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE…9231
9.0 HYDRAULIC TRACK TENSIONING SYSTEM…9232
9.0 GENERAL…9234
9.1 FUNCTIONAL DESCRIPTION…9236
9.2 PRESSURE INCREASING VALVE…9240
9.3 TENSIONING CYLINDER…9242
9.4 ADJUSTMENTS / CHECKS…9244
9.5 FUNCTIONAL TEST…9248
10.0 ACCESS LADDER HYDRAULIC OPERAGED…9249
10.0 GENERAL…9251
10.1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER…9253
11.0 HYDRAULIC OPERATED REFILLING ARM…9256
11.0 GENERAL…9258
11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM…9260
12.0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM…9261
12.0 GENERAL…9262
12.1 LEGEND FOR THE CIRCUIT DIAGRAM…9263
12.2 HOW TO READ THE CIRCUIT DIAGRAM…9271
13.0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM…9272
13.1 DESIGNATION OF ELECTRICAL DEVICES…9274
13.2 SYMBOLS…9276
13.3 GENERAL INFORMATION…9280
13.4 READING A CIRCUIT DIAGRAM…9284
13.5 COMPONENT LIST…9288
14.0 VEHICLE HEALTH MONITORING SYSTEM…9434
DATA FLOW CONTROL OF VHMS…9435
GENERAL…9436
14.1 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR OPERATORS…9413
14.1.1 GRAPHIC FLOW CHART…9415
14.1.2 INITIALIZATION SCREEN (NO. 0.0)…9417
14.1.3 OPERATOR INFORMATION SCREEN ( NO. 1.1)…9417
14.1.4 MONITORING SCREENS…9419
STANDARD MONITOR 1 (NO. 1.2)…9419
EXPANSION MONITOR 2 (NO.1.3)…9419
EXPANSION MONITOR 3 (NO. 1.4)…9419
14.1.5 BRIGHTNESS AND CONTRAST SETTING SCREEN (NO. 1.2.1)…9421
14.1.6 FUEL CONSUMPTION SCREEN (NO. 1.2.2)…9423
14.1.7 SETTINGS FOR OPERATOR, SCREEN (NO. 1.2.3)…9425
14.1.8 MAINTENANCE MONITOR (NO. 1.2.4)…9427
14.1.9 FAILURE MESSAGE ( NO. 1.2.5)…9431
14.1.10 AUTOMATIC MESSAGES…9433
14.2 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR SERVICEMEN…9354
14.2.1 GRAPHIC FLOW CHART…9356
14.2.2 SERVICE ID SETUP SCREEN (NO. 2.0)…9358
14.2.3 SERVICE MENU SELECT SCREEN (NO. 3.1)…9360
14.2.4 REAL TIME MENU SELECT SCREEN (NO. 4.1.1)…9362
ENGINE 5.1.1 – 5.1.4…9362
TRANSMISSION 5.2.1…9364
HYDRAULIC 5.3.1 – 5.4.2…9366
ELECTRICAL EQUIPMENT 5.4.1 – 5.4.2…9368
EMERGENCY STOP 5.5.1…9370
MANUAL SWITCH 5.6.1 – 5.6.3…9372
CENTRAL LUBRICATION SYSTEM 5.7.1 – 5.7.2…9374
SWING LUBRICATION SYSTEM 5.8.1 – 5.8.2…9376
OTHER ITEMS 5.9.1 – 5.9.3…9378
OUTPUT SIGNALS 5.10.1 – 5.10.6…9380
14.2.5 PM-CLINIC…9382
PM CLINIC GENERAL – 4.2.1 – 4.2.2…9382
PM CLINIC POWER CHECK – 4.2.3 – 4.2.5…9384
14.2.6 SERIAL NO. SETTING …9386
MACHINE 4.3.1…9386
ENGINE 4.3.2…9388
14.2.7 MEMORY CLEAR…9390
INPUT ID 4.3.2…9390
MEMORY CLEAR 4.4.1…9392
14.2.8 MAINTENANCE MONITOR – MAINTENANCE ACKNOWLEDGEMENT – 4.5 – 4.5.1…9394
14.2.9 FAILURE HISTORY – 4.6…9396
14.2.10 SNAPSHOT TRIGGER- 4.7…9398
14.2.11 SETTINGS…9400
CENTRAL LUBRICATION SYSTEM 4.8.1…9400
SWING LUBRICATION SYSTEM 4.8.2…9402
OTHER SETTINGS 1/2…9404
LANGUAGE…9405
OPERATING HOURS…9405
DATE…9405
TIME…9406
GMT REFERENCE…9406
OTHER SETTINGS 2/2…9408
OIL VISCOSITY HYDRAULIC…9408
OIL VISCOSITY GEAR…9408
MESSAGES ON/OFF…9410
PLC-AUTOM. ON/OFF…9410
SHUT DOWN ON.OFF 4.8.5 – 4.8.10…9412
14.4 WIRING OF THE MAIN COMPONENTS…9341
14.4.1 WIRING OF THE ENGINE…9345
14.4.2 WIRING OF THE VHMS CONTROLLER…9347
14.4.3 WIRING OF THE CGC MONITOR…9351
14.4.4 WIRING OF THE PLC…9353
15.0 LUBRICATION SYSTEMS…9441
15.1 HYDRAULICALLY DRIVEN LUBE PUMP…9441
FUNCTION…9447
ADJUSTMENTS…9451
15.2 ONE LINE SYSTEM WITH HYDRAULICALLY DRIVEN "PUMP MASTER III" PUMP…9453
FUNCTION…9455
ELECTRICAL FUNCTION…9459
SONAR SENSOR FOR GREASE LEVEL…9463
ADJUSTMENTS…9465
END LINE SWITCH…9465
INJECTORS…9467
15.3 PINION TYPE SYSTEM WITH HYDRAULIC DRIVEN "POWER MASTER III" PUMP…9469
FUNCTION…9472
ELECTRICAL FUNCTION…9475
LUBRICANT LEVEL…9479
ADJUSTMENTS…9481
END OF LINE SWITCH SETTING…9481
INJECTORS…9483
15.4 COMPONENTS…9485
HYDRAULICALLY DRIVEN "POWER MASTER III" LUBE PUMP…9487
LUBRICANT INJECTORS…9491
END-OF-LINE SWITCH…9497
FILTER…9499
VENT VALVE…9501
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ELECTRICAL PLAN 942 106 40 PAGE 71 OF 73…9659
ELECTRICAL PLAN 942 106 40 PAGE 70 OF 73…9660
ELECTRICAL PLAN 942 106 40 PAGE 72 OF 73…9661
ELECTRICAL PLAN 942 106 40 PAGE 73 OF 73…9662
SMPC40008172 – Hydraulic Mining Shovel PC4000-6 Shop Manual…9663
COVER…9663
CONTENTS…9665
TABLE OF CONTENTS…9665
SAFETY…9666
FOREWARD…9669
HOISTING INSTRUCTIONS…9670
STANDARD TIGHTENING TORQUE…9672
CONVERSION TABLE…9673
1.0 MAIN ASSEMBLY GROUPS…9680
1.0 MAIN ASSEMBLY GROUPS – GENERAL LAY OUT…9682
1. GENERAL LAY OUT – LEGEND FOR ILLUSTRATION\…9682
1.1 SUPERSTRUCTURE – LEGEND FOR ILLUSTRATION…9684
1.1.1 MACHINE HOUSE – LEGEND FOR ILLUSTRATION…9686
1.1.2 HYDRAULIC OIL RESERVOIR – LEGEND FOR ILLUSTRATION…9688
1.1.3 HYDRAULIC OIL COOLER – LEGEND FOR ILLUSTRATION…9690
1.1.4 FUEL TANK (FUEL RESERVOIR) – LEGEND FOR ILLUSTRATION…9692
1.1.5 COUNTERWEIGHT – LEGEND FOR ILLUSTRATION…9694
1.1.6 CAB SUPPORT – LEGEND FOR ILLUSTRATION…9696
1.1.7 OPERATOR'S CAB – LEGEND FOR ILLUSTRATION…9698
1.1.8 CONTROL BLOCKS – LEGEND FOR ILLUSTRATION…9700
1.1.9 SWING GEARS – LEGEND FOR ILLUSTRATION…9702
1.2 UNDER CARRIAGE – LEGEND FOR ILLUSTRATION…9704
1.3 ATTACHMENT – LEGEND FOR ILLUSTRATION…9706
1.3.1 BACKHOE ATTACHMENT (BHA) – LEGEND FOR ILLUSTRATION…9706
1.3.2 FRONT SHOVEL ATTACHMENT – LEGEND FOR ILLUSTRATION…9708
2.0 PRIME DRIVE ASSEMBLY…9709
2.0 PRIME DRIVE ASSEMBLY – GENERAL LAY OUT…9709
2.0 PRIME DRIVE ASSEMBLY – LEGEND FOR ILLUSTRATION…9711
2.1 ENGINE AND PTO MOUNT…9713
2.2 COUPLING…9717
2.2 COUPLING LEGEND FOR ILLUSTRATION…9717
2.3 AIR FILTER…9719
2.3 AIR FILTER – LEGEND FOR ILLUSTRATION…9719
2.4 FAN DRIVE AND RADIATOR ASSEMBLY…9721
2.4 FAN DRIVE AND RADIATOR ASSEMBLY – LEGEND FOR ILLUSTRATION…9721
2.5 RADIATOR FAN DRIVE SPEED ADJUSTMENT…9725
2.6 PUMP DISTRIBUTOR GEARBOX (PTO)…9729
2.7 PUMP-SPLINE LUBRICATION…9731
2.8 PTO LUBRICATION AND COOLING…9733
2.8 PTO LUBRICATION AND COOLING – LEGEND OF ILLUSTRATION…9733
2.9 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES…9737
3.0 HYDRAULIC OIL RESERVOIR…9738
3.0 HYDRAULIC OIL RESERVOIR GENERAL LAYOUT…9738
3.1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS ETC…9742
3.2 SUCTION OIL TANK WITH STRAINERS…9744
3.3 RETURN OIL COLLECTOR TUBE WITH STRAINER…9746
3.4 BACK PRESSURE VALVE…9748
3.5 TRANSFER PUMP (OPTIONAL EQUIPMENT)…9750
3.6 RETURN AND LEAK OIL FILTER…9752
3.7 BREATHER FILTER…9754
4.0 HYDRAULIC OIL COOLING…9755
4.1 GENERAL…9757
4.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT…9759
4.3 ADJUSTMENT OF THE BACK PRESSURE VALVE…9761
4.4 FAN DRIVE (TWO STAGE COOLER FAN PRM CONTROL)…9763
4.5 PRESSURE RELIEF VALVES AND SOLENOID VALVE…9765
4.6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING…9769
5.0 CONTROLLING…9770
5.0 GENERAL LAYOUT – LEGEND FOR ILLUSTRATIONS…9772
5.1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS (VALVES, SWITCHES, SENSORS ETC)…9774
5.2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS…9778
5.3 REMOTE CONTROL VALVES ARRANGEMENT…9784
5.4 FUNCTION PRINCIPLEOF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL…9786
5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK)…9790
5.6 POTENTIOMETER CONTROL (PEDAL)…9792
5.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A…9794
5.8 PROPORTIONAL AMPLIFIER MODULE, TYPE B…9796
5.9 RAMP TIME MODULE…9798
5.10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)…9800
5.11 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION…9802
5.12 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION…9806
5.13 ADJUSTING THE RAMP TIME MODULE…9810
6.0 COMPONENTS…9815
6.1 HYDRAULIC…9815
6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER – FRONT SHOVEL ATTACHMENT…9817
6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACK HOE ATTACHMENT…9819
6.1.3 DISTRIBUTOR MAINFOLD – LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES – FRONT SHOVEL ATTACHMENT…9821
6.1.4 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES – BACKHOE ATTACHMENT…9823
6.1.5 SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM FRONT SHOVEL ATTACHMENT…9825
6.1.6 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE…9827
6.1.7 ANTI CAVITATION VALVE BLOCK…9829
6.1.8 REMOTE CONTROL VALVE…9831
6.1.9 DIRECTIONAL SOLENOID VALVES (THREE POSITIONS / 4-WAY)…9833
6.1.10 PROPORTIONAL SOLENOID VALVE…9835
6.1.11 HIGH PRESSURE FILTER…9837
6.1.12 CONTROL BLOCKS AND VALVES…9839
6.1.13 TRAVEL BRAKE VALVE…9851
6.1.14 PRESSURE REDUCING VALVE…9853
6.1.15 DIRECTIONAL SOLENOID VALVES (TWO POSITIONS / 4-WAYS)…9855
6.1.16 PRESSURE INCREASING VALVE…9857
7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM…9858
7.0 GENERAL LAYOUT (HYDRAULIC ONLY)…9860
7.0 GENERAL LAYOUG (PUMP REGULATION SYSTEM)…9862
7.1 MAIN PUMPS…9868
7.1.1 LOCATION OF PUMPS…9868
7.1.2 PUMP BEARING FLUSHING / LUBRICATION…9870
7.1.3 OPERATING PRINCIPLES…9872
7.1.4 CHECKS / ADJUSTMENTS…9888
7.2 ELECTRONIC PUMP REGULATION SYSTEM…9898
7.2.1 ELECTRONIC LOAD LIMITING CONTROL – GENERAL…9898
7.2.2 MICROCONTROLLER MC7…9900
7.2.3 CHECKS AND ADJUSTMENTS…9902
METHOD A X1 PRESSURE WITH 24V SUPPLY…9904
METHOD B – WITH ELECTRONIC SERVICE TOOL…9906
LANGUAGE SELECTION…9906
EXCAVATOR TYPE SELECTION…9910
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT…9914
METHOD C – WITH A LAPTOP COMPUTER…9918
STARTING THE PROGRAM…9918
LANGUAGE SELECTION…9922
EXCAVATOR TYPE SELECTION…9924
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT…9926
7.3 HYDRAULIC CONSTANT REGULATION SYSTEM…9928
7.3.1 GENERAL…9928
7.3.2 X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE)…9930
7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)…9932
8.0 OPERATING HYDRAULIC…9933
OPERATING HYDRAULIC – GENERAL…9935
8.1 HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA…9938
8.1.1 ELECTRIC/HYDRAULIC FLOWCHART "BOOM RAISING"…9940
8.1.2 ELECTRIC/HYDRAULIC FLOWCHART "BOOM LOWERING"…9944
8.1.3 ELECTRIC/HYDRAULIC FLOWCHART "STICK EXTENDING"…9948
8.1.4 ELECTRIC/HYDRAULIC FLOWCHART "STICK RETRACTING"…9952
8.1.5 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET FILLING"…9956
8.1.6 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET EMPTYING"…9960
8.1.7 ELECTRIC/HYDRAULIC FLOWCHART "CLAM OPENING"…9964
8.1.8 ELECTRIC/HYDRAULIC FLOWCHARG "CLAM CLOSING"…9966
8.1.9 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES …9968
8.1.10 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES…9972
Boom cylinder “Piston side” FSA +BHA…9974
Boom cylinder “Piston rod side” FSA +BHA…9976
Stick cylinder “Piston side” FSA…9980
Stick cylinder “Piston side” BHA…9984
Stick cylinder “Piston rod side” FSA…9988
Stick cylinder “Piston rod side” BHA…9992
Bucket cylinder “Piston side” FSA…9996
Bucket cylinder “Piston side” BHA…10000
Bucket cylinder “Piston rod side” FSA…10004
Bucket cylinder “Piston rod side” BHA…10008
Clam cylinder “Piston rod side” FSA…10012
Clam cylinder “Piston side” FSA…10014
8.1.11 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED…10016
Boom cylinder FSA…10018
Boom cylinder BHA…10022
Stick cylinder BHA…10028
Bucket cylinder FSA…10030
Bucket cylinder BHA…10032
Clam cylinder BHA…10034
8.2 HYDRAULIC FOR THE SWING CIRCUIT…10035
8.2.1 SWING CIRCUIT…10037
8.2.2 SWING MOTOR…10041
8.2.3 SWING GEAR BOX…10045
8.2.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE)…10047
8.2.5 SWING BRAKE VALVE…10049
8.2.6 ELECTRIC/HYDRAULIC FLOWCHART "SWING LEFT"…10053
8.2.7 ELECTRIC/HYDRAULIC FLOWCHART "SWING RIGHT"…10055
8.2.8 SWING MONITORING SYSTEM…10057
8.2.9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT…10061
8.2.10 FUNCTION FOR THE SWING PARKING BRAKE…10067
8.3 HYDRAULIC FOR THE SWING CIRCUIT…10068
8.3.1 TRAVEL CIRCUIT…10070
8.3.2 TRAVEL MOTOR…10074
8.3.3 ROTARY DISTRIBUTOR…10076
8.3.4 TRAVEL GEAR…10078
8.3.5 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)…10080
8.3.6 TRAVEL BRAKE VALVE…10082
8.3.7 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING FORWARD"…10084
8.3.8 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING BACKWARD"…10086
8.3.9 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT…10088
8.3.10 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE…10090
9.0 HYDRAULIC TRACK TENSIONING SYSTEM…10091
9.0 GENERAL…10093
9.1 FUNCTIONAL DESCRIPTION…10095
9.2 PRESSURE INCREASING VALVE…10099
9.3 TENSIONING CYLINDER…10101
9.4 ADJUSTMENTS / CHECKS…10103
9.5 FUNCTIONAL TEST…10107
10.0 ACCESS LADDER HYDRAULIC OPERAGED…10108
10.0 GENERAL…10110
10.1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER…10112
11.0 HYDRAULIC OPERATED REFILLING ARM…10115
11.0 GENERAL…10117
11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM…10119
12.0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM…10120
12.0 GENERAL…10121
12.1 LEGEND FOR THE CIRCUIT DIAGRAM…10122
12.2 HOW TO READ THE CIRCUIT DIAGRAM…10130
13.0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM…10131
13.1 DESIGNATION OF ELECTRICAL DEVICES…10133
13.2 SYMBOLS…10135
13.3 GENERAL INFORMATION…10139
13.4 READING A CIRCUIT DIAGRAM…10143
13.5 COMPONENT LIST…10147
14.0 VEHICLE HEALTH MONITORING SYSTEM…10293
DATA FLOW CONTROL OF VHMS…10294
GENERAL…10295
14.1 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR OPERATORS…10272
14.1.1 GRAPHIC FLOW CHART…10274
14.1.2 INITIALIZATION SCREEN (NO. 0.0)…10276
14.1.3 OPERATOR INFORMATION SCREEN ( NO. 1.1)…10276
14.1.4 MONITORING SCREENS…10278
STANDARD MONITOR 1 (NO. 1.2)…10278
EXPANSION MONITOR 2 (NO.1.3)…10278
EXPANSION MONITOR 3 (NO. 1.4)…10278
14.1.5 BRIGHTNESS AND CONTRAST SETTING SCREEN (NO. 1.2.1)…10280
14.1.6 FUEL CONSUMPTION SCREEN (NO. 1.2.2)…10282
14.1.7 SETTINGS FOR OPERATOR, SCREEN (NO. 1.2.3)…10284
14.1.8 MAINTENANCE MONITOR (NO. 1.2.4)…10286
14.1.9 FAILURE MESSAGE ( NO. 1.2.5)…10290
14.1.10 AUTOMATIC MESSAGES…10292
14.2 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR SERVICEMEN…10213
14.2.1 GRAPHIC FLOW CHART…10215
14.2.2 SERVICE ID SETUP SCREEN (NO. 2.0)…10217
14.2.3 SERVICE MENU SELECT SCREEN (NO. 3.1)…10219
14.2.4 REAL TIME MENU SELECT SCREEN (NO. 4.1.1)…10221
ENGINE 5.1.1 – 5.1.4…10221
TRANSMISSION 5.2.1…10223
HYDRAULIC 5.3.1 – 5.4.2…10225
ELECTRICAL EQUIPMENT 5.4.1 – 5.4.2…10227
EMERGENCY STOP 5.5.1…10229
MANUAL SWITCH 5.6.1 – 5.6.3…10231
CENTRAL LUBRICATION SYSTEM 5.7.1 – 5.7.2…10233
SWING LUBRICATION SYSTEM 5.8.1 – 5.8.2…10235
OTHER ITEMS 5.9.1 – 5.9.3…10237
OUTPUT SIGNALS 5.10.1 – 5.10.6…10239
14.2.5 PM-CLINIC…10241
PM CLINIC GENERAL – 4.2.1 – 4.2.2…10241
PM CLINIC POWER CHECK – 4.2.3 – 4.2.5…10243
14.2.6 SERIAL NO. SETTING …10245
MACHINE 4.3.1…10245
ENGINE 4.3.2…10247
14.2.7 MEMORY CLEAR…10249
INPUT ID 4.3.2…10249
MEMORY CLEAR 4.4.1…10251
14.2.8 MAINTENANCE MONITOR – MAINTENANCE ACKNOWLEDGEMENT – 4.5 – 4.5.1…10253
14.2.9 FAILURE HISTORY – 4.6…10255
14.2.10 SNAPSHOT TRIGGER- 4.7…10257
14.2.11 SETTINGS…10259
CENTRAL LUBRICATION SYSTEM 4.8.1…10259
SWING LUBRICATION SYSTEM 4.8.2…10261
OTHER SETTINGS 1/2…10263
LANGUAGE…10264
OPERATING HOURS…10264
DATE…10264
TIME…10265
GMT REFERENCE…10265
OTHER SETTINGS 2/2…10267
OIL VISCOSITY HYDRAULIC…10267
OIL VISCOSITY GEAR…10267
MESSAGES ON/OFF…10269
PLC-AUTOM. ON/OFF…10269
SHUT DOWN ON.OFF 4.8.5 – 4.8.10…10271
14.4 WIRING OF THE MAIN COMPONENTS…10200
14.4.1 WIRING OF THE ENGINE…10204
14.4.2 WIRING OF THE VHMS CONTROLLER…10206
14.4.3 WIRING OF THE CGC MONITOR…10210
14.4.4 WIRING OF THE PLC…10212
15.0 LUBRICATION SYSTEMS…10300
15.1 HYDRAULICALLY DRIVEN LUBE PUMP…10300
FUNCTION…10306
ADJUSTMENTS…10310
15.2 ONE LINE SYSTEM WITH HYDRAULICALLY DRIVEN "PUMP MASTER III" PUMP…10312
FUNCTION…10314
ELECTRICAL FUNCTION…10318
SONAR SENSOR FOR GREASE LEVEL…10322
ADJUSTMENTS…10324
END LINE SWITCH…10324
INJECTORS…10326
15.3 PINION TYPE SYSTEM WITH HYDRAULIC DRIVEN "POWER MASTER III" PUMP…10328
FUNCTION…10331
ELECTRICAL FUNCTION…10334
LUBRICANT LEVEL…10338
ADJUSTMENTS…10340
END OF LINE SWITCH SETTING…10340
INJECTORS…10342
15.4 COMPONENTS…10344
HYDRAULICALLY DRIVEN "POWER MASTER III" LUBE PUMP…10346
LUBRICANT INJECTORS…10350
END-OF-LINE SWITCH…10356
FILTER…10358
VENT VALVE…10360
FLOWCHART 942 107 40 …10370
FLOWCHART 942 107 40 PAGE 1 OF 70…10370
…
ELECTRICAL PLAN 942 106 40 PAGE 73 OF 73…10521

Komatsu Hydraulic Mining Shovel PC4000 Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 10, 2025 by admin

Komatsu Hydraulic Mining Shovel PC3000 Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Mining Shovel PC3000-1, PC3000-6, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Mining Shovel PC3000-1, PC3000-6 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SMPC30006171 – Hydraulic Mining Shovel PC3000-1 Shop Manual.pdf
SMPC30006174 – Hydraulic Mining Shovel PC3000-1 Shop Manual.pdf
SMPC30006182 – Hydraulic Mining Shovel PC3000-1 Shop Manual.pdf
SMPC30006194 – Hydraulic Mining Shovel PC3000-1 Shop Manual.pdf
SMPC30006199 – Hydraulic Mining Shovel PC3000-1 Shop Manual.pdf
SMPC30006202 – Hydraulic Mining Shovel PC3000-1 Shop Manual.pdf
SMPC30006208 – Hydraulic Mining Shovel PC3000-6 Service Manual.pdf
SMPC30006219 – Hydraulic Mining Shovel PC3000-6 Shop Manual.pdf
SMPC30006224 – Hydraulic Mining Shovel PC3000-6 Shop Manual.pdf
SMPC30006225 – Hydraulic Mining Shovel PC3000-1 Shop Manual.pdf
FAMPC3000-07 – Hydraulic Mining Shovel PC3000-6 General Assembly Procedure.pdf
GZEAM06253 – Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual.pdf
Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual (SN06208 &up).pdf
Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual (SN06208 &up, SN46151&up).pdf
Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual (SN46172 &up).pdf
OMPC30006171 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual.pdf
OMPC30006174 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual.pdf
OMPC30006182 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual.pdf
OMPC30006193 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual.pdf
OMPC30006194 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual.pdf
OMPC30006199 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual.pdf
OMPC30006202 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual.pdf
OMPC30006219 – Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual.pdf
OMPC30006224 – Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual.pdf
OMPC30006225 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 10,121 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
FAMPC3000-07 – Hydraulic Mining Shovel PC3000-6 General Assembly Procedure….3
Cover….3
Contents….5
1. General ….7
1.1 Delivery of the Excavator ….7
1.2 Assembling of the Excavator ….7
1.3 Transportation and Lifting ….9
1.4 Manpower / Assembly Time* ….11
1.5 Assembly Site Requirements ….13
1.6 Space and Placing Requirements ….17
1.7 Preparation for Assembly ….17
1.8 Basic Measurements (Z24015) ….19
1.9 Transport Dimensions and Weights (as example) ….19
1.10 Illust. Configuration of Components on Erection Site ….21
2.0 Assembly sequence ….21
2.1. Assembly of Undercarriage (Z 24016; Z 24017; Z 20418) ….23
2.1.1 Assembly ….23
2.1.2 Determination of the tightening torque ….27
2.1.3 Final works ….31
2.2 Assembly of Superstructure onto the Undercarriage (Z 9031a) ….33
2.3. Mounting of Boom and Boom cylinders(Z 9032; Z 20949)….37
2.4. Mounting of Fuel Tank (Z 21924) ….39
2.5 Mounting of Hydraulic access Ladder (Z 24022) ….41
2.5. Mounting of Cab Base (Z 24023) ….43
2.6. Mounting of Counterweight (Z 24024) ….45
2.7. Mounting of Handrails, Steps and Gratings (Z 24025) ….47
2.8. Mounting of Cab (Z 24029) ….49
2.9 Pre-checks prior Initial Start up ….51
2.10 Mounting of Stick ….55
2.10.1 Backhoe Attachment (Z 24030) ….55
2.10.2 Bullclam Bucket Attachment (Z 20950; Z 20951; 20952) ….57
2.11 Assembly of the bucket to the stick ….63
2.11.1 Assembly of the backhoe to the stick (Z 23005) ….63
2.11.2 Assembly of the bullclam bucket to the stick (Z 20953) ….65
2.12 Mounting of the Pin Seals ….69
2.12.1 Backhoe (Z 23006) ….69
2.12.2 Bullclam bucket (Z 21963) ….71
2.13 Putting the Central Lubrication System into operation (Z 24031) ….73
2.14 Standard Application Torque Chart ….75
2.14.1 Metric standard thread ….75
2.14.2 Metric fine thread ….77
2.14.3 Torque Chart for Flange Joints ….78
GZEAM06253 – Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual….79
COVER….79
1. INTRODUCTION….81
1.1 CONTENTS OF THE BINDER….82
1.2 DIVISION OF THE BINDER….83
1.3 DESIGNATED USE OF THE SHOVEL….84
1.4 DELIVERY OF THE SHOVEL….85
1.5 EXPLANATION OF ABBREVIATIONS….86
1.6 TABLE OF CONTENTS….87
2. SAFETY….93
2.1 SAFETY INSTRUCTIONS….94
2.1.1 WARNINGS AND SYMBOLS….94
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL….94
2.1.3 ORGANIZATIONAL MEASURES….95
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES….97
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES….98
2.1.6 WARNING OF SPECIAL DANGERS….101
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING….103
2.1.8 SPECIAL SAFETY EQUIPMENT….103
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)….107
3. OPERATION….115
3.1 FOREWORD….116
3.2 CONSTRUCTION OF THE SHOVEL….117
3.2.1 OVERALL VIEW….117
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE….118
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER….124
3.2.4 EMERGENCY ESCAPE LADDER….128
3.2.5 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE (SPECIAL EQUIPMENT)….130
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM….132
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)….134
3.2.8 ENGINE OIL MANAGEMENT SYSTEM….142
3.3 OPERATOR’S CAB – CONTROLS….150
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT….150
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET….154
3.3.3 OPERATOR’S CONSOLE….159
3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM….166
3.4.1 INTRODUCTION….167
3.4.2 SYSTEM COMPONENTS….171
3.4.3 FUNCTIONS OF THE ETM SYSTEM….173
3.4.4 DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY….177
3.4.5 SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME….189
3.4.6 SETTINGS OF THE TEXT DISPLAY UNIT….191
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING….206
3.5.1 CONTROL MODULE FOR AUXILIARY CAB HEATER (IF SO EQUIPPED)….211
3.5.2 AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED)….213
3.5.3 AUXILLIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED)….215
3.5.4 FUEL PUMP ARRANGEMENT….217
3.6 MACHINERY HOUSE….218
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES….219
3.7 ELECTRICAL EQUIPMENT IN CAB BASE….220
3.7.1 SWITCH BOX (X2) IN CAB BASE….225
3.7.2 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE….229
3.8 PREHEATING SYSTEMS….234
3.8.1 FOR OIL, COOLANT AND BATTERIES….234
3.8.2 HEATERS FOR MACHINERY HOUSE (SPECIAL EQUIPMENT)….240
3.9 CHECKS BEFORE STARTING THE ENGINE….242
3.10 STARTING THE ENGINE….248
3.10.1 STARTING PROCEDURE….249
3.10.2 STARTING PROCEDURE AT AMBIENT TEMPERATURE UP TO -25….251
3.11 MOVING THE SHOVEL….260
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS….260
3.11.2 TRAVELLING INSTRUCTIONS….263
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE….264
3.12.1 SLEWING THE SUPERSTRUCTURE….264
3.13 WORKING WITH THE ATTACHMENT….267
3.13.1 MACHINES EQUIPPED WITH”EURO” CONTROL SYSTEM….267
3.13.2 MACHINES EQUIPPED WITH”KMG” CONTROL SYSTEM….268
3.13.3 BOTTOM DUMP BUCKET….269
3.13.4 DROP BALL OPERATION….270
3.13.5 COMBINED OPERATION CYCLES….273
3.14 WORKING INSTRUCTIONS….275
3.14.1 STABILITY OF THE SHOVEL….275
3.14.2 SHOVEL OPERATION….275
3.15 PARKING THE SHOVEL….278
3.16 STOPPING THE ENGINE….280
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM….283
3.17 AUTOMATIC LUBRICATION SYSTEMS….284
3.17.1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS….285
3.18 FIRE DETECTION AND SUPPRESSION SYSTEM….288
3.18.1 HIGH LEVEL ALARM ”FIRE”….291
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE….291
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM….291
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S….293
3.18.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER….295
3.19 CENTRAL REFILLING SYSTEM….296
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM….297
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM….299
3.19.3 RECEIVER PANEL WITH MONITOR BOX….301
3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS….305
3.20 TRANSFER PUMP FOR HYDRAULIC OIL….306
3.20.1 OPERATING THE TRANSFER PUMP….307
3.20.2 FUNCTIONS OF THE TRANSFER PUMP….307
3.21 WORK ON THE LOADER ATTACHMENT….310
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL….311
3.22.1 DISASSEMBLING OF THE SHOVEL….311
3.22.2 TRANSPORTATION AND LIFTING….311
3.23 RETRIEVAL PROCEDURE….312
3.24 SHOVEL STORAGE….313
3.24.1 PREPARING FOR STORAGE….313
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD….314
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD….314
3.24.4 PREPARING FOR OPERATION….315
3.25 TROUBLE SHOOTING….316
3.25.1 ENGINE….316
3.25.2 HYDRAULIC SYSTEM….317
3.25.3 FINAL DRIVES AND SWING GEAR….318
3.25.4 CRAWLER TRACKS….318
4. MAINTENANCE….319
4.1 FOREWORD….320
4.2 PRECAUTIONS FOR MAINTENANCE….321
4.3 FLUIDS AND LUBRICANTS….323
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES….323
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES….324
4.4 FILLING CAPACITIES….326
4.5 STANDARD TORQUE LIST….327
4.6 LUBRICATION AND MAINTENANCE SCHEDULE….328
4.6.1 INITIAL SERVICING….328
4.6.2 PERIODIC SERVICING INTERVALS….328
4.6.3 PERIODIC SERVICING SCHEDULE….329
4.6.4 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….335
4.6.5 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM….339
4.6.6 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL….341
4.6.7 MAINTENANCE OF THE ENGINE….345
4.7 WHEN NECESSARY….346
4.7.1 ENGINE AIR CLEANER MAINTENANCE….347
4.7.2 SWING CIRCLE TOOTHING LUBRICATION….351
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS….353
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS….357
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER….359
4.8 EVERY 10 OPERATING HOURS OR DAILY….360
4.8.1 WALK – AROUND INSPECTION….361
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER….373
4.8.3 RADIATOR – CHECK COOLANT LEVEL….375
4.8.4 TRACK GROUPS – CLEAN….375
4.8.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER….377
4.9 EVERY 50 OPERATING HOURS OR WEEKLY….378
4.9.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHECK OIL LEVEL….379
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS….383
4.9.3 PTO (PUMP DISTRIBUTOR GEAR) – CHECK OIL LEVEL….387
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR….389
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY….391
4.10 EVERY 250 OPERATING HOURS OR MONTHLY….392
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION….393
4.10.2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER – MAINTENANCE CHECK….395
4.10.3 GENERATOR – CHECK BELT TENSION….399
4.10.4 SIGNAL HORN COMPRESSOR – LUBRICATE….401
4.10.5 HYDRAULIC OIL COOLER FAN – CHECK CONDITION AND FASTENING….401
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER….403
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT….407
4.10.8 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL….409
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL….409
4.11 EVERY 500 OPERATING HOURS OR MONTHLY….410
4.11.1 BATTERIES – CHECK FLUID LEVEL….411
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL….413
4.11.3 FUEL TANK – DRAIN CONDENSATION….415
4.11.4 CRAWLER TRACK – INSPECTION….417
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH….422
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD….423
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE….455
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR AND TRAVEL GEARS – OIL SAMPLE ANALYSIS….469
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE….471
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS….473
4.12.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES….475
4.12.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES….475
4.13 EVERY 2000 OPERATING HOURS OR YEARLY….476
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER….477
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION….491
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR….492
4.14.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHANGE OIL….493
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL….501
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL….505
4.15 FIRE PREVENTION….508
4.16 WELD REPAIRS….510
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE….513
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT….515
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE….517
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE….519
Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual (SN06208 &up)….526
COVER….526
1. INTRODUCTION….528
1.1 CONTENTS OF THE BINDER….529
1.2 DIVISION OF THE BINDER….530
1.3 DESIGNATED USE OF THE SHOVEL….531
1.4 DELIVERY OF THE SHOVEL….532
1.5 EXPLANATION OF ABBREVIATIONS….533
1.6 TABLE OF CONTENTS….534
2. SAFETY….540
2.1 SAFETY INSTRUCTIONS….541
2.1.1 WARNINGS AND SYMBOLS….541
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL….541
2.1.3 ORGANIZATIONAL MEASURES….542
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES….544
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES….545
2.1.6 WARNING OF SPECIAL DANGERS….548
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING….550
2.1.8 SPECIAL SAFETY EQUIPMENT….550
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)….554
3. OPERATION….562
3.1 FOREWORD….563
3.2 CONSTRUCTION OF THE SHOVEL….564
3.2.1 OVERALL VIEW….564
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE….565
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER….571
3.2.4 EMERGENCY ESCAPE LADDER….575
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM….577
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)….579
3.2.7 ENGINE OIL MANAGEMENT SYSTEM….587
3.3 OPERATOR’S CAB – CONTROLS….595
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT….595
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET….599
3.3.3 OPERATOR’S CONSOLE….604
3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM….611
3.4.1 INTRODUCTION….612
3.4.2 SYSTEM COMPONENTS….616
3.4.3 FUNCTIONS OF THE ETM SYSTEM….618
3.4.4 DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY….622
3.4.5 SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME….634
3.4.6 SETTINGS OF THE TEXT DISPLAY UNIT….636
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING….651
3.6 MACHINERY HOUSE….653
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES….654
3.7 ELECTRICAL EQUIPMENT IN CAB BASE….655
3.7.1 SWITCH BOX (X2) IN CAB BASE….660
3.8 CHECKS BEFORE STARTING THE ENGINE….663
3.9 STARTING THE ENGINE….669
3.9.1 STARTING PROCEDURE….672
3.10 MOVING THE SHOVEL….678
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS….678
3.10.2 TRAVELLING INSTRUCTIONS….681
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE….682
3.11.1 SLEWING THE SUPERSTRUCTURE….682
3.12 WORKING WITH THE ATTACHMENT….685
3.12.1 MACHINES EQUIPPED WITH”EURO” CONTROL SYSTEM….685
3.12.2 MACHINES EQUIPPED WITH”KMG” CONTROL SYSTEM….686
3.12.3 BOTTOM DUMP BUCKET….687
3.12.4 DROP BALL OPERATION….688
3.12.5 COMBINED OPERATION CYCLES….691
3.13 WORKING INSTRUCTIONS….693
3.13.1 STABILITY OF THE SHOVEL….693
3.13.2 SHOVEL OPERATION….693
3.14 PARKING THE SHOVEL….696
3.15 STOPPING THE ENGINE….697
3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM….700
3.16 AUTOMATIC LUBRICATION SYSTEMS….701
3.16.1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS….702
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM….705
3.17.1 HIGH LEVEL ALARM ”FIRE”….708
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE….708
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM….708
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S….710
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER….712
3.18 CENTRAL REFILLING SYSTEM….713
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM….714
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM….716
3.18.3 RECEIVER PANEL WITH MONITOR BOX….718
3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS….722
3.19 TRANSFER PUMP FOR HYDRAULIC OIL….723
3.19.1 OPERATING THE TRANSFER PUMP….724
3.19.2 FUNCTIONS OF THE TRANSFER PUMP….724
3.20 WORK ON THE LOADER ATTACHMENT….727
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL….728
3.21.1 DISASSEMBLING OF THE SHOVEL….728
3.21.2 TRANSPORTATION AND LIFTING….728
3.22 RETRIEVAL PROCEDURE….729
3.23 SHOVEL STORAGE….730
3.23.1 PREPARING FOR STORAGE….730
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD….731
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD….731
3.23.4 PREPARING FOR OPERATION….732
3.24 TROUBLE SHOOTING….733
3.24.1 ENGINE….733
3.24.2 HYDRAULIC SYSTEM….734
3.24.3 FINAL DRIVES AND SWING GEAR….735
3.24.4 CRAWLER TRACKS….735
4. MAINTENANCE….736
4.1 FOREWORD….737
4.2 PRECAUTIONS FOR MAINTENANCE….738
4.3 FUEL AND LUBRICANTS….740
4.4 FILLING CAPACITIES….742
4.5 STANDARD TORQUE LIST….743
4.6 LUBRICATION AND MAINTENANCE SCHEDULE….744
4.6.1 INITIAL SERVICING….744
4.6.2 PERIODIC SERVICING INTERVALS….744
4.6.3 PERIODIC SERVICING SCHEDULE….745
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM….752
4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL….754
4.6.6 MAINTENANCE OF THE ENGINE….756
4.7 WHEN NECESSARY….757
4.7.1 ENGINE AIR CLEANER MAINTENANCE….758
4.7.2 SWING CIRCLE TOOTHING LUBRICATION….762
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS….764
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS….768
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER….770
4.8 EVERY 10 OPERATING HOURS OR DAILY….771
4.8.1 WALK – AROUND INSPECTION….772
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER….780
4.8.3 RADIATOR – CHECK COOLANT LEVEL….782
4.8.4 TRACK GROUPS – CLEAN….782
4.8.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER….784
4.8.6 GROUND CABLES – CHECK CONNECTION POINTS….786
4.9 EVERY 50 OPERATING HOURS OR WEEKLY….787
4.9.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHECK OIL LEVEL….788
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS….792
4.9.3 PTO (PUMP DISTRIBUTOR GEAR) – CHECK OIL LEVEL….796
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR….798
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY….800
4.10 EVERY 250 OPERATING HOURS OR MONTHLY….801
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION….802
4.10.2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER – MAINTENANCE CHECK….804
4.10.3 GENERATOR – CHECK BELT TENSION….808
4.10.4 SIGNAL HORN COMPRESSOR – LUBRICATE….810
4.10.5 HYDRAULIC OIL COOLER FAN – CHECK CONDITION AND FASTENING….810
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER….812
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT….816
4.10.8 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL….818
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL….818
4.11 EVERY 500 OPERATING HOURS OR MONTHLY….819
4.11.1 BATTERIES – CHECK FLUID LEVEL….820
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL….822
4.11.3 FUEL TANK – DRAIN CONDENSATION….824
4.11.4 CRAWLER TRACK – INSPECTION….826
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH….831
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD….832
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE….864
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR AND TRAVEL GEARS – OIL SAMPLE ANALYSIS….878
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE….880
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS….882
4.12.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES….884
4.12.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES….884
4.13 EVERY 2000 OPERATING HOURS OR YEARLY….885
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER….886
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION….900
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR….901
4.14.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHANGE OIL….902
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL….910
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL….914
4.15 FIRE PREVENTION….917
4.16 WELD REPAIRS….919
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE….922
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT….924
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE….926
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE….928
Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual (SN06208 &up, SN46151&up)….935
I. INTRODUCTION….937
II. SAFETY….949
III. SPECIFICATIONS….955
1. MAIN ASSEMBLY GROUPS….969
1.1 General layout….970
1.2 Superstructure….972
1.3 Power House….974
1.4 Hydraulic Oil Reservoir….976
1.5 Hydraulic Oil Cooler….978
1.6 Fuel tank (Fuel reservoir)….980
1.7 Counter weight….982
1.8 Cab support….984
1.9 Operators cab….986
1.10 Control blocks….988
1.11 Swing gears….990
1.12 Under carriage….992
2. DRIVE….995
2.1 Prime drive assembly….996
2.2 Engine and gearbox mount….998
2.3 Torque supports….1001
2.4 Radiator fan Drive Assy….1002
2.5 Pump distributor gearbox (PTO)….1004
2.5.1 Spline shaft housing….1006
2.5.2 PTO lubrication and cooling….1008
2.5.3 PTO valve adjustments….1010
2.6 Coupling….1014
2.7 Air Filter….1016
3. HYDRAULIC OIL RESERVOIR….1019
3.1 Hydraulic oil reservoir….1020
3.2 Return and leak oil filter….1024
3.3 Breather Filter….1028
3.4 Location of electrical components….1030
4. HYDRAULIC OIL COOLING….1033
4.1 General….1034
4.2 Hydraulic oil cooling circuit….1036
4.3 Back pressure valve adjustment….1040
4.4 Fan drive….1042
4.4.1 Fan pump….1044
4.4.2 Pressure relieve valve….1045
4.4.3 Temperature relay….1047
4.5 Cooler fan drive adjustment….1048
5. CONTROLLING….1051
5.1 Pilot pressure supply and adjustment….1052
5.1.1 Pilot control arrangement….1054
5.1.2 Pilot pressure adjustment….1056
5.1.3 Check of Control Pressure….1058
5.2 Slew brakes….1060
5.3 Travel parking brake….1063
5.4 Check of the pilot control logic….1065
5.4.1 Check sheet FSA Page 1….1067
5.4.2 Check sheet BHA Page 1….1080
6. COMPONENTS….1089
6.1 Main control block and valve arrangement….1090
6.1.1 FSA arrangement….1092
6.1.2 BHA arrangement….1096
6.2 Distributor manifold….1100
6.2.1 Front shovel attachment FSA….1100
6.2.2 Back hoe attachment BHA….1102
6.2.3 SRV with throttle check valve….1104
6.2.4 Anti cavitation valve (check valve)….1106
6.3 Main control block….1108
6.3.1 Load holding valve….1114
6.3.2 High pressure filter….1116
6.3.3 Pressure relieve valves and anti-cavitation valve….1118
6.3.4 Pressure relieve valves and anti-cavitation valve….1120
6.4 Compact valve blocks….1122
6.5 Compact valve blocks….1124
6.6 Auxiliary gear pumps….1126
6.7 Hydraulic cylinder….1128
6.8 Swing ring….1130
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION….1133
7.1 General….1134
7.1.1 Pump location….1136
7.2 Main pump operating principles….1138
7.2.1 Main pump function….1143
7.3 Main pump checks and adjustments….1146
7.3.1 Peak point diesel engine test….1146
7.3.2 Pressure transducer test….1148
7.3.3 Cut off function….1149
7.3.4 Pump regulation….1151
7.3.5 Swing pump volume reduction….1152
7.4 Electronic pump regulation….1153
7.5 Pump Controller CR700….1156
7.6 Multi Monitor….1158
7.7 Multimonitor software instruction….1160
7.7.1 Multimonitor main control….1160
7.7.2 Service Menu screen….1160
7.7.3 Monitoring (menu item 01)….1161
7.7.4 Abnormality Record (menu item 02)….1162
7.7.5 Default (menu item 03)….1165
7.7.6 Adjustment (menu item 04)….1166
7.7.7 Display Setup (menu item 05)….1168
7.7.8 Table of fault messages and adjustments….1169
7.8 Trouble shooting pump and pump regulation….1178
8. OPERATING HYDRAULIC….1179
8.1 General layout….1180
8.2 Floating function of boom and stick only FSA….1184
8.3 Check and Adjustments for MRV’s and SRV’s….1186
8.3.1 Check and Adjustments for MRV….1188
8.3.2 Check and Adjustment for SRV’s….1190
8.3.3 Check and adjustment of the throttle check valves….1198
8.4 Hydraulic for the swing circuit….1200
8.4.1 Hydraulic for the swing circuit….1204
8.4.2 Slew gear box L & S….1208
8.4.3 Slew parking brake….1212
8.4.4 Slew service brake valve….1216
8.4.5 Checks and adjustment of the slew pressure valve….1221
8.5 Travel circuit….1224
8.5.1 Rotary joint….1226
8.5.2 Travel motor A2FMt….1228
8.5.3 Travel gear….1230
8.5.4 Travel parking brake….1232
8.5.5 Travel control function….1234
8.5.6 Check and Adjustment SRV travel system….1237
9. TRACK TENSION SYSTEM….1239
9.1 General layout….1240
9.2 Track tensioning function….1242
9.2.1 Cushioning….1244
9.2.2 Pressure Increasing valve PIV….1246
9.3 Track tensioning adjustment….1250
9.3.1 Track tensioning function check….1252
10. ACCESS LADDER HYDRAULICALLY OPERATED….1255
10.1 Access ladder….1256
10.2 Access ladder functional description….1258
11. CENTRAL REFILLING SYSTEM….1263
11.0.1 Functional description….1264
12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM….1269
12.1 General….1270
12.2 Symbolic….1272
12.2.1 Lines, unions….1273
12.2.2 Components, valves….1275
12.2.3 Sensors….1275
12.2.4 Valves, valve components….1276
12.2.5 Pump, motor, cylinder….1280
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM….1285
13.1 Designation of electrical components….1287
13.2 Electric symbols….1288
13.3 Symbols….1290
13.3.1 Drawing concept….1292
13.3.2 Reading of the circuit diagram….1298
14. ELECTRONIC TEXT MONITORING SYSTEM ETM….1303
14.1 General Function….1304
15. AUTOMATIC LUBRICATION SYSTEM….1307
15.1 General Function….1308
15.2 Function of a lubrication cycle….1310
15.3 Lubrication pump drive….1318
15.4 Lubrication pump….1320
15.4.1 Adjustments lubricating pump speed….1322
15.4.2 Adjustments lubricating pump pressure….1324
15.5 Lubricant Injector (metering valve)….1326
15.5.1 Connection of one or more injectors….1328
15.5.2 Function lubrication injector (metering valve)….1330
15.6 End line pressure switch….1334
15.7 Lubricant in line filter….1336
15.8 Lubricant level sensor….1338
15.8.1 Capacitive digital type for machines with ETM….1338
15.8.2 Capacitive analog type for machines with PLC….1340
15.9 Lubrication system function and controlling….1342
15.9.1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000)….1343
15.9.2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000)….1347
15.10 Adjustment of the lubrication system with ETM….1353
15.11 Trouble shooting lubricating system….1354
15.11.1 Lubrication pump cylinder does not move….1355
15.11.2 Lubricant pressure built up very slowly or not at all….1357
15.11.3 Insufficient lubricant supply to one or more attachment bearings….1357
15.11.4 Insufficient lubricant at the swing ring gear….1359
Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual (SN46172 &up)….1369
COVER….1369
1. INTRODUCTION….1371
1.1 CONTENTS OF THE BINDER….1372
1.2 DIVISION OF THE BINDER….1373
1.3 DESIGNATED USE OF THE SHOVEL….1374
1.4 DELIVERY OF THE SHOVEL….1375
1.5 EXPLANATION OF ABBREVIATIONS….1376
1.6 TABLE OF CONTENTS….1377
2. SAFETY….1383
2.1 SAFETY INSTRUCTIONS….1384
2.1.1 WARNINGS AND SYMBOLS….1384
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL….1384
2.1.3 ORGANIZATIONAL MEASURES….1385
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES….1387
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES….1388
2.1.6 WARNING OF SPECIAL DANGERS….1391
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING….1393
2.1.8 SPECIAL SAFETY EQUIPMENT….1393
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)….1397
3. OPERATION….1405
3.1 FOREWORD….1406
3.2 CONSTRUCTION OF THE SHOVEL….1407
3.2.1 OVERALL VIEW….1407
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE….1408
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER….1414
3.2.4 EMERGENCY ESCAPE LADDER….1418
3.2.5 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE (SPECIAL EQUIPMENT)….1420
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM….1422
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)….1424
3.2.8 ENGINE OIL MANAGEMENT SYSTEM….1432
3.3 OPERATOR’S CAB – CONTROLS….1440
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT….1440
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET….1444
3.3.3 OPERATOR’S CONSOLE….1449
3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM….1456
3.4.1 INTRODUCTION….1457
3.4.2 SYSTEM COMPONENTS….1461
3.4.3 FUNCTIONS OF THE ETM SYSTEM….1463
3.4.4 DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY….1467
3.4.5 SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME….1479
3.4.6 SETTINGS OF THE TEXT DISPLAY UNIT….1481
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING….1496
3.6 MACHINERY HOUSE….1500
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES….1501
3.7 ELECTRICAL EQUIPMENT IN CAB BASE….1502
3.7.1 SWITCH BOX (X2) IN CAB BASE….1507
3.8 CHECKS BEFORE STARTING THE ENGINE….1510
3.9 STARTING THE ENGINE….1516
3.9.1 STARTING PROCEDURE….1519
3.10 MOVING THE SHOVEL….1525
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS….1525
3.10.2 TRAVELLING INSTRUCTIONS….1528
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE….1529
3.11.1 SLEWING THE SUPERSTRUCTURE….1529
3.12 WORKING WITH THE ATTACHMENT….1532
3.12.1 MACHINES EQUIPPED WITH”EURO” CONTROL SYSTEM….1532
3.12.2 MACHINES EQUIPPED WITH”KMG” CONTROL SYSTEM….1533
3.12.3 BOTTOM DUMP BUCKET….1534
3.12.4 DROP BALL OPERATION….1535
3.12.5 COMBINED OPERATION CYCLES….1538
3.13 WORKING INSTRUCTIONS….1540
3.13.1 STABILITY OF THE SHOVEL….1540
3.13.2 SHOVEL OPERATION….1540
3.14 PARKING THE SHOVEL….1543
3.15 STOPPING THE ENGINE….1544
3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM….1547
3.16 AUTOMATIC LUBRICATION SYSTEMS….1548
3.16.1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS….1549
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM….1552
3.17.1 HIGH LEVEL ALARM ”FIRE”….1555
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE….1555
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM….1555
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S….1557
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER….1559
3.18 CENTRAL REFILLING SYSTEM….1560
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM….1561
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM….1563
3.18.3 RECEIVER PANEL WITH MONITOR BOX….1565
3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS….1569
3.19 TRANSFER PUMP FOR HYDRAULIC OIL….1570
3.19.1 OPERATING THE TRANSFER PUMP….1571
3.19.2 FUNCTIONS OF THE TRANSFER PUMP….1571
3.20 WORK ON THE LOADER ATTACHMENT….1574
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL….1575
3.21.1 DISASSEMBLING OF THE SHOVEL….1575
3.21.2 TRANSPORTATION AND LIFTING….1575
3.22 RETRIEVAL PROCEDURE….1576
3.23 SHOVEL STORAGE….1577
3.23.1 PREPARING FOR STORAGE….1577
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD….1578
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD….1578
3.23.4 PREPARING FOR OPERATION….1579
3.24 TROUBLE SHOOTING….1580
3.24.1 ENGINE….1580
3.24.2 HYDRAULIC SYSTEM….1581
3.24.3 FINAL DRIVES AND SWING GEAR….1582
3.24.4 CRAWLER TRACKS….1582
4. MAINTENANCE….1583
4.1 FOREWORD….1584
4.2 PRECAUTIONS FOR MAINTENANCE….1585
4.3 FLUIDS AND LUBRICANTS….1587
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES….1587
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES….1588
4.4 FILLING CAPACITIES….1590
4.5 STANDARD TORQUE LIST….1591
4.6 LUBRICATION AND MAINTENANCE SCHEDULE….1592
4.6.1 INITIAL SERVICING….1592
4.6.2 PERIODIC SERVICING INTERVALS….1592
4.6.3 PERIODIC SERVICING SCHEDULE….1593
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES….1598
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1599
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM….1603
4.6.7 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL….1605
4.6.8 MAINTENANCE OF THE ENGINE….1607
4.7 WHEN NECESSARY….1608
4.7.1 ENGINE AIR CLEANER MAINTENANCE….1609
4.7.2 SWING CIRCLE TOOTHING LUBRICATION….1613
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS….1615
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS….1619
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER….1621
4.8 EVERY 10 OPERATING HOURS OR DAILY….1622
4.8.1 WALK – AROUND INSPECTION….1623
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER….1633
4.8.3 RADIATOR – CHECK COOLANT LEVEL….1635
4.8.4 TRACK GROUPS – CLEAN….1635
4.8.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER….1637
4.8.6 GROUND CABLES – CHECK CONNECTION POINTS….1639
4.9 EVERY 50 OPERATING HOURS OR WEEKLY….1640
4.9.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHECK OIL LEVEL….1641
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS….1645
4.9.3 PTO (PUMP DISTRIBUTOR GEAR) – CHECK OIL LEVEL….1649
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR….1651
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY….1653
4.10 EVERY 250 OPERATING HOURS OR MONTHLY….1654
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION….1655
4.10.2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER – MAINTENANCE CHECK….1657
4.10.3 GENERATOR – CHECK BELT TENSION….1661
4.10.4 SIGNAL HORN COMPRESSOR – LUBRICATE….1663
4.10.5 HYDRAULIC OIL COOLER FAN – CHECK CONDITION AND FASTENING….1663
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER….1665
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT….1669
4.10.8 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL….1671
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL….1671
4.11 EVERY 500 OPERATING HOURS OR MONTHLY….1672
4.11.1 BATTERIES – CHECK FLUID LEVEL….1673
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL….1675
4.11.3 FUEL TANK – DRAIN CONDENSATION….1677
4.11.4 CRAWLER TRACK – INSPECTION….1679
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH….1684
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD….1685
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE….1717
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR AND TRAVEL GEARS – OIL SAMPLE ANALYSIS….1731
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE….1733
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS….1735
4.12.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES….1737
4.12.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES….1737
4.13 EVERY 2000 OPERATING HOURS OR YEARLY….1738
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER….1739
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION….1753
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR….1754
4.14.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHANGE OIL….1755
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL….1763
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL….1767
4.15 FIRE PREVENTION….1770
4.16 WELD REPAIRS….1772
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE….1775
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT….1777
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE….1779
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE….1781
OMPC30006171 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual….1788
Cover….1788
Introduction….1789
Introduction….1789
General Content….1795
Table of Contents….1795
Part 1: Operation Manual….1801
Table of Contents….1801
Foreword….1805
Construction of the Excavator….1807
Safety Instructions….1821
Operator's Cab-Controls….1864
Operator's Cab-Monitors….1874
Operator's Instructions….1964
Working Instructions….2026
Parking the Excavator….2032
Refilling System….2034
Exchange of Attachment and/or Components….2051
Transportation and Lifting of the Excavator….2053
Retrieval Procedure….2055
Part 2: Lubrication and Maintenance Manual….2057
Subject….2057
Table of Contents….2057
Foreword….2059
Safety Instructions….2075
Fuel and Lubricants….2079
Filling Capacities….2083
Lubrication and Maintenance Schedule….2085
Lubrication and Maintenance Work….2106
Excavator Storage….2283
Troubleshooting….2289
Part 3: Diverse Literature….2294
OMPC30006174 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual….2295
COVER….2295
INTRODUCTION….2296
GENERAL CONTENT….2302
TABLE OF CONTENTS….2302
PART 1. OPERATION MANUAL….2306
A. EXPLANATION OF ABBREVIATIONS….2308
TABLE OF CONTENTS….2306
1. FOREWORD….2310
CONSTRUCTION OF THE EXCAVATOR….2311
CONSTRUCTION OF THE EXCAVATOR….2311
CATWALK IN FRONT OF THE OPERATOR'S CAB….2323
EMERGENCY ESCAPE LADDER….2325
SAFETY INSTRUCTIONS….2328
SAFETY INSTRUCTIONS….2328
LADDERS, WALKWAYS AND ACCESS DOORS….2361
EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN….2363
OPERATOR'S CAB….2365
OPERATOR'S SEAT….2367
OPERATOR'S CAB, CONTROLS….2369
OPERATOR'S CAB, CONTROLS….2369
OPERATOR'S CAB, MONITORS….2379
ELECTRONIC TEXT AND MONITORING SYSTEM ETM….2379
POWER HOUSE CONTROLS….2443
MAIN SWITCH BOARD IN CAB BASE….2447
PREHEATING SYSTEMS….2449
GENERATOR SET….2459
OPERATING INSTRUCTIONS….2469
BEFORE STARTING THE ENGINE….2470
STARTING THE ENGINE….2473
STOPPING THE ENGINE….2483
MOVING THE EXCAVATOR….2487
SLEWING AND BRAKING THE SUPERSTRUCTURE….2495
WORKING WITH THE ATTACHMENT….2499
COMBINED OPERATION CYCLES….2509
OPERATING THE HEATER AND AIR CONDITIONING….2511
OPERATING THE LUBRICATION SYSTEMS….2515
FIRE DETECTION AND SUPPRESSION SYSTEM….2523
WORKING INSTRUCTIONS….2531
WORKING INSTRUCTIONS….2531
PARKING THE EXCAVATOR….2537
PARKING THE EXCAVATOR….2537
REFILLING SYSTEM….2539
CENTRAL REFILLING SYSTEM….2539
SERVICE CRANE FOR GREASE BARRELS….2549
EXCHANGE OF ATTACHMENT AND/OR COMPONENTS….2556
EXCHANGE OF ATTACHMENTS AND/OR COMPONENTS….2556
TRANSPORTATION AND LIFTING OF THE EXCAVATOR….2558
TRANSPORTATION AND LIFTING OF THE EXCAVATOR….2558
RETRIEVAL PROCEDURE….2560
RETRIEVAL PROCEDURE….2560
PART 2. LUBRICATION AND MAINTENANCE MANUAL….2562
TABLE OF CONTENTS….2562
FOREWORD….2564
FIRE PREVENTION….2567
REPAIR WELDINGS….2571
SAFETY INSTRUCTIONS….2580
SAFETY INSTRUCTIONS….2580
FUEL AND LUBRICANTS….2584
FUEL AND LUBRICANTS….2584
FILLING CAPACITIES….2588
FILLING CAPACITIES….2588
LUBRICATION AND MAINTENANCE SCHEDULE….2590
LUBRICATION AND MAINTENANCE SCHEDULE….2590
INITIAL SERVICING….2590
PERIODIC SERVICING SCHEDULE….2608
MAINTENANCE OF ENGINE AND MOTOR….2606
LUBRICATION AND MAINTENANCE WORK….2609
EVERY 10 HOURS OF OPERATION OR DAILY….2610
EVERY 50 HOURS OF OPERATION OR WEEKLY….2630
EVERY 250 HOURS OF OPERATION OR MONTHLY….2646
EVERY 500 HOURS OF OPERATION OR EVERY 3 MONTHS….2666
EVERY 1000 HOURS OF OPERATION OR EVERY 6 MONTHS….2688
EVERY 2000 HOURS OF OPERATION OR ANNUALLY….2746
EVERY 3000 HOURS OF OPERATION BUT AT LEAST ONCE A YEAR….2756
WHEN NECESSARY….2770
EXCAVATOR STORAGE….2789
GENERAL….2789
PREPARING FOR STORAGE….2789
ONE MONTH SERVICE PERIOD….2790
SIX MONTH SERVICE PERIOD….2790
PREPARING FOR OPERATION….2791
TROUBLESHOOTING….2793
GENERAL….2793
ENGINE….2793
HYDRAULIC SYSTEM….2794
TRAVEL AND SLEW GEARS….2795
CRAWLER TRACKS….2795
OMPC30006182 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual….2797
Cover….2797
Introduction….2798
Introduction….2798
General Content….2804
Table of Contents….2804
Part 1: Operation Manual….2810
Table of Contents….2810
Foreword….2814
Construction of the Excavator….2816
Safety Instructions….2830
Operator's Cab-Controls….2873
Operator's Cab-Monitors….2883
Operator's Instructions….2973
Working Instructions….3035
Parking the Excavator….3041
Refilling System….3043
Exchange of Attachment and/or Components….3060
Transportation and Lifting of the Excavator….3062
Retrieval Procedure….3064
Part 2: Lubrication and Maintenance Manual….3066
Subject….3066
Table of Contents….3066
Foreword….3068
Safety Instructions….3084
Fuel and Lubricants….3088
Filling Capacities….3092
Lubrication and Maintenance Schedule….3094
Lubrication and Maintenance Work….3115
Excavator Storage….3292
Troubleshooting….3298
Part 3: Diverse Literature….3303
OMPC30006193 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual….3304
COVER….3304
INTRODUCTION….3305
GENERAL CONTENT….3311
TABLE OF CONTENTS….3311
PART 1. OPERATION MANUAL….3315
A. EXPLANATION OF ABBREVIATIONS….3317
TABLE OF CONTENTS….3315
1. FOREWORD….3319
CONSTRUCTION OF THE EXCAVATOR….3320
CONSTRUCTION OF THE EXCAVATOR….3320
CATWALK IN FRONT OF THE OPERATOR'S CAB….3332
EMERGENCY ESCAPE LADDER….3334
SAFETY INSTRUCTIONS….3337
SAFETY INSTRUCTIONS….3337
LADDERS, WALKWAYS AND ACCESS DOORS….3370
EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN….3372
OPERATOR'S CAB….3374
OPERATOR'S SEAT….3376
OPERATOR'S CAB, CONTROLS….3378
OPERATOR'S CAB, CONTROLS….3378
OPERATOR'S CAB, MONITORS….3388
ELECTRONIC TEXT AND MONITORING SYSTEM ETM….3388
POWER HOUSE CONTROLS….3452
MAIN SWITCH BOARD IN CAB BASE….3456
PREHEATING SYSTEMS….3458
GENERATOR SET….3468
OPERATING INSTRUCTIONS….3478
BEFORE STARTING THE ENGINE….3479
STARTING THE ENGINE….3482
STOPPING THE ENGINE….3492
MOVING THE EXCAVATOR….3496
SLEWING AND BRAKING THE SUPERSTRUCTURE….3504
WORKING WITH THE ATTACHMENT….3508
COMBINED OPERATION CYCLES….3518
OPERATING THE HEATER AND AIR CONDITIONING….3520
OPERATING THE LUBRICATION SYSTEMS….3524
FIRE DETECTION AND SUPPRESSION SYSTEM….3532
WORKING INSTRUCTIONS….3540
WORKING INSTRUCTIONS….3540
PARKING THE EXCAVATOR….3546
PARKING THE EXCAVATOR….3546
REFILLING SYSTEM….3548
CENTRAL REFILLING SYSTEM….3548
SERVICE CRANE FOR GREASE BARRELS….3558
EXCHANGE OF ATTACHMENT AND/OR COMPONENTS….3565
EXCHANGE OF ATTACHMENTS AND/OR COMPONENTS….3565
TRANSPORTATION AND LIFTING OF THE EXCAVATOR….3567
TRANSPORTATION AND LIFTING OF THE EXCAVATOR….3567
RETRIEVAL PROCEDURE….3569
RETRIEVAL PROCEDURE….3569
PART 2. LUBRICATION AND MAINTENANCE MANUAL….3571
TABLE OF CONTENTS….3571
FOREWORD….3573
FIRE PREVENTION….3576
REPAIR WELDINGS….3580
SAFETY INSTRUCTIONS….3589
SAFETY INSTRUCTIONS….3589
FUEL AND LUBRICANTS….3593
FUEL AND LUBRICANTS….3593
FILLING CAPACITIES….3597
FILLING CAPACITIES….3597
LUBRICATION AND MAINTENANCE SCHEDULE….3599
LUBRICATION AND MAINTENANCE SCHEDULE….3599
INITIAL SERVICING….3599
PERIODIC SERVICING SCHEDULE….3617
MAINTENANCE OF ENGINE AND MOTOR….3615
LUBRICATION AND MAINTENANCE WORK….3618
EVERY 10 HOURS OF OPERATION OR DAILY….3619
EVERY 50 HOURS OF OPERATION OR WEEKLY….3639
EVERY 250 HOURS OF OPERATION OR MONTHLY….3655
EVERY 500 HOURS OF OPERATION OR EVERY 3 MONTHS….3675
EVERY 1000 HOURS OF OPERATION OR EVERY 6 MONTHS….3697
EVERY 2000 HOURS OF OPERATION OR ANNUALLY….3755
EVERY 3000 HOURS OF OPERATION BUT AT LEAST ONCE A YEAR….3765
WHEN NECESSARY….3779
EXCAVATOR STORAGE….3798
GENERAL….3798
PREPARING FOR STORAGE….3798
ONE MONTH SERVICE PERIOD….3799
SIX MONTH SERVICE PERIOD….3799
PREPARING FOR OPERATION….3800
TROUBLESHOOTING….3802
GENERAL….3802
ENGINE….3802
HYDRAULIC SYSTEM….3803
TRAVEL AND SLEW GEARS….3804
CRAWLER TRACKS….3804
OMPC30006194 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual….3806
Cover….3806
Introduction….3807
Introduction….3807
General Content….3813
Table of Contents….3813
Part 1: Operation Manual….3819
Table of Contents….3819
Foreword….3823
Construction of the Excavator….3825
Safety Instructions….3839
Operator's Cab-Controls….3882
Operator's Cab-Monitors….3892
Operator's Instructions….3982
Working Instructions….4044
Parking the Excavator….4050
Refilling System….4052
Exchange of Attachment and/or Components….4069
Transportation and Lifting of the Excavator….4071
Retrieval Procedure….4073
Part 2: Lubrication and Maintenance Manual….4075
Subject….4075
Table of Contents….4075
Foreword….4077
Safety Instructions….4093
Fuel and Lubricants….4097
Filling Capacities….4101
Lubrication and Maintenance Schedule….4103
Lubrication and Maintenance Work….4124
Excavator Storage….4301
Troubleshooting….4307
Part 3: Diverse Literature….4312
OMPC30006199 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual….4313
Cover….4313
Introduction….4314
Introduction….4314
General Content….4320
Table of Contents….4320
Part 1: Operation Manual….4326
Table of Contents….4326
Foreword….4330
Construction of the Excavator….4332
Safety Instructions….4346
Operator's Cab-Controls….4389
Operator's Cab-Monitors….4399
Operator's Instructions….4489
Working Instructions….4551
Parking the Excavator….4557
Refilling System….4559
Exchange of Attachment and/or Components….4576
Transportation and Lifting of the Excavator….4578
Retrieval Procedure….4580
Part 2: Lubrication and Maintenance Manual….4582
Subject….4582
Table of Contents….4582
Foreword….4584
Safety Instructions….4600
Fuel and Lubricants….4604
Filling Capacities….4608
Lubrication and Maintenance Schedule….4610
Lubrication and Maintenance Work….4631
Excavator Storage….4808
Troubleshooting….4814
Part 3: Diverse Literature….4819
OMPC30006202 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual….4820
Cover….4820
Introduction….4821
Part 1 – Operation Manual….4827
Table of Contents – Operation Manual….4827
Section A – Explanation of Abbreviations Used in this Manual….4829
Section 1.0 – Foreward….4831
Section 2.0 – Construction of the Excavator….4833
2. – Overall View….4833
2.1 – Superstructure….4835
2.3 – Attachment….4839
Backhoe Attachment….4839
Section 3.0 – Safety Instructions….4841
Fundamental Safety Instructions….4842
1.1 – Warnings and Symbols….4842
1.2 – Basic Operation and Designated Use of Hydraulic Excavator….4842
1.3 – Organizational Measures….4843
1.4 – Selection and Qualification of Personal….4845
1.5 – Safety Instructions Governing Specific Operational Phases….4846
1.6 – Warning of Special Dangers….4851
1.7 – Transporting and Towing – Recommissioning….4854
1.8 – Special Safety Equipment….4855
Safety Harness….4857
Instructions for Use….4857
Prior to Using Harness….4859
Recommendations for Use of Holding Hooks and Hold-Back Hooks….4861
Instructions for Use of Strap-Type Fall Absorber….4861
Section 3.1 – Ladder, Walkways, and Access Doors….4863
Superstructure….4863
Sea Protection Covers….4866
Section 3.2 – Transport of Excavator….4867
Short Transport with Calm Sea Conditions Drawing….4868
Long Transport with Rough Sea Conditions Drawing….4869
Location of Plug Socket for Hydraulic Oil Heating System….4870
Section 3.3 – Operator's Seat….4873
Section 4.0 – Operator's Cab – Controls and Monitors….4875
Control Levers and Control Pedals….4875
Safety Circuit for Controls….4875
Switch Board….4879
Instruments and Pontoon Controls….4881
Section 5.0 – Electronic Text Monitoring System Komatsu ETM….4883
Introduction….4883
Further Features of the ETM System….4883
Messages are Divided into Two Main Groups….4883
Function of the Keys (1 to 8) of Keyboard….4885
System Components….4887
Switches for Adjustment of the ETM….4889
Message Classification….4889
Functions of the ETM System….4891
Display the Content of Record (PROTOCOL) Memory….4897
Display the Content of Static Memory….4899
Print Out Content of Static Memory….4901
Print Out Content of Record (PROTOCOL) Memory….4901
Change-over from English to German Language….4907
Change-over from German to English Language….4907
Several Massage Conditions Occur at Same Time….4909
Setting the Display Unit….4911
Erase Record (PROTOCOL) and STATISTICS Memory….4913
Return to System Level….4915
Setting Screen Brightness….4915
Table of Messages….4916
Basic Display (Message Page no. 0)….4916
Message Page Number 1 to 5….4916
Message Page Number 6 to 11….4917
Message Page Number 12 to 18….4918
Message Page Number 19 to 26….4919
Message Page Number 27 to 30….4920
Message Page Number 31 to 38….4921
Message Page Number 39 to 44….4922
Message Page Number 45 to 52….4923
Message Page Number 53 to 64….4924
Grouping Messages According to their Priority….4926
1st Priority Group….4926
2nd Priority Group….4927
3rd Priority Group….4927
4th Priority Group….4928
Explanation of the Statics Print-Out….4929
Time Diagram of Statics Print….4930
Section 5.1 – Power House Controls….4933
Section 5.2 – Electrical Equipment in Cab Base….4937
Main Switch X2 in Cab Base….4939
Diagnostic Fault Codes of Engine Centry System….4939
Switch Box X7 for Cab Heating and Air Conditioning….4941
Section 5.3 – Preheating System for Hydraulic Oil….4943
General….4943
Operating the Heating System….4943
Section 5.4 – Engine Oil Management System….4945
General….4945
Centinel Diagnostic Lamps….4947
Check Centinel Diagnostic Lamps for Faults….4947
Clearing Active Faults and Reset the Centinel System….4949
Resetting the Centinel System is Necessary….4949
Check the Centinel System for Proper Operation….4949
Calibration Plug for Engine Oil Quality….4949
Oil Burning System Centinel Combined with Reverse System….4950
Eliminator Engine Oil Filter….4951
Section 5.5 – Operator's Cab Arrangement of Components….4953
Section 6.1 – Ceheck Before Starting the Engine….4955
Section 6.2 – Starting the Engine….4959
Before Starting….4959
Starting Procedure….4959
Cold Weather Starting….4961
After Starting….4961
Automatic Engine Shut-Down System (Safety Chain)….4963
Untitled….4965
Engine Warm-Up….4965
Hydraulic Oil Warm-Up….4965
Hydraulic Oil Viscosity and Temperature Chart….4967
Section 6.3 – Stopping the Engine….4969
Stopping Procedure….4969
Section 6.4 – Pontoon Operation….4971
Warping of the Pontoon….4973
Float Position of Backhoe Attachment….4973
Determination of Directions….4973
Shut-off Cocks for the Pontoon Hydraulic System….4975
Section 6.5 – Slewing and Braking the Superstructure….4977
6.5.1 – Rotating the Superstructure….4977
6.5.2 – Swing Angle Limitation System….4977
6.5.3 – Braking the Superstructure….4977
6.5.4 – Swing Parking Brake….4979
Section 6.6 – Working with the Attachment….4981
Section 6.7 – Combined Operation Cycles….4985
Section 6.8 – Operating the Heater, Ventilation, and Air Conditioning….4987
Heating….4987
Air Conditioning (Special Equipment….4989
Combined Operation of Air Conditioning and Heating….4989
Section 6.11 – Automatic Lubrication Systems….4991
Central Lubrication System and Swing Ring Gear Lubrication System….4991
Controls of Automatic Lubrication Systems….4991
Factory Adjustments….4993
Section 6.13 – Fire Detection and Suppression System (Special Equipment)….4995
Section 6.15 – Transfer Pump for Hydraulic Oil Reservoir….5003
Functions of the Transfer Pump….5003
Transfer Procedure….5005
Section 7.0 – Working Instructions….5009
Excavator Operation….5009
Barge Warping….5009
Pontoon Warping….5011
Maintaining the Pontoon in the Flow….5011
Slowing Down Pontoon Motions….5011
Working Ashore or at Banks from the Pontoon….5011
Working in Shallow Waters….5011
Depositing the Attachment During Working Breaks….5013
Section 7.1 – Emergency Operation System….5015
Section 9.0 – Refueling the Excavator….5017
Section 10.0 – Exchange of Attachment and/or Components….5019
Part 2 – Lubrication and Maintenance Manual….5021
Table of Contents – Lubrication and Maintenance Manual….5021
Section 1.0 – Foreward….5023
Section Contents….5023
Definitions….5024
Section 1.1 – Fire Prevention….5027
Section 1.2 – Repair Welding….5031
Section 2.0 – Safety Instructions….5039
Section 3.0 – Fuel and Lubricants….5041
Section 4.0 – Filling Capacities….5043
Section 5.0 – Lubrication and Maintenance Schedule….5045
5.1 – Initial Servicing….5045
5.2 – Periodic Servicing Intervals….5045
Service Interval Chart….5046
Replacement of Hydraulic Hose Lines….5051
Inspection of Hydraulic Hose Lines….5051
5.3 – Extended Service Intervals for Engines with Engine Oil Management System….5053
Servicing Intervals….5053
Every 10 Operating Hours….5053
Every 500 Operating Hours….5055
Every 4000 Operating Hours….5055
Engine Oil Reserve Tank….5055
5.3.1 – Resetting of Engine Oil Burning System Centinel….5057
5.4 – Maintenance of Engine….5057
5.5 – Maintenance of Eliminator Oil Filtration System….5057
Lubrication Point and Maintence Chart….5058
Section 6.1 – Every 10 Operating Hours or Daily….5061
1. – Visual Inspection….5061
1.1 – Central Lubrication System….5065
Backhoe Attachment….5065
Bullclam Bucket Attachment….5067
Slweing Connection….5069
1.2 – Grease Injectors, Corrective Actions….5069
1.3 – Check Slew Ring Teeth for Proper Lubrication….5071
2. – Maintenance of Engines….5073
3. – Lubrication of Attachment….5073
3.1 – Lubrication of Backhoe Attachment….5073
3.2 – Lubrication of Front Loader Attachment….5073
4. – Lubrication of Slewing Connection….5075
5. – Engine Air Cleaners….5077
6. – Not Used….5077
7. – Radiator – Check Coolant Level….5079
8. – Track Groups….5079
9. – Fuel System, Water Separator….5079
Section 6.2 – Every 50 Operating Hours or Weekly….5081
10. – Slew Gear and Motor Adapter Housing….5081
11. – Not Used….5083
12. – Pump Distributor Geat (PTO) and Oil Reservoirs….5083
13. – Radiator and Hydraulic Oil Coolers….5087
14. – Air Conditioning….5087
15. – Maintenance of Engines….5087
Section 6.3 – Every 250 Operating Hours or Monthly….5089
50. – Engine….5089
51. – Drive Belts….5089
52. – Not Used….5097
53. – Not Used….5097
54. – Hydraulic Oil Cooler – Lubricate Fan Bearings….5097
55. – Not Used….5097
56. – Not Used….5097
57. – Compressor for Signal Horn….5099
58. – Automatic Lubrication Systems, Clean In-Line-Grease-Filters….5101
59. – Air Cleaner for Operator's Cab….5103
60. – Air Conditioning….5103
61. – Not Used….5103
62. – Not Used….5103
63. – Air Conditioning Refrigerant Compressor….5105
Section 6.4 – Every 500 Operating Hours or Every 3 Months….5107
70. – Engine….5107
71. – Batteries….5107
72. – Fuel Tank, Drain Water and Sediments….5109
73. – Flexible Drive Coupling….5111
74. – Rotary Distributor Lubrication….5113
Section 6.5 – Every 1000 Operating Hours or Every 6 Months….5115
80. – High-Strength Bolt Connections….5115
Bolt Torque Chart….5139
81. – Maintenance of Engines….5141
82. – Hydraulic System….5141
83. – Pump Distributor Gears, Slew Gears, and Travel Gears….5155
84. – Compressor for Signal Horn….5157
85. – Not Used….5157
86. – Air Conditioning….5157
Section 6.6 – Every 2000 Operating Hours or Yearly….5159
100. – Hydraulic System….5159
Section 6.7 – Every 3000 operating operating Hours but at Least Once a Year….5167
111. – Slew Gear and Motor Adapter Housing….5167
111. – Pump Distributor Gear (PTO)….5171
Section – 6.8 – When Necessary….5175
120. – Servicing the Engine Air Cleaners….5175
121. – Additional Fuel System Water Separator….5181
122. – Slew Gear….5183
123. – Automatic Lubrication Systems with Replaceable Grease Barrels….5185
124. – Not Used….5187
125. – Not Used….5187
126. – Not Used….5187
127. – Not Used….5187
128. – Hydraulic System….5187
129. – Cold Starting Aid, Replace Fluid Cylinder….5187
130. – Electrical Switch Board (X2)….5189
Section 7.0 – Excavator Storage….5191
General….5191
1. Preparing for Storage….5191
2. One Month Repetitive Service Peroid….5192
3. Six Month Repetitive Service Period….5192
4. Preparing for Operation….5193
Section 8.0 – Troubleshooting….5195
General….5195
Engine….5195
Hydraulic System….5196
Travel and Slew Gears….5197
Crawler Tracks….5197
OMPC30006219 – Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual….5198
COVER….5198
1. INTRODUCTION….5200
1.1 CONTENTS OF THE BINDER….5201
1.2 DIVISION OF THE BINDER….5202
1.3 DESIGNATED USE OF THE SHOVEL….5203
1.4 DELIVERY OF THE SHOVEL….5204
1.5 EXPLANATION OF ABBREVIATIONS….5205
1.6 TABLE OF CONTENTS….5206
2. SAFETY….5212
2.1 SAFETY INSTRUCTIONS….5213
2.1.1 WARNINGS AND SYMBOLS….5213
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL….5213
2.1.3 ORGANIZATIONAL MEASURES….5214
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES….5216
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES….5217
2.1.6 WARNING OF SPECIAL DANGERS….5220
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING….5222
2.1.8 SPECIAL SAFETY EQUIPMENT….5222
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)….5226
3. OPERATION….5234
3.1 FOREWORD….5235
3.2 CONSTRUCTION OF THE SHOVEL….5236
3.2.1 OVERALL VIEW….5236
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE….5237
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER….5243
3.2.4 EMERGENCY ESCAPE LADDER….5247
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM….5249
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)….5251
3.2.7 ENGINE OIL MANAGEMENT SYSTEM….5259
3.3 OPERATOR’S CAB – CONTROLS….5267
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT….5267
Hydraulic Control System….5268
Safety Circuit for Controls….5268
EURO Control Pattern….5270
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET….5271
Hydraulic Control System….5272
Safety Circuit for Controls….5272
Automatic Float Position for Boom and Stick….5272
EURO Control Pattern….5274
3.3.3 OPERATOR’S CONSOLE….5276
Control Panel….5278
Rear Panel Controls….5282
3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM….5283
3.4.1 INTRODUCTION….5284
Function of the keys (1 to 8) of Keyboard (B):….5286
3.4.2 SYSTEM COMPONENTS….5288
Message Classification….5290
3.4.3 FUNCTIONS OF THE ETM SYSTEM….5290
3.4.4 DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY….5294
Display the Contents of Record Memory….5296
Print out Contents of Statistics Memory:….5298
Print out Contents of Record (PROTOCOL) memory….5298
Print out the last Entries of the Record (PROTOCOL) Memory….5302
Change – over from English to German Language….5304
Change-over from German to English Language….5304
3.4.5 SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME….5306
3.4.6 SETTINGS OF THE TEXT DISPLAY UNIT….5308
TABLE OF MESSAGES….5311
Message Pages Number 1 to 7….5311
Message Pages Number 8 to 15….5312
Message Pages Number 16 to 24….5313
Message Pages Number 25 to 34….5314
Message Pages Number 35 to 43….5315
Message Pages Number 44 to 51….5316
Message Pages Number 52 to 60….5317
Message Pages Number 61 to 64….5318
Grouping of the Messages according to their Priority….5319
1st Priority Group:….5319
2nd Priority Group:….5319
3rd Priority Group:….5320
4th Priority Group….5320
Explanation of the statistics print-out….5321
Time Diagram of Statistics Print….5322
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING….5323
3.6 MACHINERY HOUSE….5325
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES….5326
3.7 ELECTRICAL EQUIPMENT IN CAB BASE….5327
3.7.1 SWITCH BOX (X2) IN CAB BASE….5332
3.8 CHECKS BEFORE STARTING THE ENGINE….5335
3.9 STARTING THE ENGINE….5341
3.9.1 STARTING PROCEDURE….5344
3.10 MOVING THE SHOVEL….5350
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS….5350
3.10.2 TRAVELLING INSTRUCTIONS….5353
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE….5354
3.11.1 SLEWING THE SUPERSTRUCTURE….5354
3.12 WORKING WITH THE ATTACHMENT….5357
3.12.1 MACHINES EQUIPPED WITH”EURO” CONTROL SYSTEM….5357
3.12.2 MACHINES EQUIPPED WITH”KMG” CONTROL SYSTEM….5358
3.12.3 BOTTOM DUMP BUCKET….5359
3.12.4 DROP BALL OPERATION….5360
SAFETY DEVICES (SPECIAL EQUIPMENT)….5361
WORKING HINTS….5362
3.12.5 COMBINED OPERATION CYCLES….5363
3.13 WORKING INSTRUCTIONS….5365
3.13.1 STABILITY OF THE SHOVEL….5365
3.13.2 SHOVEL OPERATION….5365
3.14 PARKING THE SHOVEL….5368
3.15 STOPPING THE ENGINE….5369
3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM….5372
3.16 AUTOMATIC LUBRICATION SYSTEMS….5373
3.16.1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS….5374
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM….5377
3.17.1 HIGH LEVEL ALARM ”FIRE”….5380
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE….5380
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM….5380
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM….5382
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF….5384
3.18 CENTRAL REFILLING SYSTEM….5385
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM….5386
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM….5388
3.18.3 RECEIVER PANEL WITH MONITOR BOX….5390
3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS….5394
3.19 TRANSFER PUMP FOR HYDRAULIC OIL….5395
3.19.1 OPERATING THE TRANSFER PUMP….5396
3.19.2 FUNCTIONS OF THE TRANSFER PUMP….5396
3.20 WORK ON THE LOADER ATTACHMENT….5399
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL….5400
3.21.1 DISASSEMBLING OF THE SHOVEL….5400
3.21.2 TRANSPORTATION AND LIFTING….5400
3.22 RETRIEVAL PROCEDURE….5401
3.23 SHOVEL STORAGE….5402
3.23.1 PREPARING FOR STORAGE….5402
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD….5403
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD….5403
3.23.4 PREPARING FOR OPERATION….5404
3.24 TROUBLE SHOOTING….5405
3.24.1 ENGINE….5405
3.24.2 HYDRAULIC SYSTEM….5406
3.24.3 FINAL DRIVES AND SWING GEAR….5407
3.24.4 CRAWLER TRACKS….5407
4. MAINTENANCE….5408
4.1 FOREWORD….5409
4.2 PRECAUTIONS FOR MAINTENANCE….5410
4.3 FUEL AND LUBRICANTS….5412
4.4 FILLING CAPACITIES….5414
4.5 STANDARD TORQUE LIST….5415
4.6 LUBRICATION AND MAINTENANCE SCHEDULE….5416
4.6.1 INITIAL SERVICING….5416
4.6.2 PERIODIC SERVICING INTERVALS….5416
4.6.3 PERIODIC SERVICING SCHEDULE….5417
Lubrication Chart….5421
REPLACEMENT OF HYDRAULIC HOSE LINES….5422
INSPECTION OF HYDRAULIC HOSE LINES….5422
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM….5424
4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL….5426
4.6.6 MAINTENANCE OF THE ENGINE….5428
4.7 WHEN NECESSARY….5429
4.7.1 ENGINE AIR CLEANER MAINTENANCE….5430
4.7.2 SWING CIRCLE TOOTHING LUBRICATION….5434
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS….5436
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS….5440
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER….5442
4.8 EVERY 10 OPERATING HOURS OR DAILY….5443
4.8.1 WALK – AROUND INSPECTION….5444
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER….5452
4.8.3 RADIATOR – CHECK COOLANT LEVEL….5454
4.8.4 TRACK GROUPS – CLEAN….5454
4.8.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER….5456
4.9 EVERY 50 OPERATING HOURS OR WEEKLY….5457
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY….5470
4.9.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHECK OIL LEVEL….5458
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS….5462
4.9.3 PTO (PUMP DISTRIBUTOR GEAR) – CHECK OIL LEVEL….5466
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR….5468
4.10 EVERY 250 OPERATING HOURS OR MONTHLY….5471
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION….5472
4.10.2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER – MAINTENANCE CHECK….5474
4.10.3 GENERATOR – CHECK BELT TENSION….5478
4.10.4 SIGNAL HORN COMPRESSOR – LUBRICATE….5480
4.10.5 HYDRAULIC OIL COOLER FAN – CHECK CONDITION AND FASTENING….5480
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER….5482
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT….5486
4.10.8 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL….5488
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL….5488
4.11 EVERY 500 OPERATING HOURS OR MONTHLY….5489
4.11.1 BATTERIES – CHECK FLUID LEVEL….5490
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL….5492
4.11.3 FUEL TANK – DRAIN CONDENSATION….5494
4.11.4 CRAWLER TRACK – INSPECTION….5496
CHECK ADJUSTING RANGE FOR GUIDE WHEELS….5498
CHECK ADJUSTING RANGE FOR GUIDE WHEELS….5500
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS….5501
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD….5502
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE….5534
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR AND TRAVEL GEARS – OIL SAMPLE ANALYSIS….5548
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE….5550
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS….5552
4.12.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES….5554
4.12.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES….5554
4.13 EVERY 2000 OPERATING HOURS OR YEARLY….5555
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER….5556
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION….5570
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR….5571
4.14.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHANGE OIL….5572
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL….5580
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL….5584
4.15 FIRE PREVENTION….5587
4.16 WELD REPAIRS….5589
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE….5592
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT….5594
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE….5596
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE….5598
OMPC30006224 – Hydraulic Mining Shovel PC3000-6 Operation & Maintenance Manual….5600
COVER….5600
1. INTRODUCTION….5602
1.1 CONTENTS OF THE BINDER….5603
1.2 DIVISION OF THE BINDER….5604
1.3 DESIGNATED USE OF THE SHOVEL….5605
1.4 DELIVERY OF THE SHOVEL….5606
1.5 EXPLANATION OF ABBREVIATIONS….5607
1.6 TABLE OF CONTENTS….5608
2. SAFETY….5614
2.1 SAFETY INSTRUCTIONS….5615
2.1.1 WARNINGS AND SYMBOLS….5615
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL….5615
2.1.3 ORGANIZATIONAL MEASURES….5616
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES….5618
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES….5619
2.1.6 WARNING OF SPECIAL DANGERS….5622
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING….5624
2.1.8 SPECIAL SAFETY EQUIPMENT….5624
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)….5628
3. OPERATION….5636
3.1 FOREWORD….5637
3.2 CONSTRUCTION OF THE SHOVEL….5638
3.2.1 OVERALL VIEW….5638
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE….5639
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER….5645
3.2.4 EMERGENCY ESCAPE LADDER….5649
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM….5651
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)….5653
3.2.7 ENGINE OIL MANAGEMENT SYSTEM….5661
3.3 OPERATOR’S CAB – CONTROLS….5669
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT….5669
Hydraulic Control System….5670
Safety Circuit for Controls….5670
EURO Control Pattern….5672
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET….5673
Hydraulic Control System….5674
Safety Circuit for Controls….5674
Automatic Float Position for Boom and Stick….5674
EURO Control Pattern….5676
3.3.3 OPERATOR’S CONSOLE….5678
Control Panel….5680
Rear Panel Controls….5684
3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM….5685
3.4.1 INTRODUCTION….5686
Function of the keys (1 to 8) of Keyboard (B):….5688
3.4.2 SYSTEM COMPONENTS….5690
Message Classification….5692
3.4.3 FUNCTIONS OF THE ETM SYSTEM….5692
3.4.4 DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY….5696
Display the Contents of Record Memory….5698
Print out Contents of Statistics Memory:….5700
Print out Contents of Record (PROTOCOL) memory….5700
Print out the last Entries of the Record (PROTOCOL) Memory….5704
Change – over from English to German Language….5706
Change-over from German to English Language….5706
3.4.5 SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME….5708
3.4.6 SETTINGS OF THE TEXT DISPLAY UNIT….5710
TABLE OF MESSAGES….5713
Message Pages Number 1 to 7….5713
Message Pages Number 8 to 15….5714
Message Pages Number 16 to 24….5715
Message Pages Number 25 to 34….5716
Message Pages Number 35 to 43….5717
Message Pages Number 44 to 51….5718
Message Pages Number 52 to 60….5719
Message Pages Number 61 to 64….5720
Grouping of the Messages according to their Priority….5721
1st Priority Group:….5721
2nd Priority Group:….5721
3rd Priority Group:….5722
4th Priority Group….5722
Explanation of the statistics print-out….5723
Time Diagram of Statistics Print….5724
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING….5725
3.6 MACHINERY HOUSE….5727
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES….5728
3.7 ELECTRICAL EQUIPMENT IN CAB BASE….5729
3.7.1 SWITCH BOX (X2) IN CAB BASE….5734
3.8 CHECKS BEFORE STARTING THE ENGINE….5737
3.9 STARTING THE ENGINE….5743
3.9.1 STARTING PROCEDURE….5746
3.10 MOVING THE SHOVEL….5752
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS….5752
3.10.2 TRAVELLING INSTRUCTIONS….5755
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE….5756
3.11.1 SLEWING THE SUPERSTRUCTURE….5756
3.12 WORKING WITH THE ATTACHMENT….5759
3.12.1 MACHINES EQUIPPED WITH”EURO” CONTROL SYSTEM….5759
3.12.2 MACHINES EQUIPPED WITH”KMG” CONTROL SYSTEM….5760
3.12.3 BOTTOM DUMP BUCKET….5761
3.12.4 DROP BALL OPERATION….5762
SAFETY DEVICES (SPECIAL EQUIPMENT)….5763
WORKING HINTS….5764
3.12.5 COMBINED OPERATION CYCLES….5765
3.13 WORKING INSTRUCTIONS….5767
3.13.1 STABILITY OF THE SHOVEL….5767
3.13.2 SHOVEL OPERATION….5767
3.14 PARKING THE SHOVEL….5770
3.15 STOPPING THE ENGINE….5771
3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM….5774
3.16 AUTOMATIC LUBRICATION SYSTEMS….5775
3.16.1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS….5776
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM….5779
3.17.1 HIGH LEVEL ALARM ”FIRE”….5782
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE….5782
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM….5782
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM….5784
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF….5786
3.18 CENTRAL REFILLING SYSTEM….5787
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM….5788
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM….5790
3.18.3 RECEIVER PANEL WITH MONITOR BOX….5792
3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS….5796
3.19 TRANSFER PUMP FOR HYDRAULIC OIL….5797
3.19.1 OPERATING THE TRANSFER PUMP….5798
3.19.2 FUNCTIONS OF THE TRANSFER PUMP….5798
3.20 WORK ON THE LOADER ATTACHMENT….5801
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL….5802
3.21.1 DISASSEMBLING OF THE SHOVEL….5802
3.21.2 TRANSPORTATION AND LIFTING….5802
3.22 RETRIEVAL PROCEDURE….5803
3.23 SHOVEL STORAGE….5804
3.23.1 PREPARING FOR STORAGE….5804
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD….5805
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD….5805
3.23.4 PREPARING FOR OPERATION….5806
3.24 TROUBLE SHOOTING….5807
3.24.1 ENGINE….5807
3.24.2 HYDRAULIC SYSTEM….5808
3.24.3 FINAL DRIVES AND SWING GEAR….5809
3.24.4 CRAWLER TRACKS….5809
4. MAINTENANCE….5810
4.1 FOREWORD….5811
4.2 PRECAUTIONS FOR MAINTENANCE….5812
4.3 FUEL AND LUBRICANTS….5814
4.4 FILLING CAPACITIES….5816
4.5 STANDARD TORQUE LIST….5817
4.6 LUBRICATION AND MAINTENANCE SCHEDULE….5818
4.6.1 INITIAL SERVICING….5818
4.6.2 PERIODIC SERVICING INTERVALS….5818
4.6.3 PERIODIC SERVICING SCHEDULE….5819
Lubrication Chart….5823
REPLACEMENT OF HYDRAULIC HOSE LINES….5824
INSPECTION OF HYDRAULIC HOSE LINES….5824
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM….5826
4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL….5828
4.6.6 MAINTENANCE OF THE ENGINE….5830
4.7 WHEN NECESSARY….5831
4.7.1 ENGINE AIR CLEANER MAINTENANCE….5832
4.7.2 SWING CIRCLE TOOTHING LUBRICATION….5836
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS….5838
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS….5842
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER….5844
4.8 EVERY 10 OPERATING HOURS OR DAILY….5845
4.8.1 WALK – AROUND INSPECTION….5846
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER….5854
4.8.3 RADIATOR – CHECK COOLANT LEVEL….5856
4.8.4 TRACK GROUPS – CLEAN….5856
4.8.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER….5858
4.9 EVERY 50 OPERATING HOURS OR WEEKLY….5859
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY….5872
4.9.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHECK OIL LEVEL….5860
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS….5864
4.9.3 PTO (PUMP DISTRIBUTOR GEAR) – CHECK OIL LEVEL….5868
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR….5870
4.10 EVERY 250 OPERATING HOURS OR MONTHLY….5873
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION….5874
4.10.2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER – MAINTENANCE CHECK….5876
4.10.3 GENERATOR – CHECK BELT TENSION….5880
4.10.4 SIGNAL HORN COMPRESSOR – LUBRICATE….5882
4.10.5 HYDRAULIC OIL COOLER FAN – CHECK CONDITION AND FASTENING….5882
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER….5884
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT….5888
4.10.8 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL….5890
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL….5890
4.11 EVERY 500 OPERATING HOURS OR MONTHLY….5891
4.11.1 BATTERIES – CHECK FLUID LEVEL….5892
4.11.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL….5894
4.11.3 FUEL TANK – DRAIN CONDENSATION….5896
4.11.4 CRAWLER TRACK – INSPECTION….5898
CHECK ADJUSTING RANGE FOR GUIDE WHEELS….5900
CHECK ADJUSTING RANGE FOR GUIDE WHEELS….5902
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS….5903
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD….5904
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE….5936
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR AND TRAVEL GEARS – OIL SAMPLE ANALYSIS….5950
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE….5952
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS….5954
4.12.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES….5956
4.12.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES….5956
4.13 EVERY 2000 OPERATING HOURS OR YEARLY….5957
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER….5958
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION….5972
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR….5973
4.14.1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHANGE OIL….5974
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL….5982
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL….5986
4.15 FIRE PREVENTION….5989
4.16 WELD REPAIRS….5991
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE….5994
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT….5996
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE….5998
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE….6000
OMPC30006225 – Hydraulic Mining Shovel PC3000-1 Operation & Maintenance Manual….6002
COVER….6002
INTRODUCTION….6003
1.0 CONTENTS OF THE BINDER….6003
1.1 DIVISION OF THE BINDER….6003
1.2 DESIGNATED USE OF THE HYDRAULIC EXCAVATOR….6004
GENERAL CONTENT….6006
PART 1: OPERATION MANUAL….6006
PART 2: LUBRICATION AND MAINTENANCE MANUAL….6006
PART 3: DIVERSE LITERATURE….6007
PART 1: OPERATION MANUAL….6009
TABLE OF CONTENTS….6009
A EXPLANATION OF ABBREVIATIONS USED IN THIS MANUAL….6010
1.0 FOREWORD….6011
2.0 CONSTRUCTION OF THE EXCAVATOR….6013
2.1 CATWALK IN FRONT OF THE OPERATOR'S CAB….6025
3.0 SAFETY INSTRUCTIONS….6027
3.1 LADDER, WALKWAYS AND ACCESS DOORS….6049
3.3 EMERGENCY ENGINE SHUT DOWN FROM GROUND MAN AND OPERATOR WARNING SYSTEM….6051
3.4 OPERATOR'S CAB….6053
3.5 OPEARTOR'S SEAT….6055
4.0 OPERATOR'S CAB – CONTROLS….6057
5.0 ELECTRONIC TEXT MONITORING SYSTEM DEMAG ETM….6067
5.1 POWER HOUSE CONTROLS….6116
5.2 MAIN SWITCH BOARD IN CAB BASE….6120
5.3 HEATING SYSTEMS (SPECIAL EQUIPMENT)….6122
5.5 GENERATOR SET….6132
6.1 CHECKS BEFORE STARTING THE ENGINE….6142
6.2 STARTING THE ENGINE….6146
6.3 STOPPING THE ENGINE….6156
6.4 MOVING THE EXCAVATOR….6160
6.5 SLEWING AND BRAKING THE SUPERSTRUCTURE….6167
6.6 WORKING WITH THE ATTACHMENT….6171
6.7 COMBINED OPERATION CYCLES….6181
6.8 OPERATING THE HEATER VENTILATION AND AIR CONDITIONING….6183
6.11 OPERATION OF THE LUBRICATION SYSTEM….6187
6.13 FIRE DETECTION AND SUPPRESSION SYSTEM (SPECIAL EQUIPMENT)….6195
7.0 WORKING INSTRUCTIONS….6203
8.0 PARKING THE EXCAVATOR….6209
9.0 CENTRAL REFILLING SYSTEM….6211
9.1 SERVICE CRANE (SPECIAL EQUIPMENT)….6221
10.0 EXCHANGE OF ATTACHMENT AND/OR COMPONENTS….6226
11.0 TRANSPORTATION AND LIFTING OF THE EXCAVATOR….6227
12.0 RETRIEVAL PROCEDURE….6228
PART 2: LUBRICATION AND MAINTENANCE MANUAL….6229
1.0 FOREWORD….6230
1.1 FIRE PREVENTION….6233
1.2 REPAIR WELDINGS….6237
2.0 SAFETY INSTRUCTIONS….6244
3.0 FUEL AND LUBRICANTS….6246
4.0 FILLING CAPACITIES….6248
5.0 LUBRICATION AND MAINTENANCE SCHEDULE….6249
5.1 INITIAL SERVICING….6249
5.2 PERIODIC SERVICING SCHEDULE….6249
5.3 MAINTENANCE OF THE ENGINE….6257
6.1 EVERY 10 HOURS OF OPERATION OR DAILY….6261
6.2 EVERY 50 OPERATING HOURS OR WEEKLY….6281
6.3 EVERY 250 OPERATING HOURS OR MONTHLY….6297
6.4 EVERY 500 OPERATING HOURS OR MONTHLY….6317
6.5 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS….6339
6.6 EVERY 2000 OPERATING HOURS OR YEARLY….6394
6.7 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR….6404
6.8 WHEN NECESSARY….6418
7.0 EXCAVATOR STORAGE….6435
8.0 TROUBLE SHOOTING….6438
SMPC30006171 – Hydraulic Mining Shovel PC3000-1 Shop Manual….6441
Cover….6441
Introduction….6442
Symbols….6443
Foreword….6444
Table of Contents….6446
Section 1 – Main Assembly Groups….6447
Table of Contents, Section 1….6447
General Layout….6449
Drive….6451
Control Blocks, Slew Gear….6453
Undercarriage, Travel Drive….6455
Driver's Cab….6457
Section 2 – Drive….6459
Table of Contents, Section 2….6459
Prime Drive Assembly….6461
Engine Mounts….6463
Fan Drive and Cooler Assy….6465
Coupling….6467
Air Filter….6469
Pump Distributor Gear….6471
Pump Spline – Lubrication….6473
PTO – Gear Ludrication….6475
Section 3 – Hydraulic Oil Tank….6481
Table of Contents, Section 3….6481
Main Oil Tank….6483
Return and Leak Oil Filter….6485
Breather Filter….6487
Location of Pressure Switches and Sensors….6489
Section 4 – Hydraulic Oil Cooling….6491
Table of Contents, Section 4….6491
General….6493
Hydraulic Oil Cooling Circuit….6495
Measuring / Setting the Back Pressure Valve….6497
Fan Drive….6501
Axial Piston Pump….6505
Measuring and Setting of the Fan Speed….6507
Function Check for RPM-Control….6511
Section 5 – Controlling….6513
Table of Contents, Section 5….6513
Pilot Pressure Supplu….6515
General….6515
Function….6517
Checks and Adjustment of Pilot Pressure….6519
Measuring and Adjustment of Control Pressure….6521
Checking of Accumulator Function….6521
Checking of Accumulator Pre-charge Pressure….6521
Travel Parking Brake….6523
Function Check of Travel Parking Brake….6525
Slew Parking (House) Brake….6527
Section 6 – Components….6529
Table of Content….6529
Main Control Blocks and High Pressure Filter (Bull-Clam Attachment….6531
Main Control Blocks and High Pressure Filter (Back Hoe Attachment….6533
Distributor Manifold (Bull-Clam Attachment)….6535
Distributor Manifold (Back Hoe Attachment….6537
Restrictor Block with Pressure Valve….6539
Restrictor Block….6541
Anti Cavitation Valve Block….6543
Proportional Solenoid Valve….6545
Pressure Filter….6547
Control Blocks….6549
Control Blocks and Valves….6551
Valve at the Control Block….6555
Load Holding Valve….6557
Travel Brake Valve….6559
Pressure Reducing Valve….6561
Directional Control Valve (Solenoid Valve)….6563
Hydraulic Cylinder….6565
Auxiliary Pumps, Fan Drive….6567
Auxiliary Gear Pumps….6569
Slew Ring….6571
Section 7 – Main Hydraulic Pumps and Pump Regulation….6573
Table of Content….6573
Main Hydraulic Pump A7V / HD D….6575
SL-Bearing….6579
Function of the Pump Governor….6581
Pump Bearing Lubrication….6587
Pump Governor Adjustments….6591
Pump Regulation, General….6601
Determination of Peak Point (Engine Performance Test)….6607
Hydraulic Regulation Adjustment, Stop Gap Operation….6609
Detailed Explanation for Electronic Pump Regulation….6611
Adjustments / Checks for Electronic Pump Regulation….6613
Adjusting the RPM Sensor (MPU)….6615
Adjustments at the ELL – Module, Normal Fine Tuning….6617
Checks / Function Test / Fault Finding at JOBSITE….6621
EPM – Module, Function and Test….6623
ERM – Module, Function and Test….6625
ELL – Module, Function and Test….6629
Amplifier Module, Function and Test….6633
Simplified Trouble Shooting of Electronic Regulation….6635
Section 8 – Operating Hydraulic….6639
Table of Content….6639
Hydraulic for Attachment Cylinder….6641
Adjustments for Attachment Cylinder Hydraulic….6645
Slew Circuit, General….6663
Slew Motor….6667
Slew Gear and House Brake….6671
Slew Brake Valve….6675
Slew Function….6680
Checks and Adjustments….6691
Travel Citcuit….6699
Rotary Distributor….6703
Travel Motor (Axial Piston Motor A2FM)….6705
Travel Gear and House Brake….6709
Travel Gear….6709
Travel Gear House Brake….6711
Travel, Function….6713
Anti-Cavitation Circuit….6717
Adjustments / Checks….6719
Section 9 – Hydraulic Tank Tension System….6725
Table of Content….6725
Hydraulic Track Tension System….6727
Function….6729
Pressure Increasing Valve….6733
Pressure Relief Valve, Direct Operated….6735
Adjustments / Pressure Checks….6737
Section 10 – Hints for the Hydraulic Circuit Diagram….6745
Table of Content….6745
Hints for Reading Circuit Diagrams….6749
Legend of the Hydraulic Circuit Diagram….6750
Pressure Check Points….6754
How to Read the Circuit Diagram….6756
Hydraulic Diagram (1/3)….6757
Hydraulic Diagram (2/3)….6758
Hydraulic Diagram (3/3)….6759
Section 11 – Hints for the Electric Circuit Diagram….6761
Table of Content….6761
Markings of Electrical Components in Circuit Diagrams….6763
Symbols….6765
KGM Circuit Diagrams….6769
General Information….6769
Explanation of the Drawing Concept….6771
Terminal Plans….6773
Location of Main Terminal Boxes and Important Components….6775
Reading a Circuit Diagram….6777
Adjustments….6781
Component List / Function….6782
Electrical Diagrams….6788
Electrical Diagrams – 897 818 40 (1/49)….6788
Electrical Diagrams – 897 818 40 (2/49)….6789
Electrical Diagrams – 897 818 40 (3/49)….6790
Electrical Diagrams – 897 818 40 (4/49)….6791
Electrical Diagrams – 897 818 40 (5/49)….6792
Electrical Diagrams – 897 818 40 (6/49)….6793
Electrical Diagrams – 897 818 40 (7/49)….6794
Electrical Diagrams – 897 818 40 (8/49)….6795
Electrical Diagrams – 897 818 40 (9/49)….6796
Electrical Diagrams – 897 818 40 (10/49)….6797
Electrical Diagrams – 897 818 40 (11/49)….6798
Electrical Diagrams – 897 818 40 (12/49)….6799
Electrical Diagrams – 897 818 40 (13/49)….6800
Electrical Diagrams – 897 818 40 (14/49)….6801
Electrical Diagrams – 897 818 40 (15/49)….6802
Electrical Diagrams – 897 818 40 (16/49)….6803
Electrical Diagrams – 897 818 40 (17/49)….6804
Electrical Diagrams – 897 818 40 (18/49)….6805
Electrical Diagrams – 897 818 40 (19/49)….6806
Electrical Diagrams – 897 818 40 (20/49)….6807
Electrical Diagrams – 897 818 40 (21/49)….6808
Electrical Diagrams – 897 818 40 (22/49)….6809
Electrical Diagrams – 897 818 40 (23/49)….6810
Electrical Diagrams – 897 818 40 (24/49)….6811
Electrical Diagrams – 897 818 40 (25/49)….6812
Electrical Diagrams – 897 818 40 (26/49)….6813
Electrical Diagrams – 897 818 40 (27/49)….6814
Electrical Diagrams – 897 818 40 (28/49)….6815
Electrical Diagrams – 897 818 40 (29/49)….6816
Electrical Diagrams – 897 818 40 (30/49)….6817
Electrical Diagrams – 897 818 40 (31/49)….6818
Electrical Diagrams – 897 818 40 (32/49)….6819
Electrical Diagrams – 897 818 40 (33/49)….6820
Electrical Diagrams – 897 818 40 (34/49)….6821
Electrical Diagrams – 897 818 40 (35/49)….6822
Electrical Diagrams – 897 818 40 (36/49)….6823
Electrical Diagrams – 897 818 40 (37/49)….6824
Electrical Diagrams – 897 818 40 (38/49)….6825
Electrical Diagrams – 897 818 40 (39/49)….6826
Electrical Diagrams – 897 818 40 (40/49)….6827
Electrical Diagrams – 897 818 40 (41/49)….6828
Electrical Diagrams – 897 818 40 (42/49)….6829
Electrical Diagrams – 897 818 40 (43/49)….6830
Electrical Diagrams – 897 818 40 (44/49)….6831
Electrical Diagrams – 897 818 40 (45/49)….6832
Electrical Diagrams – 897 818 40 (46/49)….6833
Electrical Diagrams – 897 818 40 (47/49)….6834
Electrical Diagrams – 897 818 40 (48/49)….6835
Electrical Diagrams – 897 818 40 (49/49)….6836
Section 12 – Electronic Text Monitoring System….6838
Table of Content….6838
Introduction….6839
Function….6842
Lay Out of Dash Board….6848
Text Monitoring System….6856
Frequency / Voltage Converter (EFD-Module)….6916
SMPC30006174 – Hydraulic Mining Shovel PC3000-1 Shop Manual….6920
Cover….6920
Introduction….6921
Symbols….6922
Foreword….6923
Table of Contents….6925
Section 1 – Main Assembly Groups….6926
Table of Contents, Section 1….6926
General Layout….6928
Drive….6930
Control Blocks, Slew Gear….6932
Undercarriage, Travel Drive….6934
Driver's Cab….6936
Section 2 – Drive….6938
Table of Contents, Section 2….6938
Prime Drive Assembly….6940
Engine Mounts….6942
Fan Drive and Cooler Assy….6944
Coupling….6946
Air Filter….6948
Pump Distributor Gear….6950
Pump Spline – Lubrication….6952
PTO – Gear Ludrication….6954
Section 3 – Hydraulic Oil Tank….6960
Table of Contents, Section 3….6960
Main Oil Tank….6962
Return and Leak Oil Filter….6964
Breather Filter….6966
Location of Pressure Switches and Sensors….6968
Section 4 – Hydraulic Oil Cooling….6970
Table of Contents, Section 4….6970
General….6972
Hydraulic Oil Cooling Circuit….6974
Measuring / Setting the Back Pressure Valve….6976
Fan Drive….6980
Axial Piston Pump….6984
Measuring and Setting of the Fan Speed….6986
Function Check for RPM-Control….6990
Section 5 – Controlling….6992
Table of Contents, Section 5….6992
Pilot Pressure Supplu….6994
General….6994
Function….6996
Checks and Adjustment of Pilot Pressure….6998
Measuring and Adjustment of Control Pressure….7000
Checking of Accumulator Function….7000
Checking of Accumulator Pre-charge Pressure….7000
Travel Parking Brake….7002
Function Check of Travel Parking Brake….7004
Slew Parking (House) Brake….7006
Section 6 – Components….7008
Table of Content….7008
Main Control Blocks and High Pressure Filter (Bull-Clam Attachment….7010
Main Control Blocks and High Pressure Filter (Back Hoe Attachment….7012
Distributor Manifold (Bull-Clam Attachment)….7014
Distributor Manifold (Back Hoe Attachment….7016
Restrictor Block with Pressure Valve….7018
Restrictor Block….7020
Anti Cavitation Valve Block….7022
Proportional Solenoid Valve….7024
Pressure Filter….7026
Control Blocks….7028
Control Blocks and Valves….7030
Valve at the Control Block….7034
Load Holding Valve….7036
Travel Brake Valve….7038
Pressure Reducing Valve….7040
Directional Control Valve (Solenoid Valve)….7042
Hydraulic Cylinder….7044
Auxiliary Pumps, Fan Drive….7046
Auxiliary Gear Pumps….7048
Slew Ring….7050
Section 7 – Main Hydraulic Pumps and Pump Regulation….7052
Table of Content….7052
Main Hydraulic Pump A7V / HD D….7054
SL-Bearing….7058
Function of the Pump Governor….7060
Pump Bearing Lubrication….7066
Pump Governor Adjustments….7070
Pump Regulation, General….7080
Determination of Peak Point (Engine Performance Test)….7086
Hydraulic Regulation Adjustment, Stop Gap Operation….7088
Detailed Explanation for Electronic Pump Regulation….7090
Adjustments / Checks for Electronic Pump Regulation….7092
Adjusting the RPM Sensor (MPU)….7094
Adjustments at the ELL – Module, Normal Fine Tuning….7096
Checks / Function Test / Fault Finding at JOBSITE….7100
EPM – Module, Function and Test….7102
ERM – Module, Function and Test….7104
ELL – Module, Function and Test….7108
Amplifier Module, Function and Test….7112
Simplified Trouble Shooting of Electronic Regulation….7114
Section 8 – Operating Hydraulic….7118
Table of Content….7118
Hydraulic for Attachment Cylinder….7120
Adjustments for Attachment Cylinder Hydraulic….7124
Slew Circuit, General….7142
Slew Motor….7146
Slew Gear and House Brake….7150
Slew Brake Valve….7154
Slew Function….7159
Checks and Adjustments….7170
Travel Citcuit….7178
Rotary Distributor….7182
Travel Motor (Axial Piston Motor A2FM)….7184
Travel Gear and House Brake….7188
Travel Gear….7188
Travel Gear House Brake….7190
Travel, Function….7192
Anti-Cavitation Circuit….7196
Adjustments / Checks….7198
Section 9 – Hydraulic Tank Tension System….7204
Table of Content….7204
Hydraulic Track Tension System….7206
Function….7208
Pressure Increasing Valve….7212
Pressure Relief Valve, Direct Operated….7214
Adjustments / Pressure Checks….7216
Section 10 – Hints for the Hydraulic Circuit Diagram….7224
Table of Content….7224
Hints for Reading Circuit Diagrams….7228
Legend of the Hydraulic Circuit Diagram….7229
Pressure Check Points….7233
How to Read the Circuit Diagram….7235
Hydraulic Diagram – 897 913 40 (1/3)….7236
Hydraulic Diagram – 897 913 40 (2/3)….7237
Hydraulic Diagram – 897 913 40 (3/3)….7238
Section 11 – Hints for the Electric Circuit Diagram….7240
Table of Content….7240
Markings of Electrical Components in Circuit Diagrams….7242
Symbols….7244
KGM Circuit Diagrams….7248
General Information….7248
Explanation of the Drawing Concept….7250
Terminal Plans….7252
Location of Main Terminal Boxes and Important Components….7254
Reading a Circuit Diagram….7256
Adjustments….7260
Component List / Function….7261
Electrical Diagrams….0
Electrical Diagrams – 897 825 40 (1/49)….7267
Electrical Diagrams – 897 825 40 (2/49)….7268
Electrical Diagrams – 897 825 40 (3/49)….7269
Electrical Diagrams – 897 825 40 (4/49)….7270
Electrical Diagrams – 897 825 40 (5/49)….7271
Electrical Diagrams – 897 825 40 (6/49)….7272
Electrical Diagrams – 897 825 40 (7/49)….7273
Electrical Diagrams – 897 825 40 (8/49)….7274
Electrical Diagrams – 897 825 40 (9/49)….7275
Electrical Diagrams – 897 825 40 (10/49)….7276
Electrical Diagrams – 897 825 40 (11/49)….7277
Electrical Diagrams – 897 825 40 (12/49)….7278
Electrical Diagrams – 897 825 40 (13/49)….7279
Electrical Diagrams – 897 825 40 (14/49)….7280
Electrical Diagrams – 897 825 40 (15/49)….7281
Electrical Diagrams – 897 825 40 (16/49)….7282
Electrical Diagrams – 897 825 40 (17/49)….7283
Electrical Diagrams – 897 825 40 (18/49)….7284
Electrical Diagrams – 897 825 40 (19/49)….7285
Electrical Diagrams – 897 825 40 (20/49)….7286
Electrical Diagrams – 897 825 40 (21/49)….7287
Electrical Diagrams – 897 825 40 (22/49)….7288
Electrical Diagrams – 897 825 40 (23/49)….7289
Electrical Diagrams – 897 825 40 (24/49)….7290
Electrical Diagrams – 897 825 40 (25/49)….7291
Electrical Diagrams – 897 825 40 (26/49)….7292
Electrical Diagrams – 897 825 40 (27/49)….7293
Electrical Diagrams – 897 825 40 (28/49)….7294
Electrical Diagrams – 897 825 40 (29/49)….7295
Electrical Diagrams – 897 825 40 (30/49)….7296
Electrical Diagrams – 897 825 40 (31/49)….7297
Electrical Diagrams – 897 825 40 (32/49)….7298
Electrical Diagrams – 897 825 40 (33/49)….7299
Electrical Diagrams – 897 825 40 (34/49)….7300
Electrical Diagrams – 897 825 40 (35/49)….7301
Electrical Diagrams – 897 825 40 (36/49)….7302
Electrical Diagrams – 897 825 40 (37/49)….7303
Electrical Diagrams – 897 825 40 (38/49)….7304
Electrical Diagrams – 897 825 40 (39/49)….7305
Electrical Diagrams – 897 825 40 (40/49)….7306
Electrical Diagrams – 897 825 40 (41/49)….7307
Electrical Diagrams – 897 825 40 (42/49)….7308
Electrical Diagrams – 897 825 40 (43/49)….7309
Electrical Diagrams – 897 825 40 (44/49)….7310
Electrical Diagrams – 897 825 40 (45/49)….7311
Section 12 – Electronic Text Monitoring System….7313
Table of Content….7313
Introduction….7314
Function….7317
Lay Out of Dash Board….7323
Text Monitoring System….7331
Frequency / Voltage Converter (EFD-Module)….7391
SMPC30006182 – Hydraulic Mining Shovel PC3000-1 Shop Manual….7395
COVER….7395
INTRODUCTION….7396
FOREWORD….7398
ABBREVIATIONS ….7402
TABLE OF CONTENTS….7400
SECTION 1. MAIN ASSEMBLY GROUPS….7404
TABLE OF CONTENTS….7404
GENERAL LAYOUT….7405
DRIVE….7407
CONTROL BLOCKS, SLEW GEARS….7409
UNDER CARRIAGE, TRAVEL DRIVE….7411
DRIVERS CAB….7413
SECTION 2. DRIVE….7416
TABLE OF CONTENTS….7416
PRIME DRIVE ASSEMBLY….7417
ENGINE MOUNTS….7419
FAN DRIVE ASSEMBLY….7421
COUPLING….7423
AIR CLEANER….7425
PUMP DISTRIBUTOR GEARBOX….7427
PUMP SPINE LUBRICATION….7429
PTO-GEAR LUBRICATION….7431
HYDRAULIC PUMP LOCATION….7435
SECTION 3. HYDRAULIC OIL TANK….7438
TABLE OF CONTENTS….7438
MAIN HYDRAULIC TANK….7439
RETURN AND LEAK OIL FILTER….7441
BREATHER FILTER….7443
LOCATION OF PRESSURE SWITCHES AND SENSORS….7445
SECTION 4. HYDRAULIC OIL COOLING….7448
TABLE OF CONTENTS….7448
GENERAL ….7449
COOLING CIRCUIT….7451
ADJUSTMENTS….7453
FAN DRIVE….7457
PRESSURE RELIEF VALVE AND SOLENOID VALVE….7459
AXIAL PISTON PUMP….7461
ADJUSTMENTS….7463
FUNCTION CHECK OF FAN SPEED CONTROL….7467
FUNCTION CHECK OF HYD. OIL HIGH TEMPERATURE MONITORING….7469
SECTION 5. CONTROLLING….7472
TABLE OF CONTENTS….7472
PILOT PRESSURE SUPPLY….7473
CHECKS AND ADJUSTMENTS OF PILOT PRESSURE….7479
CHECKING THE ACCUMULATOR FUNCTION….7481
TRAVEL PARKING BRAKE….7483
FUNCTION CHECK OF TRAVEL PARKING BRAKE….7485
SLEW PARKING (HOUSE) BRAKE….7487
SECTION 6. COMPONENTS….7490
TABLE OF CONTENTS….7490
MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER….7491
DISTRIBUTOR MANIFOLD….7493
RESTRICTOR BLOCK….7495
ANTI CAVITATION VALVE BLOCK….7497
PROPORTIONAL SOLENOID VALVE, PUMP REGULATION….7499
HIGH PRESSURE FILTER….7501
CONTROL BLOCKS AND VALVES ATTACHED….7490
PIPE BURST SAFETY VALVE….7513
PRESSURE REDUCING VALVE….7515
DIRECTIONAL SOLENOID VALVES….7517
HYDRAULIC CYLINDER….7519
SECTION 7. MAIN HYDRAULIC PUMPS….7520
ADJUSTMENTS/CHECKS FOR THE ELECTRONIC REGULATION….7520
TESTING THE ERM-MODULE, A32….7528
TESTING THE ELL-MODULE, A34….7532
TESTING THE PROPORTIONAL AMPLIFIER MODULE, A36….7536
SIMPLIFIED TROUBLESHOOTING OF THE ELECTRONIC CONTROL….7538
SECTION 8. OPERATING HYDRAULIC….7542
TABLE OF CONTENTS….7542
HYDRAULIC FOR THE ATTACHMENT CYLINDER….7543
ADJUSTMENTS FOR ATTACHMENT CYLINDER HYDRAULIC….7554
SLEW CIRCUIT, GENERAL….7557
SLEW MOTOR….7561
SLEW GEAR AND HOUSE BRAKE….7565
SLEW, FUNCTION….7573
CHECKS AND ADJUSTMENTS….7583
PIPE BURST SAFETY VALVE….7591
ADJUSTMENT PROCEDURE….7593
TRAVEL CIRCUIT, GENERAL….7597
ROTARY DISTRIBUTOR….7601
TRAVEL MOTORS….7603
TRAVEL GEAR AND HOUSE BRAKE….7607
TRAVEL FUNCTION….7611
ADJUSTMENTS/CHECKS….7617
SECTION 9. HYDRAULIC TRACK TENSION SYSTEM….7624
TABLE OF CONTENTS….7624
HYDRAULIC TRACK TENSION SYSTEM….7626
FUNCTION….7628
PRESSURE INCREASING VALVE….7632
PRESSURE RELIEF VALVE; PILOT OPERATED….7634
ADJUSTMENTS/PRESSURE CHECKS….7636
SECTION 10. HINTS FOR READING THE CIRCUIT DIAGRAM….7644
TABLE OF CONTENTS….7644
HINTS FOR READING THE CIRCUIT DIAGRAM….7645
LEGEND OF THE HYDRAULIC CIRCUIT DIAGRAM….7647
PRESSURE CHECK POINTS….7655
HOW TO READ THE CIRCUIT DIAGRAM….7659
SECTION 11. HINTS FOR THE ELECTRICAL CIRCUIT DIAGRAM….7662
TABLE OF CONTENTS….7662
MARKING OF ELECTRICAL COMPONENETS IN THE CIRCUIT DIAGRAMS….7664
SYMBOLS….7667
KOMATSU CIRCUIT DIAGRAMS, GENERAL INFORMATION….7671
EXPLANATION OF THE DRAWING CONCEPT….7673
LOCATION OF THE MAIN TERMINAL BOXES AND SOME COMPONENTS….7676
READING A CIRCUIT DIAGRAM….7678
ADJUSTMENTS….7682
COMPONENT LIST….7684
SECTION 12. PART 1 ELECTRONIC TEXT MONITORING SYSTEM….7706
TABLE OF CONTENTS….7706
INTRODUCTION….7708
FUNCTION….7709
EFD-MODULE, FUNCTION AND TROUBLESHOOTING….7714
SECTION 12. PART 2 ELECTRONIC TEXT MONITORING SYSTEM….7718
TABLE OF CONTENT….7718
INTRODUCTION….7720
FUNCTION….7724
FREQUENCY/VOLTAGE CONVERTER(EFD-MODULE)….7730
HYDRAULIC PLAN….7734
HYDRAULIC DIAGRAM – 897 973 40 (1/3)….7734
HYDRAULIC DIAGRAM – 897 973 40 (2/3)….7735
HYDRAULIC DIAGRAM – 897 973 40 (3/3)….7736
ELECTRIC PLAN….7737
Electrical Diagrams – 897 855 40 (1/39)….7737
Electrical Diagrams – 897 855 40 (2/39)….7738
Electrical Diagrams – 897 855 40 (3/39)….7739
Electrical Diagrams – 897 855 40 (4/39)….7740
Electrical Diagrams – 897 855 40 (5/39)….7741
Electrical Diagrams – 897 855 40 (6/39)….7742
Electrical Diagrams – 897 855 40 (7/39)….7743
Electrical Diagrams – 897 855 40 (8/39)….7744
Electrical Diagrams – 897 855 40 (9/39)….7745
Electrical Diagrams – 897 855 40 (10/39)….7746
Electrical Diagrams – 897 855 40 (11/39)….7747
Electrical Diagrams – 897 855 40 (12/39)….7748
Electrical Diagrams – 897 855 40 (13/39)….7749
Electrical Diagrams – 897 855 40 (14/39)….7750
Electrical Diagrams – 897 855 40 (15/39)….7751
Electrical Diagrams – 897 855 40 (16/39)….7752
Electrical Diagrams – 897 855 40 (17/39)….7737
Electrical Diagrams – 897 855 40 (18/39)….7754
Electrical Diagrams – 897 855 40 (19/39)….7755
Electrical Diagrams – 897 855 40 (20/39)….7756
Electrical Diagrams – 897 855 40 (21/39)….7757
Electrical Diagrams – 897 855 40 (22/39)….7758
Electrical Diagrams – 897 855 40 (23/39)….7759
Electrical Diagrams – 897 855 40 (24/39)….7760
Electrical Diagrams – 897 855 40 (25/39)….7761
Electrical Diagrams – 897 855 40 (26/39)….7762
Electrical Diagrams – 897 855 40 (27/39)….7763
Electrical Diagrams – 897 855 40 (28/39)….7764
Electrical Diagrams – 897 855 40 (29/39)….7765
Electrical Diagrams – 897 855 40 (30/39)….7766
Electrical Diagrams – 897 855 40 (31/39)….7767
Electrical Diagrams – 897 855 40 (32/39)….7768
Electrical Diagrams – 897 855 40 (33/39)….7769
Electrical Diagrams – 897 855 40 (34/39)….7770
Electrical Diagrams – 897 855 40 (35/39)….7771
Electrical Diagrams – 897 855 40 (36/39)….7772
Electrical Diagrams – 897 855 40 (37/39)….7773
Electrical Diagrams – 897 855 40 (38/39)….7774
Electrical Diagrams – 897 855 40 (39/39)….7775
SMPC30006194 – Hydraulic Mining Shovel PC3000-1 Shop Manual….7776
Cover….7776
Introduction….7777
Foreward….7778
Table of Contents….7781
Section 1 – Main Assembly Groups….7783
Table of Contents….7783
General Layout….7785
Drive….7787
Control Blocks, Swing Gear….7789
Undercarriage, Travel Drive….7791
Driver's Cab….7793
Section 2 – Drive….7795
Table of Contents….7795
Prime Drive Assembly….7797
Engine Mounts….7799
Fan Drive and Cooler Assembly….7801
Coupling….7803
Air Filter….7805
Pump Distributor Gear….7807
Spline – Lubrication….7809
Gear Lubrication….7811
Location of Pumps, Drive Speeds, and Flow Rates….7815
Section 3 – Hydraulic Oil Tank….7817
Table of Contents….7817
Main Oil Tank….7819
Return and Leak Oil Filter….7821
Breather Filter….7823
Location of Pressure Switches and Sensors….7825
Section 4 – Hydraulic Oil Cooling….7827
Table of Contents….7827
General….7829
Hydraulic Oil Cooling Circuit….7831
Measuring / Setting the Back Pressure Valve….7833
Fan Drive….7837
Pressure Relief Valve and Solenoid Valve….7839
Axial Piston Pump….7841
Measuring and Setting the Fan Speed….7843
Function Check for RPM-Control….7847
Section 5 – Controlling….7849
Table of Contents….7849
Pilot Pressure Supply….7851
Checks and Adjustments of Pilot Pressure….7855
Measuring and Adjustment of Control Pressure….7857
Checking of Accumulator Function….7857
Checking of Pre-charge Pressure….7857
Travel Parking Brake….7859
Function Check of Travel Parking Brake….7861
Function Check of Pressure Switch (B48)….7861
Swing Parking (House) Brake….7863
Section 6 – Components….7865
Table of Contents….7865
Main Control Blocks and High Pressure Filter….7867
Bull-clam Attachment….7867
Back Hoe Attachment….7869
Distributor Manifold….7871
Bull-clam Attachment….7871
Back Hoe Attachment….7873
Restrictor Block with Pressure Relief Valve….7875
Restrictor Block….7877
Anti-Cavitation Valve Block….7879
Proportional Solenoid Valve….7881
Pressure Filter….7883
Control Blocks….7885
Control Blocks and Valves….7887
Valve at the Control Block….7891
Load Holding Valve….7893
Travel Brake Valve….7895
Pressure Reducing Valve….7897
Directional Control Valves (Solenoid Valve)….7899
Hydraulic Cylinder….7901
Auxilliary Pumps (Fan Drive)….7903
Auxilliary Gear Pumps….7905
Swing Ring….7907
Section 7 – Main Hydraulic Pumps….7909
Table of Contents….7909
Main Hydraulic Pump A7V / HD D….7911
SL-bearing….7915
Function of the Pump Governor….7917
Pump Bearing Lubrication….7923
Pump Governor Adjustments….7927
Measuring and Setting Pressure of the Pressure Cut-off Valves….7927
Measuring and Setting the start of De-stroking the Main Pumps….7931
Adjusting the Damper Bolt….7933
Pump Regulation, General….7935
Stop Gap Operation (Emergency Use Only)….7937
Electronic Regulation….7937
Detailed Explanation for Hydraulic Regulation….7939
Hydraulic Regulation….7939
Determination of Peak Point (Corner Value)….7941
Setting the X1-Pressure….7943
Detailed Explanation for Electronic Regulation….7945
Adjustments / Checks for Electronic Regulation….7947
Adjusting the RPM Sensor (MPU)….7949
Adjustments at the ELL Module….7951
Testing / Setting for Complete Regulation….7953
Checks / Function Test / Fault Finding at JOB SITE….7955
EPM – Module, Function and Test….7957
ERM – Module, Function and Test….7959
ELL – Module, Function and Test….7963
Amplifier Module, Function and Test….7967
Simplified Troubleshooting of the Electronic Control….7969
Pre-Conditions….7971
Checking Proportional Solenoid Valve Function….7971
Section 8 – Operating Hydraulic….7973
Table of Contents….7973
Hydraulic for Attachment Cylinders….7975
Adjustments for Attachment Cylinder Hydraulic….7979
Main Relief Valves….7979
Service Line Relief Valves….7981
Boom Cylinder….7981
Stick Cylinder….7983
Bucket Cylinder….7985
Clam Cylinder….7987
Opening….7987
Closing….7989
Floating Function of Boom and Stick Cylinders….7991
Adjustments / Checks….7993
Swing Circuit, General….7997
Swing Motor….8001
Swing Gear and Swing Parking Brake….8005
Swing Brake Valve….8009
Swing Function….8015
Function: R.H. Rotation….8015
Function: L.H. Rotation….8015
Swinging Down Path (Delay)….8017
Anticavitation Circuit….8019
Braking….8021
Swing Parking Brake….8023
Checks and Adjustments….8025
Adjustments for the Swing Circuit….8027
Checking Pilot Pressure for Swing Brake….8031
Travel Circuit, General….8033
Rotary Distributor….8037
Travel Motor (Axial Piston Motor A2FM)….8039
Travel Gear and Parking Brake….8043
Travel Gear….8043
Travel Parking Brake….8045
Travel, Function….8047
Anti-Cavitation Circuit….8051
Adjustments / Checks….8053
Test / Park Brake Release Pressure (House Brake Pressure)….8057
Section 9 – Hydraulic Track Tension System….8059
Table of Contents….8059
Hydraulic Track Tension System….8061
Function….8063
Pressure Increasing Valve Type: MO 7010….8067
Pressure Relief Valve, Direct Operated Type: DBD S….8069
Adjustments / Pressure Checks….8071
Adjustments….8071
Basic Adjustment….8073
Setting Procedure….8075
Function Check….8077
Section 10 – Access Ladder Hydraulic Operated….8079
Table of Contents….8079
Access Ladder Hydraulic Operated….8081
Section 11 – Central Refilling System….8085
Table of Contents….8085
Central Refilling System….8087
Section 12 – Hints for Hydraulic Circuit Diagrams….8091
Table of Contents….8091
Hints for Reading Circuit Diagrams….8095
Legend to the Hydraulic Circuit Diagram….8096
How to Read Circuit Diagrams….8102
Hydraulic Diagrams – 897 883 40….8103
Hydraulic Diagram – 897 883 40 (1/3)….8103
Hydraulic Diagram – 897 883 40 (2/3)….8104
Hydraulic Diagram – 897 883 40 (3/3)….8105
Section 13 – Hints for Electric Circuit Diagrams….8107
Table of Contents….8107
Markings of Electrical Components in Circuit Diagrams….8109
Symbols….8111
KMG Circuit, General Information….8115
Ecplanation of the Drawing Concept….8117
Location of Main Terminal Boxes and Important Components….8119
Reading a Circuit Diagram….8123
Adjustments….8127
Component List….8128
Electrical Circuit Diagrams – 897 882 40….8133
Electrical Circuit Diagrams – 897 882 40 (1/40)….8133
Electrical Circuit Diagrams – 897 882 40 (2/40)….8134
Electrical Circuit Diagrams – 897 882 40 (3/40)….8135
Electrical Circuit Diagrams – 897 882 40 (4/40)….8136
Electrical Circuit Diagrams – 897 882 40 (5/40)….8137
Electrical Circuit Diagrams – 897 882 40 (6/40)….8138
Electrical Circuit Diagrams – 897 882 40 (7/40)….8139
Electrical Circuit Diagrams – 897 882 40 (8/40)….8140
Electrical Circuit Diagrams – 897 882 40 (9/40)….8141
Electrical Circuit Diagrams – 897 882 40 (10/40)….8142
Electrical Circuit Diagrams – 897 882 40 (11/40)….8143
Electrical Circuit Diagrams – 897 882 40 (12/40)….8144
Electrical Circuit Diagrams – 897 882 40 (13/40)….8145
Electrical Circuit Diagrams – 897 882 40 (14/40)….8146
Electrical Circuit Diagrams – 897 882 40 (15/40)….8147
Electrical Circuit Diagrams – 897 882 40 (16/40)….8148
Electrical Circuit Diagrams – 897 882 40 (17/40)….8149
Electrical Circuit Diagrams – 897 882 40 (18/40)….8150
Electrical Circuit Diagrams – 897 882 40 (19/40)….8151
Electrical Circuit Diagrams – 897 882 40 (20/40)….8152
Electrical Circuit Diagrams – 897 882 40 (21/40)….8153
Electrical Circuit Diagrams – 897 882 40 (22/40)….8154
Electrical Circuit Diagrams – 897 882 40 (23/40)….8155
Electrical Circuit Diagrams – 897 882 40 (24/40)….8156
Electrical Circuit Diagrams – 897 882 40 (25/40)….8157
Electrical Circuit Diagrams – 897 882 40 (26/40)….8158
Electrical Circuit Diagrams – 897 882 40 (27/40)….8159
Electrical Circuit Diagrams – 897 882 40 (28/40)….8160
Electrical Circuit Diagrams – 897 882 40 (29/40)….8161
Electrical Circuit Diagrams – 897 882 40 (30/40)….8162
Electrical Circuit Diagrams – 897 882 40 (31/40)….8163
Electrical Circuit Diagrams – 897 882 40 (32/40)….8164
Electrical Circuit Diagrams – 897 882 40 (33/40)….8165
Electrical Circuit Diagrams – 897 882 40 (34/40)….8166
Electrical Circuit Diagrams – 897 882 40 (35/40)….8167
Electrical Circuit Diagrams – 897 882 40 (36/40)….8168
Electrical Circuit Diagrams – 897 882 40 (37/40)….8169
Electrical Circuit Diagrams – 897 882 40 (38/40)….8170
Section 14 – Electronic Text Monitoring System….8171
Table of Contents….8171
Introduction….8173
General….8173
Function….8177
Layout of Dash Board….8183
Text Monitoring System….8189
Features of the ETM System….8189
Two Main Message Groups….8189
Function of Keys on Keyboard….8191
System Components….8193
Switches for the Adjustment of ETM….8195
Message Classification….8195
Function of ETM System and their Utilization….8197
Display the Content Record (PROTOCOL) Memory….8201
Print Out Content of Statistics Memory….8204
Print Out Last Entries of Record (PROTOCOL) Memory….8206
Change-over From English to German….8207
Change-over from German to English….8207
Several Message Conditions Occur at Same Time….8208
Settongs of Text Display Unit….8211
Return to System Level….8214
Setting Screen Brightness….8214
Grouping of Message Numbers in Input Signal Modules….8215
Table of Messages….8216
Message Numbers 1 to 5….8216
Message Numbers 6 to 11….8217
Message Numbers 12 to 18….8218
Message Numbers 19 to 26….8219
Message Numbers 27 to 30….8220
Message Numbers 31 to 38….8221
Message Numbers 39 to 44….8222
Message Numbers 45 to 52….8223
Message Numbers 53 to 64….8224
Grouping of Messages According to Priority….8225
Explanation of Statistics Print-Out….8229
Time Diagram of Ststics Print….8230
EFD – Module, Function and Troubleshooting….8233
SMPC30006199 – Hydraulic Mining Shovel PC3000-1 Shop Manual….8236
Cover….8236
Introduction….8237
Foreward….8238
Table of Contents….8241
Section 1 – Main Assembly Groups….8243
Table of Contents….8243
General Layout….8245
Drive….8247
Control Blocks, Swing Gear….8249
Undercarriage, Travel Drive….8251
Driver's Cab….8253
Section 2 – Drive….8255
Table of Contents….8255
Prime Drive Assembly….8257
Engine Mounts….8259
Fan Drive and Cooler Assembly….8261
Coupling….8263
Air Filter….8265
Pump Distributor Gear….8267
Spline – Lubrication….8269
Gear Lubrication….8271
Location of Pumps, Drive Speeds, and Flow Rates….8275
Section 3 – Hydraulic Oil Tank….8277
Table of Contents….8277
Main Oil Tank….8279
Return and Leak Oil Filter….8281
Breather Filter….8283
Location of Pressure Switches and Sensors….8285
Section 4 – Hydraulic Oil Cooling….8287
Table of Contents….8287
General….8289
Hydraulic Oil Cooling Circuit….8291
Measuring / Setting the Back Pressure Valve….8293
Fan Drive….8297
Pressure Relief Valve and Solenoid Valve….8299
Axial Piston Pump….8301
Measuring and Setting the Fan Speed….8303
Function Check for RPM-Control….8307
Section 5 – Controlling….8309
Table of Contents….8309
Pilot Pressure Supply….8311
Checks and Adjustments of Pilot Pressure….8315
Measuring and Adjustment of Control Pressure….8317
Checking of Accumulator Function….8317
Checking of Pre-charge Pressure….8317
Travel Parking Brake….8319
Function Check of Travel Parking Brake….8321
Function Check of Pressure Switch (B48)….8321
Swing Parking (House) Brake….8323
Section 6 – Components….8325
Table of Contents….8325
Main Control Blocks and High Pressure Filter….8327
Bull-clam Attachment….8327
Back Hoe Attachment….8329
Distributor Manifold….8331
Bull-clam Attachment….8331
Back Hoe Attachment….8333
Restrictor Block with Pressure Relief Valve….8335
Restrictor Block….8337
Anti-Cavitation Valve Block….8339
Proportional Solenoid Valve….8341
Pressure Filter….8343
Control Blocks….8345
Control Blocks and Valves….8347
Valve at the Control Block….8351
Load Holding Valve….8353
Travel Brake Valve….8355
Pressure Reducing Valve….8357
Directional Control Valves (Solenoid Valve)….8359
Hydraulic Cylinder….8361
Auxilliary Pumps (Fan Drive)….8363
Auxilliary Gear Pumps….8365
Swing Ring….8367
Section 7 – Main Hydraulic Pumps….8369
Table of Contents….8369
Main Hydraulic Pump A7V / HD D….8371
SL-bearing….8375
Function of the Pump Governor….8377
Pump Bearing Lubrication….8383
Pump Governor Adjustments….8387
Measuring and Setting Pressure of the Pressure Cut-off Valves….8387
Measuring and Setting the start of De-stroking the Main Pumps….8391
Adjusting the Damper Bolt….8393
Pump Regulation, General….8395
Stop Gap Operation (Emergency Use Only)….8397
Electronic Regulation….8397
Detailed Explanation for Hydraulic Regulation….8399
Hydraulic Regulation….8399
Determination of Peak Point (Corner Value)….8401
Setting the X1-Pressure….8403
Detailed Explanation for Electronic Regulation….8405
Adjustments / Checks for Electronic Regulation….8407
Adjusting the RPM Sensor (MPU)….8409
Adjustments at the ELL Module….8411
Testing / Setting for Complete Regulation….8413
Checks / Function Test / Fault Finding at JOB SITE….8415
EPM – Module, Function and Test….8417
ERM – Module, Function and Test….8419
ELL – Module, Function and Test….8423
Amplifier Module, Function and Test….8427
Simplified Troubleshooting of the Electronic Control….8429
Pre-Conditions….8431
Checking Proportional Solenoid Valve Function….8431
Section 8 – Operating Hydraulic….8433
Table of Contents….8433
Hydraulic for Attachment Cylinders….8435
Adjustments for Attachment Cylinder Hydraulic….8439
Main Relief Valves….8439
Service Line Relief Valves….8441
Boom Cylinder….8441
Stick Cylinder….8443
Bucket Cylinder….8445
Clam Cylinder….8447
Opening….8447
Closing….8449
Floating Function of Boom and Stick Cylinders….8451
Adjustments / Checks….8453
Swing Circuit, General….8457
Swing Motor….8461
Swing Gear and Swing Parking Brake….8465
Swing Brake Valve….8469
Swing Function….8475
Function: R.H. Rotation….8475
Function: L.H. Rotation….8475
Swinging Down Path (Delay)….8477
Anticavitation Circuit….8479
Braking….8481
Swing Parking Brake….8483
Checks and Adjustments….8485
Adjustments for the Swing Circuit….8487
Checking Pilot Pressure for Swing Brake….8491
Travel Circuit, General….8493
Rotary Distributor….8497
Travel Motor (Axial Piston Motor A2FM)….8499
Travel Gear and Parking Brake….8503
Travel Gear….8503
Travel Parking Brake….8505
Travel, Function….8507
Anti-Cavitation Circuit….8511
Adjustments / Checks….8513
Test / Park Brake Release Pressure (House Brake Pressure)….8517
Section 9 – Hydraulic Track Tension System….8519
Table of Contents….8519
Hydraulic Track Tension System….8521
Function….8523
Pressure Increasing Valve Type: MO 7010….8527
Pressure Relief Valve, Direct Operated Type: DBD S….8529
Adjustments / Pressure Checks….8531
Adjustments….8531
Basic Adjustment….8533
Setting Procedure….8535
Function Check….8537
Section 10 – Access Ladder Hydraulic Operated….8539
Table of Contents….8539
Access Ladder Hydraulic Operated….8541
Section 11 – Central Refilling System….8545
Table of Contents….8545
Central Refilling System….8547
Section 12 – Hints for Hydraulic Circuit Diagrams….8551
Table of Contents….8551
Hints for Reading Circuit Diagrams….8555
Legend to the Hydraulic Circuit Diagram….8556
How to Read Circuit Diagrams….8562
Hydraulic Diagrams – 927 596 40….8563
Hydraulic Diagram – 927 596 40 (1/3)….8563
Hydraulic Diagram – 927 596 40 (2/3)….8564
Hydraulic Diagram – 927 596 40 (3/3)….8565
Section 13 – Hints for Electric Circuit Diagrams….8573
Table of Contents….8573
Markings of Electrical Components in Circuit Diagrams….8575
Symbols….8577
KMG Circuit, General Information….8581
Ecplanation of the Drawing Concept….8583
Location of Main Terminal Boxes and Important Components….8585
Reading a Circuit Diagram….8589
Adjustments….8593
Component List….8594
Electrical Circuit Diagrams – 927 595 40….8599
Electrical Circuit Diagrams – 927 595 40 (1/40)….8599
Electrical Circuit Diagrams – 927 595 40 (2/40)….8600
Electrical Circuit Diagrams – 927 595 40 (3/40)….8601
Electrical Circuit Diagrams – 927 595 40 (4/40)….8602
Electrical Circuit Diagrams – 927 595 40 (5/40)….8603
Electrical Circuit Diagrams – 927 595 40 (6/40)….8604
Electrical Circuit Diagrams – 927 595 40 (7/40)….8605
Electrical Circuit Diagrams – 927 595 40 (8/40)….8606
Electrical Circuit Diagrams – 927 595 40 (9/40)….8607
Electrical Circuit Diagrams – 927 595 40 (10/40)….8608
Electrical Circuit Diagrams – 927 595 40 (11/40)….8609
Electrical Circuit Diagrams – 927 595 40 (12/40)….8610
Electrical Circuit Diagrams – 927 595 40 (13/40)….8611
Electrical Circuit Diagrams – 927 595 40 (14/40)….8612
Electrical Circuit Diagrams – 927 595 40 (15/40)….8613
Electrical Circuit Diagrams – 927 595 40 (16/40)….8614
Electrical Circuit Diagrams – 927 595 40 (17/40)….8615
Electrical Circuit Diagrams – 927 595 40 (18/40)….8616
Electrical Circuit Diagrams – 927 595 40 (19/40)….8617
Electrical Circuit Diagrams – 927 595 40 (20/40)….8618
Electrical Circuit Diagrams – 927 595 40 (21/40)….8619
Electrical Circuit Diagrams – 927 595 40 (22/40)….8620
Electrical Circuit Diagrams – 927 595 40 (23/40)….8621
Electrical Circuit Diagrams – 927 595 40 (24/40)….8622
Electrical Circuit Diagrams – 927 595 40 (25/40)….8623
Electrical Circuit Diagrams – 927 595 40 (26/40)….8624
Electrical Circuit Diagrams – 927 595 40 (27/40)….8625
Electrical Circuit Diagrams – 927 595 40 (28/40)….8626
Electrical Circuit Diagrams – 927 595 40 (29/40)….8627
Electrical Circuit Diagrams – 927 595 40 (30/40)….8628
Electrical Circuit Diagrams – 927 595 40 (31/40)….8629
Electrical Circuit Diagrams – 927 595 40 (32/40)….8630
Electrical Circuit Diagrams – 927 595 40 (33/40)….8631
Electrical Circuit Diagrams – 927 595 40 (34/40)….8632
Electrical Circuit Diagrams – 927 595 40 (35/40)….8633
Electrical Circuit Diagrams – 927 595 40 (36/40)….8634
Electrical Circuit Diagrams – 927 595 40 (37/40)….8635
Electrical Circuit Diagrams – 927 595 40 (38/40)….8636
Electrical Circuit Diagrams – 927 595 40 (39/40)….8637
Section 14 – Electronic Text Monitoring System….8639
Table of Contents….8639
Introduction….8641
General….8641
Function….8645
Layout of Dash Board….8651
Text Monitoring System….8657
Features of the ETM System….8657
Two Main Message Groups….8657
Function of Keys on Keyboard….8659
System Components….8661
Switches for the Adjustment of ETM….8663
Message Classification….8663
Function of ETM System and their Utilization….8665
Display the Content Record (PROTOCOL) Memory….8669
Print Out Content of Statistics Memory….8672
Print Out Last Entries of Record (PROTOCOL) Memory….8674
Change-over From English to German….8675
Change-over from German to English….8675
Several Message Conditions Occur at Same Time….8676
Settongs of Text Display Unit….8679
Return to System Level….8682
Setting Screen Brightness….8682
Grouping of Message Numbers in Input Signal Modules….8683
Table of Messages….8684
Message Numbers 1 to 5….8684
Message Numbers 6 to 11….8685
Message Numbers 12 to 18….8686
Message Numbers 19 to 26….8687
Message Numbers 27 to 30….8688
Message Numbers 31 to 38….8689
Message Numbers 39 to 44….8690
Message Numbers 45 to 52….8691
Message Numbers 53 to 64….8692
Grouping of Messages According to Priority….8693
Explanation of Statistics Print-Out….8697
Time Diagram of Ststics Print….8698
EFD – Module, Function and Troubleshooting….8701
SMPC30006202 – Hydraulic Mining Shovel PC3000-1 Shop Manual….8704
Cover….8704
Introduction….8705
Foreword….8706
Table of Contents….8708
Section 1 – Main Assembly Groups….8710
Table of Contents, Section 1….8710
Main Assembly Groups….8710
General Layout….8712
Drive….8714
Control Blocks, Swing Gear….8716
Undercarriage, Travel Drive….8718
Driver's Cab….8720
Section 2 – Drive….8722
Table of Contents, Section 2….8722
Prime Drive Assembly….8724
Engine Mounts….8726
Fan Drive and Cooler Assembly….8728
Coupling….8730
Air Filter….8732
Pump Distributor Gear….8734
Pump Spline Lubrication….8736
Gear Lubrication – PTO….8738
Location of the Pumps, Drive Speeds and, Flow Rates….8742
Section 3 – Hydraulic Oil Tank….8744
Table of Contents, Section 3….8744
Main Oil Tank….8746
Return and Leak Oil Filter….8748
Breather Filter….8750
Location of Pressure Switches and Sensors….8752
Section 4 – Hydraulic Oil Cooling….8754
Table of Contents, Section 4….8754
General….8756
Hydraulic Oil Cooling Circuit….8758
Measuring / Setting the Back Pressure Valve….8760
If Adjustment is Required….8760
Checks to be Performed….8762
Precondition for These Checks….8762
Fan Drive….8764
Pressure Valve and Solenoid Valve….8766
Axial Piston Pump….8768
Meaasuring and Setting Fan Speed….8770
Basic Adjustment….8770
Function Check for RPM-Control….8774
Section 5 – Controlling….8776
Table of Contents, Section 5….8776
Pilot Pressure Supply….8778
Checks and Adjustment of Pilot Pressure….8782
Measuring and Adjusting of Control Pressure….8784
Travel Parking Brake….8786
Function Check of Travel Parking Brake….8788
Swing Parking (House) Brake….8790
Section 6 – Components….8792
Table of Contents, Section 6….8792
Main Control Blocks and High Pressure Filter….8794
Bull-Clam Attachment….8794
Back Hoe Attachment….8796
Distributor Manifold….8798
Bull-Clam Attachment….8798
Back Hoe Attachment….8800
Restrictor Block with Pressure Relief Valve….8802
Anti-Cavitation Valve Block….8806
Proportional Solenoid Valve….8808
Pressure Filter….8810
Control Blocks….8812
Control Blocks and Valves….8814
Valve at the Control Block….8818
Load Holding Valve….8820
Travel Brake Valve….8822
Pressure Reducing Valve….8824
Directional Control Valve (Solenoid Valve)….8826
Hydraulic Cylinder….8828
Auxiliary Pumps (Fan Drive)….8830
Auxiliary Gear Pumps….8832
Swing Ring….8834
Section 7 – Main Hydraulic Pumps….8836
Table of Contents, Section 7….8836
Main Hydraulic Pump A7V / HD D….8838
Description of SL-bearing….8842
Function of the Pump Governor….8844
Pump Bearing Lubrication….8850
Pump Governor Adjustments….8854
Measuring and setting pressure of the pressure cut-off valves….8854
Measuring / Setting of the Start of De-stroking of the Main Pump….8858
Adjusting the Damper Bolt….8860
Pump Regulation, General….8862
Determination of the Peak Point (Corner Value)….8868
Hydraulic regulation adjustment, Stop Gap Operation….8870
Detailed Explanation for the Electronic Regulation….8872
Adjustments / Checks for the Electronic Regulation….8874
Adjusting the RPM Sensor (MPU)….8876
Adjustments at the ELL Module….8878
Testing and Setting for the Complete Regulation….8880
Checks / Function Test / Fault Finding at JOB SITE….8882
EPM – module, Function and Test….8884
ERM – module, Function and Test….8886
ELL – module, Function and Test….8890
Testing the Proportional Amplifier Module, A36….8894
Simplified Trouble Shooting of the Electronic Control….8896
Section 8 – Operating Hydraulic….8900
Table of Contents, Section 8….8900
Hydraulic for Attachment Cylinder….8902
Attachments for Attachment Cylinder Hydraulic….8906
Swing Circuit, General….8924
Swing Motor….8928
Swing Gear and Swing Parking Brake….8932
Swing Brake Valve….8936
Swing, Function….8940
Function: R.H. rotation….8940
Swinging Down Path (Delay)….8942
Anticavation Circuit….8944
Braking….8946
Swing Parking Brake….8948
Checks and Adjustments….8950
Performance check of swing parking brake (house brake)….8950
Adjustments for the Swing Circuit….8952
High pressure check / adjustment….8952
Low pressure check / adjustment….8954
Checking the pilot pressure for the swing brake….8956
Travel Circuit….8958
Rotary Distributor….8962
Travel Motor (Axial Piston Motor A2FM)….8964
Travel Gear and Parking Brake….8968
Travel Gear….8968
Travel Parking Brake….8970
Travel, Function….8972
Anti-Cavitation Circuit….8976
Adjustments / Checks….8978
Untitled….8982
Section 9 – Hydraulic Track Tension System….8984
Table of Contents, Section 9….8984
Hydraulic Track Tension System….8986
Function….8988
Pressure Increasing Valve Type: MO 7010….8992
Pressure Relief Valve, Direct Operated Type: DBD S….8994
Adjustments / Pressure Checks….8996
Basic Adjustment….8998
Setting Procedure….9000
Function Check….9002
Section 10 – Access Ladder Hydraulic Operated….9004
Table of Contents, Section 10….9004
Access Ladder Hydraulic Operated….9006
Section 11 – Central Refilling System….9010
Table of Contents, Section 11….9010
Central Refilling System….9012
Section 12 – Hints for the Hydraulic Circuit Diagram….9016
Table of Contents, Section 12….9016
Hints for Reading the Circuit Diagram….9020
Legend of the Hydraulic Circuit Diagram….9021
Pressure Check Points….9025
How to Read the Circuit Diagram….9028
Hydraulic Diagrams – 927 026 40….9030
Hydraulic Diagrams – 927 026 40 (1/4….9030
Hydraulic Diagrams – 927 026 40 (2/4….9031
Hydraulic Diagrams – 927 026 40 (3/4….9032
Hydraulic Diagrams – 927 026 40 (4/4….9033
Section 13 – Hints for the Electric Circuit Diagram….9043
Table of Contents, Section 13….9043
Marking of Electrical Components in the Circuit Diagrams….9044
Symbols….9046
KMG Circuit Diagrams, General Information….9050
Explanation of the Drawing Concept….9052
Location of the Main Terminal Boxes ans some Important Components….9054
Reading a Circuit Diagram….9058
Adjustments….9062
Electrical Circuit Diagrams – 927 027 40….9069
Electrical Circuit Diagrams – 927 027 40 (1/72)….9069
Electrical Circuit Diagrams – 927 027 40 (2/72)….9070
Electrical Circuit Diagrams – 927 027 40 (3/72)….9071
Electrical Circuit Diagrams – 927 027 40 (4/72)….9072
Electrical Circuit Diagrams – 927 027 40 (5/72)….9073
Electrical Circuit Diagrams – 927 027 40 (6/72)….9074
Electrical Circuit Diagrams – 927 027 40 (7/72)….9075
Electrical Circuit Diagrams – 927 027 40 (8/72)….9076
Electrical Circuit Diagrams – 927 027 40 (9/72)….9077
Electrical Circuit Diagrams – 927 027 40 (10/72)….9078
Electrical Circuit Diagrams – 927 027 40 (11/72)….9079
Electrical Circuit Diagrams – 927 027 40 (12/72)….9080
Electrical Circuit Diagrams – 927 027 40 (13/72)….9081
Electrical Circuit Diagrams – 927 027 40 (14/72)….9082
Electrical Circuit Diagrams – 927 027 40 (15/72)….9083
Electrical Circuit Diagrams – 927 027 40 (16/72)….9084
Electrical Circuit Diagrams – 927 027 40 (17/72)….9085
Electrical Circuit Diagrams – 927 027 40 (18/72)….9086
Electrical Circuit Diagrams – 927 027 40 (19/72)….9087
Electrical Circuit Diagrams – 927 027 40 (20/72)….9088
Electrical Circuit Diagrams – 927 027 40 (21/72)….9089
Electrical Circuit Diagrams – 927 027 40 (22/72)….9090
Electrical Circuit Diagrams – 927 027 40 (23/72)….9091
Electrical Circuit Diagrams – 927 027 40 (24/72)….9092
Electrical Circuit Diagrams – 927 027 40 (25/72)….9093
Electrical Circuit Diagrams – 927 027 40 (26/72)….9094
Electrical Circuit Diagrams – 927 027 40 (27/72)….9095
Electrical Circuit Diagrams – 927 027 40 (28/72)….9096
Electrical Circuit Diagrams – 927 027 40 (29/72)….9097
Electrical Circuit Diagrams – 927 027 40 (30/72)….9098
Electrical Circuit Diagrams – 927 027 40 (31/72)….9099
Electrical Circuit Diagrams – 927 027 40 (32/72)….9100
Electrical Circuit Diagrams – 927 027 40 (33/72)….9101
Electrical Circuit Diagrams – 927 027 40 (34/72)….9102
Electrical Circuit Diagrams – 927 027 40 (35/72)….9103
Electrical Circuit Diagrams – 927 027 40 (36/72)….9104
Electrical Circuit Diagrams – 927 027 40 (37/72)….9105
Electrical Circuit Diagrams – 927 027 40 (38/72)….9106
Electrical Circuit Diagrams – 927 027 40 (39/72)….9107
Electrical Circuit Diagrams – 927 027 40 (40/72)….9108
Electrical Circuit Diagrams – 927 027 40 (41/72)….9109
Electrical Circuit Diagrams – 927 027 40 (42/72)….9110
Electrical Circuit Diagrams – 927 027 40 (43/72)….9111
Electrical Circuit Diagrams – 927 027 40 (44/72)….9112
Electrical Circuit Diagrams – 927 027 40 (45/72)….9113
Electrical Circuit Diagrams – 927 027 40 (46/72)….9114
Electrical Circuit Diagrams – 927 027 40 (47/72)….9115
Electrical Circuit Diagrams – 927 027 40 (48/72)….9116
Electrical Circuit Diagrams – 927 027 40 (49/72)….9117
Electrical Circuit Diagrams – 927 027 40 (50/72)….9118
Electrical Circuit Diagrams – 927 027 40 (51/72)….9119
Electrical Circuit Diagrams – 927 027 40 (52/72)….9120
Electrical Circuit Diagrams – 927 027 40 (53/72)….9121
Electrical Circuit Diagrams – 927 027 40 (54/72)….9122
Electrical Circuit Diagrams – 927 027 40 (55/72)….9123
Electrical Circuit Diagrams – 927 027 40 (56/72)….9124
Electrical Circuit Diagrams – 927 027 40 (57/72)….9125
Electrical Circuit Diagrams – 927 027 40 (58/72)….9126
Electrical Circuit Diagrams – 927 027 40 (59/72)….9127
Electrical Circuit Diagrams – 927 027 40 (60/72)….9128
Electrical Circuit Diagrams – 927 027 40 (61/72)….9129
Electrical Circuit Diagrams – 927 027 40 (62/72)….9130
Electrical Circuit Diagrams – 927 027 40 (63/72)….9131
Electrical Circuit Diagrams – 927 027 40 (64/72)….9132
Electrical Circuit Diagrams – 927 027 40 (65/72)….9133
Electrical Circuit Diagrams – 927 027 40 (66/72)….9134
Electrical Circuit Diagrams – 927 027 40 (67/72)….9135
Electrical Circuit Diagrams – 927 027 40 (68/72)….9136
Electrical Circuit Diagrams – 927 027 40 (69/72)….9137
Electrical Circuit Diagrams – 927 027 40 (70/72)….9138
Electrical Circuit Diagrams – 927 027 40 (71/72)….9139
Electrical Circuit Diagrams – 927 027 40 (72/72)….9140
Section 14 – Electronic Text Monitoring System….9142
Table of Contents, Section 14….9142
Introduction….9143
Function….9146
Layout of Dash Board….9152
Text Monitoring System….9158
Function of Keys 1 to 8 of Keyboard….9160
System Components….9162
Switches for Adjustments of the ETM….9164
Message Classification….9164
Functions of ETM System and their Utilizations….9166
Basic Display (Message #0)….9166
Steps for Operating the ETM Keyboard….9167
Call Up Basic Display from any Message….9167
Call Up Message with Basic Display on Screen (A)….9168
Display Content of Record (PROTOCOL) Memory….9170
Display Content of Statistic Memory….9172
Print Out Content of Statistics Memory….9173
Print Out Content of Record (PROTOCOL) Memory….9173
Print Out the Last Entries of Record (PROTOCOL) Memory….9175
Change-Over from English to German Language….9176
Change-Over from German to English Language….9176
Several Message Conditions Occur at the Same Time….9177
Settings of the Text Display Unit….9180
Return to System Level….9183
Setting Screen Brightness….9183
Grouping of Message Numbers in the Input Signal Modules….9184
Table of Messages….9185
Basic Display (Message Page #0)….9185
Message Pages 1 to 5….9185
Message Pages 6 to 11….9186
Message Pages 12 to 18….9187
Message Pages 19 to 26….9188
Message Pages 27 to 30….9189
Message Pages 31 to 38….9190
Message Pages 39 to 44….9191
Message Pages 45 to 52….9192
Message Pages 53 to 64….9193
Grouping of Messages According to their Priority….9194
Explanation of Statistics Print-Out….9198
Frequency / Voltage Converter (EFD-Module)….9202
Function Control….9204
Adjustment of the MPU….9204
SMPC30006208 – Hydraulic Mining Shovel PC3000-6 Service Manual….9206
COVER….9206
I. INTRODUCTION….9208
II. SAFETY….9220
III. SPECIFICATIONS….9226
1. MAIN ASSEMBLY GROUPS….9240
1.1 General layout….9241
1.2 Superstructure….9243
1.3 Power House….9245
1.4 Hydraulic Oil Reservoir….9247
1.5 Hydraulic Oil Cooler….9249
1.6 Fuel tank (Fuel reservoir)….9251
1.7 Counter weight….9253
1.8 Cab support….9255
1.9 Operators cab….9257
1.10 Control blocks….9259
1.11 Swing gears….9261
1.12 Under carriage….9263
2. DRIVE….9266
2.1 Prime drive assembly….9267
2.2 Engine and gearbox mount….9269
2.3 Torque supports….9272
2.4 Radiator fan Drive Assy….9273
2.5 Pump distributor gearbox (PTO)….9275
2.5.1 Spline shaft housing….9277
2.5.2 PTO lubrication and cooling….9279
2.5.3 PTO valve adjustments….9281
2.6 Coupling….9285
2.7 Air Filter….9287
3. HYDRAULIC OIL RESERVOIR….9290
3.1 Hydraulic oil reservoir….9291
3.2 Return and leak oil filter….9295
3.3 Breather Filter….9299
3.4 Location of electrical components….9301
4. HYDRAULIC OIL COOLING….9304
4.1 General….9305
4.2 Hydraulic oil cooling circuit….9307
4.3 Back pressure valve adjustment….9311
4.4 Fan drive….9313
4.4.1 Fan pump….9315
4.4.2 Pressure relieve valve….9316
4.4.3 Temperature relay….9318
4.5 Cooler fan drive adjustment….9319
5. CONTROLLING….9322
5.1 Pilot pressure supply and adjustment….9323
5.1.1 Pilot control arrangement….9325
5.1.2 Pilot pressure adjustment….9327
5.1.3 Check of Control Pressure….9329
5.2 Slew brakes….9331
5.3 Travel parking brake….9334
5.4 Check of the pilot control logic….9336
5.4.1 Check sheet FSA Page 1….9338
5.4.2 Check sheet BHA Page 1….9351
6. COMPONENTS….9360
6.1 Main control block and valve arrangement….9361
6.1.1 FSA arrangement….9363
6.1.2 BHA arrangement….9367
6.2 Distributor manifold….9371
6.2.1 Front shovel attachment FSA….9371
6.2.2 Back hoe attachment BHA….9373
6.2.3 SRV with throttle check valve….9375
6.2.4 Anti cavitation valve (check valve)….9377
6.3 Main control block….9379
6.3.1 Load holding valve….9385
6.3.2 High pressure filter….9387
6.3.3 Pressure relieve valves and anti-cavitation valve….9389
6.3.4 Pressure relieve valves and anti-cavitation valve….9391
6.4 Compact valve blocks….9393
6.5 Compact valve blocks….9395
6.6 Auxiliary gear pumps….9397
6.7 Hydraulic cylinder….9399
6.8 Swing ring….9401
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION….9404
7.1 General….9405
7.1.1 Pump location….9407
7.2 Main pump operating principles….9409
7.2.1 Main pump function….9414
7.3 Main pump checks and adjustments….9417
7.3.1 Peak point diesel engine test….9417
7.3.2 Pressure transducer test….9419
7.3.3 Cut off function….9420
7.3.4 Pump regulation….9422
7.3.5 Swing pump volume reduction….9423
7.4 Electronic pump regulation….9424
7.5 Pump Controller CR700….9427
7.6 Multi Monitor….9429
7.7 Multimonitor software instruction….9431
7.7.1 Multimonitor main control….9431
7.7.2 Service Menu screen….9431
7.7.3 Monitoring (menu item 01)….9432
7.7.4 Abnormality Record (menu item 02)….9433
7.7.5 Default (menu item 03)….9436
7.7.6 Adjustment (menu item 04)….9437
7.7.7 Display Setup (menu item 05)….9439
7.7.8 Table of fault messages and adjustments….9440
7.8 Trouble shooting pump and pump regulation….9449
8. OPERATING HYDRAULIC….9450
8.1 General layout….9451
8.2 Floating function of boom and stick only FSA….9455
8.3 Check and Adjustments for MRV’s and SRV’s….9457
8.3.1 Check and Adjustments for MRV….9459
8.3.2 Check and Adjustment for SRV’s….9461
8.3.3 Check and adjustment of the throttle check valves….9469
8.4 Hydraulic for the swing circuit….9471
8.4.1 Hydraulic for the swing circuit….9475
8.4.2 Slew gear box L & S….9479
8.4.3 Slew parking brake….9483
8.4.4 Slew service brake valve….9487
8.4.5 Checks and adjustment of the slew pressure valve….9492
8.5 Travel circuit….9495
8.5.1 Rotary joint….9497
8.5.2 Travel motor A2FMt….9499
8.5.3 Travel gear….9501
8.5.4 Travel parking brake….9503
8.5.5 Travel control function….9505
8.5.6 Check and Adjustment SRV travel system….9508
9. TRACK TENSION SYSTEM….9510
9.1 General layout….9511
9.2 Track tensioning function….9513
9.2.1 Cushioning….9515
9.2.2 Pressure Increasing valve PIV….9517
9.3 Track tensioning adjustment….9521
9.3.1 Track tensioning function check….9523
10. ACCESS LADDER HYDRAULICALLY OPERATED….9526
10.1 Access ladder….9527
10.2 Access ladder functional description….9529
11. CENTRAL REFILLING SYSTEM….9534
11.0.1 Functional description….9535
12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM….9540
12.1 General….9541
12.2 Symbolic….9543
12.2.1 Lines, unions….9544
12.2.2 Components, valves….9546
12.2.3 Sensors….9546
12.2.4 Valves, valve components….9547
12.2.5 Pump, motor, cylinder….9551
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM….9556
13.1 Designation of electrical components….9558
13.2 Electric symbols….9559
13.3 Symbols….9561
13.3.1 Drawing concept….9563
13.3.2 Reading of the circuit diagram….9569
14. ELECTRONIC TEXT MONITORING SYSTEM ETM….9574
14.1 General Function….9575
15. AUTOMATIC LUBRICATION SYSTEM….9578
15.1 General Function….9579
15.2 Function of a lubrication cycle….9581
15.3 Lubrication pump drive….9589
15.4 Lubrication pump….9591
15.4.1 Adjustments lubricating pump speed….9593
15.4.2 Adjustments lubricating pump pressure….9595
15.5 Lubricant Injector (metering valve)….9597
15.5.1 Connection of one or more injectors….9599
15.5.2 Function lubrication injector (metering valve)….9601
15.6 End line pressure switch….9605
15.7 Lubricant in line filter….9607
15.8 Lubricant level sensor….9609
15.8.1 Capacitive digital type for machines with ETM….9609
15.8.2 Capacitive analog type for machines with PLC….9611
15.9 Lubrication system function and controlling….9613
15.9.1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000)….9614
15.9.2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000)….9618
15.10 Adjustment of the lubrication system with ETM….9624
15.11 Trouble shooting lubricating system….9625
15.11.1 Lubrication pump cylinder does not move….9626
15.11.2 Lubricant pressure built up very slowly or not at all….9628
15.11.3 Insufficient lubricant supply to one or more attachment bearings….9628
15.11.4 Insufficient lubricant at the swing ring gear….9630
SMPC30006219 – Hydraulic Mining Shovel PC3000-6 Shop Manual….9640
COVER….9640
I. INTRODUCTION….9642
I.I CONTENTS OF BINDER….9643
I.II FOREWARD….9644
I.III EXPLANATION OF ABBREVATIONS….9646
I.IV TABLE OF CONTENTS….9647
II. SAFETY….9654
II.I SAFETY INSTRUCTIONS….9655
II.II GENERAL PRECAUTIONS….9656
II.III PREPARATIONS FOR WORK….9657
II.IV PRECAUTIONS DURING WORK….9658
III. SPECIFICATIONS….9660
III.I LIFTING GEARS….9661
III.II STANDARD TIGHTENING TORQUE CHART….9663
III.III CONVERSION TABLE….9664
III.IV EXPLANATION OF ABBREVATIONS….9670
III.V GENERAL SPECIFICATIONS….9671
1. MAIN ASSEMBLY GROUPS….9672
1.1 General layout….9673
1.2 Superstructure….9675
1.3 Power House….9677
1.4 Hydraulic Oil Reservoir….9679
1.5 Hydraulic Oil Cooler….9681
1.6 Fuel tank (Fuel reservoir)….9683
1.7 Counter weight….9685
1.8 Cab support….9687
1.9 Operators cab….9689
1.10 Control blocks….9691
1.11 Swing gears….9693
1.12 Under carriage….9695
2. DRIVE….9698
2.1 Prime drive assembly….9699
2.2 Engine and gearbox mount….9701
2.3 Torque supports….9704
2.4 Radiator fan Drive Assy….9705
2.5 Pump distributor gearbox (PTO)….9707
2.5.1 Spline shaft housing….9709
2.5.2 PTO lubrication and cooling….9711
2.5.3 PTO valve adjustments….9713
2.6 Coupling….9717
2.7 Air Filter….9719
3. HYDRAULIC OIL RESERVOIR….9722
3.1 Hydraulic oil reservoir….9723
3.2 Return and leak oil filter….9727
3.3 Breather Filter….9731
3.4 Location of electrical components….9733
4. HYDRAULIC OIL COOLING….9736
4.1 General….9737
4.2 Hydraulic oil cooling circuit….9739
4.3 Back pressure valve adjustment….9743
4.4 Fan drive….9745
4.4.1 Fan pump….9747
4.4.2 Pressure relieve valve….9748
4.4.3 Temperature relay….9750
4.5 Cooler fan drive adjustment….9751
5. CONTROLLING….9754
5.1 Pilot pressure supply and adjustment….9755
5.1.1 Pilot control arrangement….9758
5.1.2 Pilot pressure adjustment….9760
5.1.3 Check of Control Pressure….9762
5.2 Slew brakes….9764
5.3 Travel parking brake….9767
5.4 Check of the pilot control logic….9769
5.4.1 Check sheet BHA Page 1….9771
5.4.2 Check sheet FSA Page 1….9784
6. COMPONENTS….9794
6.1 Main control block and valve arrangement….9795
6.1.1 FSA arrangement….9797
6.1.2 BHA arrangement….9801
6.2 Distributor manifold….9805
6.2.1 Front shovel attachment FSA….9805
6.2.2 Back hoe attachment BHA….9807
6.2.3 SRV with throttle check valve….9809
6.2.4 Anti cavitation valve (check valve)….9811
6.3 Main control block….9813
6.3.1 Load holding valve….9821
6.3.2 High pressure filter auxiliary filter….9823
6.3.3 High pressure filter auxiliary filter….9825
6.3.4 High pressure filter auxiliary filter….9827
6.4 Compact valve blocks….9829
6.5 Compact valve blocks….9831
6.6 Auxiliary gear pumps….9833
6.7 Hydraulic cylinder….9835
6.8 Swing ring….9837
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION….9840
7.1 General….9841
7.1.1 Pump location….9843
7.2 Main pump operating principles….9845
7.2.1 Main pump function….9850
7.3 Main pump checks and adjustments….9853
7.3.1 Peak point diesel engine test….9853
7.3.2 Pressure transducer test….9855
7.3.3 Cut off function….9856
7.3.4 Pump regulation….9858
7.3.5 Swing pump volume reduction….9859
7.4 Electronic pump regulation….9860
7.4.1 Pump Controller CR700….9862
7.4.2 Multi Monitor….9864
7.4.3 Multimonitor software instruction….9866
7.4.4 Table of fault messages and adjustments….9873
7.5 Trouble shooting pump and pump regulation….9882
8. OPERATING HYDRAULIC….9886
8.1 General layout….9887
8.2 Floating function of boom and stick only FSA….9891
8.3 Check and Adjustments for MRV’s and SRV’s….9893
8.3.1 Check and Adjustments for MRV….9895
8.3.2 Check and Adjustment for SRV’s….9897
8.3.3 Check and adjustment of the throttle check valves….9905
8.4 Hydraulic for the swing circuit….9907
8.4.1 Hydraulic for the swing circuit….9911
8.4.2 Slew gear box L & S….9915
8.4.3 Slew parking brake….9919
8.4.4 Slew service brake valve….9923
8.4.5 Checks and adjustment of the slew pressure valve….9928
8.5 Travel circuit….9931
8.5.1 Rotary joint….9933
8.5.2 Travel motor A2FMt….9935
8.5.3 Travel gear….9937
8.5.4 Travel parking brake….9939
8.5.5 Travel control function….9941
9. TRACK TENSION SYSTEM….9946
9.1 General layout….9947
9.2 Track tensioning function….9949
9.2.1 Cushioning….9951
9.2.2 Pressure Increasing valve PIV….9953
9.3 Truck tensioning adjustment….9957
9.3.1 Truck tensioning function check….9959
10. ACCESS LADDER HYDRAULICALLY OPERATED….9962
10.1 Access ladder….9963
10.2 Access ladder functional description….9965
11. CENTRAL REFILLING SYSTEM….9970
11.0.1 Functional description….9971
12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM….9976
12.1 General….9977
12.2 Symbolic….9979
12.2.1 Lines, unions….9980
12.2.2 Components, valves….9982
12.2.3 Sensors….9982
12.2.4 Valves, valve components….9983
12.2.5 Pump, motor, cylinder….9987
Hydraulic Diagrams – 942 761 40….9991
Hydraulic Diagrams – 942 761 40 (1/3)….9991
Hydraulic Diagrams – 942 761 40 (2/3)….9992
Hydraulic Diagrams – 942 761 40 (3/3)….9993
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM….10000
13.1 Designation of electrical components….10002
13.2 Electric symbols….10003
13.3 Symbols….10005
13.3.1 Drawing concept….10007
13.3.2 Reading of the circuit diagram….10013
Electrical Diagrams – 942 762 40….10017
Electrical Diagrams – 942 762 40 (1/53….10017
Electrical Diagrams – 942 762 40 (2/53….10018
Electrical Diagrams – 942 762 40 (3/53….10019
Electrical Diagrams – 942 762 40 (4/53….10020
Electrical Diagrams – 942 762 40 (5/53….10021
Electrical Diagrams – 942 762 40 (6/53….10022
Electrical Diagrams – 942 762 40 (7/53….10023
Electrical Diagrams – 942 762 40 (8/53….10024
Electrical Diagrams – 942 762 40 (9/53….10025
Electrical Diagrams – 942 762 40 (10/53….10026
Electrical Diagrams – 942 762 40 (11/53….10027
Electrical Diagrams – 942 762 40 (12/53….10028
Electrical Diagrams – 942 762 40 (13/53….10029
Electrical Diagrams – 942 762 40 (14/53….10030
Electrical Diagrams – 942 762 40 (15/53….10031
Electrical Diagrams – 942 762 40 (16/53….10032
Electrical Diagrams – 942 762 40 (17/53….10033
Electrical Diagrams – 942 762 40 (18/53….10034
Electrical Diagrams – 942 762 40 (19/53….10035
Electrical Diagrams – 942 762 40 (20/53….10036
Electrical Diagrams – 942 762 40 (21/53….10037
Electrical Diagrams – 942 762 40 (22/53….10038
Electrical Diagrams – 942 762 40 (23/53….10039
Electrical Diagrams – 942 762 40 (24/53….10040
Electrical Diagrams – 942 762 40 (25/53….10041
Electrical Diagrams – 942 762 40 (26/53….10042
Electrical Diagrams – 942 762 40 (27/53….10043
Electrical Diagrams – 942 762 40 (28/53….10044
Electrical Diagrams – 942 762 40 (29/53….10045
Electrical Diagrams – 942 762 40 (30/53….10046
Electrical Diagrams – 942 762 40 (31/53….10047
Electrical Diagrams – 942 762 40 (32/53….10048
Electrical Diagrams – 942 762 40 (33/53….10049
Electrical Diagrams – 942 762 40 (34/53….10050
Electrical Diagrams – 942 762 40 (35/53….10051
Electrical Diagrams – 942 762 40 (36/53….10052
Electrical Diagrams – 942 762 40 (37/53….10053
Electrical Diagrams – 942 762 40 (38/53….10054
Electrical Diagrams – 942 762 40 (39/53….10055
Electrical Diagrams – 942 762 40 (40/53….10056
Electrical Diagrams – 942 762 40 (41/53….10057
Electrical Diagrams – 942 762 40 (42/53….10058
Electrical Diagrams – 942 762 40 (43/53….10059
Electrical Diagrams – 942 762 40 (44/53….10060
Electrical Diagrams – 942 762 40 (45/53….10061
Electrical Diagrams – 942 762 40 (46/53….10062
Electrical Diagrams – 942 762 40 (47/53….10063
Electrical Diagrams – 942 762 40 (48/53….10064
Electrical Diagrams – 942 762 40 (49/53….10065
Electrical Diagrams – 942 762 40 (50/53)….10066
Electrical Diagrams – 942 762 40 (51/53)….10067
Electrical Diagrams – 942 762 40 (52/53)….10068
Electrical Diagrams – 942 762 40 (53/53)….10069
14. ELECTRONIC TEXT MONITORING SYSTEM ETM….10071
14.1 General Function….10072
15. AUTOMATIC LUBRICATION SYSTEM….10075
15.1 General Function….10076
15.2 Function of a lubrication cycle….10078
15.3 Lubrication pump drive….10086
15.4 Lubrication pump….10088
15.4.1 Adjustments lubricating pump speed….10090
15.4.2 Adjustments lubricating pump pressure….10092
15.5 Lubricant Injector (metering valve)….10094
15.5.1 Connection of one or more injectors….10096
15.5.2 Function lubrication injector (metering valve)….10098
15.6 End line pressure switch….10102
15.7 Lubricant in line filter….10104
15.8 Lubricant level sensor….10106
15.8.1 Capacitive digital type for machines with ETM….10106
15.8.2 Capacitive analog type for machines with PLC….10108
15.9 Lubrication system function and controlling….10111
15.9.1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000)….10112
15.9.2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000)….10116
15.10 Adjustment of the lubrication system with ETM….10122
15.11 Trouble shooting lubricating system….10124
15.11.1 Lubrication pump cylinder does not move….10125
15.11.2 Lubricant pressure built up very slowly or not at all….10127
15.11.3 Insufficient lubricant supply to one or more attachment bearings….10127
15.11.4 Insufficient lubricant at the swing ring gear….10129
SMPC30006224 – Hydraulic Mining Shovel PC3000-6 Shop Manual….10137
COVER….10137
I. INTRODUCTION….10139
I.I CONTENTS OF BINDER….10140
I.II FOREWARD….10141
I.III EXPLANATION OF ABBREVATIONS….10143
I.IV TABLE OF CONTENTS….10144
II. SAFETY….10151
II.I SAFETY INSTRUCTIONS….10152
II.II GENERAL PRECAUTIONS….10153
II.III PREPARATIONS FOR WORK….10154
II.IV PRECAUTIONS DURING WORK….10155
III. SPECIFICATIONS….10157
III.I LIFTING GEARS….10158
III.II STANDARD TIGHTENING TORQUE CHART….10160
III.III CONVERSION TABLE….10161
III.IV EXPLANATION OF ABBREVATIONS….10167
III.V GENERAL SPECIFICATIONS….10168
1. MAIN ASSEMBLY GROUPS….10169
1.1 General layout….10170
1.2 Superstructure….10172
1.3 Power House….10174
1.4 Hydraulic Oil Reservoir….10176
1.5 Hydraulic Oil Cooler….10178
1.6 Fuel tank (Fuel reservoir)….10180
1.7 Counter weight….10182
1.8 Cab support….10184
1.9 Operators cab….10186
1.10 Control blocks….10188
1.11 Swing gears….10190
1.12 Under carriage….10192
2. DRIVE….10195
2.1 Prime drive assembly….10196
2.2 Engine and gearbox mount….10198
2.3 Torque supports….10201
2.4 Radiator fan Drive Assy….10202
2.5 Pump distributor gearbox (PTO)….10204
2.5.1 Spline shaft housing….10206
2.5.2 PTO lubrication and cooling….10208
2.5.3 PTO valve adjustments….10210
2.6 Coupling….10214
2.7 Air Filter….10216
3. HYDRAULIC OIL RESERVOIR….10219
3.1 Hydraulic oil reservoir….10220
3.2 Return and leak oil filter….10224
3.3 Breather Filter….10228
3.4 Location of electrical components….10230
4. HYDRAULIC OIL COOLING….10233
4.1 General….10234
4.2 Hydraulic oil cooling circuit….10236
4.3 Back pressure valve adjustment….10240
4.4 Fan drive….10242
4.4.1 Fan pump….10244
4.4.2 Pressure relieve valve….10245
4.4.3 Temperature relay….10247
4.5 Cooler fan drive adjustment….10248
5. CONTROLLING….10251
5.1 Pilot pressure supply and adjustment….10252
5.1.1 Pilot control arrangement….10255
5.1.2 Pilot pressure adjustment….10257
5.1.3 Check of Control Pressure….10259
5.2 Slew brakes….10261
5.3 Travel parking brake….10264
5.4 Check of the pilot control logic….10266
5.4.1 Check sheet BHA Page 1….10268
5.4.2 Check sheet FSA Page 1….10281
6. COMPONENTS….10291
6.1 Main control block and valve arrangement….10292
6.1.1 FSA arrangement….10294
6.1.2 BHA arrangement….10298
6.2 Distributor manifold….10302
6.2.1 Front shovel attachment FSA….10302
6.2.2 Back hoe attachment BHA….10304
6.2.3 SRV with throttle check valve….10306
6.2.4 Anti cavitation valve (check valve)….10308
6.3 Main control block….10310
6.3.1 Load holding valve….10318
6.3.2 High pressure filter auxiliary filter….10320
6.3.3 High pressure filter auxiliary filter….10322
6.3.4 High pressure filter auxiliary filter….10324
6.4 Compact valve blocks….10326
6.5 Compact valve blocks….10328
6.6 Auxiliary gear pumps….10330
6.7 Hydraulic cylinder….10332
6.8 Swing ring….10334
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION….10337
7.1 General….10338
7.1.1 Pump location….10340
7.2 Main pump operating principles….10342
7.2.1 Main pump function….10347
7.3 Main pump checks and adjustments….10350
7.3.1 Peak point diesel engine test….10350
7.3.2 Pressure transducer test….10352
7.3.3 Cut off function….10353
7.3.4 Pump regulation….10355
7.3.5 Swing pump volume reduction….10356
7.4 Electronic pump regulation….10357
7.4.1 Pump Controller CR700….10359
7.4.2 Multi Monitor….10361
7.4.3 Multimonitor software instruction….10363
7.4.4 Table of fault messages and adjustments….10370
7.5 Trouble shooting pump and pump regulation….10379
8. OPERATING HYDRAULIC….10383
8.1 General layout….10384
8.2 Floating function of boom and stick only FSA….10388
8.3 Check and Adjustments for MRV’s and SRV’s….10390
8.3.1 Check and Adjustments for MRV….10392
8.3.2 Check and Adjustment for SRV’s….10394
8.3.3 Check and adjustment of the throttle check valves….10402
8.4 Hydraulic for the swing circuit….10404
8.4.1 Hydraulic for the swing circuit….10408
8.4.2 Slew gear box L & S….10412
8.4.3 Slew parking brake….10416
8.4.4 Slew service brake valve….10420
8.4.5 Checks and adjustment of the slew pressure valve….10425
8.5 Travel circuit….10428
8.5.1 Rotary joint….10430
8.5.2 Travel motor A2FMt….10432
8.5.3 Travel gear….10434
8.5.4 Travel parking brake….10436
8.5.5 Travel control function….10438
9. TRACK TENSION SYSTEM….10443
9.1 General layout….10444
9.2 Track tensioning function….10446
9.2.1 Cushioning….10448
9.2.2 Pressure Increasing valve PIV….10450
9.3 Truck tensioning adjustment….10454
9.3.1 Truck tensioning function check….10456
10. ACCESS LADDER HYDRAULICALLY OPERATED….10459
10.1 Access ladder….10460
10.2 Access ladder functional description….10462
11. CENTRAL REFILLING SYSTEM….10467
11.0.1 Functional description….10468
12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM….10473
12.1 General….10474
12.2 Symbolic….10476
12.2.1 Lines, unions….10477
12.2.2 Components, valves….10479
12.2.3 Sensors….10479
12.2.4 Valves, valve components….10480
12.2.5 Pump, motor, cylinder….10484
Hydraulic Diagrams – 938 367 40….10488
Hydraulic Diagrams – 938 367 40 (1/3)….10488
Hydraulic Diagrams – 938 367 40 (2/3)….10489
Hydraulic Diagrams – 938 367 40 (3/3)….10490
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM….10492
13.1 Designation of electrical components….10494
13.2 Electric symbols….10495
13.3 Symbols….10497
13.3.1 Drawing concept….10499
13.3.2 Reading of the circuit diagram….10505
Electrical Diagrams….10509
Electrical Diagrams – 938 368 40 (1/54)….10509
Electrical Diagrams – 938 368 40 (2/54)….10510
Electrical Diagrams – 938 368 40 (3/54)….10511
Electrical Diagrams – 938 368 40 (4/54)….10512
Electrical Diagrams – 938 368 40 (5/54)….10513
Electrical Diagrams – 938 368 40 (6/54)….10514
Electrical Diagrams – 938 368 40 (7/54)….10515
Electrical Diagrams – 938 368 40 (8/54)….10516
Electrical Diagrams – 938 368 40 (9/54)….10517
Electrical Diagrams – 938 368 40 (10/54)….10518
Electrical Diagrams – 938 368 40 (11/54)….10519
Electrical Diagrams – 938 368 40 (12/54)….10520
Electrical Diagrams – 938 368 40 (13/54)….10521
Electrical Diagrams – 938 368 40 (14/54)….10522
Electrical Diagrams – 938 368 40 (15/54)….10523
Electrical Diagrams – 938 368 40 (16/54)….10524
Electrical Diagrams – 938 368 40 (17/54)….10525
Electrical Diagrams – 938 368 40 (18/54)….10526
Electrical Diagrams – 938 368 40 (19/54)….10527
Electrical Diagrams – 938 368 40 (20/54)….10528
Electrical Diagrams – 938 368 40 (21/54)….10529
Electrical Diagrams – 938 368 40 (22/54)….10530
Electrical Diagrams – 938 368 40 (23/54)….10531
Electrical Diagrams – 938 368 40 (24/54)….10532
Electrical Diagrams – 938 368 40 (25/54)….10533
Electrical Diagrams – 938 368 40 (26/54)….10534
Electrical Diagrams – 938 368 40 (27/54)….10535
Electrical Diagrams – 938 368 40 (28/54)….10536
Electrical Diagrams – 938 368 40 (29/54)….10537
Electrical Diagrams – 938 368 40 (30/54)….10538
Electrical Diagrams – 938 368 40 (31/54)….10539
Electrical Diagrams – 938 368 40 (32/54)….10540
Electrical Diagrams – 938 368 40 (33/54)….10541
Electrical Diagrams – 938 368 40 (34/54)….10542
Electrical Diagrams – 938 368 40 (35/54)….10543
Electrical Diagrams – 938 368 40 (36/54)….10544
Electrical Diagrams – 938 368 40 (37/54)….10545
Electrical Diagrams – 938 368 40 (38/54)….10546
Electrical Diagrams – 938 368 40 (39/54)….10547
Electrical Diagrams – 938 368 40 (40/54)….10548
Electrical Diagrams – 938 368 40 (41/54)….10549
Electrical Diagrams – 938 368 40 (42/54)….10550
Electrical Diagrams – 938 368 40 (43/54)….10551
Electrical Diagrams – 938 368 40 (44/54)….10552
Electrical Diagrams – 938 368 40 (45/54)….10553
Electrical Diagrams – 938 368 40 (46/54)….10554
Electrical Diagrams – 938 368 40 (47/54)….10555
Electrical Diagrams – 938 368 40 (48/54)….10556
Electrical Diagrams – 938 368 40 (49/54)….10557
Electrical Diagrams – 938 368 40 (50/54)….10558
Electrical Diagrams – 938 368 40 (51/54)….10559
Electrical Diagrams – 938 368 40 (52/54)….10560
Electrical Diagrams – 938 368 40 (53/54)….10561
Electrical Diagrams – 938 368 40 (54/54)….10562
14. ELECTRONIC TEXT MONITORING SYSTEM ETM….10564
14.1 General Function….10565
15. AUTOMATIC LUBRICATION SYSTEM….10568
15.1 General Function….10569
15.2 Function of a lubrication cycle….10571
15.3 Lubrication pump drive….10579
15.4 Lubrication pump….10581
15.4.1 Adjustments lubricating pump speed….10583
15.4.2 Adjustments lubricating pump pressure….10585
15.5 Lubricant Injector (metering valve)….10587
15.5.1 Connection of one or more injectors….10589
15.5.2 Function lubrication injector (metering valve)….10591
15.6 End line pressure switch….10595
15.7 Lubricant in line filter….10597
15.8 Lubricant level sensor….10599
15.8.1 Capacitive digital type for machines with ETM….10599
15.8.2 Capacitive analog type for machines with PLC….10601
15.9 Lubrication system function and controlling….10604
15.9.1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000)….10605
15.9.2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000)….10609
15.10 Adjustment of the lubrication system with ETM….10615
15.11 Trouble shooting lubricating system….10617
15.11.1 Lubrication pump cylinder does not move….10618
15.11.2 Lubricant pressure built up very slowly or not at all….10620
15.11.3 Insufficient lubricant supply to one or more attachment bearings….10620
15.11.4 Insufficient lubricant at the swing ring gear….10622
SMPC30006225 – Hydraulic Mining Shovel PC3000-1 Shop Manual….10630
COVER….10630
INTRODUCTION….10631
FOREWORD….10632
TABLE OF CONTENTS….10634
SECTION 1 MAIN ASSEMBLY GROUPS….10635
TABLE OF CONTENTS….10635
GENERAL LAYOUT….10637
DRIVE….10639
CONTROL BLOCKS, SWING GEAR….10641
UNDERCARRIAGE, TRAVEL DRIVE….10643
DRIVER'S CAB….10645
SECTION 2 DRIVE….10646
TABLE OF CONTENTS….10646
PRIME DRIVE ASSEMBLY….10648
ENGINE MOUNTS….10650
FAN DRIVE AND COOLER ASSY….10652
COUPLING….10654
AIR FILTER….10656
PUMP DISTRIBUTOR GEAR….10658
SPLING LUBRICATION….10660
GEAT LUBRICATION….10662
LOCATION OF THE PUMPS, DRIVE SPEEDS AND FLOW RATES….10666
SECTION 3 HYDRAULIC OIL TANK….10667
TABLE OF CONTENTS….10667
MAIN OIL TANK….10669
RETURN AND LEAK OIL FILTER….10671
BREATHER FILTER….10673
LOCATION OF PRESSURE SWITCHES AND SENSORS….10675
SECTION 4 HYDRAULIC OIL COOLING….10676
TABLE OF CONTENTS….10676
GENERAL….10678
HYDRAULIC OIL COOLING CIRCUIT….10680
ADJUSTMENTS….10682
FAN DRIVE….10686
PRESSURE RELIEF VALVE AND SOLENOID VALVE….10688
AXIAL PISTON PUMP….10690
ADJUSTMENTS….10692
FUNCTION CHECK FOR RPM-CONTROL….10696
SECTION 5 CONTROLLING….10697
TABLE OF CONTENTS….10697
PILOT PRESSURE SUPPLY….10699
CHECKS AND ADJUSTMENTS OF PILOT PRESSURE….10703
CHECKING THE ACCUMULATOR FUNCTION….10705
TRAVEL PARKING BRAKE….10707
FUNCTION CHECK OF TRAVEL PARKING BRAKE….10709
SWING PARKING (HOUSE) BRAKE….10711
SECTION 6 COMPONENTS….10712
TABLE OF CONTENTS….10712
DISTRIBUTOR MANIFOLD….10718
RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE….10722
ANTI CAVITATION VALVE BLOCK….10726
PROPORTIONAL SOLENOID VALVE….10728
PRESSURE FILTER….10730
CONTROL BLOCKS….10732
TRAVEL BRAKE VALVE….10742
PRESSURE REDUCING VALVE….10744
DIRECTIONAL CONTROL VALVE ("SOLENOID VALVE")\….10746
HYDRAULIC CYLINDER….10748
AUXILIARY PUMPS (FAN DRIVE)….10750
AUXILIARY GEAR PUMPS….10752
SWING RING….10754
SECTION 7 MAIN HYDRAULIC PUMPS….10755
TABLE OF CONTENTS….10755
MAIN HYDRAULIC PUMP A7V / HD D….10757
DESCRIPTION OF THE SL-BEARING….10761
FUNCTION OF THE PUMP GOVERNOR….10763
PUMP BEARING LUBRICATION….10769
PUMP GOVERNOR ADJUSTMENTS….10773
PUMP REGULATION, GENERAL….10781
DETERMINATION OF THE PEAK POINT (CORNER VALUE)….10787
HYDRAULIC REGULATION ADJUSTMENT, STOP GAP OPERATION….10789
DETAILED EXLANATION FOR THE ELECTRONIC REGULATION….10791
ADJUSTMENTS / CHECKS FOR THE ELECTRONIC REGULATION….10793
ADJUSTING THE RPM SENSOR (MPU)….10795
ADJUSTMENTS / CHECKS FOR THE ELL – MODULE, NOMINAL FINE TUNING….10797
TESTING AND SETTING FOR THE COMPLETE REGULATION….10799
CHECKS / FUNCTION TEST / FAULT FINDING AT JOB SITE….10801
EPM – MODULE, FUNCTION AND TEST….10803
ERM – MODULE, FUNCTION AND TEST….10805
ELL – MODULE, FUNCTION AND TEST….10809
TESTING THE PROPORTIONAL AMPLIFIER MODULE, A36….10813
SIMPLIFIED TROUBLE SHOOTING OF THE ELECTRONIC CONTROL….10815
SECTION 8 OPERATING HYDRAULIC….10818
TABLE OF CONTENTS….10818
HYDRAULIC FOR ATTACHMENT CYLINDER….10820
ADJUSTMENTS FOR ATTACHMENT CYLINDER HYDRAULIC….10824
SWING CIRCUIT, GENERAL….10842
SWING MOTOR….10846
SWING GEAR AND SWING PARKING BRAKE….10850
SWING BRAKE VALVE….10854
SWING, FUNCTION….10859
CHECKS AND ADJUSTMENTS….10869
TRAVEL CIRCUIT….10877
ROTARY DISTRIBUTOR….10881
TRAVEL MOTOR (AXIAL PISTON MOTOR A2FM)….10883
TRAVEL GEAR AND PARKING BRAKE….10887
TRAVEL, FUNCTION….10891
ADJUSTMENTS / CHECKS….10897
SECTION 9 HYDRAULIC TRACK TENSION SYSTEM….10902
TABLE OF CONTENTS….10902
HYDRAULIC TRACK TENSION SYSTEM….10904
FUNCTION: Z 22281….10906
PRESSURE INCREASING VALVE TYPE: MO 7010….10910
PRESSURE RELIEF VALVE, DIRECT OPERATED TYPE: DBD S….10912
ADJUSTMENTS / PRESSURE CHECKS….10914
SECTION 10 ACCESS LADDER HYDRAULIC OPERATED….10921
TABLE OF CONTENTS….10921
ACCESS LADDER HYDRAULIC OPERATED….10923
SECTION 11 CENTRAL REFILLING SYSTEM….10926
TABLE OF CONTENTS….10926
CENTRAL REFILLING SYSTEM….10926
SECTION 12 HINTS FOR THE HYDRAULIC CIRCUIT DIAGRAM….10931
TABLE OF CONTENTS….10931
HINTS FOR READING THE CIRCUIT DIAGRAM….10935
LEGEND TO THE HYDRAULIC CIRCUIT DIAGRAM PC 3000, WITH DIESEL ENGINE….10936
PRESSURE CHECK POINTS….10941
HOW TO READ THE CIRCUIT DIAGRAM….10943
SECTION 13 HINTS FOR THE ELECTRIC CIRCUIT DIAGRAM….10944
TABLE OF CONTENTS….10944
MARKINGS OF ELECTRICAL COMPONENTS IN THE CIRCUIT DIAGRAMS….10945
SYMBOLS….10947
KMG CIRCUIT DIAGRAMS….10951
EXPLANATION OF THE DRAWING CONCEPT….10953
LOCATION OF THE MAIN TERMINAL BOXES AND SOME IMPORTANT COMPONENTS….10955
READING A CIRCUIT DIAGRAM….10958
ADJUSTMENTS….10961
COMPONENT LIST….10962
SECTION 14 ELECTRONIC TEXT MONITORING SYSTEM….10967
TABLE OF CONTENTS….10967
INTRODUCTION….10968
FUNCTION….10971
LAYOUT OF DASH BOARD….10977
TEXT MONITORING SYSTEM….10982
EFD – MODULE, FUNCTION AND TROUBLE SHOOTING….11024
Hydraulic Plan 943 208 40 – 8 Pages….11027
…
Electrical Plan 943 207 40 Page 36 of 36….11070

Komatsu Hydraulic Mining Shovel PC3000 Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 10, 2025 by admin

Komatsu Hydraulic Excavator GALEO PC2000 Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator GALEO PC2000-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator GALEO PC2000-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 7,121 pages
File Format: PDF
Language: English

GEN00060-12 – Hydraulic Excavator PC2000-8 Field Assembly Manual.pdf
SEN01607-06 – Hydraulic Excavator GALEO PC2000-8 Shop Manual.pdf
SEN01607-19 – Hydraulic Excavator PC2000-8 Shop Manual.pdf
TEN00133-05 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00236-03 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00323-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00324-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00365-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00366-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00430-04 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00431-05 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf

MAIN SECTIONS
GEN00060-12 – Hydraulic Excavator PC2000-8 Field Assembly Manual…2
COVER…2
FOREWORD…3
CONTENTS…4
SPECIFICATIONS…7
PRECAUTIONS FOR FIELD ASSEMBLY…8
DISPOSAL OF REMOVED PARTS…9
ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE…10
FLOWCHART OF MAIN ASSEMBLY PROCEDURE…11
KIT LAYOUT DIAGRAM…12
TRANSPORTATION POSTURES…13
LIST OF PARTS SENT INDIVIDUALLY…22
TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY…43
TIGHTENING TORQUE…45
COATING MATERIALS LIST…49
A. ASSEMBLY OF CHASSIS…51
<ASSEMBLY OF UNDERCARRIAGE>…0
A- 1. Assembly of track frame assembly and center frame assembly…52
A- 2. Installation of idler cushion cylinder piping…55
A- 3. Installation of travel motor piping…56
A- 4. Installation of travel motor cover…57
A- 5. Filling swing circle with grease…60
A- 6. Assembly of revolving frame assembly and undercarriage…61
A- 7. Installation of swing machinery (front) assembly (27t)…63
A- 7. Installation of swing motor (front) assembly (32t)…63
A- 8. Connection of swivel joint piping…64
A- 9. Connection of swing circle grease piping…66
<ASSEMBLY OF UPPER STRUCTURE>…0
A-10. Installation of hydraulic tank assembly…67
A-11. Installation of fuel tank assembly…72
A-12. Connection of fuel tank assembly piping and wiring…73
A-13. Installation of cab base assembly…75
A-14. Installation of emergency escape ladder…77
A-15. Installation of left floor assembly…78
A-16. Connection of cab base assembly piping…82
A-17. Connection of cab base assembly wiring…85
A-18. Connection of left floor assembly heater piping…91
<COUPLING OF POWER CONTAINER>…0
A-19. Connection of left floor assembly wiring…92
A-20. Installation of tail pipe…94
A-21. Installation of power container assembly…95
A-22. Connection of suction piping…97
A-23. Connection of oil cooler piping and pump drain piping…99
A-24. Connection of fan motor drain piping…100
A-25. Installation of suction unit undercover…101
A-26. Connection of delivery piping…102
A-27. Connection of pilot piping and fan motor piping…104
A-28. Connection of power container assembly fuel piping…105
A-29. Connection of power container assembly air conditioner piping…107
A-30. Connection of power container assembly heater piping…108
A-31. Connection of power container assembly wiring…109
<COUPLING OF OPERATOR'S CAB>…0
A-32. Installation of operator's cab assembly…113
A-33. Installation of rotary lamp (if equipped)…117
A-34. Installation of ORBCOMM antenna (if equipped)…119
A-35. Connection of operator's cab assembly wiring…120
A-36. Connection of operator's cab assembly hydraulic piping…123
A-37. Connection of operator's cab assembly window washer hose…125
A-38. Connection of operator's cab assembly air conditioner piping…126
A-39. Connection of operator's cab assembly heater piping…127
A-40. Installation of operator's cab rear floor assembly…128
A-41. Installation of handrail around operator's cab…129
<COUPLING OF EXTERIOR PARTS, COUNTERWEIGHT, ETC.>…0
A-42. Installation of track frame ladder…130
A-43. Installation of power container side catwalk assemblies (right and left)…131
A-44. Installation of right floor assembly, grease can cover assembly and center floor…132
A-45. Installation of fuel tank right catwalk assembly…134
A-46. Installation of fuel tank front catwalk assembly…135
A-47. Adjustment of exterior parts clearance…136
A-48. Connection of grease reel piping…137
A-49. Installation of access ladder assembly…138
A-50. Installation of counterweight assembly…139
A-51. Installation of deformation preventing stoppers for catwalk assemblies (left and right) on the side of power container…140
A-52. Installation of handrail on counterweight…141
A-53. Installation of handrail clamps…142
A-54. Connection of fuel cut wire…145
A-55. Connection of drain piping under power container…146
A-56. Connection of battery wiring…147
<STARTING OF ENGINE AND INSPECTION AND SERVICING PROCEDURES>…0
A-57. Setting of hydraulic tank strainer…148
A-58. Starting engine, checking oil and coolant levels, bleeding air from each part, and adjusting track…149
A-59. Permanent tightening of swing circle bolt…164
A-60. Parts to be touched up after field assembly (chassis side)…165
A-61. Connection of engine heater connection port…166
A-62. Installation of optional harness…169
A-63. Installation of rear lamps…170
A-64. Installation of rear camera…175
A-65. Connection of emergency stop switch (if equipped) (at the right below container)178…184
A-66. Connection of emergency stop switch (if equipped) (at the left side of ladder)…185
A-67. Installation of engine oil and PTO oil pipings…186
A-68. Installation of coolant piping…187
A-69. Installation of guard bracket (if equipped)…188
C. ASSEMBLY OF BACKHOE…189
<COUPLING OF BOOM>…0
C- 1. Installation of boom cylinder…190
C- 2. Installation of boom cylinder hoses (Serial No. 20095 and up)…192
C- 3. Assembly of boom sub assembly…193
C- 4. Installation of boom assembly…198
C- 5. Installation of boom cylinder head side…200
<COUPLING OF ARM>…0
C- 6. Installation of hoses between boom and chassis…202
C- 7. Installation of arm assembly…203
C- 8. Installation of arm cylinder…206
C- 9. Connection of hoses between boom and arm…207
C-10. Connection of auto grease piping…208
C-11. Connection of wiring between boom and chassis…209
<COUPLING OF BUCKET>…0
C-12. Installation of bucket assembly…210
C-13. Installation of bucket link…213
C-14. Bleeding air from cylinders…215
C-15. Parts to be touched up after field assembly (work equipment side)…218
C-16. Bleeding air from auto grease circuit…219
LS. ASSEMBLY OF LOADING SHOVEL WORK EQUIPMENT…223
LS- 1. Installation of arm cylinder bottom parts…224
LS- 2. Installation of boom cylinder to machine body…225
LS- 3. Installation of boom cylinder hoses…227
LS- 4. Installation of boom cylinder piping…228
LS- 5. Installation of boom assembly…229
LS- 6. Installation of boom cylinder head pins…230
LS- 7. Installation of hose between machine body and boom…231
LS- 8. Installation of bucket cylinder assembly…233
LS- 9. Installation of arm assembly…234
LS-10. Installation of arm cylinder assembly…235
LS-11. Installation of hoses between boom and arm…236
LS-12. Installation of bucket cylinder hoses…237
LS-13. Installation of grease feed hose of bucket cylinder…238
LS-14. Installation of bucket assembly…240
LS-15. Installation of arm cylinder junction hoses…241
LS-16. Installation of bottom dump hose and grease feed hose between arm and bucket…242
LS-17. Installation of arm dump cushion (proximity switch)…243
M. INSPECTION AND SERVICING PROCEDURES AFTER ASSEMBLY…245
M- 1. Inspection of oil levels and coolant levels and using standard of fuel and lubricant…246
M- 2. Flushing of hydraulic circuit…248
M- 3. Releasing residual pressure from hydraulic circuit…251
M- 4. Releasing residual pressure from HIC circuit and check of gas pressure in HIC accumulator…252
M- 5. Charging air conditioner with refrigerant…253
M- 6. Installed angles of mirrors…256
M- 7. Installed angles of lights…259
VHMS CONTOROLLER INITIAL SETTING PROCEDURE…263
PC2000-8 Main pump air bleeding check sheet…281
FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)…283
FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)…309
SEN01607-06 – Hydraulic Excavator GALEO PC2000-8 Shop Manual…334
COVER…334
00 INDEX AND FOREWORD…0
INDEX…336
COMPOSITION OF SHOP MANUAL…337
TABLE OF CONTENTS…339
FOREWORD AND GENERAL INFORMATION…352
SAFETY NOTICE…353
HOW TO READ THE SHOP MANUAL…358
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…360
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT…362
HANDLING OF CONNECTORS NEWLY USED FOR ENGINES…371
HOW TO READ ELECTRIC WIRE CODE…374
PRECAUTIONS WHEN CARRYING OUT OPERATION…377
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER…380
STANDARD TIGHTENING TORQUE TABLE…383
CONVERSION TABLE…387
01 SPECIFICATION…0
SPECIFICATION AND TECHNICAL DATA…394
SPECIFICATION DRAWINGS…395
SPECIFICATIONS…399
WEIGHT TABLE…403
TABLE OF FUEL, COOLANT AND LUBRICANTS…409
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…0
ENGINE AND COOLING SYSTEM…412
RADIATOR AND OIL COOLER…413
PTO…415
PTO LUBRICATION SYSTEM…417
POWER TRAIN…419
POWER TRAIN…420
SWING MACHINERY…422
SWING CIRCLE…424
FINAL DRIVE…425
SPROCKET…427
UNDERCARRIAGE AND FRAME…430
TRACK FRAME…431
IDLER…433
CARRIER ROLLER…435
TRACK ROLLER…436
TRACK SHOE…437
HIC SYSTEM…442
HYDRAULIC SYSTEM, PART 1…445
HYDRAULIC PIPING DRAWING…448
HYDRAULIC TANK…452
OIL COOLER…454
LINE OIL FILTER…456
PILOT OIL FILTER…457
RETURN OIL FILTER…458
MOTOR DRAIN OIL FILTER…459
PUMP DRAIN FILTER…460
ACCUMULATOR…461
TRAVEL JUNCTION VALVE…463
SOLENOID VALVE…466
HYDRAULIC CYLINDER…474
GREASING SYSTEM…478
CENTER SWIVEL JOINT…488
HYDRAULIC SYSTEM, PART 2…491
CONTROL VALVE…492
ELECTRONIC OLSS SYSTEM…520
SWING MOTOR…524
COOLING FAN MOTOR (FOR RADIATOR AND OIL COOLER)…532
COOLING FAN PUMP…538
HYDRAULIC SYSTEM, PART 3…553
TRAVEL MOTOR…554
HYDRAULIC PUMP…566
PPC VALVE…584
VARIABLE BACK PRESSURE VALVE…596
SUCTION SELECTOR VALVE…600
PPC CUT-OFF VALVE…604
WORK EQUIPMENT…613
WORK EQUIPMENT…614
DIMENSIONS OF WORK EQUIPMENT…618
CAB AND ITS ATTACHMENTS…623
AIR CONDITIONER PIPING…624
CAB…625
ELECTRICAL SYSTEM…629
ENGINE CONTROL…630
ELECTRICAL CONTROL SYSTEM…641
MONITOR SYSTEM…683
SENSOR…711
ORBCOMM TERMINAL…723
20 STANDARD VALUE TABLE…0
STANDARD SERVICE VALUE TABLE…725
STANDARD SERVICE VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…726
STANDARD SERVICE VALUE TABLE FOR CHASSIS…727
30 TESTING AND ADJUSTING…0
TESTING AND ADJUSTING, PART 1…739
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…741
MEASURING ENGINE SPEED…744
TESTING AIR BOOST PRESSURE…745
TESTING EXHAUST TEMPERATURE…746
TESTING EXHAUST COLOR…747
ADJUSTING VALVE CLEARANCE…749
TESTING COMPRESSION PRESSURE…751
TESTING BLOW-BY PRESSURE…753
TESTING ENGINE OIL PRESSURE…754
HANDLING FUEL SYSTEM PARTS…755
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM…755
TESTING FUEL PRESSURE…756
TESTING LEAKAGE FROM PRESSURE LIMITER AND RETURN RATE FROM INJECTOR…757
BLEEDING AIR FROM FUEL CIRCUIT…760
BLEEDING AIR FROM FUEL CIRCUIT (LOW-GRADE FUEL SPECIFICATION)…764
TESTING FUEL SYSTEM FOR LEAKAGE…766
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION …768
TESTING AND ADJUSTING, PART 2…770
TESTING SWING CIRCLE BEARING CLEARANCE…772
REMAINING PRESSURE RELIEF FROM HIC CIRCUIT…773
GAS FILLING IN HIC CIRCUIT ACCUMULATOR…773
BLEEDING AIR FROM HIC CIRCUIT AND SUPPLYING OIL TO IT…775
TESTING AND ADJUSTING TRACK SHOE TENSION…777
TESTING AND ADJUSTING WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT OIL PRESSURES…780
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE (OUTPUT PRESSURE OF SELF PRESSURE REDUCING VALVE)…784
TESTING AND ADJUSTING MAIN PUMP CONTROL SIGNAL…786
MEASURING FAN SPEED…789
MEASURING FAN PUMP EPC SOLENOID CURRENT…790
MEASURING FAN PUMP EPC SOLENOID VALVE OUTPUT PRESSURE…791
OIL PRESSURE MEASURING POINTS FOR PUMP DISCHARGE PRESSURE OR JET SENSOR DIFFERENTIAL PRESSURE…793
MEASURING PPC VALVE OUTPUT PRESSURE…794
MEASURING SOLENOID VALVE OUTLET PRESSURE…798
ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE…800
TESTING AND ADJUSTING TRAVEL DEVIATION…801
TESTING WORK EQUIPMENT HYDRAULIC DRIFT CAUSE PORTION…803
TESTING OIL LEAKAGE…804
REMAINING PRESSURE RELIEF FROM HYDRAULIC CIRCUIT…807
AIR BLEEDING FROM EACH COMPONENT…808
AIR BLEEDING FROM PPC CIRCUIT…813
TESTING AND ADJUSTING AUTO GREASE SYSTEM…815
ADJUSTING MIRRORS…818
TESTING AND ADJUSTING, PART 3…821
SPECIAL FUNCTIONS OF MACHINE MONITOR…822
HANDLING CONTROLLER VOLTAGE CIRCUIT…877
TESTING AND ADJUSTING, PART 4…879
VHMS CONTROLLER INITIAL SETTING PROCEDURE…880
PRECAUTIONS FOR REPLACING VHMS CONTROLLER…897
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…903
PM-CLINIC SERVICE…905
MEASUREMENT PROCEDURE…906
40 TROUBLESHOOTING…0
FAILURE CODE TABLE AND FUSE LOCATIONS…921
FAILURE CODE TABLE…922
BEFORE CARRYING OUT TROUBLESHOOTING OF ELECTRICAL SYSTEM…929
GENERAL INFORMATION ON TROUBLESHOOTING…935
POINTS TO REMEMBER WHEN TROUBLESHOOTING…936
SEQUENCE OF EVENTS IN TROUBLESHOOTING…937
CHECKS BEFORE TROUBLESHOOTING…938
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…939
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…943
T-ADAPTER BOX AND T-ADAPTER TABLE…976
TROUBLESHOOTING BY FAILURE CODE, PART 1…980
FAILURE CODE [0410KA] FUEL LV. SENSOR FAILURE…982
FAILURE CODE [0410KB] FUEL LV. SENSOR FAILURE…983
FAILURE CODE [6014NX] HYDRAULIC OIL FILTER CLOGGING (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 51)…984
FAILURE CODE [8800ZG] AUTO GREASE ABNORMALLY…985
FAILURE CODE [7@HAZL] VR1/P1F RELIEF PRESS ABNORMALITY…986
FAILURE CODE [7@HBZL] VL1/P1R RELIEF PRESS ABNORMALITY…987
FAILURE CODE [7@HCZL] VR2/P2F RELIEF PRESS ABNORMALITY…988
FAILURE CODE [7@HDZL] VL2/P2R RELIEF PRESS ABNORMALITY…989
FAILURE CODE [AA10NX] AIRCLEANER CLOGGING…991
FAILURE CODE [AB00KE] CHARGE VOLTAGE LOW…993
FAILURE CODE [aB00KE] LOW UPPER ALR CHARGE VOLTAGE (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 11)…995
FAILURE CODE [B@BAZG] ENG. OIL PRESS. LOW…997
FAILURE CODE [B@BAZK] ENG. OIL LEVEL LOW…999
FAILURE CODE [B@BCNS] ENG. WATER OVERHEAT…1001
FAILURE CODE [B@BCZK] ENG. WATER LVL LOW…1003
FAILURE CODE [B@CBNS] PTO OIL OVERHEAT (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 61)…1005
FAILURE CODE [B@HANS] HYDR. OIL OVERHEAT…1007
FAILURE CODE [B@HAZK] LOW HYDRAULIC OIL LEVEL (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 52)…1009
FAILURE CODE [CA111] ECM CRITICAL INTERNAL FAILURE…1011
FAILURE CODE [CB111] ECM CRITICAL INTERNAL FAILURE…1013
FAILURE CODE [CA115] ENG. NE AND BKUP SPEED SENS ERROR…1015
FAILURE CODE [CB115] ENG. NE AND BKUP SPEED SENS ERROR…1016
FAILURE CODE [CA122] CHG AIR PRESS SENSOR HIGH ERROR…1017
FAILURE CODE [CA123] CHG AIR PRESS SENSOR LOW ERROR…1019
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR…1020
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR…1022
FAILURE CODE [CA135] ENG OIL PRESS SENSOR HIGH ERROR…1023
FAILURE CODE [CA141] ENG OIL PRESS SENSOR LOW ERROR…1025
FAILURE CODE [CA144] COOLANT TEMP SENS HIGH ERROR…1026
FAILURE CODE [CA145] COOLANT TEMP SENS LOW ERROR…1028
FAILURE CODE [CA153] CHG AIR TEMP SENSOR HIGH ERROR…1030
FAILURE CODE [CA154] CHG AIR TEMP SENSOR LOW ERROR…1032
FAILURE CODE [CA187] SENS SUPPLY 2 VOLT LOW ERROR…1034
FAILURE CODE [CB187] SENS SUPPLY 2 VOLT LOW ERROR…1034
FAILURE CODE [CA212] ENG OIL TEMP SENSOR HIGH ERROR…1035
FAILURE CODE [CA213] ENG OIL TEMP SENSOR LOW ERROR…1037
TROUBLESHOOTING BY FAILURE CODE, PART 2…1039
FAILURE CODE [CA221] AMBIENT PRESS SENS HIGH ERROR…1041
FAILURE CODE [CA222] AMBIENT PRESS SENS LOW ERROR…1043
FAILURE CODE [CA227] SENS SUPPLY 2 VOLT HIGH ERROR…1044
FAILURE CODE [CB227] SENS SUPPLY 2 VOLT HIGH ERROR…1046
FAILURE CODE [CA234] ENG OVER SPEED…1048
FAILURE CODE [CA238] NE SPEED SENS SUPPLY VOLT ERROR…1049
FAILURE CODE [CB238] NE SPEED SENS SUPPLY VOLT ERROR…1051
FAILURE CODE [CA263] FUEL TEMP SENSOR HIGH ERROR…1053
FAILURE CODE [CB263] FUEL TEMP SENSOR HIGH ERROR…1055
FAILURE CODE [CA265] FUEL TEMP SENSOR LOW ERROR…1056
FAILURE CODE [CB265] FUEL TEMP SENSOR LOW ERROR…1056
FAILURE CODE [CA271] IMV/PCV1 SHORT ERROR…1057
FAILURE CODE [CB271] IMV/PCV1 SHORT ERROR…1059
FAILURE CODE [CA272] IMV/PCV1 OPEN ERROR…1061
FAILURE CODE [CB272] IMV/PCV1 OPEN ERROR…1063
FAILURE CODE [CA273] PCV2 SHORT ERROR…1065
FAILURE CODE [CB273] PCV2 SHORT ERROR…1067
FAILURE CODE [CA274] PCV2 OPEN ERROR…1069
FAILURE CODE [CB274] PCV2 OPEN ERROR…1071
FAILURE CODE [CA322] INJ #1(L#1) OPEN/SHORT ERROR…1072
FAILURE CODE [CA323] INJ #5(L#5) OPEN/SHORT ERROR…1074
FAILURE CODE [CA324] INJ #3(L#3) OPEN/SHORT ERROR…1076
FAILURE CODE [CA325] INJ #6(L#6) OPEN/SHORT ERROR…1078
FAILURE CODE [CA331] INJ #2(L#2) OPEN/SHORT ERROR…1080
FAILURE CODE [CA332] INJ #4(L#4) OPEN/SHORT ERROR…1082
FAILURE CODE [CA342] CALIBRATION CODE INCOMPATIBILITY…1084
FAILURE CODE [CB342] CALIBRATION CODE INCOMPATIBILITY…1084
FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR…1085
FAILURE CODE [CB351] INJECTORS DRIVE CIRCUIT ERROR…1087
FAILURE CODE [CA352] SENS SUPPLY 1 VOLT LOW ERROR…1089
FAILURE CODE [CB352] SENS SUPPLY 1 VOLT LOW ERROR…1089
FAILURE CODE [CA386] SENS SUPPLY 1 VOLT HIGH ERROR…1090
FAILURE CODE [CB386] SENS SUPPLY 1 VOLT HIGH ERROR…1092
FAILURE CODE [CA441] BATTERY VOLTAGE LOW ERROR…1094
FAILURE CODE [CB441] BATTERY VOLTAGE LOW ERROR…1094
FAILURE CODE [CA442] BATTERY VOLTAGE HIGH ERROR…1095
FAILURE CODE [CB442] BATTERY VOLTAGE HIGH ERROR…1095
FAILURE CODE [CA449] RAIL PRESS VERY HIGH ERROR…1096
FAILURE CODE [CB449] RAIL PRESS VERY HIGH ERROR…1096
TROUBLESHOOTING BY FAILURE CODE, PART 3…1098
FAILURE CODE [CA451] RAIL PRESS SENSOR HIGH ERROR…1100
FAILURE CODE [CB451] RAIL PRESS SENSOR HIGH ERROR…1102
FAILURE CODE [CA452] RAIL PRESS SENSOR LOW ERROR…1104
FAILURE CODE [CB452] RAIL PRESS SENSOR LOW ERROR…1104
FAILURE CODE [CA553] RAIL PRESS HIGH ERROR…1105
FAILURE CODE [CB553] RAIL PRESS HIGH ERROR…1106
FAILURE CODE [CA554] RAIL PRESS SENSOR IN RANGE ERROR…1107
FAILURE CODE [CB554] RAIL PRESS SENSOR IN RANGE ERROR…1107
FAILURE CODE [CA559] RAIL PRESS LOW ERROR…1108
FAILURE CODE [CB559] RAIL PRESS LOW ERROR…1112
FAILURE CODE [CA689] ENG NE SPEED SENSOR ERROR…1116
FAILURE CODE [CB689] ENG NE SPEED SENSOR ERROR…1118
FAILURE CODE [CA691] INTAKE AIR TEMP SENS HIGH ERROR…1120
FAILURE CODE [CA692] INTAKE AIR TEMP SENS LOW ERROR…1122
FAILURE CODE [CA731] ENG BKUP SPEED SENS PHASE ERROR…1123
FAILURE CODE [CB731] ENG BKUP SPEED SENS PHASE ERROR…1123
FAILURE CODE [CA757] ALL PERSISTENT DATA LOST ERROR…1124
FAILURE CODE [CB757] ALL PERSISTENT DATA LOST ERROR…1124
FAILURE CODE [CA778] ENG BKUP SPEED SENSOR ERROR…1125
FAILURE CODE [CB778] ENG BKUP SPEED SENSOR ERROR…1127
FAILURE CODE [CA781] CEN COMMUNICATION ERROR…1129
FAILURE CODE [CB781] CEN COMMUNICATION ERROR…1131
FAILURE CODE [CA1117] PERSISTENT DATA LOST ERROR…1132
FAILURE CODE [CB1117] PERSISTENT DATA LOST ERROR…1132
FAILURE CODE [CA1257] HARNESS KEY ERROR…1133
FAILURE CODE [CB1257] HARNESS KEY ERROR…1134
FAILURE CODE [CB1548] INJ #7(R#1) OPEN/SHORT ERROR…1135
FAILURE CODE [CB1549] INJ #8(R#2) OPEN/SHORT ERROR…1137
FAILURE CODE [CB1551] INJ #10(R#4) OPEN/SHORT ERROR…1139
FAILURE CODE [CB1552] INJ #11(R#5) OPEN/SHORT ERROR…1141
FAILURE CODE [CB1553] INJ #12(R#6) OPEN/SHORT ERROR…1143
FAILURE CODE [CB1622] INJ #9(R#3) OPEN/SHORT ERROR…1145
FAILURE CODE [CA1633] KOMNET DATA LINK TIME OUT ERROR…1147
FAILURE CODE [CA2185] THROT SENS SUP VOLT HIGH ERROR…1149
FAILURE CODE [CA2186] THROT SENS SUP VOLT LOW ERROR…1151
FAILURE CODE [CA2249] RAIL PRESS VERY LOW ERROR…1152
FAILURE CODE [CB2249] RAIL PRESS VERY LOW ERROR…1152
FAILURE CODE [CA2555] GRID HEATER RELAY VOLT LOW ERROR…1153
FAILURE CODE [CA2556] GRID HEATER RELAY VOLT HIGH ERROR…1154
TROUBLESHOOTING BY FAILURE CODE, PART 4…1157
FAILURE CODE [D110KB] BATTERY RELAY DRIVE S/C…1159
FAILURE CODE [D163KB] FLASH LIGHT RELAY S/C…1161
FAILURE CODE [D195KA] STEP LIGHT RELAY DISC…1163
FAILURE CODE [D195KY] STEP LIGHT RELAY S/C…1165
FAILURE CODE [D1E9KB] WIPER DRIVE RELAY 1 S/C…1167
FAILURE CODE [D1EAKB] WIPER DRIVE RELAY 2 S/C…1169
FAILURE CODE [D1EBKB] LOWER WIPER BRAKE RELAY SHORT CIRCUIT…1171
FAILURE CODE [D1ECKB] UPPER WIPER BRAKE RELAY SHORT CIRCUIT…1173
FAILURE CODE [DA22KK] PUMP 1 SOLENOID POWER LOW ERROR…1175
FAILURE CODE [dA22KK] PUMP 2 SOLENOID POWER LOW ERROR…1177
FAILURE CODE [DA25KP] PUMP 1 SENS SUPPLY VOL LOW ERROR…1179
FAILURE CODE [dA25KP] PUMP 2 SENS SUPPLY VOL LOW ERROR…1181
FAILURE CODE [DA26KP] 5V SENSOR 2 POWER ABNORMALITY…1183
FAILURE CODE [DA29KQ] PUMP 1 MODEL SELECT ABNORMALITY…1185
FAILURE CODE [dA29KQ] PUMP 2 MODEL SELECT ABNORMALITY…1187
FAILURE CODE [DA2RMC] CAN DISCON (PUMP 1 CON DETECTED)…1189
FAILURE CODE [dA2RMC] CAN DISCON (PUMP 2 CON DETECTED)…1191
FAILURE CODE [DA2TMC] PUMP COMM. ECM CHILD ABNORMALITY…1193
FAILURE CODE [DBB0KK] VHMS SOURCE VOLTAGE ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 01)…1195
FAILURE CODE [DBB0KQ] VHMS CONNECTOR MISMATCH (OR CHANGE OF VHMS-LED DISPLAY FROM nF TO 11)…1197
FAILURE CODE [DBB5KP] VHMS 5V SOURCE SYS ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 04)…1199
FAILURE CODE [DBB6KP] VHMS 24V SOURCE SYS ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 02)…1201
FAILURE CODE [DBBQKR] KOM-NET/C ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n8 TO 02)…1203
FAILURE CODE [DGE5KX] AMBIENT AIR TEMP SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n4 TO 01)…1205
FAILURE CODE [DGH2KB] HYDR. OIL TEMP. SENSOR S/C…1207
FAILURE CODE [DGT3KZ] PTO TEMP SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 01)…1209
TROUBLESHOOTING BY FAILURE CODE, PART 5…1212
FAILURE CODE [DGT5KA] EXHAUST TEMP. SENSOR LBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 12)…1214
FAILURE CODE [dGT5KA] EXHAUST TEMP. SENSOR LBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 22)…1216
FAILURE CODE [DGT5KB] EXHAUST TEMP. SENSOR LBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 11)…1218
FAILURE CODE [dGT5KB] EXHAUST TEMP. SENSOR LBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 21)…1220
FAILURE CODE [DGT6KA] EXHAUST TEMP. SENSOR RBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 24)…1222
FAILURE CODE [dGT6KA] EXHAUST TEMP. SENSOR RBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 26)…1224
FAILURE CODE [DGT6KB] EXHAUST TEMP. SENSOR RBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 23)…1226
FAILURE CODE [dGT6KB] EXHAUST TEMP. SENSOR RBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM N3 TO 26)…1228
FAILURE CODE [DH25KX] VR1/P1F J/S DIF PRESS SENSOR ABNORMALITY…1230
FAILURE CODE [DH26KX] VL1/P1R J/S DIF PRESS SENSOR ABNORMALITY…1232
FAILURE CODE [DH27KX] VR2/P2F J/S DIF PRESS SENSOR ABNORMALITY…1234
FAILURE CODE [DH28KX] VL2/P2R J/S DIF PRESS SENSOR ABNORMALITY…1236
FAILURE CODE [DHE5KB] BLOWBY PRES. SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 32)…1238
FAILURE CODE [DHE5KY] BLOWBY PRES. SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 31)…1240
FAILURE CODE [DHH2KA] HYDRAULIC OIL FILTER SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 53)…1242
FAILURE CODE [DHPEKX] VR1/P1F PUMP P. SENSOR ABNORMALITY…1243
FAILURE CODE [DHPFKX] VL1/P1R PUMP P. SENSOR ABNORMALITY…1245
FAILURE CODE [DHPGKX] VR2/P2F PUMP P. SENSOR ABNORMALITY…1247
FAILURE CODE [DHPHKX] VL2/P2R PUMP P. SENSOR ABNORMALITY…1249
FAILURE CODE [DHPSKX] AUTO GREASE PRESS SENSOR ABNORMALITY…1251
FAILURE CODE [DHPTKX] FAN(RAD) PUMP P. SENSOR OPEN CIRCUIT…1253
FAILURE CODE [DHPUKX] FAN(O/C) PUMP P. SENSOR OPEN CIRCUIT…1255
FAILURE CODE [DHS3KX] ARM DIG PPC PRESS SENSOR ABNORMALITY…1257
FAILURE CODE [DHS4KX] BUCKET CURL PPC PRESS SENSOR ABNORMALITY…1259
FAILURE CODE [DHS8KX] BOOM RAISE PPC PRESS SENSOR ABNORMALITY…1261
FAILURE CODE [DHS9KX] BOOM LOWER PPC PRESS SENSOR ABNORMALITY…1263
FAILURE CODE [DHSAKX] SWING RIGHT PPC PRESS SENSOR ABNORMALITY…1265
FAILURE CODE [DHSBKX] SWING LEFT PPC PRESS SENSOR ABNORMALITY…1267
FAILURE CODE [DHSCKX] ARM DUMP PPC PRESS SENSOR ABNORMALITY…1269
FAILURE CODE [DHSDKX] BUCKET DUMP PPC PRESS SENSOR ABNORMALITY…1271
TROUBLESHOOTING BY FAILURE CODE, PART 6…1274
FAILURE CODE [DUM3KB] AUTO GREASE CAUTION LED SHORT CIRCUIT…1276
FAILURE CODE [DUM4KB] FAN REVERSE LED SHORT CIRCUIT…1277
FAILURE CODE [DV20KB] TRAVEL ALARM S/C…1278
FAILURE CODE [DW41KA] SWING PRIORITY SOL OPEN CIRCUIT…1280
FAILURE CODE [DW41KB] SWING PRIORITY SOL SHORT CIRCUIT…1282
FAILURE CODE [DW45KA] SWING BRAKE SOL. DISC…1284
FAILURE CODE [DW45KB] SWING BRAKE SOL. S/C…1287
FAILURE CODE [DW91KA] STRAIGHT-TRAVEL SOL. DISC…1289
FAILURE CODE [DW91KB] STRAIGHT-TRAVEL SOL. S/C…1291
FAILURE CODE [DW4XKA] BUCKET CURL HI CANCEL SOL. DISC…1293
FAILURE CODE [DW4XKB] BUCKET CURL HI CANCEL SOL. S/C…1294
FAILURE CODE [DW7BKA] FAN MOTOR (RAD) REVERSE SOL OPEN CIRCUIT…1295
FAILURE CODE [DW7BKB] FAN REVERSE SOL. S/C…1297
FAILURE CODE [DW7HKA] FAN MOTOR(O/C) REVERSE SOL OPEN CIRCUIT…1299
FAILURE CODE [DW7HKB] FAN MOTOR(O/C) REVERSE SOL SHORT CIRCUIT…1301
FAILURE CODE [DWA3KA] ARM THROTTLE VALVE/L SOL OPEN CIRCUIT…1303
FAILURE CODE [DWA3KB] ARM THROTTLE VALVE/L SOL SHORT CIRCUIT…1305
FAILURE CODE [DWA4KA] ARM THROTTLE VALVE/R SOL OPEN CIRCUIT…1307
FAILURE CODE [DWA4KB] ARM THROTTLE VALVE/R SOL SHORT CIRCUIT…1309
FAILURE CODE [DWA5KA] AUTO GREASE SOL OPEN CIRCUIT…1311
FAILURE CODE [DWA5KB] AUTO GREASE SOL SHORT CIRCUIT…1313
FAILURE CODE [DWA6KA] BOOM THROTTLE VALVE SOL OPEN CIRCUIT…1314
FAILURE CODE [DWA6KB] BOOM THROTTLE VALVE SOL SHORT CIRCUIT…1316
FAILURE CODE [DWK0KA] 2-STAGE RELIEF SOL. DISC…1318
FAILURE CODE [DWK0KB] 2-STAGE RELIEF SOL. S/C…1320
FAILURE CODE [DWK2KA] BACK PRESS COMP VALVE SOL OPEN CIRCUIT…1321
FAILURE CODE [DWK2KB] BACK PRESS COMP VALVE SOL SHORT CIRCUIT…1322
TROUBLESHOOTING BY FAILURE CODE, PART 7…1324
FAILURE CODE [DWN5KA] FAN (RAD) PUMP EPC SOL OPEN CIRCUIT…1326
FAILURE CODE [DWN5KB] FAN (RAD) PUMP EPC SOL SHORT CIRCUIT…1328
FAILURE CODE [DWNCKA] FAN (O/C) PUMP EPC SOL OPEN CIRCUIT…1329
FAILURE CODE [DWNCKB] FAN (O/C) PUMP EPC SOL SHORT CIRCUIT…1330
FAILURE CODE [DXAAKA] P1F EPC SOL DISC…1331
FAILURE CODE [DXAAKB] P1F EPC SOL S/C…1333
FAILURE CODE [DXABKA] P1R PUMP EPC SOL. DISC…1335
FAILURE CODE [DXABKB] P1R PUMP EPC SOL. S/C…1337
FAILURE CODE [DXACKA] P2F PUMP EPC SOL. DISC…1339
FAILURE CODE [DXACKB] P2F PUMP EPC SOL. S/C…1341
FAILURE CODE [DXADKA] P2R PUMP EPC SOL. DISC…1343
FAILURE CODE [DXADKB] P2R PUMP EPC SOL. S/C…1345
FAILURE CODE [DY2CKB] WASHER DRIVE S/C…1347
FAILURE CODE [DY20MA] LOW WIPER WORKING ABNORMALITY…1349
FAILURE CODE [DY2FMA] UPPER WIPER WORKING ABNORMALITY…1352
FAILURE CODE [F@BBZL] HIGH BLOWBY PRESSURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 38)…1355
FAILURE CODE [F@BYNR] VERY HIGH LBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 62)…1357
FAILURE CODE [f@BYNR] VERY HIGH LBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 72)…1359
FAILURE CODE [F@BYNS] HIGH LBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 61)…1361
FAILURE CODE [f@BYNS] HIGH LBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 71)…1363
FAILURE CODE [F@BZNR] VERY HIGH RBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 82)…1365
FAILURE CODE [f@BZNR] VERY HIGH RBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 92)…1367
FAILURE CODE [F@BZNS] HIGH RBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 81)…1369
FAILURE CODE [f@BZNS] HIGH RBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 91)…1371
FAILURE CODE [LA10ZL] RAD SYSTEM FAN PUMP RELIEF PRESSURE HIGH ERROR …1373
FAILURE CODE [LA20ZL] O/C SYSTEM PUMP RELIEF PRESSURE HIGH ERROR…1374
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…1377
CONTENTS OF TROUBLESHOOTING TABLE…1381
E-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DISPLAYS NOTHING…1383
E-2 WHEN STARTING SWITCH TURNED ON (BEFORE STARTING ENGINE), BASIC CHECK ITEM LIGHTS UP…1385
E-3 ENGINE DOES NOT START (ENGINE DOES NOT TURN)…1387
E-4 AUTO-DECELERATOR DOES NOT OPERATE…1391
E-5 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE…1392
E-6 PREHEATER DOES NOT WORK…1393
E-7 WHOLE WORK EQUIPMENT, SWING OPERATION AND MACHINE TRAVEL OPERATION ARE DISABLED…1395
E-8 MACHINE PUSH-UP FUNCTION DOES NOT WORK…1397
E-9 BOOM SHOCKLESS FUNCTION CANNOT BE RELEASED…1399
E-10 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS…1401
E-11 CONTENTS OF DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE…1402
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…1403
E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY…1404
E-14 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY…1405
E-15 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY…1407
E-16 MACHINE MONITOR DISPLAY ANYTHING EVEN WHEN OPERATED ON MONITOR SWITCH SECTION…1409
E-17 WIPER DOES NOT WORK…1410
E-18 MONITORING FUNCTION DOES NOT DISPLAY "TRAVEL" NORMALLY…1416
E-19 TRAVEL ALARM DOES NOT SOUND…1418
E-20 ALL OF ROOM LAMP, HEADLAMP AND WORKING LAMP DO NOT LIGHT UP…1419
E-21 AIR CONDITIONER DOES NOT WORK…1423
E-22 STEP LIGHT DOES NOT LIGHT UP OR GOES OFF…1425
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…1430
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS…1432
TABLE OF FAILURE MODES AND CAUSES…1436
INFORMATION IN TROUBLESHOOTING TABLE…1438
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, AND SWING IS LOW…1439
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS…1441
H-3 WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE…1442
H-4 ABNORMAL NOISE COMES FROM AROUND HYDRAULIC PUMP…1444
H-5 SPEED OR POWER OF BOOM IS LOW…1445
H-6 SPEED OR POWER OF ARM IS LOW…1447
H-7 SPEED OR POWER OF BUCKET IS LOW…1448
H-8 BOOM DOES NOT MOVE…1449
H-9 ARM DOES NOT MOVE…1449
H-10 BUCKET DOES NOT MOVE…1449
H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE…1450
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE…1451
H-13 HEAVY LIFT FUNCTION DOES NOT WORK OR IS NOT RESET…1452
H-14 MACHINE PUSH-UP FUNCTION DOES NOT WORK OR IS NOT RESET…1452
H-15 BOOM SHOCKLESS FUNCTION DOES NOT WORK OR IS NOT RESET…1452
H-16 MACHINE GRADUALLY DEVIATES DURING TRAVELING…1453
H-17 MACHINE DEVIATES EXCESSIVELY WHEN STARTED TO TRAVEL…1456
H-18 MACHINE DEVIATES EXCESSIVELY DURING MULTIPLE OPERATIONS…1457
H-19 TRAVELING SPEED OR POWER IS LOW…1457
H-20 TRAVEL SYSTEM DOES NOT MOVE (ONLY ONE SIDE)…1458
H-21 UPPER STRUCTURE DOES NOT SWING…1459
H-22 SWING SPEED OR ACCELERATION IS LOW…1461
H-23 IN COMPOUND OPERATION OF WORK EQUIPMENT, SWING SPEED OR ACCELERATION IS LOW…1463
H-24 UPPER STRUCTURE OVERRUNS REMARKABLY WHEN IT STOPS SWINGING…1464
H-25 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING…1465
H-26 LARGE ABNORMAL SOUND COMES FROM WHEN UPPER STRUCTURE STOPS SWINGING…1466
H-27 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE IN SWING OPERATION…1467
H-28 FAN ROTATION IS ABNORMAL (LARGE NOISE OR VIBRATION OF FANS, OR FAN OVERHEATING)…1468
TROUBLESHOOTING OF MECHANICAL SYSTEM (S-MODE)…1470
METHOD OF USING TROUBLESHOOTING CHARTS…1472
S-1 STARTING PERFORMANCE IS POOR…1475
S-2 ENGINE DOES NOT START…1476
S-3 ENGINE DOES NOT PICK UP SMOOTHLY…1479
S-4 ENGINE STOPS DURING OPERATIONS…1480
S-5 ENGINE DOES NOT ROTATE SMOOTHLY…1481
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…1482
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…1484
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…1485
S-9 OIL BECOMES CONTAMINATED QUICKLY…1486
S-10 FUEL CONSUMPTION IS EXCESSIVE…1487
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…1488
S-12 OIL PRESSURE DROPS…1489
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)…1490
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…1491
S-15 ABNORMAL NOISE IS MADE…1492
S-16 VIBRATION IS EXCESSIVE…1493
50 DISASSEMBLY AND ASSEMBLY…0
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY…1495
HOW TO READ THIS MANUAL…1496
COATING MATERIALS LIST…1498
SPECIAL TOOL LIST…1501
SKETCHES OF SPECIAL TOOLS…1504
ENGINE AND COOLING SYSTEM (12V140E-3)…1510
REMOVAL AND INSTALLATION OF POWER CONTAINER ASSEMBLY…1511
REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY…1516
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…1528
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY…1529
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY…1531
REMOVAL AND INSTALLATION OF FUEL COOLER ASSEMBLY…1532
REMOVAL AND INSTALLATION OF COOLING ASSEMBLY…1533
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY…1537
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY…1538
ENGINE (12V140E-3) …1542
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…1543
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…1546
REMOVAL AND INSTALLATION OF FUEL INJECTOR…1560
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…1571
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…1574
POWER TRAIN…1580
REMOVAL AND INSTALLATION OF PTO ASSEMBLY…1581
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY…1582
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…1586
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY…1588
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…1598
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY…1599
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY…1601
UNDERCARRIAGE AND FRAME…1614
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY…1615
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY…1617
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…1618
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUST CYLINDER ASSEMBLY…1620
REMOVAL AND INSTALLATION OF IDLER CUSHION CYLINDER ASSEMBLY…1621
DISASSEMBLY AND ASSEMBLY OF IDLER CUSHION CYLINDER ASSEMBLY…1622
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY…1623
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…1624
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY…1626
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…1627
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…1631
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY…1634
HYDRAULIC SYSTEM…1636
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY…1637
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY…1640
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL…1645
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY…1646
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…1653
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…1657
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…1658
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY…1659
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY…1660
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY…1661
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY…1663
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…1664
WORK EQUIPMENT…1672
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY…1673
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY…1675
REMOVAL AND INSTALLATION OF ARM CYLINDER…1677
REMOVAL AND INSTALLATION OF ARM ASSEMBLY…1679
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY…1681
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY…1683
CAB AND ITS ATTACHMENTS…1686
REMOVAL AND INSTALLATION OF OPERATOR CAB ASSEMBLY…1687
REMOVAL AND INSTALLATION OF OPERATOR CAB GLASS (ADHESION GLASS)…1690
REMOVAL AND INSTALLATION OF OPERATOR CAB (ASSEMBLY-TYPE)…1697
REMOVAL AND INSTALLATION OF CAB BASE ASSEMBLY…1698
ELECTRICAL SYSTEM …1701
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY…1702
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY…1706
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY…1707
REMOVAL AND INSTALLATION OF PUMP CONTROLLER ASSEMBLY…1708
REMOVAL AND INSTALLATION OF VHMS CONTROLLER ASSEMBLY…1709
REMOVAL AND INSTALLATION OF ORBCOMM TERMINAL ASSEMBLY FOR VHMS…1709
90 DIAGRAMS AND DRAWINGS…0
HYDRAULIC DIAGRAMS AND DRAWINGS…1711
HYDRAULIC CIRCUIT DIAGRAM…1712
ELECTRICAL DIAGRAMS AND DRAWINGS…1714
ELECTRICAL CIRCUIT DIAGRAM (1/2)…1716
ELECTRICAL CIRCUIT DIAGRAM (2/2)…1717
CONNECTOR ARRANGEMENT DIAGRAM…1718
SEN01607-19 – Hydraulic Excavator PC2000-8 Shop Manual…1721
COVER…1721
00 Index and foreword…0
Index…1723
Composition of shop manual…1724
Table of contents…1726
Foreword and general information…1739
Safety notice…1740
How to read the shop manual…1745
Explanation of terms for maintenance standard…1747
Handling of electric equipment and hydraulic component…1749
Handling of connectors newly used for engines…1758
How to read electric wire code…1761
Precautions when carrying out operation…1764
Method of disassembling and connecting push-pull type coupler…1767
Standard tightening torque table…1770
Conversion table…1774
01 Specification…0
Specification and technical data…1781
Specification drawings…1782
Specifications…1786
Weight table…1790
Table of fuel, coolant and lubricants…1796
10 Structure, function and maintenance standard…0
Engine and cooling system…1799
Radiator and oil cooler…1800
PTO…1802
PTO lubrication system…1804
Power train…1807
Power train…1808
Swing machinery…1810
Swing circle…1812
Final drive…1814
Sprocket…1816
Undercarriage and frame…1819
Track frame…1820
Idler…1822
Carrier roller…1824
Track roller…1825
Track shoe…1826
HIC system…1831
Hydraulic system, Part 1…1839
Hydraulic piping drawing…1842
Hydraulic tank…1846
Oil cooler…1848
Line oil filter…1850
Pilot oil filter…1851
Return oil filter…1852
Motor drain oil filter…1853
Pump drain filter…1854
Accumulator…1855
Travel junction valve…1857
Solenoid valve…1860
Hydraulic cylinder…1868
Greasing system…1872
Center swivel joint…1882
Hydraulic ladder system…1883
Service center system…1888
Hydraulic system, Part 2…1895
Hydraulic system, Part 2…1896
Control valve…1896
Electronic OLSS system…1924
Swing motor…1928
Cooling fan motor (For radiator and oil cooler)…1936
Cooling fan pump…1942
Hydraulic system, Part 3…1957
Travel motor…1958
Hydraulic pump…1970
PPC valve…1990
Variable back pressure valve…2002
Suction selector valve…2006
PPC cut-off valve…2010
Work equipment…2019
Work equipment…2020
Dimensions of work equipment…2024
Cab and its attachments…2029
Cab and its attachments…2030
Air conditioner piping…2030
Cab…2031
Electrical system…2035
Engine control…2036
Electrical control system…2047
Monitor system…2089
Sensor…2117
ORBCOMM terminal…2129
20 Standard value table…0
Standard service value table…2131
Standard service value table for engine…2132
Standard service value table for chassis (Backhoe specification)…2133
Standard service value table for chassis (Loading shovel specification)…2144
30 Testing and adjusting…0
Testing and adjusting, Part 1…2157
Tools for testing, adjusting, and troubleshooting…2159
Measuring engine speed…2162
Testing air boost pressure…2163
Testing exhaust temperature…2164
Testing exhaust color…2165
Adjusting valve clearance…2167
Testing compression pressure…2169
Testing blow-by pressure…2171
Testing engine oil pressure…2172
Handling fuel system parts…2173
Releasing residual pressure in fuel system…2173
Testing fuel pressure…2174
Reduced cylinder mode operation…2175
No-injection cranking…2175
Testing leakage from pressure limiter and return rate from injector…2176
Bleeding air from fuel circuit…2179
Bleeding air from fuel circuit (lowgrade fuel specification)…2183
Testing fuel system for leakage…2185
Testing and adjusting alternator belt tension…2186
Testing and adjusting air conditioner compressor belt tension…2187
Handling controller high-voltage circuit…2188
Testing and adjusting, Part 2…2191
Testing swing circle bearing clearance…2193
Remaining pressure relief from HIC circuit…2194
Gas filling in HIC circuit accumulator…2195
Bleeding air from HIC circuit and supplying oil to it…2198
Testing and adjusting track shoe tension…2202
Testing and adjusting work equipment, swing and travel circuit oil pressures…2206
Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve)…2210
Testing and adjusting main pump control signal…2212
Measuring fan speed…2215
Measuring fan pump EPC solenoid current…2216
Measuring fan pump EPC solenoid valve output pressure…2217
Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure…2219
Measuring PPC valve output pressure…2220
Measuring solenoid valve outlet pressure…2224
Adjusting work equipment and swing PPC valve…2226
Testing and adjusting travel deviation…2227
Testing work equipment hydraulic drift cause portion…2229
Testing oil leakage…2230
Remaining pressure relief from hydraulic circuit…2233
Air bleeding from each component…2234
Testing and adjusting auto grease system…2240
Adjusting mirrors…2243
Testing and adjusting clearance of hydraulic ladder proximity switch…2245
Testing and adjusting position of hydraulic ladder position sensor plate…2247
Testing and adjusting clearance to service arm proximity switch…2248
Testing and adjusting, Part 3…2251
Special functions of machine monitor…2252
Handling controller voltage circuit…2307
Testing and adjusting, Part 4…2309
VHMS controller initial setting procedure…2310
Precautions for replacing VHMS controller…2329
Preparation work for troubleshooting of electrical system…2335
Pm-clinic service…2337
Measurement procedure…2338
40 Troubleshooting…0
Failure code table and fuse locations…2357
Failure code table…2358
Before carrying out troubleshooting of electrical system…2365
General information on troubleshooting…2373
Points to remember when troubleshooting…2374
Sequence of events in troubleshooting…2375
Checks before troubleshooting…2376
Classification and procedures of troubleshooting…2377
Connection table for connector pin numbers…2381
T- branch box and T- branch adapter table…2417
Troubleshooting by failure code, Part 1…2421
Failure code [0410KA] Fuel LV. Sensor Failure…2424
Failure code [0410KB] Fuel LV. Sensor Failure…2426
Failure code [6014NX] Hydraulic Oil Filter Clogging (or change of VHMS-LED display from n5 to 51)…2428
Failure code [8800ZG] Auto grease abnormally…2429
Failure code [7@HAZL] VR1/P1F Relief Press Abnormality…2430
Failure code [7@HBZL] VL1/P1R Relief Press Abnormality…2431
Failure code [7@HCZL] VR2/P2F Relief Press Abnormality…2432
Failure code [7@HDZL] VL2/P2R Relief Press Abnormality…2434
Failure code [AA10NX] Aircleaner Clogging…2436
Failure code [AB00KE] Charge Voltage Low…2438
Failure code [aB00KE] Low Upper ALR Charge Voltage (or change of VHMS-LED display from n9 to 11)…2440
Failure code [B@BAZG] Eng. Oil Press. Low…2442
Failure code [B@BAZK] Eng. Oil Level Low…2444
Failure code [B@BCNS] Eng. Water Overheat…2446
Failure code [B@BCZK] Eng. Water Lvl Low…2448
Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED display from n5 to 61)…2450
Failure code [B@HANS] Hydr. Oil Overheat…2452
Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMSLED display from n5 to 52)…2454
Failure code [CA111] ECM Critical Internal Failure…2456
Failure code [CB111] ECM Critical Internal Failure…2458
Failure code [CA115] Eng. Ne and Bkup Speed Sens Error…2460
Failure code [CB115] Eng. Ne and Bkup Speed Sens Error…2461
Failure code [CA122] Chg Air Press Sensor High Error…2462
Failure code [CA123] Chg Air Press Sensor Low Error…2464
Failure code [CA131] Throttle Sensor High Error…2466
Failure code [CA132] Throttle Sensor Low Error…2468
Failure code [CA135] Eng Oil Press Sensor High Error…2470
Failure code [CA141] Eng Oil Press Sensor Low Error…2472
Failure code [CA144] Coolant Temp Sens High Error…2474
Failure code [CA145] Coolant Temp Sens Low Error…2476
Failure code [CA153] Chg Air Temp Sensor High Error…2478
Failure code [CA154] Chg Air Temp Sensor Low Error…2480
Failure code [CA187] Sens Supply 2 Volt Low Error…2482
Failure code [CB187] Sens Supply 2 Volt Low Error…2482
Failure code [CA212] Eng Oil Temp Sensor High Error…2484
Failure code [CA213] Eng Oil Temp Sensor Low Error…2486
Troubleshooting by failure code, Part 2…2489
Failure code [CA221] Ambient Press Sens High Error…2492
Failure code [CA222] Ambient Press Sens Low Error…2494
Failure code [CA227] Sens Supply 2 Volt High Error…2496
Failure code [CB227] Sens Supply 2 Volt High Error…2498
Failure code [CA234] Eng Over Speed…2500
Failure code [CA238] Ne Speed Sens Supply Volt Error…2502
Failure code [CB238] Ne Speed Sens Supply Volt Error…2504
Failure code [CA263] Fuel Temp Sensor High Error…2506
Failure code [CB263] Fuel Temp Sensor High Error…2508
Failure code [CA265] Fuel Temp Sensor Low Error…2509
Failure code [CB265] Fuel Temp Sensor Low Error…2509
Failure code [CA271] IMV/PCV1 Short Error…2510
Failure code [CB271] IMV/PCV1 Short Error…2512
Failure code [CA272] IMV/PCV1 Open Error…2514
Failure code [CB272] IMV/PCV1 Open Error…2516
Failure code [CA273] PCV2 Short Error…2518
Failure code [CB273] PCV2 Short Error…2520
Failure code [CA274] PCV2 Open Error…2522
Failure code [CB274] PCV2 Open Error…2524
Failure code [CA322] Inj #1(L/B#1) Open/Short Error…2526
Failure code [CA323] Inj #5(L/B#5) Open/Short Error…2528
Failure code [CA324] Inj #3(L/B#3) Open/Short Error…2530
Failure code [CA325] Inj #6(L/B#6) Open/Short Error…2532
Failure code [CA331] Inj #2(L/B#2) Open/Short Error…2534
Failure code [CA332] Inj #4(L/B#4) Open/Short Error…2536
Failure code [CA342] Calibration Code Incompatibility…2538
Failure code [CB342] Calibration Code Incompatibility…2538
Failure code [CA351] Injectors Drive Circuit Error…2540
Failure code [CB351] Injectors Drive Circuit Error…2542
Failure code [CA352] Sens Supply 1 Volt Low Error…2544
Failure code [CB352] Sens Supply 1 Volt Low Error…2544
Failure code [CA386] Sens Supply 1 Volt High Error…2546
Failure code [CB386] Sens Supply 1 Volt High Error…2548
Failure code [CA441] Battery Voltage Low Error…2550
Failure code [CB441] Battery Voltage Low Error…2550
Failure code [CA442] Battery Voltage High Error…2551
Failure code [CB442] Battery Voltage High Error…2551
Failure code [CA449] Rail Press Very High Error…2552
Failure code [CB449] Rail Press Very High Error…2552
Troubleshooting by failure code, Part 3…2555
Failure code [CA451] Rail Press Sensor High Error…2558
Failure code [CB451] Rail Press Sensor High Error…2560
Failure code [CA452] Rail Press Sensor Low Error…2562
Failure code [CB452] Rail Press Sensor Low Error…2562
Failure code [CA553] Rail Press High Error…2563
Failure code [CB553] Rail Press High Error…2564
Failure code [CA554] Rail Press Sensor In Range Error…2565
Failure code [CB554] Rail Press Sensor In Range Error…2565
Failure code [CA559] Rail Press Low Error…2566
Failure code [CB559] Rail Press Low Error…2570
Failure code [CA689] Eng Ne Speed Sensor Error…2574
Failure code [CB689] Eng Ne Speed Sensor Error…2576
Failure code [CA691] Intake Air Temp Sens High Error…2578
Failure code [CA692] Intake Air Temp Sens Low Error…2580
Failure code [CA731] Eng Bkup Speed Sens Phase Error…2581
Failure code [CB731] Eng Bkup Speed Sens Phase Error…2581
Failure code [CA757] All Persistent Data Lost Error…2582
Failure code [CB757] All Persistent Data Lost Error…2582
Failure code [CA778] Eng Bkup Speed Sensor Error…2584
Failure code [CB778] Eng Bkup Speed Sensor Error…2586
Failure code [CA781] CEN Communication Error…2588
Failure code [CB781] CEN Communication Error…2590
Failure code [CA1257] Harness Key Error…2592
Failure code [CB1257] Harness Key Error…2593
Failure code [CB1548] Inj #7(R/B#1) Open/Short Error…2594
Failure code [CB1549] Inj #8(R/B#2) Open/Short Error…2596
Failure code [CB1551] Inj #10(R/B#4) Open/Short Error…2598
Failure code [CB1552] Inj #11(R/B#5) Open/Short Error…2600
Failure code [CB1553] Inj #12(R/B#6) Open/Short Error…2602
Failure code [CB1622] Inj #9(R/B#3) Open/Short Error…2604
Failure code [CA1633] KOMNET Data link Time out Error…2606
Failure code [CA2185] Throt Sens Sup Volt High Error…2608
Failure code [CA2186] Throt Sens Sup Volt Low Error…2610
Failure code [CA2249] Rail Press Very Low Error…2611
Failure code [CB2249] Rail Press Very Low Error…2611
Failure code [CA2555] Grid Heater Relay Volt Low Error…2612
Failure code [CA2556] Grid Heater Relay Volt High Error…2614
Troubleshooting by failure code, Part 4…2617
Failure code [D110KB] Battery Relay Drive S/C…2620
Failure code [D163KB] Flash Light Relay S/C…2622
Failure code [D195KA] Step Light Relay Disc…2624
Failure code [D195KY] Step Light Relay S/C…2626
Failure code [D1E9KB] Wiper Drive Relay 1 S/C…2628
Failure code [D1EAKB] Wiper Drive Relay 2 S/C…2630
Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit…2632
Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit…2634
Failure code [DA22KK] Pump 1 Solenoid Power Low Error…2636
Failure code [dA22KK] Pump 2 Solenoid Power Low Error…2638
Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error…2640
Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error…2642
Failure code [DA26KP] 5V Sensor 2 Power Abnormality…2644
Failure code [DA29KQ] Pump 1 Model Select Abnormality…2646
Failure code [dA29KQ] Pump 2 Model Select Abnormality…2648
Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected)…2650
Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected)…2652
Failure code [DAFRMC] CAN Discon (Monitor Detected)…2654
Failure code [DA2TMC] Pump Comm. ECM Child Abnormality…2656
Failure code [DBB0KK] VHMS Source Voltage Error (or change of VHMS-LED display from n9 to 01)…2658
Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nF to 11)…2660
Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMSLED display from n9 to 04)…2662
Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02)…2664
Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02)…2666
Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of VHMS-LED display from n4 to 01)…2668
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C…2670
Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMSLED display from n5 to 01)…2672
Troubleshooting by failure code, Part 5…2675
Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 12)…2678
Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 22)…2680
Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 11)…2682
Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 21)…2684
Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 24)…2686
Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)…2688
Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 23)…2690
Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)…2692
Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality…2694
Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality…2696
Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality…2698
Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality…2700
Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32)…2702
Failure code [DHE5KY] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 31)…2704
Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of VHMS-LED display from n5 to 53)…2706
Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality…2708
Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality…2710
Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality…2712
Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality…2714
Failure code [DHPSKX] Auto Grease Press Sensor Abnormality…2716
Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit…2718
Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit…2720
Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality…2722
Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality…2724
Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality…2726
Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality…2728
Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality…2730
Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality…2732
Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality…2734
Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality…2736
Troubleshooting by failure code, Part 6…2739
Failure code [DUM3KB] Auto Grease Caution LED Short Circuit…2741
Failure code [DUM4KB] FAN Reverse LED Short Circuit…2742
Failure code [DV20KB] Travel Alarm S/C…2743
Failure code [DW41KA] Swing Priority Sol Open Circuit…2745
Failure code [DW41KB] Swing Priority Sol Short Circuit…2747
Failure code [DW45KA] Swing Brake Sol. Disc…2749
Failure code [DW45KB] Swing Brake Sol. S/C…2752
Failure code [DW91KA] Straight-Travel Sol. Disc…2754
Failure code [DW91KB] Straight-Travel Sol. S/C…2756
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc…2758
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C…2759
Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit…2760
Failure code [DW7BKB] Fan Motor (RAD) Reverse Sol. S/C…2762
Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit…2764
Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit…2766
Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit…2768
Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit…2770
Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit…2772
Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit…2774
Failure code [DWA5KA] Auto Grease Sol Open Circuit…2776
Failure code [DWA5KB] Auto Grease Sol Short Circuit…2778
Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit…2779
Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit…2781
Failure code [DWK0KA] 2-stage Relief Sol. Disc…2783
Failure code [DWK0KB] 2-stage Relief Sol. S/C…2785
Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit…2786
Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit…2787
Troubleshooting by failure code, Part 7…2789
Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit…2791
Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit…2792
Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit…2793
Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit…2794
Failure code [DXAAKA] P1F EPC Sol Disc…2796
Failure code [DXAAKB] P1F EPC Sol S/C…2798
Failure code [DXABKA] P1R Pump EPC Sol. Disc…2800
Failure code [DXABKB] P1R Pump EPC Sol. S/C…2802
Failure code [DXACKA] P2F Pump EPC Sol. Disc…2804
Failure code [DXACKB] P2F Pump EPC Sol. S/C…2806
Failure code [DXADKA] P2R Pump EPC Sol. Disc…2808
Failure code [DXADKB] P2R Pump EPC Sol. S/C…2810
Failure code [DY2CKB] Washer Drive S/C…2812
Failure code [DY20MA] Low Wiper Working Abnormality…2814
Failure code [DY2FMA] Upper Wiper Working Abnormality…2817
Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38)…2820
Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 62)…2822
Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 72)…2824
Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 61)…2826
Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 71)…2828
Failure code [F@BZNR] Very High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 82)…2830
Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 92)…2832
Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 81)…2834
Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 91)…2836
Failure code [LA10ZL] RAD system fan pump relief pressure high error…2838
Failure code [LA20ZL] O/C system pump relief pressure high error…2840
Troubleshooting of electrical system (E-mode)…2843
Before carrying out troubleshooting of electrical system…2845
Contents of troubleshooting table…2852
E-1 When starting switch is turned ON, machine monitor displays nothing…2854
E-2 When starting switch turned ON (before starting engine), basic check item lights up…2856
E-3 Engine does not start (Engine does not turn)…2858
E-4 Auto-decelerator does not operate…2862
E-5 Automatic warm-up system does not operate…2863
E-6 Preheater does not work…2864
E-7 Whole work equipment, swing operation and machine travel operation are disabled…2866
E-8 Machine push-up function does not work…2868
E-9 Boom shockless function cannot be released…2870
E-10 Machine monitor does not display some items…2872
E-11 Contents of display by machine monitor are different from applicable machine…2873
E-12 Fuel level monitor lights up in red while engine is running…2874
E-13 Hydraulic oil temperature gauge does not indicate normally…2875
E-14 Fuel level gauge does not indicate normally…2876
E-15 Swing lock monitor does not indicate normally…2878
E-16 Machine monitor display anything even when operated on monitor switch section…2880
E-17 Wiper does not work…2881
E-18 Monitoring function does not display "Travel" normally…2888
E-19 Travel alarm does not sound…2890
E-20 All of room lamp, headlamp and working lamp do not light up…2891
E-21 Air conditioner does not work…2896
E-22 Step light does not light up or goes off…2898
Troubleshooting of hydraulic and mechanical system (H-mode)…2903
Before troubleshooting for hydraulic and mechanical systems…2905
Table of failure modes and causes…2910
Information in troubleshooting table…2912
H-1 Speed or power of whole work equipment, travel, and swing is low…2913
H-2 Engine speed lowers remarkably or engine stalls…2915
H-3 Work equipment, swing, and travel mechanism do not move…2916
H-4 Abnormal noise comes from around hydraulic pump…2918
H-5 Speed or power of boom is low…2919
H-6 Speed or power of arm is low…2921
H-7 Speed or power of bucket is low…2922
H-8 Boom does not move…2923
H-9 Arm does not move…2923
H-10 Bucket does not move…2923
H-11 Hydraulic drift of work equipment is large…2924
H-12 Time lag of work equipment is large…2925
H-13 Heavy lift function does not work or is not reset…2926
H-14 Machine push-up function does not work or is not reset…2926
H-15 Boom shockless function does not work or is not reset…2926
H-16 Machine gradually deviates during traveling…2928
H-17 Machine deviates excessively when started to travel…2931
H-18 Machine deviates excessively during multiple operations…2932
H-19 Traveling speed or power is low…2932
H-20 Travel system does not move (only one side)…2933
H-21 Upper structure does not swing…2934
H-22 Swing speed or acceleration is low…2936
H-23 In compound operation of work equipment, swing speed or acceleration is low…2938
H-24 Upper structure overruns remarkably when it stops swinging…2939
H-25 Large shock is made when upper structure stops swinging…2940
H-26 Large abnormal sound comes from when upper structure stops swinging…2941
H-27 Hydraulic drift of work equipment is large in swing operation…2942
H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating)…2943
H-29 Bottom dump speed or power is lower (Loading shovel specification)…2944
H-30 Bottom dump cylinder does not move (Loading shovel specification)…2945
Troubleshooting of mechanical system (S-mode)…2947
Method of using troubleshooting charts…2949
S-1 Starting performance is poor…2952
S-2 Engine does not start…2953
S-3 Engine does not pick up smoothly…2956
S-4 Engine stops during operations…2957
S-5 Engine does not rotate smoothly…2958
S-6 Engine lacks output (or lacks power)…2960
S-7 Exhaust smoke is black (incomplete combustion)…2962
S-8 Oil consumption is excessive (or exhaust smoke is blue)…2963
S-9 Oil becomes contaminated quickly…2964
S-10 Fuel consumption is excessive…2965
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…2966
S-12 Oil pressure drops…2967
S-13 Oil level rises (Entry of coolant or fuel)…2968
S-14 Coolant temperature becomes too high (overheating)…2969
S-15 Abnormal noise is made…2970
S-16 Vibration is excessive…2971
50 Disassembly and assembly…0
General information on disassembly and assembly…2973
How to read this manual…2974
Coating materials list…2976
Special tool list…2979
Sketches of special tools…2983
Engine and cooling system…2987
Removal and installation of power container assembly…2988
Removal and installation of engine, PTO and hydraulic pump assembly…2993
Removal and installation of radiator assembly…3005
Removal and installation of aftercooler assembly…3006
Removal and installation of hydraulic oil cooler assembly…3008
Removal and installation of fuel cooler assembly…3009
Removal and installation of cooling assembly…3010
Removal and installation of fan motor assembly…3014
Removal and installation of fuel tank assembly…3015
Engine…3019
Removal and installation of fuel supply pump assembly…3020
Removal and installation of cylinder head assembly…3024
Removal and installation of fuel injector…3038
Removal and installation of engine front oil seal…3049
Removal and installation of engine rear oil seal…3052
Power train…3057
Removal and installation of PTO assembly…3058
Disassembly and assembly of PTO assembly…3059
Removal and installation of swing motor and swing machinery assembly…3063
Disassembly and assembly of swing machinery assembly…3065
Removal and installation of swing circle assembly…3075
Removal and installation of final drive assembly…3076
Disassembly and assembly of final drive assembly…3078
Undercarriage and frame…3091
Removal and installation of track shoe assembly…3092
Removal and installation of idler assembly…3094
Disassembly and assembly of idler assembly…3095
Disassembly and assembly of idler adjust cylinder assembly…3097
Removal and installation of idler cushion cylinder assembly…3098
Disassembly and assembly of idler cushion cylinder assembly…3099
Removal and installation of track roller assembly…3100
Disassembly and assembly of track roller assembly…3101
Removal and installation of carrier roller assembly…3103
Disassembly and assembly of carrier roller assembly…3104
Removal and installation of revolving frame assembly…3108
Removal and installation of counterweight assembly…3111
Removal and installation of hydraulic ladder…3112
Hydraulic system…3115
Removal and installation of hydraulic tank assembly…3116
Removal and installation of hydraulic pump assembly…3119
Removal and installation of hydraulic pump input shaft oil seal…3124
Removal and installation of control valve assembly…3125
Disassembly and assembly of control valve assembly…3132
Removal and installation of center swivel joint assembly…3136
Disassembly and assembly of center swivel joint assembly…3137
Removal and installation of swing motor assembly…3138
Removal and installation of travel motor assembly…3139
Disassembly and assembly of work equipment PPC valve assembly…3140
Disassembly and assembly of travel PPC valve assembly…3142
Disassembly and assembly of hydraulic cylinder assembly (Backhoe specification)…3145
Disassembly and assembly of hydraulic cylinder assembly (Loading shovel specification)…3152
Work equipment…3159
Removal and installation of bucket cylinder assembly (Backhoe specification)…3160
Removal and installation of bucket cylinder assembly (Loading shovel specification)…3162
Removal and installation of bucket assembly (Backhoe specification)…3164
Removal and installation of bucket assembly (Loading shovel specification)…3166
Removal and installation of arm cylinder (Backhoe specification)…3168
Removal and installation of arm cylinder (Loading shovel specification)…3170
Removal and installation of arm assembly (Backhoe specification)…3171
Removal and installation of arm assembly (Loading shovel specification)…3173
Removal and installation of boom cylinder assembly (Backhoe specification)…3174
Removal and installation of boom cylinder assembly (Loading shovel specification)…3176
Removal and installation of boom assembly (Backhoe specification)…3178
Removal and installation of boom assembly (Loading shovel specification)…3180
Removal and installation of bottom dump cylinder assembly (Loading shovel specification)…3182
Cab and its attachments…3185
Removal and installation of operator cab assembly…3186
Removal and installation of operator cab glass (adhesion glass)…3189
Removal and installation of operator cab (assembly-type)…3196
Removal and installation of cab base assembly…3197
Removal and installation of service center…3199
Electrical system…3203
Removal and installation of air conditioner unit assembly…3204
Removal and installation of monitor assembly…3208
Removal and installation of engine controller assembly…3209
Removal and installation of pump controller assembly…3210
Removal and installation of VHMS controller assembly…3211
Removal and installation of Orbcomm terminal assembly for VHMS…3211
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…3213
Hydraulic circuit diagram (Backhoe specification) Serial No.: 20001 – 20197…3215
Hydraulic circuit diagram (Backhoe specification) Serial No.: 20198 and up…3216
Hydraulic circuit diagram (Loading shovel specification) Serial No.: 20001 – 20197…3217
Hydraulic circuit diagram (Loading shovel specification) Serial No.: 20198 and up…3218
Electrical diagrams and drawings…3221
Electrical circuit diagram (1/14)…3223
Electrical circuit diagram (2/14)…3224
Electrical circuit diagram (3/14)…3225
Electrical circuit diagram (4/14)…3226
Electrical circuit diagram (5/14)…3227
Electrical circuit diagram (6/14)…3228
Electrical circuit diagram (7/14)…3229
Electrical circuit diagram (8/14)…3230
Electrical circuit diagram (9/14)…3231
Electrical circuit diagram (10/14)…3232
Electrical circuit diagram (11/14)…3233
Electrical circuit diagram (12/14)…3234
Electrical circuit diagram (13/14)…3235
Electrical circuit diagram (14/14)…3236
Connector list and stereogram…3237
TEN00133-05 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…3240
COVER…3240
FOREWORD…3241
BEFORE READING THIS MANUAL…3242
SAFETY INFORMATION…3245
INTRODUCTION…3246
USE OF MACHINE…3246
DIRECTIONS OF MACHINE…3246
VISIBILITY FROM OPERATOR'S SEAT…3247
PRODUCT INFORMATION…3248
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…3248
EPA REGULATIONS, ENGINE NUMBER PLATE…3248
SERVICE METER LOCATION…3249
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…3249
CONTENTS…3250
SAFETY…3255
SAFETY…3256
SAFETY LABELS…3259
LOCATION OF SAFETY LABELS…3260
SAFETY LABELS…3261
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…3266
PRECAUTIONS BEFORE STARTING OPERATION…3266
PREPARATIONS FOR SAFE OPERATION…3266
FIRE PREVENTION…3268
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…3269
DO NOT GET CAUGHT IN WORK EQUIPMENT…3271
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…3271
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…3272
UNAUTHORIZED MODIFICATION…3272
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…3273
PRECAUTIONS RELATED TO CAB GLASS…3273
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…3273
PRECAUTIONS FOR OPERATION…3274
PRECAUTIONS FOR JOBSITE…3274
STARTING ENGINE…3276
OPERATION…3278
TRANSPORTATION…3285
TOWING…3286
LIFTING OBJECTS WITH BUCKET…3286
PRECAUTIONS FOR MAINTENANCE…3287
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…3287
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…3291
OPERATION…3297
MACHINE VIEW ILLUSTRATIONS…3298
OVERALL MACHINE VIEW…3298
CONTROLS AND GAUGES…3299
DETAILED CONTROLS AND GAUGES…3303
MONITORING SYSTEM…3303
SWITCHES…3378
LAMP…3393
CONTROL LEVERS AND PEDALS…3396
DOOR LOCK…3399
EMERGENCY EXIT FROM OPERATOR'S CAB…3399
EMERGENCY ESCAPE HAMMER…3400
EMERGENCY ESCAPE EQUIPMENT…3401
FIRE EXTINGUISHER…3403
CAP WITH LOCK…3404
ASHTRAY…3405
CUP HOLDER…3405
MAGAZINE BOX…3406
HOOK…3406
UTILITY BOX…3407
AIR CONDITIONER CONTROLS…3408
RADIO…3426
AUXILIARY ELECTRIC POWER…3431
FUSE…3432
CIRCUIT BREAKER…3434
FUSE (IF EQUIPPED)…3437
CONTROLLER…3438
TOOL, CAN STORAGE PLACE…3439
HANDLING GREASE PUMP AND GREASE GUN…3439
ACCUMULATOR…3447
HANDLING OF SLIDING LADDER…3449
HANDLING MACHINES EQUIPPED WITH VHMS…3450
MACHINE OPERATIONS AND CONTROLS…3452
BEFORE STARTING ENGINE…3452
STARTING ENGINE…3482
AFTER STARTING ENGINE…3485
STOPPING THE ENGINE…3497
MACHINE OPERATION…3503
STEERING THE MACHINE…3507
SWINGING…3509
WORK EQUIPMENT CONTROLS AND OPERATIONS…3511
WORKING MODE…3513
PROHIBITED OPERATIONS…3514
GENERAL OPERATION INFORMATION…3518
TRAVELING ON SLOPES…3519
ESCAPE FROM MUD…3521
RECOMMENDED APPLICATIONS…3522
BUCKET REPLACEMENT…3523
PARKING MACHINE…3525
CHECK BEFORE SHUT OFF ENGINE…3526
MACHINE INSPECTION AFTER DAILY WORK…3526
LOCKING…3527
TRANSPORTATION…3528
TRANSPORTATION PROCEDURE…3528
PRECAUTIONS FOR TRANSPORTATION…3528
METHOD OF LIFTING UNITS FOR TRANSPORTATION…3528
TRANSPORTATION POSTURE…3528
COLD WEATHER OPERATION…3529
COLD WEATHER OPERATION INFORMATION…3529
AFTER DAILY WORK COMPLETION…3531
AFTER COLD WEATHER SEASON…3531
LONG TERM STORAGE…3532
BEFORE STORAGE…3532
DURING STORAGE…3532
AFTER STORAGE…3533
STARTING MACHINE AFTER LONG-TERM STORAGE…3533
TROUBLES AND ACTIONS…3534
RUNNING OUT OF FUEL…3534
PHENOMENA THAT ARE NOT FAILURES…3534
TOWING THE MACHINE…3535
SEVERE JOB CONDITION…3535
DISCHARGED BATTERY…3536
OTHER TROUBLE…3540
MAINTENANCE…3547
MAINTENANCE INFORMATION…3548
OUTLINE OF SERVICE…3550
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3550
ELECTRIC SYSTEM MAINTENANCE…3554
WEAR PARTS…3555
WEAR PARTS LIST…3555
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3556
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…3558
TIGHTENING TORQUE SPECIFICATIONS…3559
TIGHTENING TORQUE LIST…3559
SAFETY CRITICAL PARTS…3560
SAFETY CRITICAL PARTS LIST…3561
MAINTENANCE SCHEDULE…3562
MAINTENANCE SCHEDULE CHART…3562
MAINTENANCE PROCEDURE…3564
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…3564
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…3564
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…3564
WHEN REQUIRED…3565
CHECK BEFORE STARTING…3609
EVERY 250 HOURS MAINTENANCE…3610
EVERY 500 HOURS MAINTENANCE…3619
EVERY 1000 HOURS MAINTENANCE…3631
EVERY 2000 HOURS MAINTENANCE…3650
EVERY 4000 HOURS MAINTENANCE…3652
EVERY 5000 HOURS MAINTENANCE…3656
EVERY 8000 HOURS MAINTENANCE…3660
SPECIFICATIONS…3661
SPECIFICATIONS…3662
ATTACHMENTS, OPTIONS…3665
GENERAL PRECAUTIONS FOR SAFETY…3666
PRECAUTIONS WHEN SELECTING…3666
READ THE INSTRUCTION MANUAL THOROUGHLY…3666
PRECAUTIONS WHEN REMOVING OR INSTALLING…3666
PRECAUTIONS WHEN USING…3666
ATTACHMENT GUIDE…3667
COMBINATIONS OF WORK EQUIPMENT…3667
FRONT GUARD…3667
EMERGENCY LADDER…3668
ESCAPE PROCEDURE…3669
PRECAUTION WHEN STORING ROPE LADDER…3671
CHECK EMERGENCY LADDER…3671
HANDLING FUEL QUICK CHARGE…3672
GENERAL LOCATIONS…3672
PROCEDURE FOR OPERATING FUEL CHARGE…3673
REPLACE FUEL TANK BREATHER ELEMENT…3675
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…3676
HANDLING HYDRAULIC LADDER…3680
GENERAL LOCATIONS…3680
OTHER LAMPS AND SWITCHES…3681
PROCEDURE FOR OPERATING HYDRAULIC LADDER…3684
GREASING LADDER…3687
ACTION WHEN PROXIMITY SWITCH HAS FAILED…3688
SPECIFICATIONS…3690
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…3691
LOADING SHOVEL…3693
MACHINE VIEW ILLUSTRATIONS…3694
OVERALL MACHINE VIEW…3694
EXPLANATION OF COMPONENTS…3695
SWITCHES…3695
OPERATIONS…3697
OPERATION OF WORK EQUIPMENT…3697
PRECAUTIONS DURING OPERATION…3699
EXCAVATOR WORK…3703
PRECAUTIONS WHEN DISASSEMBLING MACHINE…3704
RELEASING PRESSURE…3704
TRANSPORTATION…3705
MACHINE CONFIGURATION FOR TRANSPORT…3705
MAINTENANCE…3706
EVERY 10 HOURS MAINTENANCE…3706
SPECIFICATION…3711
WEAR PARTS…3713
WEAR PARTS LIST…3713
COMBINATION OF WORK EQUIPMENT…3714
COMBINATION OF WORK EQUIPMENT…3714
INDEX…3715
TEN00236-03 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…3719
COVER…3719
FOREWORD…3720
BEFORE READING THIS MANUAL…3721
SAFETY INFORMATION…3724
INTRODUCTION…3725
USE OF MACHINE…3725
DIRECTIONS OF MACHINE…3725
VISIBILITY FROM OPERATOR'S SEAT…3726
PRODUCT INFORMATION…3727
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…3727
EPA REGULATIONS, ENGINE NUMBER PLATE…3727
SERVICE METER LOCATION…3728
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…3728
CONTENTS…3729
SAFETY…3734
SAFETY…3735
SAFETY LABELS…3738
LOCATION OF SAFETY LABELS…3739
SAFETY LABELS…3740
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…3745
PRECAUTIONS BEFORE STARTING OPERATION…3745
PREPARATIONS FOR SAFE OPERATION…3745
FIRE PREVENTION…3747
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…3748
DO NOT GET CAUGHT IN WORK EQUIPMENT…3750
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…3750
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…3751
UNAUTHORIZED MODIFICATION…3751
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…3752
PRECAUTIONS RELATED TO CAB GLASS…3752
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…3752
PRECAUTIONS FOR OPERATION…3753
PRECAUTIONS FOR JOBSITE…3753
STARTING ENGINE…3755
OPERATION…3757
TRANSPORTATION…3764
TOWING…3765
LIFTING OBJECTS WITH BUCKET…3765
PRECAUTIONS FOR MAINTENANCE…3766
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…3766
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…3770
OPERATION…3776
MACHINE VIEW ILLUSTRATIONS…3777
OVERALL MACHINE VIEW…3777
CONTROLS AND GAUGES…3778
DETAILED CONTROLS AND GAUGES…3782
MONITORING SYSTEM…3782
SWITCHES…3857
LAMP…3872
CONTROL LEVERS AND PEDALS…3875
DOOR LOCK…3878
EMERGENCY EXIT FROM OPERATOR'S CAB…3878
EMERGENCY ESCAPE HAMMER…3879
EMERGENCY ESCAPE EQUIPMENT…3880
FIRE EXTINGUISHER…3882
CAP WITH LOCK…3883
ASHTRAY…3884
CUP HOLDER…3884
MAGAZINE BOX…3885
HOOK…3885
UTILITY BOX…3886
AIR CONDITIONER CONTROLS…3887
RADIO…3905
AUXILIARY ELECTRIC POWER…3910
FUSE…3911
CIRCUIT BREAKER…3913
FUSE (IF EQUIPPED)…3916
CONTROLLER…3917
TOOL, CAN STORAGE PLACE…3918
HANDLING GREASE PUMP AND GREASE GUN…3918
ACCUMULATOR…3926
HANDLING OF SLIDING LADDER…3928
HANDLING MACHINES EQUIPPED WITH VHMS…3929
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER…3931
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER…3941
MACHINE OPERATIONS AND CONTROLS…3957
BEFORE STARTING ENGINE…3957
STARTING ENGINE…3987
AFTER STARTING ENGINE…3991
STOPPING THE ENGINE…4003
MACHINE OPERATION…4009
STEERING THE MACHINE…4013
SWINGING…4015
WORK EQUIPMENT CONTROLS AND OPERATIONS…4017
WORKING MODE…4019
PROHIBITED OPERATIONS…4020
GENERAL OPERATION INFORMATION…4024
TRAVELING ON SLOPES…4025
ESCAPE FROM MUD…4027
RECOMMENDED APPLICATIONS…4028
BUCKET REPLACEMENT…4029
PARKING MACHINE…4031
CHECK BEFORE SHUT OFF ENGINE…4032
MACHINE INSPECTION AFTER DAILY WORK…4032
LOCKING…4033
TRANSPORTATION…4034
TRANSPORTATION PROCEDURE…4034
PRECAUTIONS FOR TRANSPORTATION…4034
METHOD OF LIFTING UNITS FOR TRANSPORTATION…4034
TRANSPORTATION POSTURE…4034
COLD WEATHER OPERATION…4035
COLD WEATHER OPERATION INFORMATION…4035
AFTER DAILY WORK COMPLETION…4037
AFTER COLD WEATHER SEASON…4037
LONG TERM STORAGE…4038
BEFORE STORAGE…4038
DURING STORAGE…4038
AFTER STORAGE…4039
STARTING MACHINE AFTER LONG-TERM STORAGE…4039
TROUBLES AND ACTIONS…4040
RUNNING OUT OF FUEL…4040
PHENOMENA THAT ARE NOT FAILURES…4040
TOWING THE MACHINE…4041
SEVERE JOB CONDITION…4041
DISCHARGED BATTERY…4042
OTHER TROUBLE…4046
MAINTENANCE…4052
MAINTENANCE INFORMATION…4053
OUTLINE OF SERVICE…4055
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4055
ELECTRIC SYSTEM MAINTENANCE…4059
WEAR PARTS…4060
WEAR PARTS LIST…4060
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4061
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4063
TIGHTENING TORQUE SPECIFICATIONS…4064
TIGHTENING TORQUE LIST…4064
SAFETY CRITICAL PARTS…4065
SAFETY CRITICAL PARTS LIST…4066
MAINTENANCE SCHEDULE…4067
MAINTENANCE SCHEDULE CHART…4067
MAINTENANCE PROCEDURE…4069
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…4069
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…4069
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…4069
WHEN REQUIRED…4070
CHECK BEFORE STARTING…4114
EVERY 250 HOURS MAINTENANCE…4115
EVERY 500 HOURS MAINTENANCE…4124
EVERY 1000 HOURS MAINTENANCE…4136
EVERY 2000 HOURS MAINTENANCE…4155
EVERY 4000 HOURS MAINTENANCE…4157
EVERY 5000 HOURS MAINTENANCE…4161
EVERY 8000 HOURS MAINTENANCE…4165
SPECIFICATIONS…4166
SPECIFICATIONS…4167
ATTACHMENTS, OPTIONS…4170
GENERAL PRECAUTIONS FOR SAFETY…4171
PRECAUTIONS WHEN SELECTING…4171
READ THE INSTRUCTION MANUAL THOROUGHLY…4171
PRECAUTIONS WHEN REMOVING OR INSTALLING…4171
PRECAUTIONS WHEN USING…4171
ATTACHMENT GUIDE…4172
COMBINATIONS OF WORK EQUIPMENT…4172
FRONT GUARD…4172
EMERGENCY LADDER…4173
ESCAPE PROCEDURE…4174
PRECAUTION WHEN STORING ROPE LADDER…4176
CHECK EMERGENCY LADDER…4176
HANDLING HYDRAULIC LADDER…4177
GENERAL LOCATIONS…4177
OTHER LAMPS AND SWITCHES…4178
PROCEDURE FOR OPERATING HYDRAULIC LADDER…4181
GREASING LADDER…4184
ACTION WHEN PROXIMITY SWITCH HAS FAILED…4185
SPECIFICATIONS…4187
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…4188
LOADING SHOVEL…4190
MACHINE VIEW ILLUSTRATIONS…4191
OVERALL MACHINE VIEW…4191
EXPLANATION OF COMPONENTS…4192
SWITCHES…4192
OPERATIONS…4194
OPERATION OF WORK EQUIPMENT…4194
PRECAUTIONS DURING OPERATION…4196
EXCAVATOR WORK…4200
PRECAUTIONS WHEN DISASSEMBLING MACHINE…4201
RELEASING PRESSURE…4201
TRANSPORTATION…4202
MACHINE CONFIGURATION FOR TRANSPORT…4202
MAINTENANCE…4203
EVERY 10 HOURS MAINTENANCE…4203
SPECIFICATION…4208
WEAR PARTS…4210
WEAR PARTS LIST…4210
COMBINATION OF WORK EQUIPMENT…4211
COMBINATION OF WORK EQUIPMENT…4211
INDEX…4212
TEN00323-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…4216
COVER…4216
FOREWORD…4217
BEFORE READING THIS MANUAL…4218
SAFETY INFORMATION…4219
INTRODUCTION…4220
USE OF MACHINE…4220
DIRECTIONS OF MACHINE…4220
VISIBILITY FROM OPERATOR'S SEAT…4221
PRODUCT INFORMATION…4222
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…4222
EPA REGULATIONS, ENGINE NUMBER PLATE…4222
SERVICE METER LOCATION…4223
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…4223
CONTENTS…4224
SAFETY…4229
SAFETY…4230
SAFETY LABELS…4233
LOCATION OF SAFETY LABELS…4234
SAFETY LABELS…4235
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…4240
PRECAUTIONS BEFORE STARTING OPERATION…4240
PREPARATIONS FOR SAFE OPERATION…4240
FIRE PREVENTION…4242
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…4243
DO NOT GET CAUGHT IN WORK EQUIPMENT…4245
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4245
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…4246
UNAUTHORIZED MODIFICATION…4246
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4247
PRECAUTIONS RELATED TO CAB GLASS…4247
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…4247
PRECAUTIONS FOR OPERATION…4248
PRECAUTIONS FOR JOBSITE…4248
STARTING ENGINE…4250
OPERATION…4252
TRANSPORTATION…4259
TOWING…4260
LIFTING OBJECTS WITH BUCKET…4260
PRECAUTIONS FOR MAINTENANCE…4261
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…4261
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4265
OPERATION…4271
MACHINE VIEW ILLUSTRATIONS…4272
OVERALL MACHINE VIEW…4272
CONTROLS AND GAUGES…4273
DETAILED CONTROLS AND GAUGES…4277
MONITORING SYSTEM…4277
SWITCHES (INSIDE OPERATOR'S CAB)…4352
SWITCHES (INSIDE CAB BASE ROOM)…4362
SWITCHES (OUTSIDE OF MACHINE)…4365
LAMP (INSIDE OPERATOR'S CAB)…4376
LAMP (OUTSIDE OF MACHINE)…4380
CONTROL LEVERS AND PEDALS…4382
DOOR LOCK…4385
EMERGENCY EXIT FROM OPERATOR'S CAB…4385
EMERGENCY ESCAPE HAMMER…4386
HANDLING EMERGENCY LADDER…4387
FIRE EXTINGUISHER…4391
CAP WITH LOCK…4392
ASHTRAY…4393
CUP HOLDER…4393
MAGAZINE BOX…4394
HOOK…4394
UTILITY BOX…4395
AIR CONDITIONER CONTROLS…4396
RADIO…4414
AUXILIARY ELECTRIC POWER…4419
FUSE…4420
CIRCUIT BREAKER…4422
FUSE (IF EQUIPPED)…4425
CONTROLLER…4426
TOOL, CAN STORAGE PLACE…4427
HANDLING GREASE PUMP AND GREASE GUN…4427
ACCUMULATOR…4435
HANDLING HYDRAULIC LADDER…4437
HANDLING MACHINES EQUIPPED WITH VHMS…4444
MACHINE OPERATIONS AND CONTROLS…4446
BEFORE STARTING ENGINE…4446
STARTING ENGINE…4477
AFTER STARTING ENGINE…4480
STOPPING THE ENGINE…4492
MACHINE OPERATION…4501
STEERING THE MACHINE…4505
SWINGING…4507
WORK EQUIPMENT CONTROLS AND OPERATIONS…4509
WORKING MODE…4511
PROHIBITED OPERATIONS…4512
GENERAL OPERATION INFORMATION…4516
TRAVELING ON SLOPES…4517
ESCAPE FROM MUD…4519
RECOMMENDED APPLICATIONS…4520
BUCKET REPLACEMENT…4521
PARKING MACHINE…4523
CHECK BEFORE SHUT OFF ENGINE…4524
MACHINE INSPECTION AFTER DAILY WORK…4524
LOCKING…4525
TRANSPORTATION…4526
TRANSPORTATION PROCEDURE…4526
PRECAUTIONS FOR TRANSPORTATION…4526
METHOD OF LIFTING UNITS FOR TRANSPORTATION…4526
TRANSPORTATION POSTURE…4526
COLD WEATHER OPERATION…4527
COLD WEATHER OPERATION INFORMATION…4527
AFTER DAILY WORK COMPLETION…4529
AFTER COLD WEATHER SEASON…4529
LONG TERM STORAGE…4530
BEFORE STORAGE…4530
DURING STORAGE…4530
AFTER STORAGE…4531
STARTING MACHINE AFTER LONG-TERM STORAGE…4531
TROUBLES AND ACTIONS…4532
RUNNING OUT OF FUEL…4532
PHENOMENA THAT ARE NOT FAILURES…4532
TOWING THE MACHINE…4533
SEVERE JOB CONDITION…4533
DISCHARGED BATTERY…4534
OTHER TROUBLE…4539
MAINTENANCE…4545
MAINTENANCE INFORMATION…4546
OUTLINE OF SERVICE…4548
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4548
ELECTRIC SYSTEM MAINTENANCE…4552
WEAR PARTS…4553
WEAR PARTS LIST…4553
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4554
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4556
TIGHTENING TORQUE SPECIFICATIONS…4557
TIGHTENING TORQUE LIST…4557
SAFETY CRITICAL PARTS…4558
SAFETY CRITICAL PARTS LIST…4559
MAINTENANCE SCHEDULE…4560
MAINTENANCE SCHEDULE CHART…4560
MAINTENANCE PROCEDURE…4562
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…4562
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…4562
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…4562
WHEN REQUIRED…4563
CHECK BEFORE STARTING…4606
EVERY 250 HOURS MAINTENANCE…4607
EVERY 500 HOURS MAINTENANCE…4616
EVERY 1000 HOURS MAINTENANCE…4630
EVERY 2000 HOURS MAINTENANCE…4650
EVERY 4000 HOURS MAINTENANCE…4652
EVERY 5000 HOURS MAINTENANCE…4656
EVERY 8000 HOURS MAINTENANCE…4660
SPECIFICATIONS…4661
SPECIFICATIONS…4662
ATTACHMENTS, OPTIONS…4665
GENERAL PRECAUTIONS FOR SAFETY…4666
PRECAUTIONS WHEN SELECTING…4666
READ THE INSTRUCTION MANUAL THOROUGHLY…4666
PRECAUTIONS WHEN REMOVING OR INSTALLING…4666
PRECAUTIONS WHEN USING…4666
ATTACHMENT GUIDE…4667
COMBINATIONS OF WORK EQUIPMENT…4667
FRONT GUARD…4667
HANDLING FUEL QUICK CHARGE…4668
GENERAL LOCATIONS…4668
PROCEDURE FOR OPERATING FUEL CHARGE…4669
REPLACE FUEL TANK BREATHER ELEMENT…4671
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…4672
HANDLING SERVICE CENTER…4676
GENERAL LOCATIONS…4676
PROCEDURE FOR OPERATING SERVICE ARM…4677
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…4680
GREASING LADDER SERVICE ARM…4690
REPLACE FUEL TANK BREATHER ELEMENT…4691
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…4692
HANDLING JUMP START RECEPTACLE…4696
GENERAL LOCATIONS…4696
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…4696
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…4698
LOADING SHOVEL…4699
MACHINE VIEW ILLUSTRATIONS…4700
OVERALL MACHINE VIEW…4700
EXPLANATION OF COMPONENTS…4701
SWITCHES…4701
OPERATIONS…4703
OPERATION OF WORK EQUIPMENT…4703
PRECAUTIONS DURING OPERATION…4705
EXCAVATOR WORK…4709
PRECAUTIONS WHEN DISASSEMBLING MACHINE…4710
RELEASING PRESSURE…4710
TRANSPORTATION…4711
MACHINE CONFIGURATION FOR TRANSPORT…4711
MAINTENANCE…4712
EVERY 10 HOURS MAINTENANCE…4712
SPECIFICATION…4717
WEAR PARTS…4719
WEAR PARTS LIST…4719
COMBINATION OF WORK EQUIPMENT…4720
COMBINATION OF WORK EQUIPMENT…4720
INDEX…4721
TEN00324-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…4725
COVER…4725
FOREWORD…4726
BEFORE READING THIS MANUAL…4727
SAFETY INFORMATION…4728
INTRODUCTION…4729
USE OF MACHINE…4729
DIRECTIONS OF MACHINE…4729
VISIBILITY FROM OPERATOR'S SEAT…4730
PRODUCT INFORMATION…4731
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…4731
EPA REGULATIONS, ENGINE NUMBER PLATE…4731
SERVICE METER LOCATION…4732
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…4732
CONTENTS…4733
SAFETY…4738
SAFETY…4739
SAFETY LABELS…4742
LOCATION OF SAFETY LABELS…4743
SAFETY LABELS…4744
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…4749
PRECAUTIONS BEFORE STARTING OPERATION…4749
PREPARATIONS FOR SAFE OPERATION…4749
FIRE PREVENTION…4751
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…4752
DO NOT GET CAUGHT IN WORK EQUIPMENT…4754
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4754
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…4755
UNAUTHORIZED MODIFICATION…4755
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4756
PRECAUTIONS RELATED TO CAB GLASS…4756
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…4756
PRECAUTIONS FOR OPERATION…4757
PRECAUTIONS FOR JOBSITE…4757
STARTING ENGINE…4759
OPERATION…4761
TRANSPORTATION…4768
TOWING…4769
LIFTING OBJECTS WITH BUCKET…4769
PRECAUTIONS FOR MAINTENANCE…4770
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…4770
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4774
OPERATION…4780
MACHINE VIEW ILLUSTRATIONS…4781
OVERALL MACHINE VIEW…4781
CONTROLS AND GAUGES…4782
DETAILED CONTROLS AND GAUGES…4786
MONITORING SYSTEM…4786
SWITCHES (INSIDE OPERATOR'S CAB)…4861
SWITCHES (INSIDE CAB BASE ROOM)…4871
SWITCHES (OUTSIDE OF MACHINE)…4874
LAMP (INSIDE OPERATOR'S CAB)…4885
LAMP (OUTSIDE OF MACHINE)…4889
CONTROL LEVERS AND PEDALS…4891
DOOR LOCK…4894
EMERGENCY EXIT FROM OPERATOR'S CAB…4894
EMERGENCY ESCAPE HAMMER…4895
HANDLING EMERGENCY LADDER…4896
FIRE EXTINGUISHER…4900
CAP WITH LOCK…4901
ASHTRAY…4902
CUP HOLDER…4902
MAGAZINE BOX…4903
HOOK…4903
UTILITY BOX…4904
AIR CONDITIONER CONTROLS…4905
RADIO…4923
AUXILIARY ELECTRIC POWER…4928
FUSE…4929
CIRCUIT BREAKER…4931
FUSE (IF EQUIPPED)…4934
CONTROLLER…4935
TOOL, CAN STORAGE PLACE…4936
HANDLING GREASE PUMP AND GREASE GUN…4936
ACCUMULATOR…4944
HANDLING HYDRAULIC LADDER…4946
HANDLING MACHINES EQUIPPED WITH VHMS…4953
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER…4955
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER…4965
MACHINE OPERATIONS AND CONTROLS…4981
BEFORE STARTING ENGINE…4981
STARTING ENGINE…5012
AFTER STARTING ENGINE…5016
STOPPING THE ENGINE…5028
MACHINE OPERATION…5037
STEERING THE MACHINE…5041
SWINGING…5043
WORK EQUIPMENT CONTROLS AND OPERATIONS…5044
WORKING MODE…5046
PROHIBITED OPERATIONS…5047
GENERAL OPERATION INFORMATION…5051
TRAVELING ON SLOPES…5052
ESCAPE FROM MUD…5054
RECOMMENDED APPLICATIONS…5055
BUCKET REPLACEMENT…5056
PARKING MACHINE…5058
CHECK BEFORE SHUT OFF ENGINE…5059
MACHINE INSPECTION AFTER DAILY WORK…5059
LOCKING…5060
TRANSPORTATION…5061
TRANSPORTATION PROCEDURE…5061
PRECAUTIONS FOR TRANSPORTATION…5061
METHOD OF LIFTING UNITS FOR TRANSPORTATION…5061
TRANSPORTATION POSTURE…5061
COLD WEATHER OPERATION…5062
COLD WEATHER OPERATION INFORMATION…5062
AFTER DAILY WORK COMPLETION…5064
AFTER COLD WEATHER SEASON…5064
LONG TERM STORAGE…5065
BEFORE STORAGE…5065
DURING STORAGE…5065
AFTER STORAGE…5066
STARTING MACHINE AFTER LONG-TERM STORAGE…5066
TROUBLES AND ACTIONS…5067
RUNNING OUT OF FUEL…5067
PHENOMENA THAT ARE NOT FAILURES…5067
TOWING THE MACHINE…5068
SEVERE JOB CONDITION…5068
DISCHARGED BATTERY…5069
OTHER TROUBLE…5074
MAINTENANCE…5080
MAINTENANCE INFORMATION…5081
OUTLINE OF SERVICE…5083
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…5083
ELECTRIC SYSTEM MAINTENANCE…5087
WEAR PARTS…5088
WEAR PARTS LIST…5088
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…5089
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…5091
TIGHTENING TORQUE SPECIFICATIONS…5092
TIGHTENING TORQUE LIST…5092
SAFETY CRITICAL PARTS…5093
SAFETY CRITICAL PARTS LIST…5094
MAINTENANCE SCHEDULE…5095
MAINTENANCE SCHEDULE CHART…5095
MAINTENANCE PROCEDURE…5097
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…5097
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…5097
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…5097
WHEN REQUIRED…5098
CHECK BEFORE STARTING…5141
EVERY 250 HOURS MAINTENANCE…5142
EVERY 500 HOURS MAINTENANCE…5151
EVERY 1000 HOURS MAINTENANCE…5165
EVERY 2000 HOURS MAINTENANCE…5185
EVERY 4000 HOURS MAINTENANCE…5187
EVERY 5000 HOURS MAINTENANCE…5191
EVERY 8000 HOURS MAINTENANCE…5195
SPECIFICATIONS…5196
SPECIFICATIONS…5197
ATTACHMENTS, OPTIONS…5200
GENERAL PRECAUTIONS FOR SAFETY…5201
PRECAUTIONS WHEN SELECTING…5201
READ THE INSTRUCTION MANUAL THOROUGHLY…5201
PRECAUTIONS WHEN REMOVING OR INSTALLING…5201
PRECAUTIONS WHEN USING…5201
ATTACHMENT GUIDE…5202
COMBINATIONS OF WORK EQUIPMENT…5202
FRONT GUARD…5202
HANDLING SERVICE CENTER…5203
GENERAL LOCATIONS…5203
PROCEDURE FOR OPERATING SERVICE ARM…5204
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…5207
GREASING LADDER SERVICE ARM…5217
REPLACE FUEL TANK BREATHER ELEMENT…5218
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…5219
HANDLING JUMP START RECEPTACLE…5223
GENERAL LOCATIONS…5223
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…5223
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…5225
LOADING SHOVEL…5226
MACHINE VIEW ILLUSTRATIONS…5227
OVERALL MACHINE VIEW…5227
EXPLANATION OF COMPONENTS…5228
SWITCHES…5228
OPERATIONS…5230
OPERATION OF WORK EQUIPMENT…5230
PRECAUTIONS DURING OPERATION…5232
EXCAVATOR WORK…5236
PRECAUTIONS WHEN DISASSEMBLING MACHINE…5237
RELEASING PRESSURE…5237
TRANSPORTATION…5238
MACHINE CONFIGURATION FOR TRANSPORT…5238
MAINTENANCE…5239
EVERY 10 HOURS MAINTENANCE…5239
SPECIFICATION…5244
WEAR PARTS…5246
WEAR PARTS LIST…5246
COMBINATION OF WORK EQUIPMENT…5247
COMBINATION OF WORK EQUIPMENT…5247
INDEX…5248
TEN00365-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…5252
COVER…5252
FOREWORD…5253
BEFORE READING THIS MANUAL…5254
SAFETY INFORMATION…5255
INTRODUCTION…5256
USE OF MACHINE…5256
DIRECTIONS OF MACHINE…5256
VISIBILITY FROM OPERATOR'S SEAT…5257
PRODUCT INFORMATION…5258
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…5258
EPA REGULATIONS, ENGINE NUMBER PLATE…5258
SERVICE METER LOCATION…5259
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…5259
CONTENTS…5260
SAFETY…5265
SAFETY…5266
SAFETY LABELS…5269
LOCATION OF SAFETY LABELS…5270
SAFETY LABELS…5271
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…5276
PRECAUTIONS BEFORE STARTING OPERATION…5276
PREPARATIONS FOR SAFE OPERATION…5276
FIRE PREVENTION…5278
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…5279
DO NOT GET CAUGHT IN WORK EQUIPMENT…5281
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…5281
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…5282
UNAUTHORIZED MODIFICATION…5282
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…5283
PRECAUTIONS RELATED TO CAB GLASS…5283
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…5283
PRECAUTIONS FOR OPERATION…5284
PRECAUTIONS FOR JOBSITE…5284
STARTING ENGINE…5286
OPERATION…5288
TRANSPORTATION…5295
TOWING…5296
LIFTING OBJECTS WITH BUCKET…5296
PRECAUTIONS FOR MAINTENANCE…5297
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…5297
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…5301
OPERATION…5307
MACHINE VIEW ILLUSTRATIONS…5308
OVERALL MACHINE VIEW…5308
CONTROLS AND GAUGES…5309
DETAILED CONTROLS AND GAUGES…5313
MONITORING SYSTEM…5313
SWITCHES (INSIDE OPERATOR'S CAB)…5388
SWITCHES (INSIDE CAB BASE ROOM)…5398
SWITCHES (OUTSIDE OF MACHINE)…5401
LAMP (INSIDE OPERATOR'S CAB)…5412
LAMP (OUTSIDE OF MACHINE)…5416
CONTROL LEVERS AND PEDALS…5418
DOOR LOCK…5421
EMERGENCY EXIT FROM OPERATOR'S CAB…5421
EMERGENCY ESCAPE HAMMER…5422
HANDLING EMERGENCY LADDER…5423
FIRE EXTINGUISHER…5427
CAP WITH LOCK…5428
ASHTRAY…5429
CUP HOLDER…5429
MAGAZINE BOX…5430
HOOK…5430
UTILITY BOX…5431
AIR CONDITIONER CONTROLS…5432
RADIO…5450
AUXILIARY ELECTRIC POWER…5455
FUSE…5456
CIRCUIT BREAKER…5458
FUSE (IF EQUIPPED)…5461
CONTROLLER…5462
TOOL, CAN STORAGE PLACE…5463
HANDLING GREASE PUMP AND GREASE GUN…5463
ACCUMULATOR…5471
HANDLING HYDRAULIC LADDER…5473
HANDLING MACHINES EQUIPPED WITH VHMS…5480
MACHINE OPERATIONS AND CONTROLS…5482
BEFORE STARTING ENGINE…5482
STARTING ENGINE…5513
AFTER STARTING ENGINE…5516
STOPPING THE ENGINE…5528
MACHINE OPERATION…5537
STEERING THE MACHINE…5541
SWINGING…5543
WORK EQUIPMENT CONTROLS AND OPERATIONS…5544
WORKING MODE…5546
PROHIBITED OPERATIONS…5547
GENERAL OPERATION INFORMATION…5551
TRAVELING ON SLOPES…5552
ESCAPE FROM MUD…5554
RECOMMENDED APPLICATIONS…5555
BUCKET REPLACEMENT…5556
PARKING MACHINE…5558
CHECK BEFORE SHUT OFF ENGINE…5559
MACHINE INSPECTION AFTER DAILY WORK…5559
LOCKING…5560
TRANSPORTATION…5561
TRANSPORTATION PROCEDURE…5561
PRECAUTIONS FOR TRANSPORTATION…5561
METHOD OF LIFTING UNITS FOR TRANSPORTATION…5561
TRANSPORTATION POSTURE…5561
COLD WEATHER OPERATION…5562
COLD WEATHER OPERATION INFORMATION…5562
AFTER DAILY WORK COMPLETION…5564
AFTER COLD WEATHER SEASON…5564
LONG TERM STORAGE…5565
BEFORE STORAGE…5565
DURING STORAGE…5565
AFTER STORAGE…5566
STARTING MACHINE AFTER LONG-TERM STORAGE…5566
TROUBLES AND ACTIONS…5567
RUNNING OUT OF FUEL…5567
PHENOMENA THAT ARE NOT FAILURES…5567
TOWING THE MACHINE…5568
SEVERE JOB CONDITION…5568
DISCHARGED BATTERY…5569
OTHER TROUBLE…5574
MAINTENANCE…5581
MAINTENANCE INFORMATION…5582
OUTLINE OF SERVICE…5584
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…5584
ELECTRIC SYSTEM MAINTENANCE…5588
WEAR PARTS…5589
WEAR PARTS LIST…5589
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…5590
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…5592
TIGHTENING TORQUE SPECIFICATIONS…5593
TIGHTENING TORQUE LIST…5593
SAFETY CRITICAL PARTS…5594
SAFETY CRITICAL PARTS LIST…5595
MAINTENANCE SCHEDULE…5596
MAINTENANCE SCHEDULE CHART…5596
MAINTENANCE PROCEDURE…5598
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…5598
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…5598
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…5598
WHEN REQUIRED…5599
CHECK BEFORE STARTING…5641
EVERY 250 HOURS MAINTENANCE…5642
EVERY 500 HOURS MAINTENANCE…5651
EVERY 1000 HOURS MAINTENANCE…5665
EVERY 2000 HOURS MAINTENANCE…5684
EVERY 4000 HOURS MAINTENANCE…5686
EVERY 5000 HOURS MAINTENANCE…5690
EVERY 8000 HOURS MAINTENANCE…5694
SPECIFICATIONS…5695
SPECIFICATIONS…5696
ATTACHMENTS, OPTIONS…5699
GENERAL PRECAUTIONS FOR SAFETY…5700
PRECAUTIONS WHEN SELECTING…5700
READ THE INSTRUCTION MANUAL THOROUGHLY…5700
PRECAUTIONS WHEN REMOVING OR INSTALLING…5700
PRECAUTIONS WHEN USING…5700
ATTACHMENT GUIDE…5701
COMBINATIONS OF WORK EQUIPMENT…5701
FRONT GUARD…5701
HANDLING FUEL QUICK CHARGE…5702
GENERAL LOCATIONS…5702
PROCEDURE FOR OPERATING FUEL CHARGE…5703
REPLACE FUEL TANK BREATHER ELEMENT…5705
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…5706
HANDLING SERVICE CENTER…5710
GENERAL LOCATIONS…5710
PROCEDURE FOR OPERATING SERVICE ARM…5711
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…5714
GREASING LADDER SERVICE ARM…5724
REPLACE FUEL TANK BREATHER ELEMENT…5725
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…5726
HANDLING JUMP START RECEPTACLE…5730
GENERAL LOCATIONS…5730
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…5730
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…5732
LOADING SHOVEL…5733
MACHINE VIEW ILLUSTRATIONS…5734
OVERALL MACHINE VIEW…5734
EXPLANATION OF COMPONENTS…5735
SWITCHES…5735
OPERATIONS…5737
OPERATION OF WORK EQUIPMENT…5737
PRECAUTIONS DURING OPERATION…5739
EXCAVATOR WORK…5743
PRECAUTIONS WHEN DISASSEMBLING MACHINE…5744
RELEASING PRESSURE…5744
TRANSPORTATION…5745
MACHINE CONFIGURATION FOR TRANSPORT…5745
MAINTENANCE…5746
EVERY 10 HOURS MAINTENANCE…5746
SPECIFICATION…5751
WEAR PARTS…5753
WEAR PARTS LIST…5753
COMBINATION OF WORK EQUIPMENT…5754
COMBINATION OF WORK EQUIPMENT…5754
INDEX…5755
TEN00366-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…5759
COVER…5759
FOREWORD…5760
BEFORE READING THIS MANUAL…5761
SAFETY INFORMATION…5762
INTRODUCTION…5763
USE OF MACHINE…5763
DIRECTIONS OF MACHINE…5763
VISIBILITY FROM OPERATOR'S SEAT…5764
PRODUCT INFORMATION…5765
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…5765
EPA REGULATIONS, ENGINE NUMBER PLATE…5765
SERVICE METER LOCATION…5766
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…5766
CONTENTS…5767
SAFETY…5772
SAFETY…5773
SAFETY LABELS…5776
LOCATION OF SAFETY LABELS…5777
SAFETY LABELS…5778
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…5783
PRECAUTIONS BEFORE STARTING OPERATION…5783
PREPARATIONS FOR SAFE OPERATION…5783
FIRE PREVENTION…5785
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…5786
DO NOT GET CAUGHT IN WORK EQUIPMENT…5788
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…5788
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…5789
UNAUTHORIZED MODIFICATION…5789
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…5790
PRECAUTIONS RELATED TO CAB GLASS…5790
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…5790
PRECAUTIONS FOR OPERATION…5791
PRECAUTIONS FOR JOBSITE…5791
STARTING ENGINE…5793
OPERATION…5795
TRANSPORTATION…5802
TOWING…5803
LIFTING OBJECTS WITH BUCKET…5803
PRECAUTIONS FOR MAINTENANCE…5804
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…5804
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…5808
OPERATION…5814
MACHINE VIEW ILLUSTRATIONS…5815
OVERALL MACHINE VIEW…5815
CONTROLS AND GAUGES…5816
DETAILED CONTROLS AND GAUGES…5820
MONITORING SYSTEM…5820
SWITCHES (INSIDE OPERATOR'S CAB)…5895
SWITCHES (INSIDE CAB BASE ROOM)…5905
SWITCHES (OUTSIDE OF MACHINE)…5908
LAMP (INSIDE OPERATOR'S CAB)…5919
LAMP (OUTSIDE OF MACHINE)…5923
CONTROL LEVERS AND PEDALS…5925
DOOR LOCK…5928
EMERGENCY EXIT FROM OPERATOR'S CAB…5928
EMERGENCY ESCAPE HAMMER…5929
HANDLING EMERGENCY LADDER…5930
FIRE EXTINGUISHER…5934
CAP WITH LOCK…5935
ASHTRAY…5936
CUP HOLDER…5936
MAGAZINE BOX…5937
HOOK…5937
UTILITY BOX…5938
AIR CONDITIONER CONTROLS…5939
RADIO…5957
AUXILIARY ELECTRIC POWER…5962
FUSE…5963
CIRCUIT BREAKER…5965
FUSE (IF EQUIPPED)…5968
CONTROLLER…5969
TOOL, CAN STORAGE PLACE…5970
HANDLING GREASE PUMP AND GREASE GUN…5970
ACCUMULATOR…5978
HANDLING HYDRAULIC LADDER…5980
HANDLING MACHINES EQUIPPED WITH VHMS…5987
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER…5989
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER…5999
MACHINE OPERATIONS AND CONTROLS…6015
BEFORE STARTING ENGINE…6015
STARTING ENGINE…6046
AFTER STARTING ENGINE…6050
STOPPING THE ENGINE…6062
MACHINE OPERATION…6071
STEERING THE MACHINE…6075
SWINGING…6077
WORK EQUIPMENT CONTROLS AND OPERATIONS…6078
WORKING MODE…6080
PROHIBITED OPERATIONS…6081
GENERAL OPERATION INFORMATION…6085
TRAVELING ON SLOPES…6086
ESCAPE FROM MUD…6088
RECOMMENDED APPLICATIONS…6089
BUCKET REPLACEMENT…6090
PARKING MACHINE…6092
CHECK BEFORE SHUT OFF ENGINE…6093
MACHINE INSPECTION AFTER DAILY WORK…6093
LOCKING…6094
TRANSPORTATION…6095
TRANSPORTATION PROCEDURE…6095
PRECAUTIONS FOR TRANSPORTATION…6095
METHOD OF LIFTING UNITS FOR TRANSPORTATION…6095
TRANSPORTATION POSTURE…6095
COLD WEATHER OPERATION…6096
COLD WEATHER OPERATION INFORMATION…6096
AFTER DAILY WORK COMPLETION…6098
AFTER COLD WEATHER SEASON…6098
LONG TERM STORAGE…6099
BEFORE STORAGE…6099
DURING STORAGE…6099
AFTER STORAGE…6100
STARTING MACHINE AFTER LONG-TERM STORAGE…6100
TROUBLES AND ACTIONS…6101
RUNNING OUT OF FUEL…6101
PHENOMENA THAT ARE NOT FAILURES…6101
TOWING THE MACHINE…6102
SEVERE JOB CONDITION…6102
DISCHARGED BATTERY…6103
OTHER TROUBLE…6108
MAINTENANCE…6114
MAINTENANCE INFORMATION…6115
OUTLINE OF SERVICE…6117
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…6117
ELECTRIC SYSTEM MAINTENANCE…6121
WEAR PARTS…6122
WEAR PARTS LIST…6122
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…6123
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…6125
TIGHTENING TORQUE SPECIFICATIONS…6126
TIGHTENING TORQUE LIST…6126
SAFETY CRITICAL PARTS…6127
SAFETY CRITICAL PARTS LIST…6128
MAINTENANCE SCHEDULE…6129
MAINTENANCE SCHEDULE CHART…6129
MAINTENANCE PROCEDURE…6131
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…6131
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…6131
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…6131
WHEN REQUIRED…6132
CHECK BEFORE STARTING…6174
EVERY 250 HOURS MAINTENANCE…6175
EVERY 500 HOURS MAINTENANCE…6184
EVERY 1000 HOURS MAINTENANCE…6198
EVERY 2000 HOURS MAINTENANCE…6217
EVERY 4000 HOURS MAINTENANCE…6219
EVERY 5000 HOURS MAINTENANCE…6223
EVERY 8000 HOURS MAINTENANCE…6227
SPECIFICATIONS…6228
SPECIFICATIONS…6229
ATTACHMENTS, OPTIONS…6232
GENERAL PRECAUTIONS FOR SAFETY…6233
PRECAUTIONS WHEN SELECTING…6233
READ THE INSTRUCTION MANUAL THOROUGHLY…6233
PRECAUTIONS WHEN REMOVING OR INSTALLING…6233
PRECAUTIONS WHEN USING…6233
ATTACHMENT GUIDE…6234
COMBINATIONS OF WORK EQUIPMENT…6234
FRONT GUARD…6234
HANDLING SERVICE CENTER…6235
GENERAL LOCATIONS…6235
PROCEDURE FOR OPERATING SERVICE ARM…6236
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…6239
GREASING LADDER SERVICE ARM…6249
REPLACE FUEL TANK BREATHER ELEMENT…6250
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…6251
HANDLING JUMP START RECEPTACLE…6255
GENERAL LOCATIONS…6255
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…6255
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…6257
LOADING SHOVEL…6258
MACHINE VIEW ILLUSTRATIONS…6259
OVERALL MACHINE VIEW…6259
EXPLANATION OF COMPONENTS…6260
SWITCHES…6260
OPERATIONS…6262
OPERATION OF WORK EQUIPMENT…6262
PRECAUTIONS DURING OPERATION…6264
EXCAVATOR WORK…6268
PRECAUTIONS WHEN DISASSEMBLING MACHINE…6269
RELEASING PRESSURE…6269
TRANSPORTATION…6270
MACHINE CONFIGURATION FOR TRANSPORT…6270
MAINTENANCE…6271
EVERY 10 HOURS MAINTENANCE…6271
SPECIFICATION…6276
WEAR PARTS…6278
WEAR PARTS LIST…6278
COMBINATION OF WORK EQUIPMENT…6279
COMBINATION OF WORK EQUIPMENT…6279
INDEX…6280
TEN00430-04 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…6284
COVER…6284
FOREWORD…6285
BEFORE READING THIS MANUAL…6286
SAFETY INFORMATION…6287
INTRODUCTION…6288
USE OF MACHINE…6288
DIRECTIONS OF MACHINE…6288
VISIBILITY FROM OPERATOR'S SEAT…6289
PRODUCT INFORMATION…6290
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…6290
EPA REGULATIONS, ENGINE NUMBER PLATE…6290
SERVICE METER LOCATION…6291
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…6291
CONTENTS…6292
SAFETY…6297
SAFETY LABELS…6301
LOCATION OF SAFETY LABELS…6302
SAFETY LABELS…6303
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…6308
PRECAUTIONS BEFORE STARTING OPERATION…6308
PREPARATIONS FOR SAFE OPERATION…6308
FIRE PREVENTION…6310
DO NOT GET CAUGHT IN WORK EQUIPMENT…6313
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…6313
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…6314
UNAUTHORIZED MODIFICATION…6314
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…6315
PRECAUTIONS RELATED TO CAB GLASS…6315
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…6315
PRECAUTIONS FOR OPERATION…6316
PRECAUTIONS FOR JOBSITE…6316
STARTING ENGINE…6318
OPERATION…6320
TRANSPORTATION…6327
TOWING…6328
LIFTING OBJECTS WITH BUCKET…6328
PRECAUTIONS FOR MAINTENANCE…6329
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…6329
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…6333
OPERATION…6339
MACHINE VIEW ILLUSTRATIONS…6340
OVERALL MACHINE VIEW…6340
CONTROLS AND GAUGES…6341
DETAILED CONTROLS AND GAUGES…6345
MONITORING SYSTEM…6345
SWITCHES (INSIDE OPERATOR'S CAB)…6420
SWITCHES (INSIDE CAB BASE ROOM)…6430
SWITCHES (OUTSIDE OF MACHINE)…6433
LAMP (INSIDE OPERATOR'S CAB)…6444
LAMP (OUTSIDE OF MACHINE)…6448
CONTROL LEVERS AND PEDALS…6450
DOOR LOCK…6453
EMERGENCY EXIT FROM OPERATOR'S CAB…6453
EMERGENCY ESCAPE HAMMER…6454
HANDLING EMERGENCY LADDER…6455
FIRE EXTINGUISHER…6459
CAP WITH LOCK…6460
ASHTRAY…6461
CUP HOLDER…6461
MAGAZINE BOX…6462
HOOK…6462
UTILITY BOX…6463
AIR CONDITIONER CONTROLS…6464
RADIO…6482
AUXILIARY ELECTRIC POWER…6487
FUSE…6488
CIRCUIT BREAKER…6490
FUSE (IF EQUIPPED)…6493
CONTROLLER…6494
TOOL, CAN STORAGE PLACE…6495
HANDLING GREASE PUMP AND GREASE GUN…6495
ACCUMULATOR…6503
HANDLING HYDRAULIC LADDER…6506
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus…6513
MACHINE OPERATIONS AND CONTROLS…6515
BEFORE STARTING ENGINE…6515
STARTING ENGINE…6546
AFTER STARTING ENGINE…6549
STOPPING THE ENGINE…6561
MACHINE OPERATION…6570
STEERING THE MACHINE…6574
SWINGING…6576
WORK EQUIPMENT CONTROLS AND OPERATIONS…6577
WORKING MODE…6579
PROHIBITED OPERATIONS…6580
GENERAL OPERATION INFORMATION…6584
TRAVELING ON SLOPES…6585
ESCAPE FROM MUD…6587
RECOMMENDED APPLICATIONS…6588
BUCKET REPLACEMENT…6589
PARKING MACHINE…6591
CHECK BEFORE SHUT OFF ENGINE…6592
MACHINE INSPECTION AFTER DAILY WORK…6592
LOCKING…6593
TRANSPORTATION…6594
TRANSPORTATION PROCEDURE…6594
PRECAUTIONS FOR TRANSPORTATION…6594
METHOD OF LIFTING UNITS FOR TRANSPORTATION…6594
TRANSPORTATION POSTURE…6594
COLD WEATHER OPERATION…6595
COLD WEATHER OPERATION INFORMATION…6595
AFTER DAILY WORK COMPLETION…6597
AFTER COLD WEATHER SEASON…6597
LONG TERM STORAGE…6598
BEFORE STORAGE…6598
DURING STORAGE…6598
AFTER STORAGE…6599
STARTING MACHINE AFTER LONG-TERM STORAGE…6599
TROUBLES AND ACTIONS…6600
RUNNING OUT OF FUEL…6600
PHENOMENA THAT ARE NOT FAILURES…6600
TOWING THE MACHINE…6601
SEVERE JOB CONDITION…6601
DISCHARGED BATTERY…6602
OTHER TROUBLE…6607
MAINTENANCE…6613
MAINTENANCE INFORMATION…6614
OUTLINE OF SERVICE…6616
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…6616
ELECTRIC SYSTEM MAINTENANCE…6620
WEAR PARTS…6621
WEAR PARTS LIST…6621
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…6622
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…6625
TIGHTENING TORQUE SPECIFICATIONS…6626
TIGHTENING TORQUE LIST…6626
SAFETY CRITICAL PARTS…6627
SAFETY CRITICAL PARTS LIST…6628
MAINTENANCE SCHEDULE…6629
MAINTENANCE SCHEDULE CHART…6629
MAINTENANCE PROCEDURE…6631
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…6631
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…6631
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…6631
WHEN REQUIRED…6632
CHECK BEFORE STARTING…6675
EVERY 250 HOURS MAINTENANCE…6676
EVERY 500 HOURS MAINTENANCE…6685
EVERY 1000 HOURS MAINTENANCE…6699
EVERY 2000 HOURS MAINTENANCE…6722
EVERY 4000 HOURS MAINTENANCE…6724
EVERY 5000 HOURS MAINTENANCE…6728
EVERY 8000 HOURS MAINTENANCE…6732
SPECIFICATIONS…6733
SPECIFICATIONS…6734
ATTACHMENTS AND OPTIONS…6737
GENERAL PRECAUTIONS FOR SAFETY…6738
PRECAUTIONS WHEN SELECTING…6738
READ THE INSTRUCTION MANUAL THOROUGHLY…6738
PRECAUTIONS WHEN REMOVING OR INSTALLING…6738
PRECAUTIONS WHEN USING…6738
ATTACHMENT GUIDE…6739
COMBINATIONS OF WORK EQUIPMENT…6739
FRONT GUARD…6739
HANDLING FUEL QUICK CHARGE…6740
GENERAL LOCATIONS…6740
PROCEDURE FOR OPERATING FUEL CHARGE…6741
REPLACE FUEL TANK BREATHER ELEMENT…6743
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…6744
HANDLING SERVICE CENTER…6748
GENERAL LOCATIONS…6748
PROCEDURE FOR OPERATING SERVICE ARM…6749
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…6752
GREASING LADDER SERVICE ARM…6762
REPLACE FUEL TANK BREATHER ELEMENT…6763
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…6764
HANDLING JUMP START RECEPTACLE…6768
GENERAL LOCATIONS…6768
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…6768
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…6770
LOADING SHOVEL…6771
MACHINE VIEW ILLUSTRATIONS…6772
OVERALL MACHINE VIEW…6772
EXPLANATION OF COMPONENTS…6773
SWITCHES…6773
OPERATIONS…6775
OPERATION OF WORK EQUIPMENT…6775
PRECAUTIONS DURING OPERATION…6777
LOADING SHOVEL WORK…6781
PRECAUTIONS WHEN DISASSEMBLING MACHINE…6782
RELEASING PRESSURE…6782
TRANSPORTATION…6783
MACHINE CONFIGURATION FOR TRANSPORT…6783
MAINTENANCE…6784
EVERY 10 HOURS MAINTENANCE…6784
SPECIFICATION…6789
WEAR PARTS…6791
WEAR PARTS LIST…6791
COMBINATION OF WORK EQUIPMENT…6792
COMBINATION OF WORK EQUIPMENT…6792
INDEX…6793
TEN00431-05 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…6797
COVER…6797
FOREWORD…6798
BEFORE READING THIS MANUAL…6799
SAFETY INFORMATION…6800
INTRODUCTION…6801
USE OF MACHINE…6801
DIRECTIONS OF MACHINE…6801
VISIBILITY FROM OPERATOR'S SEAT…6802
PRODUCT INFORMATION…6803
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…6803
EPA REGULATIONS, ENGINE NUMBER PLATE…6804
SERVICE METER LOCATION…6805
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…6805
CONTENTS…6806
SAFETY…6810
SAFETY…6811
SAFETY LABELS…6814
LOCATION OF SAFETY LABELS…6815
SAFETY LABELS…6816
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…6821
PRECAUTIONS BEFORE STARTING OPERATION…6821
PREPARATIONS FOR SAFE OPERATION…6821
FIRE PREVENTION…6823
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…6824
DO NOT GET CAUGHT IN WORK EQUIPMENT…6826
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…6826
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…6827
UNAUTHORIZED MODIFICATION…6827
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…6828
PRECAUTIONS RELATED TO CAB GLASS…6828
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…6828
PRECAUTIONS FOR OPERATION…6829
PRECAUTIONS FOR JOBSITE…6829
STARTING ENGINE…6831
OPERATION…6833
TRANSPORTATION…6840
TOWING…6841
LIFTING OBJECTS WITH BUCKET…6841
PRECAUTIONS FOR MAINTENANCE…6842
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…6842
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…6846
OPERATION…6852
MACHINE VIEW ILLUSTRATIONS…6853
OVERALL MACHINE VIEW…6853
CONTROLS AND GAUGES…6854
DETAILED CONTROLS AND GAUGES…6858
MONITORING SYSTEM…6858
SWITCHES (INSIDE OPERATOR'S CAB)…6933
SWITCHES (INSIDE CAB BASE ROOM)…6943
SWITCHES (OUTSIDE OF MACHINE)…6946
LAMP (INSIDE OPERATOR'S CAB)…6957
LAMP (OUTSIDE OF MACHINE)…6961
CONTROL LEVERS AND PEDALS…6963
DOOR LOCK…6966
EMERGENCY EXIT FROM OPERATOR'S CAB…6966
EMERGENCY ESCAPE HAMMER…6967
HANDLING EMERGENCY LADDER…6968
FIRE EXTINGUISHER…6972
CAP WITH LOCK…6973
ASHTRAY…6974
CUP HOLDER…6974
MAGAZINE BOX…6975
HOOK…6975
UTILITY BOX…6976
AIR CONDITIONER CONTROLS…6977
RADIO…6995
AUXILIARY ELECTRIC POWER…7000
FUSE…7001
CIRCUIT BREAKER…7003
FUSE (IF EQUIPPED)…7006
CONTROLLER…7007
TOOL, CAN STORAGE PLACE…7008
HANDLING GREASE PUMP AND GREASE GUN…7008
ACCUMULATOR…7016
HANDLING HYDRAULIC LADDER…7019
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus…7026
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER…7028
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER…7038
MACHINE OPERATIONS AND CONTROLS…7054
BEFORE STARTING ENGINE…7054
STARTING ENGINE…7088
AFTER STARTING ENGINE…7092
STOPPING THE ENGINE…7104
MACHINE OPERATION…7113
STEERING THE MACHINE…7117
SWINGING…7119
WORK EQUIPMENT CONTROLS AND OPERATIONS…7120
WORKING MODE…7122
PROHIBITED OPERATIONS…7123
GENERAL OPERATION INFORMATION…7127
TRAVELING ON SLOPES…7128
ESCAPE FROM MUD…7130
RECOMMENDED APPLICATIONS…7131
BUCKET REPLACEMENT…7132
PARKING MACHINE…7134
CHECK BEFORE SHUT OFF ENGINE…7135
MACHINE INSPECTION AFTER DAILY WORK…7135
LOCKING…7136
TRANSPORTATION…7137
TRANSPORTATION PROCEDURE…7137
PRECAUTIONS FOR TRANSPORTATION…7137
METHOD OF LIFTING UNITS FOR TRANSPORTATION…7137
TRANSPORTATION POSTURE…7137
COLD WEATHER OPERATION…7138
COLD WEATHER OPERATION INFORMATION…7138
AFTER DAILY WORK COMPLETION…7140
AFTER COLD WEATHER SEASON…7140
LONG TERM STORAGE…7141
BEFORE STORAGE…7141
DURING STORAGE…7141
AFTER STORAGE…7142
STARTING MACHINE AFTER LONG-TERM STORAGE…7142
TROUBLES AND ACTIONS…7143
RUNNING OUT OF FUEL…7143
PHENOMENA THAT ARE NOT FAILURES…7143
TOWING THE MACHINE…7144
SEVERE JOB CONDITION…7144
DISCHARGED BATTERY…7145
OTHER TROUBLE…7150
MAINTENANCE…7156
MAINTENANCE INFORMATION…7157
OUTLINE OF SERVICE…7159
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…7159
ELECTRIC SYSTEM MAINTENANCE…7163
WEAR PARTS…7164
WEAR PARTS LIST…7164
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…7165
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…7168
TIGHTENING TORQUE SPECIFICATIONS…7169
TIGHTENING TORQUE LIST…7169
SAFETY CRITICAL PARTS…7170
SAFETY CRITICAL PARTS LIST…7171
MAINTENANCE SCHEDULE…7172
MAINTENANCE SCHEDULE CHART…7172
MAINTENANCE PROCEDURE…7174
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…7174
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…7174
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…7174
WHEN REQUIRED…7175
CHECK BEFORE STARTING…7221
EVERY 250 HOURS MAINTENANCE…7222
EVERY 500 HOURS MAINTENANCE…7231
EVERY 1000 HOURS MAINTENANCE…7245
EVERY 2000 HOURS MAINTENANCE…7268
EVERY 4000 HOURS MAINTENANCE…7270
EVERY 8000 HOURS MAINTENANCE…7278
SPECIFICATIONS…7280
SPECIFICATIONS…7281
ATTACHMENTS AND OPTIONS…7284
GENERAL PRECAUTIONS FOR SAFETY…7285
PRECAUTIONS WHEN SELECTING…7285
READ THE INSTRUCTION MANUAL THOROUGHLY…7285
PRECAUTIONS WHEN REMOVING OR INSTALLING…7285
PRECAUTIONS WHEN USING…7285
ATTACHMENT GUIDE…7286
COMBINATIONS OF WORK EQUIPMENT…7286
FRONT GUARD…7286
HANDLING SERVICE CENTER…7287
GENERAL LOCATIONS…7287
PROCEDURE FOR OPERATING SERVICE ARM…7288
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…7291
GREASING LADDER SERVICE ARM…7302
REPLACE FUEL TANK BREATHER ELEMENT…7303
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…7304
HANDLING JUMP START RECEPTACLE…7308
GENERAL LOCATIONS…7308
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…7308
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…7310
LOADING SHOVEL…7312
MACHINE VIEW ILLUSTRATIONS…7313
OVERALL MACHINE VIEW…7313
EXPLANATION OF COMPONENTS…7314
SWITCHES…7314
OPERATIONS…7316
OPERATION OF WORK EQUIPMENT…7316
PRECAUTIONS DURING OPERATION…7318
LOADING SHOVEL WORK…7322
PRECAUTIONS WHEN DISASSEMBLING MACHINE…7323
RELEASING PRESSURE…7323
TRANSPORTATION…7324
MACHINE CONFIGURATION FOR TRANSPORT…7324
MAINTENANCE…7325
EVERY 10 HOURS MAINTENANCE…7325
SPECIFICATION…7330
WEAR PARTS…7332
WEAR PARTS LIST…7332
COMBINATION OF WORK EQUIPMENT…7333
COMBINATION OF WORK EQUIPMENT…7333
INDEX…7334

Komatsu Hydraulic Excavator GALEO PC2000 Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 10, 2025 by admin

Komatsu Hydraulic Excavator PC1800 Workshop Service Repair Manuals

INSTANT DOWNLOAD

Komatsu Hydraulic Excavator PC1800 Workshop Service Repair manual with Electrical Wiring Diagrams (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnosis & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

This manual contains high quality images, circuit diagrams, instructions to help you to maintenance, troubleshoot, diagnose, and repair. This document is printable, without restrictions, contains searchable text, bookmarks, crosslinks for easy navigation.

SEBM019105 – Hydraulic Excavator PC1800-6 Shop Manual.pdf
SEBM027708 – Hydraulic Excavator PC1800-6 Shop Manual.pdf
GEN00016-01 – Hydraulic Excavator PC1800-6 Field Assembly Instruction.pdf
SEAM022902 – Hydraulic Excavator PC1800-6 Operation & Maintenance Manual.pdf
SEAM022908T – Hydraulic Excavator GALEO PC1800-6 Operation & Maintenance Manual.pdf
SEAW002201 – Hydraulic Excavator PC1800-6 Field Assembly Manual.pdf
TEN00051-00 – Hydraulic Excavator GALEO PC1800-6 Operation & Maintenance Manual.pdf

TABLE OF CONTENTS
GEN00016-01 – Hydraulic Excavator PC1800-6 Field Assembly Instruction…2
COVER…2
CONTENTS…3
GENERAL…6
1. SPECIFICATIONS…6
2. POINTS REGARDING LOCAL ASSEMBLY…7
3. BOLT TIGHTENING TORQUE AND BOLT TIGHTENING TOOLS…8
4. SEPARATE UNITS…11
5. LIST OF PARTS SENT INDIVIDUALLY…31
6. ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE…60
7. KIT LAYOUT DIAGRAM…61
8. TOOLS AND EQUIPMENT TO BE USED…63
COMPONENTS TO BE ASSEMBLED IN HARBOR…71
COOLING SUB ASS'Y…72
FUEL TANK SUB ASS'Y…82
HYDRAULIC TANK SUB ASS'Y…88
SUCTION TUBE SUB ASS'Y…94
OIL COOLER LINE…96
SWING MACHINERY SUB ASS’Y…102
HOOD (SMALL) SUB ASS’Y…108
RIGHT SIDE DOOR SUB ASS’Y…112
RIGHT SIDE DUCT SUB ASS’Y…118
PARTITION COVER…123
MUFFLER COVER…125
BATTERY CASE SUB ASS’Y…127
A. ASSEMBY OF CHASSIS…133
A-1: ASSEMBLY OF TRACK FRAME AND AXLE…134
A-2: TRAVEL MOTOR PIPING…137
A-3: IDLER CUSHION CYLINDER PIPING…139
A-4: INSTALLATION OF TRAVEL MOTOR GUARD…140
A-5: FILLING SWING CIRCLE WITH GREASE…142
A-6: ASSEMBLY OF REVOLVING FRAME ASSEMBLY AND AXLE ASSEMBLY…143
A-7: SWIVEL TRAVEL PIPING…145
A-8: SWING CIRCLE GREASE TUBE PIPING…147
A-9: INSTALLATION OF LEFT AND RIGHT LADDERS…155
A-10: INSTALLATION OF LEFT CATWALK (STD)…156
A-11: INSATLLATION OF RIGHT CATWALK…157
A-12: INSATLLATION OF CATWALK, HANDRAIL BESIDE OPERATOR'S CAB…158
A-13: INSTALLATION OF OPERATOR'S CAB LADDER…159
A-14: INSTALLSTION OF OPERATOR'S CAB HANDRAIL…160
A-16: INSTALLSTION OF HANDRAIL AT REAR OF OPERATOR'S CAB…161
A-18: OPERATOR'S CAB FRONT FRAME, HANDRAIL…162
A-20: RIGHT DECK HANDRAIL…163
A-21: INSTALLATION OF LADDER ON TOP OF HYDRAULIC TANK…164
A-22: INSTALLATION OF COUNTERWEIGHT…165
A-23: INSTALLATION OF COUNTERWEIGHT LADDERS (LEFT AND RIGHT)…166
A-24: INSTALLATION OF HANDRAIL ON TOP OF FUEL TANK, COUNTERWEIGHT…167
A-25: INSTALLATION OF FUEL TANK VIBRATION STOPPER BRACKET…168
A-26: INSTALLATION OF GREASE REEL, HOSE, BRACKET…169
A-27: INSTALLATION OF LEFT CAB BASE ASSEMBLY…170
A-28: INSTALLATION OF OPERATOR'S CAB ASSEMBLY…175
A-29: INSTALLATION OF WIPER MOTOR COVER INSIDE OPERATOR'S CAB…176
A-30: INSTALLATION OF UPPER HANDRAIL OF LEFT-HAND DOOR COVER…177
A-31: HANDRAILS ABOVE THE RH DOOR AND BAOVE THE HYDRAULIC OIL TANK…179
A-32: EMERGENCY STOP SWITCH, FUEL CUT LEVER…180
A-33: HANDRAIL ABOVE THE RADIATOR…182
A-34: CONNECTION OF HYDRAULIC PIPING OPERATOR'S CAB ASSEMBLY…183
A-35: CONNECTION OF WINDOW WASHER HOSE OF OPERATOR'S CAB ASSEMBLY…188
A-36: CONNECTION OF AIR PIPING OF LEFT CAB BASE ASSEMBLY…189
A-37: CONNECTION OF GREASE PIPING OF OPERATION'S CAB ASSEMBLY…190
A-38: CONNECTION OF WIRING HAMESS IN CAB BASE…194
A-39: PIPING OF AIR CONDITIONER DISCHARGE HOSE…195
A-40: INSTALLATION OF HEAD GUARD…200
A-41: INSTALLATION OF ORBCOMM ANTENNA…201
A-42: CONNECTION OF BATTERY CABLE…202
A-43: START ENGINE…203
A-44: FINAL TIGHTENING OF SWING CIRCLE MOUNTING BOLTS…211
A-45: PARTS TO BE TOUCHED UP AFTER FIELD ASSEMBLY…212
L-1: INSTALLATION OF LEFT-HAND CATWALK AND POWER-ASSISTED LADDER…213
C. PC1800 INSTALLATION OF BACKHOE WORK EQUIPMENT…217
C-1: INSTALLATION OF BOOM CYLINDER TO CHASSIS…218
C-2: INSTALLATION OF BOOM CYLINDER PIPING…220
C-3: BLEEDING AIR FROM BOOM CYLINDER…221
C-4: BOOM SUB-ASSEMBLY…222
C-5: INSTALLATION OF BOOM ASSEMBLY…226
C-6: INSTALLATION OF BOOM CYLINDER TOP PIN…229
C-7: CONNECTION OF ARM ASSEMBLY TO BOOM…231
C-8: INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS…234
C-9: INSATLLATION OF ARM CYLINDER TOP PIN…236
C-10: BLEEDING AIR FROM ARM CYLINDER…238
C-11: INSTALLATION OF HYDRAULIC HOSES BETWEEN BOOM AND ARM…239
C-12: CONNECTION OF GREASE PIPING…240
C-13: CONNECTION OF WIRING BETWEEN BOOM AND CHASSIS…245
C-14: INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS…246
C-16: CONNECTION OF BUCKET ASSEMBLY TO ARM…248
C-17: INSTALLATIPN OF BUCKET LINK…251
C-18: BLEEDING AIR FROM BUCKET CYLINDER…253
ASSEMBLY MANUAL FOR LOADING SHOVEL WORK EQUIPMENT…255
LS-1: INSTALLATION OF ARM CYLINDER TUBES AND HOSES…256
LS-2: INSTALLATION OF BUCKET HOSES…257
LS-3: INSTALLATION OF BOTTOM DUMP HOSES AND TUBES…258
LS-4: INSTALLATION OF PILOT SOLENOID VALVE…259
LS-5: INSTALLATION OF BOTTOM PRIORITY VALVE…260
LS-6: INSTALLATION OF ARM PILOT DRAIN CIRCUIT…262
LS-7: INSTALLATION OF CONTROL PARTS…264
LS-8: INSTALLATION OF HORN SWITCH…266
LS-9: CHANGE OF ARM PILOT PIPING…267
LS-10: REMOVAL OF BOOM FOOT HANDRAIL…268
LS-11: INSTALLATION OF ARM CYLINDER BOTTOM PARTS…269
LS-12: INSTALLATION OF BOOM CYLINDER TO MACHINE BODY…270
LS-13: INSTALLATION OF BOOM CYLINDER PIPING…272
LS-14: INSTALLATION OF BOOM ASSEMBLY…274
LS-15: INSTALLATION OF BOOM CYLINDER HEAD PINS…275
LS-16: INSTALLATION OF GREASE FEED HOSE BETWEEN MACHINE BODY AND BOOM…276
LS-17: INSTALLATION OF BUCKET CYLINDER ASSEMBLY…277
LS-18: INSTALLATION OF ARM ASSEMBLY…278
LS-19: INSTALLATION OF ARM CYLINDER ASSEMBLY…279
LS-20: INSTALLATION OF HOSES BETWEEN BOOM AND ARM…280
LS-21: INSATLLATION OF BUCKET CYLINDER HOSES…281
LS-22: INSTALLATION OF GREASE FEED HOSE OF BUCKET CYLINDER…282
LS-23: INSTALLATION OF BUCKET ASSEMBLY…284
LS-24: INSTALLATION OF BOTTOM DUMP HOSE AND GREASE FEED HOSE BETWEEN ARM AND BUCKET…285
M. INSPECTION AND SERVICING PROCEDURES AFTER FINNISHING ALL THE ASSEMBLY AND INSTALLATION WORKS…286
M-1: 1. INSPECTING THE OIL LEVEL AND WATER LEVEL IN RESPECTIVE SECTIONS AND REFILLING THEM…287
M-1: 2. SELECTION OF THE APPROPRIATE FUEL TYPE AND LUBRICATING OIL TYPE FITTING TO THE ATMOSPHERIC TEMPERATURE RANGE…287
M-2: FLUSHING OF HYDRAULIC CIRCUIT…290
M-3: RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…291
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER…292
SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER…306
FIELD ASSEMBLY INSPECTION REPORT…323
SEAM022902 – Hydraulic Excavator PC1800-6 Operation & Maintenance Manual…375
COVER PAGE…375
1. FOREWORD…376
2. SAFETY INFORMATION…377
3. INTRODUCTION…378
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…379
5. CONTENTS…380
SAFETY…383
6. GENERAL PRECAUTIONS…384
7. PRECAUTIONS DURING OPERATION…391
7.1 BEFORE STARTING ENGINE…391
7.2 AFTER STARTING ENGINE…393
7.3 TRANSPORTATION…400
7.4 BATTERY…401
7.5 TOWING…403
7.6 LIFTING OPERATIONS…403
8. PRECAUTIONS FOR MAINTENANCE…404
8.1 BEFORE CARRYING OUT MAINTENANCE…404
8.2 DURING MAINTENANCE…408
9. POSITION FOR ATTACHING SAFETY LABELS…413
OPERATION…418
10. GENERAL VIEW…419
10.1 GENERAL VIEW OF MACHINE…419
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…420
11. EXPLANATION OF COMPONENTS…422
11.1 MACHINE MONITOR…422
11.2 SWITCHES…431
11.3 LAMP…438
11.4 CONTROL LEVERS, PEDALS…439
11.5 DOOR LOCK…442
11.6 POCKET…442
11.7 HANDLING AIR CONDITIONER…443
11.8 EMERGENCY ESCAPE HAMMER…446
11.9 EMERGENCY ESCAPE LADDER…447
11.10 CAP, COVER WITH LOCK…448
11.11 ASHTRAY…448
11.12 CAR RADIO…449
11.13 FUSE…454
11.14 CIRCUIT-BREAKER …455
11.15 CONTROLLERS…455
11.16 TOOL BOX…455
11.17 GREASE PUMP…456
11.18 HANDLING GREASE PUMP…456
11.19 HANDLING ACCUMULATOR…458
11.20 HEALTH MONITOR…460
12. OPERATION…471
12.1 CHECK BEFORE STARTING ENGINE…471
12.2 STARTING ENGINE…485
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…488
12.4 MOVING MACHINE OFF…494
12.5 STEERING MACHINE…497
12.6 STOPPING MACHINE…499
12.7 SWINGING…500
12.8 OPERATION OF WORK EQUIPMENT…501
12.9 HANDLING WORKING MODE…502
12.10 PROHIBITIONS FOR OPERATION…503
12.11 PRECAUTIONS FOR OPERATION…505
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…506
12.13 HOW TO ESCAPE FROM MUD…508
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…509
12.15 PHENOMENA THAT ARE NOT FAILURES…509
12.16 PARKING MACHINE…510
12.17 CHECK AFTER FINISHING WORK…511
12.18 STOPPING ENGINE…512
12.19 CHECK AFTER STOPPING ENGINE…515
12.20 LOCKING…515
13. TRANSPORTATION…516
13.1 PRECAUTIONS FOR TRANSPORTATION…516
13.2 PARTS FOR TRANSPORT…517
14. COLD WEATHER OPERATION…525
14.1 PRECAUTIONS FOR LOW TEMPERATURE…525
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…527
14.3 AFTER COLD WEATHER…527
15. LONG-TERM STORAGE…528
15.1 BEFORE STORAGE…528
15.2 DURING STORAGE…529
15.3 AFTER STORAGE…529
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…529
16. TROUBLESHOOTING…530
16.1 WHEN FUEL RUNS OUT…530
16.2 PHENOMENA THAT ARE NOT FAILURES…530
16.3 METHOD OF TOWING MACHINE…530
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…530
16.5 IF BATTERY IS DISCHARGED…531
16.6 OTHER TROUBLE…534
MAINTENANCE…539
17. GUIDES TO MAINTENANCE…540
18. OUTLINES OF SERVICE…544
18.1 OUTLINE OF OIL, FUEL, COOLANT…544
18.2 OUTLINE OF ELECTRICAL SYSTEM…547
18.3 OUTLINE OF HYDRAULIC SYSTEM…548
18.4 RELEASING PRESSURE…549
18.5 BLEEDING AIR FROM CIRCUIT…551
19. CONSUMABLE PARTS LIST…557
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…558
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…562
21.1 INTRODUCTION OF NECESSARY TOOLS…562
21.2 TORQUE LIST…563
22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS…564
23. MAINTENANCE SHEDULE CHART…566
23.1 MAINTENANCE SCHEDULE CHART…566
24. SERVICE PROCEDURE…566
24.1 INITIAL 100 HOURS SERVICE (ONLY AFTER THE FIRST 100 HOURS)…570
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER…570
24.2 INITIAL 250 HOURS SERVICE…570
REPLACE FUEL FILTER CARTRIDGE…570
CHANGE OIL IN SWING MACHINERY CASE…570
CHANGE OIL IN PTO CASE…570
CHANGE OIL IN FINAL DRIVE CASE…570
CHECK ENGINE VALVE CLEARANCE, ADJUST…570
24.3 WHEN REQUIRED…571
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…571
CLEAN INSIDE OF COOLING SYSTEM…573
CHECK AND TIGHTEN TRACK SHOE BOLTS…577
CHECK AND ADJUST TRACK TENSION…578
CHECK ELECTRICAL INTAKE AIR HEATER…580
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) (KOMATSU TOOTH)…581
ADJUST BUCKET CLEARANCE…582
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…583
CHECK AND ADJUST AIR CONDITIONER…584
CLEANING, REMOVING DIRT FROM LINE FILTER…585
REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER…586
24.4 CHECK BEFORE STARTING…587
CHECK COOLANT LEVEL, ADD WATER…587
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…587
CHECK FUEL LEVEL…587
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…587
CHECK FOR CLOGGING OF AIR CLEANER…587
CHECK ELECTRICAL WIRING…587
CHECK FUNCTION OF HORN…587
CHECK OIL LEVEL IN PTO CASE, ADD OIL…587
DRAIN WATER, SEDIMENT FROM FUEL TANK…587
CHECK CENTRAL MONITOR…587
24.5 EVERY 10 HOURS SERVICE…588
LUBRICATING…588
ARM-BUCKET COUPLING PIN (2 POINTS)…588
ARM-LINK COUPLING PIN (2 POINTS)…588
BUCKET CYLINDER ROD END PIN (2 POINTS)…589
LINK COUPLING PIN (4 POINTS)…589
BUCKET-LINK COUPLING PIN (2 POINTS)…589
BOOM CYLINDER FOOT PIN…590
BOOM FOOT PIN…590
BOOM CYLINDER ROD END PIN…590
ARM CYLINDER FOOT PIN…590
BUCKET CYLINDER FOOT PIN…590
BOOM-ARM COUPLING PIN…590
ARM-LINK COUPLING PIN…590
SWING CIRCLE…590
24.6 EVERY 100 HOURS SERVICE…591
CHECK OIL LEVEL IN SWING MACHINERY CASE…591
24.7 EVERY 250 HOURS SERVICE…592
LUBRICATING…592
FAN PULLEY ASSEMBLY (2 POINTS)…592
TENSION AND PULLEY ASSEMBLY (2 POINTS)…592
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…592
CHANGE DRAIN FILTER CARTRIDGE…593
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE (FRONT AND REAR ENGINE)…593
CHECK ALTERNATOR DRIVE BELT TENSION ADJUST…594
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITONER)…595
CHECK LEVEL OF BATTERY ELECTROLYTE…596
CHECK, CLEAN FUEL STRAINER…597
CHECK AND TIGHTEN TRACK SHOE BOLTS…597
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS…597
REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER…598
24.8 EVERY 500 HOURS SERVICE…599
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR COND…599
CLEAN PILOT FILTER STRAINER…600
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER…600
REPLACE FUEL FILTER CARTRIDGE…601
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…602
CHECK FAN BELT…602
CHANGE HYDRAULIC FILTER ELEMENT…603
24.9 EVERY 1000 HOURS SERVICE…604
CHANGE OIL IN SWING MACHINERY CASE…604
CHECK TURBOCHARGER CLAMPING JOINT…604
CHANGE OIL IN PTO CASE…605
REPLACE CORROSION RESISTOR CARTRIDGE…605
CHECK INSPECTION OF WELDING STRUCTURE (COLOR CHECK)…605
24.10 EVERY 2000 HOURS SERVICE…606
CHANGE OIL IN FINAL DRIVE CASE…606
CLEAN, CHECK TURBOCHARGER…606
CHECK TURBOCHARGER ROTOR PLAY…607
CHECK SWING PINION GREASE LEVEL, ADD GREASE…607
CLEAN ENGINE BREATHER…607
CLEAN HYDRAULIC TANK STRAINER…608
CHECK ALTERNATOR, STARTING MOTOR…608
CHECK ENGINE VALVE CLEARANCE, ADJUST…608
24.11 EVERY 4000 HOURS SERVICE…609
CHECK WATER PUMP…609
CHECK VIBRATION DAMPER…609
CHECK FAN PULLEY AND TENSION PULLEY…609
CHECK AIR COMPRESSOR, ADJUST…609
24.12 EVERY 5000 HOURS SERVICE…610
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…610
SPECIFICATIONS…611
25. SPECIFICATIONS…612
OPTIONS, ATTACHMENTS…614
26. GENERAL PRECAUTIONS…615
26.1 PRECAUTIONS RELATED TO SAFETY…615
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…616
27. INTRODUCTION OF ATTACHMENTS…617
27.1 GUARD…617
28. AUTO-GREASER SYSTEM…618
SEAM022908T – Hydraulic Excavator GALEO PC1800-6 Operation & Maintenance Manual…623
COVER…623
FOREWORD…624
FOREWORD…625
SAFETY INFORMATION…628
INTRODUCTION…630
DIRECTIONS OF MACHINE…630
PRODUCT INFORMATION…631
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…631
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…631
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…632
SERVICE METER LOCATION…632
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…633
CONTENTS…634
SAFETY…638
SAFETY INFORMATION…639
POSITION FOR ATTACHING SAFETY LABELS…641
POSITION FOR ATTACHING SAFETY LABELS…642
SAFETY LABELS…643
SAFETY INFORMATION…647
SAFETY RULES…647
IF ABNORMALITIES ARE FOUND…647
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…647
FIRE EXTINGUISHER AND FIRST AID KIT…647
SAFETY EQUIPMENT…648
KEEP MACHINE CLEAN…648
KEEP OPERATOR'S COMPARTMENT CLEAN…648
LEAVING OPERATOR'S SEAT WITH LOCK…648
HANDRAILS AND STEPS…649
MOUNTING AND DISMOUNTING…650
NO PERSONS ON ATTACHMENTS…650
BURN PREVENTION…650
FIRE PREVENTION AND EXPLOSION PREVENTION…651
ACTION IF FIRE OCCURS…652
WINDSHIELD WASHER FLUID…652
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…652
ATTACHMENT INSTALLATION…652
ATTACHMENT COMBINATIONS…653
CAB WIDOW GLASSES…653
UNAUTHORIZED MODIFICATIONS…653
SAFETY AT JOBSITE…653
WORKING ON LOOSE GROUND…654
DISTANCE TO HIGH VOLTAGE CABLES…654
ENSURE GOOD VISIBILITY…654
VENTILATION FOR ENCLOSED AREA…655
SIGNALMAN’S SIGNAL AND SIGNS…655
EMERGENCY EXIT FROM OPERATOR’S CAB…655
ASBESTOS DUST HAZARD PREVENTION…655
SAFETY MACHINE OPERATION…656
STARTING ENGINE…656
CHECKS BEFORE STARTING ENGINE…656
SAFETY RULES FOR STARTING ENGINE…657
STARTING ENGINE IN COLD WEATHER…657
OPERATION…658
CHECKS AFTER STARTING ENGINE…658
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…658
SAFETY RULES FOR TRAVELING…659
TRAVELING ON SLOPES…660
OPERATIONS ON SLOPES…661
PROHIBITED OPERATIONS…661
OPERATIONS ON SNOW…663
PARKING MACHINE…663
TRANSPORTATION…664
SHIPPING THE MACHINE…664
BATTERY…665
BATTERY HAZARD PREVENTION…665
STARTING ENGINE WITH BOOSTER CABLES…666
TOWING…667
SAFETY RULES FOR TOWING…667
LIFTING OBJECTS WITH BUCKET…668
SAFETY RULES FOR LIFTING OBJECTS…668
SAFETY MAINTENANCE INFORMATION…669
WARNING TAG…669
KEEP WORK PLACE CLEAN AND TIDY…669
APPOINT LEADER WHEN WORKING WITH OTHERS…669
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…670
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…671
PROPER TOOLS…671
ACCUMULATOR…672
PERSONNEL…672
ATTACHMENTS…672
WORK UNDER THE MACHINE…672
NOISE…673
WHEN USING HAMMER…673
WELDING WORKS…673
REMOVING BATTERY TERMINALS…673
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…674
DO NOT DISASSEMBLE RECOIL SPRINGS…674
SAFETY RULES FOR HIGH-PRESSURE OIL…674
PRECAUTION FOR HIGH FUEL PRESSURE…675
SAFETY HANDLING HIGH-PRESSURE HOSES…675
PRECAUTION FOR HIGH VOLTAGE…675
WASTE MATERIALS…675
AIR CONDITIONER MAINTENANCE…676
COMPRESSED AIR…676
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…676
OPERATION…678
GENERAL VIEW…679
GENERAL VIEW OF MACHINE…679
GENERAL VIEW OF CONTROLS AND GAUGES…680
EXPLANATION OF COMPONENTS…682
MACHINE MONITOR…682
BASIC CHECK ITEMS…684
CAUTION ITEMS…686
EMERGENCY STOP ITEMS…688
METER DISPLAY PORTION…690
PILOT DISPLAY…690
GAUGES AND METER…691
MONITOR SWITCHES…694
CGC MONITOR…696
CGC MONITOR…696
CHANGES OF SCREEN AND CONTENT OF DISPLAY ON CGC MONITOR…697
EXPLANATION OF SCREENS…699
SWITCHES…734
STARTER SELECTOR SWITCH…735
STARTING SWITCH…735
PREHEATING SWITCH…735
FUEL CONTROL DIAL (FRONT ENGINE)…736
FUEL CONTROL DIAL (REAR ENGINE)…736
CIGARETTE LIGHTER…736
LAMP SWITCH…736
STEP LIGHT SWITCH…737
SWING LOCK SWITCH…737
ROOM LAMP SWITCH…738
MACHINE PUSH-UP SWITCH…738
FOG LAMP SWITCH…738
BOOM SHOCKLESS CONTROL SWITCH…739
ROTATING LAMP SWITCH…739
ALARM BUZZER STOP SWITCH…739
WINDSHIELD WIPER SWITCH…740
GREASING SWITCH…740
HORN SWITCH…740
TRUCK COUNTER SWITCH…741
ROOM LAMP SWITCH…742
ROOM LAMP SWITCH…742
ROOM LAMP SWITCH…743
PUMP DRIVE EMERGENCY SWITCH…743
SWING HOLDING BRAKE REPLEASE SWITCH…743
SPARE SOCKET…744
ENGINE EMERGENCY STOP SWITCH…744
LAMP…745
ENGINE EMERGENCY STOP LAMP…746
AUTO GREASING CAUTION LAMP…747
LADDER WARNING LAMP…747
TRUCK COUNTER LAMP…748
CONTROL LEVERS, PEDALS…749
SAFETY LOCK LEVER…750
TRAVEL LEVERS…751
WORK EQUIPMENT CONTROL LEVER…752
DOOR LOCK…753
POCKET…753
EMERGENCY ESCAPE HAMMER…753
EMERGENCY ESCAPE LADDER…754
FIRE EXTINGUISHER…754
CAP, COVER WITH LOCK…755
METHOD OF OPENING AND CLOSING CAP WITH LOCK…755
METHOD OF OPENING AND CLOSING COVER WITH LOCK…755
ASHTRAY…755
HANDLING AIR CONDITIONER…756
GENERAL LOCATIONS OF CONTROL PANEL…756
USE AIR CONDITIONER WITH CARE…763
CAR RADIO…764
EXPLANATION OF COMPONENTS…764
CONTROLS OF RADIO…767
AUXILIARY ELECTRIC POWER…769
FUSE…769
CIRCUIT BREAKER…770
CIRCUIT BREAKER (20A)…770
CIRCUIT-BREAKER (40A)…770
FUSE, CIRCUIT BREAKER CAPACITY AND NAME OF CIRCUIT…771
FUSE…772
CONTROLLER (COMPUTER)…773
TOOLBOX…774
HANDLING GREASE PUMP AND GREASE GUN…774
HANDLING ACCUMULATOR…778
METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR…778
ORBCOMM CONTROLLER…779
MACHINE OPERATIONS AND CONTROLS…780
BEFORE STARTING ENGINE…780
WALK-AROUND CHECKS…780
CHECKS BEFORE STARTING…781
ADJUST BEFORE OPERATION…793
SEAT BELT…796
OPERATIONS BEFORE STARTING ENGINE…798
STARTING ENGINE…801
NORMAL STARTING…801
STARTING ENGINE IN COLD WEATHER…803
AFTER STARTING ENGINE…806
BREAKING-IN THE NEW MACHINE…806
WARMING-UP OPERATION…807
IN COLD AREAS…810
STOPPING THE ENGINE…813
NORMAL STOPPING…813
STOPPING IN EMERGENCIES…813
CHECK AFTER SHUT OFF ENGINE…816
MACHINE OPERATION…817
PREPARATIONS FOR MOVING THE MACHINE OFF…817
MOVING MACHINE FORWARD…818
MOVING MACHINE BACKWARD…819
STOPPING MACHINE…820
STEERING THE MACHINE…821
STEERING…821
SWINGING…823
WORK EQUIPMENT CONTROLS AND OPERATIONS…824
HANDLING WORKING MODE…825
WORKING MODE…825
PROHIBITED OPERATIONS…826
OPERATIONS USING SWING FORCE…826
OPERATIONS USING TRAVEL FORCE…826
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS…826
OPERATIONS USING BUCKET DROPPING FORCE…827
OPERATIONS USING MACHINE DROPPING FORCE…827
DIGGING HARD ROCKY GROUND…827
GENERAL OPERATION INFORMATION…828
TRAVELING…828
PERMISSIBLE WATER DEPTH…828
TRAVELING ON SLOPES…829
TRAVELING DOWNHILL…830
ENGINE STOPPED ON SLOPE…830
PRECAUTIONS ON SLOPES…830
ESCAPE FROM MUD…831
STUCK ONE SIDE OF TRACK…831
STUCK BOTH SIDES OF TRACKS…831
RECOMMENDED APPLICATIONS…832
BACKHOE WORK…832
LOADING WORK…832
REPLACEMENT AND INVERSION OF BUCKET…833
REPLACEMENT…833
PARKING MACHINE…835
CHECK AFTER FINISHING WORK…836
LOCKING…837
TRANSPORTATION…838
PRECAUTIONS FOR TRANSPORTATION…838
REMOVAL AND INSTALLATION OF MIRRORS…838
LIFTING MACHINE…839
PARTS FOR TRANSPORT…839
COLD WEATHER OPERATION…840
COLD WEATHER OPERATION INFORMATION…840
FUEL AND LUBRICANTS…840
COOLING SYSTEM COOLANT…840
BATTERY…841
AFTER DAILY WORK COMPLETION…842
AFTER COLD WEATHER SEASON…842
LONG TERM STORAGE…843
BEFORE STORAGE…843
DURING STORAGE…843
AFTER STORAGE…844
STARTING MACHINE AFTER LONG-TERM STORAGE…844
TROUBLESHOOTING…845
AFTER RUNNING OUT OF FUEL…845
PHENOMENA THAT ARE NOT FAILURES…846
TOWING THE MACHINE…847
PRECAUTIONS ON PARTICULAR JOBSITES…847
DISCHARGED BATTERY…848
REMOVAL AND INSTALLATION OF BATTERY…849
BATTERY CHARGES…849
STARTING ENGINE WITH BOOSTER CABLES…850
OTHER TROUBLE…852
ELECTRICAL SYSTEM…852
CHASSIS…853
ENGINE…854
ELECTRONIC CONTROL SYSTEM…856
MAINTENANCE…858
MAINTENANCE INFORMATION…859
SERVICE METER READING…859
KOMATSU GENUINE REPLACEMENT PARTS…859
KOMATSU GENUINE LUBRICANTS…859
WINDSHIELD WASHER FLUID…859
FRESH AND CLEAN LUBRICANTS…859
CHECK DRAINED OIL AND USED FILTER…859
FUEL STRAINER…859
WELDING INSTRUCTIONS…859
DO NOT DROP THINGS INSIDE MACHINE…860
DUSTY JOBSITE…860
AVOID MIXING LUBRICANTS…860
LOCKING THE INSPECTION COVERS…860
HYDRAULIC SYSTEM – AIR BLEEDING…860
HYDRAULIC HOSE INSTALLATION…860
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS…861
LUBRICANTS, COOLANT AND FILTERS…862
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…862
OIL…862
FUEL…862
COOLING SYSTEM COOLANT…863
GREASE…863
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…863
OIL AND FUEL STORAGE…864
FILTERS…865
ELECTRIC SYSTEM MAINTENANCE…865
WEAR PARTS LIST…866
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…867
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…867
TIGHTENING TORQUE SPECIFICATIONS…871
TIGHTENING TORQUE LIST…871
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…872
SAFETY CRITICAL PARTS…873
MAINTENANCE SCHEDULE…875
MAINTENANCE SCHEDULE CHART…875
Initial 100 Hours Maintenance (Only after the first 250 hours)…875
Initial 250 Hours Maintenance (Only after the first 250 hours)…875
When Required…875
Checks Before Starting…875
Every 10 Hours Maintenance…875
Every 100 Hours Maintenance…876
Every 250 Hours Maintenance…876
Every 500 Hours Maintenance…876
Every 1000 Hours Maintenance…876
Every 2000 Hours Maintenance…877
Every 4000 Hours Maintenance…877
Every 5000 Hours Maintenance…877
Every 8000 Hours Maintenance…877
MAINTENANCE PROCEDURE…878
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…878
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…878
WHEN REQUIRED…879
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…879
CLEAN INSIDE OF COOLING SYSTEM…882
CHECK AND TIGHTEN TRACK SHOE BOLTS…886
CHECK AND ADJUST TRACK TENSION…887
CHECK ELECTRICAL INTAKE AIR HEATER…890
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…891
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…894
ADJUST BUCKET CLEARANCE…895
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…896
CHECK AND ADJUST AIR CONDITIONER…897
CLEANING, REMOVING DIRT FROM LINE FILTER…898
REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER…899
GREASE LADDER…900
INSPECT SEALANT AROUND ENGINE COOLING SYSTEM…901
CHECK FOR LOOSE AFTERCOOLER HOSE CLAMPS…902
PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT…902
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…910
CHECK BEFORE STARTING…912
EVERY 10 HOURS MAINTENANCE…913
LUBRICATING…913
EVERY 100 HOURS MAINTENANCE…917
CHECK OIL LEVEL IN SWING MACHINERY CASE…917
EVERY 250 HOURS MAINTENANCE…918
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…918
CHECK LEVEL OF BATTERY ELECTROLYTE…919
REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER…921
CHECK, WASH FUEL STRAINER…922
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS…923
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…924
CHECK ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…926
EVERY 500 HOURS MAINTENANCE…928
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…928
REPLACE FUEL FILTER CARTRIDGE…931
CLEAN PILOT FILTER STRAINER…933
CLEAN HYDRAULIC FILTER STRAINER FOR AUTO GREASING DRIVE…933
CHANGE HYDRAULIC FILTER ELEMENT…934
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTER COOLER FINS…935
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM…937
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER…939
CHECK, REPLACE, ADJUST FAN BELT…940
CHECK, REPLACE HYDRAULIC PUMP DRAIN FILTER CARTRIDGE…941
REPLACING SWING MOTOR DRAIN FILTER CARTRIDGE…942
REPLACING TRAVEL MOTOR DRAIN FILTER CARTRIDGE…943
EVERY 1000 HOURS MAINTENANCE…944
CHANGE OIL IN SWING MACHINERY CASE…944
CHANGE OIL IN PTO CASE…946
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…946
REPLACE CORROSION RESISTOR CARTRIDGE…947
INSPECTION OF WELDED STRUCTURE AFTER INITIAL 4000 HOURS SERVICE…947
GREASING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY…947
EVERY 2000 HOURS MAINTENANCE…948
CHANGE OIL IN FINAL DRIVE CASE…948
CHANGE OIL IN HYDRAULIC TANK, WASH STRAINER…949
CHECK SWING PINION GREASE LEVEL, ADD GREASE…952
CLEAN ENGINE BREATHER…952
CLEAN, CHECK TURBOCHARGER…952
CHECK ALTERNATOR AND STARTING MOTOR…952
CHECK ENGINE VALVE CLEARANCES, ADJUST…953
CHECK INJECTOR…953
EVERY 4000 HOURS MAINTENENCE…954
CHECK WATER PUMP…954
CHECK VIBRATION DAMPER…954
CHECK FAN PULLEY AND TENSION PULLEY…954
REPLACE INJECTOR NOZZLE ASSEMBLY…954
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…955
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…956
CHECK, ADJUST AIR COMPRESSOR…956
CHECK WELDED STRUCTURE…957
EVERY 5000 HOURS MAINTENANCE…960
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…960
EVERY 8000 HOURS MAINTENANCE…963
REPLACE HIGH-PRESSURE PIPING CLAMP…963
REPLACE FUEL SPRAY PREVENTION CAP…963
SPECIFICATIONS…964
SPECIFICATIONS…965
ATTACHMENTS AND OPTIONS…968
GENERAL PRECAUTIONS…969
PRECAUTIONS RELATED TO SAFETY…969
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…971
ATTACHMENT GUIDE…972
COMBINATIONS OF WORK EQUIPMENT…972
PROTECTIVE GUARD…973
AUTO GREASING SYSTEM…974
CONTROL DEVICES…975
LOADING SHOVEL…978
GENERAL VIEW…979
GENERAL VIEW OF MACHINE…979
GENERAL VIEW OF CONTROLS AND GAUGES…980
EXPLANATION OF COMPONENTS…981
SWITCHES…981
AUTOMATIC LEVEL CROWDING/BUCKET ANGLE COMPENSATION SWITCH…981
AUTOMATIC LEVEL CROWDING SWITCH…981
BUCKET ANGLE COMPENSATION SWITCH…981
BOTTOM DUMP SWITCH…982
HORN SWITCH…982
CONTROL BOX…982
OPERATIONS…983
OPERATION OF WORK EQUIPMENT…983
PRECAUTIONS DURING OPERATION…985
EXCAVATOR WORK…989
PRECAUTIONS WHEN DISASSEMBLING MACHINE…990
RELEASING PRESSURE…990
RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT…990
RELEASING PRESSURE IN ACCUMULATOR CIRCUIT…990
TROUBLESHOOTING…991
WORK EQUIPMENT AUTOMATIC CONTROL CONTROLLER…991
TRANSPORTATION…992
MACHINE CONFIGURATION FOR TRANSPORT…992
MAINTENANCE SCHEDULE…993
EVERY 10 HOURS MAINTENANCE…993
PREPARATIONS BEFORE LUBRICATION…993
LUBRICATION…996
SPECIFICATION…1002
COMBINATION OF WORK EQUIPMENT…1004
COMBINATION OF WORK EQUIPMENT…1004
INDEX…1006
SEAW002201 – Hydraulic Excavator PC1800-6 Field Assembly Manual…1010
COVER…1010
CONTENTS…1011
GENERAL…1014
1. SPECIFICATIONS…1014
2. POINTS REGARDING LOCAL ASSEMBLY …1015
3. BOLT TIGHTENING TORQUE AND BOLT TIGHTENING…1016
4. SEPARATE UNITS…1019
TRANSPORTATION STYLE OF LOADING SHOVEL (WORK EQUIPMENT ONLY)…1032
5. LIST OF PARTS SENT INDIVIDUALLY…1033
6. ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE…1058
7. KIT LAYOUT DIAGRAM…1059
8. TOOLS AND EQUIPMENT TO BE USED…1060
A. ASSEMBLY OF CHASSIS…1066
A-1. ASSEMBLY OF TRUCK FRAME AND AXLE…1067
A-2. TRAVEL MOTOR PIPING…1070
A-3. IDLER CRUSHION CYLINDER PIPING…1072
A-4. INSTALLATION OF TRAVEL MOTOR GUARD AND TRACK FRAME UNDER COVER…1074
A-5. FILING SWING CIRCUIT WITH GREASE…1075
A-6. ASSEMBLY OF TRAVEL …1076
A-7. SWIVEL TRAVEL PIPING…1078
A-8. SWING CIRCLE GREASE TUBE PIPNG…1080
A-9. INSTALLNG OF LEFT AND RIGHT LADDERS…1085
A-10. INSTALLATION OF LEFT CATWALK…1086
A-11. INSTALLATION OF RIGHT CATWALK…1087
A-12. INSTALLATION OF CATWALK, HANDRAIL BESIDE OPERATOR'S CAB…1088
A-13…1011
A-14. INSTALLATION OF HANDRAIL FOR GETTING IN AND OUT OF OPERATOR'S CAB…1089
A-15…1011
A-16. INSTALLATION OF HANDRAIL AT REAR OF OPERATOR'S CAB…1091
A-17…1011
A-18. OPERATOR'S CAB FRONT FRAME, HANDRAIL…1092
A-19. LEFT DECK HANDRAIL…1093
A-20. RIGHT DECK HANDRAIL…1094
A-21. INSTALLATION OF LADDER ON TOP OF HYDRAULIC TANK…1095
A-22. INSTALLATION OF COUNTERWEIGHT…1096
A-23. INSTALLATION OF COUNTERWEIGHT LADDER (LEFT AND RIGHT)…1097
A-24. INSTALLATION OF HANDRAIL ON TOP OF FUEL TANK, COUNTERWEIGHT…1098
A-25. INSTALLATION OF FUEL TANK VIBRATION STOPPER BRACKET…1099
A-26. INSTALLATION OF GREASE REEL, HOSE, BRACKET…1100
A-27. INSTALLATION OF LEFT CAB BASE ASSEMBLY…1101
A-28. INSTALLATION OF OPERATOR'S CAB ASSEMBLY …1106
A-29. INSTALLATION OF WIPER MOTOR COVER INSIDER OPERATR'S CAB…1107
A-30. HANDRAIL ON BOOM FOOT AND LEFT PUMP…1108
A-31. HANDRAIL ABOVE THE RH DOOR AND ABOVE THE HYDRAULIC OIL TANK…1109
A-32. EMERGENCY STOP SWITCH, FUEL CUTTING…1110
A-33A. HANDRAIL ABOVE THE RADIATOR (OPTIONAL)…1112
A-33B. CONNECTION OF HYDRAULIC PIPING OPERATOR'S CAB ASSEMBLY …1113
A-34. CONNECTION OF WINDOW WASHER HOSE OF OPERATOR/S CAB ASSEMBLY …1116
A-35. CONNECTION OF AIR PIPING OF LEFT CAB ASSEMBLY…1117
A-36. CONNECTION OF GREASE PIPING OPERATOR'S CAB ASSEMBLY…1119
A-37. WIRE HARNESS (WASHER TANK, WORKING LAMP AND OPERATOR'S CAB BASE LIGHT)…1121
A-38. AIR CONDITIONER HOSE, HARNESS AND PIPING…1122
A-39. INSTALLATION OF COUNTERWEIGHT LAMP (OPERATION)…1127
A-40. START ENGINE…1128
A-41. FINAL TIGHENING OF SWING CIRCLE OF SWING CIRCLE MOUNTING BOLTS…1134
ASSEMBLY OF POWER-ASSISTED LADDER…1135
L-1 POWER-ASSISTED LADDER…1138
C. PC1800 INSTALLATION OF BACKHOE WORK EQUIPMENT…1142
C-1. INSTALLATION OF BOOM CYLINDER TO CHASSIS…1143
C-2. INSTALLATION OF BOOM CYLINDER PIPING…1145
C-3. BLEEDING AIR FROM BOOM CYLINDER…1146
C-4. BOOM SUB-ASSEMBLY…1147
C-5. INSTALLATION OF BOOM ASSEMBLY…1151
C-6. INSTALLATION OF BOOM CYLINDER TOP PIN…1154
C-7. CONNECTION OF ARM ASSEMBLY TO BOOM…1156
C-8. INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS…1159
C-9. INSTALLATION OF ARM CYLINDER PIN…1161
C-10. BLEEDING AIR FROM ARM CYLINDER…1163
C-11. INSTALLATION OF HYDRAULIC BETWEEN BOOM AND ARM…1164
C-12. CONNECTION OF GREASE PIPING FOR BOOM…1165
C-13. CONNECTION OF WIRING BETWEEN BOOM AND CHASSIS…1168
C-14. INSTALLATION OF HOSES BETWEEN BOOM AND SHASSIS…1169
C-15…1011
C-16. CONNECTION OF BUCKET ASSEMBLY TO ARM…1171
C-17. INSTALLATION OF BUCKET LINK…1174
C-18. BLEEDING AIR FROM BUCKET CYCLINDER…1176
ASSEMBLY MANUAL FOR LOADING SHOVEL WORK EQUIPMENT…1176
LS-1. INSTALLATION OF ARM CYLINDER TUBES AND HOSES…1178
LS-2. INSTALLATION OF BUCKET HOSES…1179
LS-3. INSTALLATION OF BOTTOM DUMP HOSES AND TUBES…1180
LS-4. INSTALLATION OF PILOT SOLENOID VALVE…1181
LS-5. INSTALLATION OF BOTTOM PRIORITY VALVE…1182
LS-6. INSTALLATION OF ARM PILOT DRAIN CIRCUIT…1184
LS-7. INSTALLATION OF CONTROL PARTS…1186
LS-8. INSTALLATION OF HORN SWITCH…1188
LS-9. CHANGE OF ARM PILOT PIPING…1189
LS-10. REMOVAL OF BOOM FOOT HANDRAIL…1190
LS-11. INSTALLATION OF ARM CYLINDER BOTTOM PARTS…1191
LS-12. INSTALLATION OF ARM CYLINDER BOTTOM PARTS…1192
LS-13. INSTALLATION OF BOOM CYLINDER PIPING…1194
LS-14. INSTALLATION OF BOOM ASSEMBLY…1196
LS-15. INSTALLATION OF BOOM CYLINDER HEAD PINS…1197
LS-16. INSTALLATION OF GREASE FEED HOSE BETWEEN MACHINE BODY AND BOOM…1198
LS-17. INSTALLATION OF BUCKET CYLINDER ASSEMBLY…1199
LS-18. INSTALLATION OF ARM ASSEMBLY…1200
LS-19. INSTALLATION OF ARM CYLINDER ASSEMBLY…1201
LS-20. INSTALLATION OF HOSES BETWEEN BOOM AND ARM…1202
LS-21. INSTALLATION OF BUCKET CYLINDER HOSES…1203
LS-22. INSTALLATION OF GREASE FEED HOSE OF BUCKET CYLINDER…1204
LS-23. INSTALLATION OF BUCKET ASSEMBLY…1206
LS-24. INSTALLATION OF BOTTOM DUMP HOSE AND GREASE FEED HOSE BETWEEN ARM AND BUCKET…1207
M. INSPECTION AND SERVICING PROCEDURES AFTER FINISHING ALL THE ASSEMBLY AND INSTALLATION WORKS…1208
M-1. INSPECTING THE OIL LEVEL AND WATER LEVEL IN RESPECTIVE SECTIONS AND REFILLING THEM…1209
SELECTION OF THE APPROPRIATE FUEL TYPE FITTING TO THE ATMOSPHERIC TEMPERATURE RANGE…1209
M-2. FLUSHING OF HYDRAULIC CIRCUIT…1211
M-3. RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…1212
SEBM019105 – Hydraulic Excavator PC1800-6 Shop Manual…1239
COVER PAGE…1239
CONTENTS…1240
00 FOREWARD…1246
FOREWARD…1248
HOW TO READ THE SHOP MANUAL…1249
HOISTING INSTRUCTIONS…1250
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…1251
COATING MATERIALS…1253
STANDARD TIGHTENING TORQUE…1255
ELECTRIC WIRE CODE…1258
CONVERSION TABLE…1259
UNITS…1265
01 GENERAL…1266
SPECIFICATION DRAWINGS…1479
SPECIFICATIONS…1480
WEIGHT TABLE…1482
FUEL, COOLANT AND LUBRICANTS…1484
10 STRUCTURE AND FUNCTION…1486
PTO…1487
PTO LUBRICATION SYSTEM…1488
POWER TRAIN…1489
SWING MACHINERY…1491
FINAL DRIVE…1492
HIC SYSTEM…1493
AIR SYSTEM…1495
AIR GOVERNOR…1496
AIR TANK…1496
AUTO-DRAIN VALVE…1496
SAFETY VALVE…1497
SOLENOID VALVE (FOR LUBRICATION, HORN)…1497
GREASE PUMP…1498
GREASING SYSTEM…1501
HYDRAULIC COMPONENT LAYOUT…1508
HYDRAULIC TANK…1511
HYDRAULIC PUMP…1512
SWING PUMP…1539
LINE OIL FILTER…1544
PILOT OIL FILTER…1544
RETURN OIL FILTER…1545
DRAIN OIL FILTER…1546
CONTROL AND PTO LUBRICATING PUMP…1547
ELECTRONIC OLSS…1548
CONTROL VALVE…1550
SWING CONTROL VALVE…1559
SWING MOTOR…1561
CENTER SWIVEL JOINT…1563
TRAVEL MOTOR…1564
TRAVEL BRAKE VALVE…1566
PILOT RELIEF VALVE…1567
SAFETY LOCK VALVE…1568
ACCUMULATOR…1570
PPC VALVE…1571
SOLENOID VALVE…1575
ENGINE CONTROL…1577
MACHINE CONTROL SYSTEM…1584
ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM…1607
MONITOR SYSTEM…1613
20 TESTING AND ADJUSTING…1651
STANDARD VALUE TABLE FOR ENGINE…1652
STANDARD VALUE TABLE FOR CHASSIS…1653
STANDARD VALUE FOR ELECTRICAL PARTS…1661
TESTING AND ADJUSTING…1669
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…1670
MEASURING ENGINE SPEED…1671
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)…1672
MEASURING EXHAUST TEMPERATURE…1673
MEASURING EXHAUST COLOR…1674
ADJUSTING VALVE CLEARANCE…1675
MEASURING COMPRESSION PRESSURE…1676
MEASURING BLOW-BY PRESSURE…1677
TESTING AND ADJUSTING FUEL INJECTION TIMING…1678
MEASURING ENGINE OIL PRESSURE…1679
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…1680
TESTING AND ADJUSTING FAN BELT TENSION…1680
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…1681
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE…1682
ADJUSTING ENGINE SPEED SENSOR…1683
TESTING AND ADJUSTING MAIN RELIEF VALVE…1684
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…1689
MEASURING SERVO PISTON STROKE…1693
TESTING SOLENOID VALVE OUTPUT PRESSURE…1694
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…1695
TESTING TRAVEL DEVIATION…1696
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…1699
MEASURING OIL LEAKAGE…1700
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR…1702
TESTING OIL LEAK FROM SWIVEL JOINT…1703
TESTING CLEARANCE OF SWING CIRCLE BEARING…1705
AIR BLEEDING…1706
CHARGING ACCUMULATOR WITH GAS…1711
TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK…1713
ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)…1714
TROUBLESHOOTING…1720
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1721
SEQUENCE OF EVENTS IN TROUBLESHOOTING…1722
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…1723
CHECKS BEFORE TROUBLESHOOTING…1731
CONNECTOR TYPES AND MOUNTING LOCATIONS…1732
CONNECTOR ARRANGEMENT DIAGRAM…1737
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…1743
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM…1754
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL…1755
TROUBLE HISTORY DISPLAY ON MACHINE CONTROL MONITOR…1768
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE…1775
METHOD OF USING JUDGEMENT TABLE…1780
METHOD OF USING TROUBLESHOOTING CHARTS…1782
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)…1784
CONTROLLER RESPONSES AND SYMPTOMS ON MACHINE BODY IN FAILURE OCCURRENCES…1785
N-1 [CONCURRENT OCCURENCES OF E116, E117, AND E118] COMMUNICATIONS FAILURE ON MONITOR PANEL…1787
N-2 [CONCURRENT OCCURENCES OF E117 AND E218] COMMUNICATIONS FAILURE ON REAR ENGINE GP CONTROLLER…1789
N-3 [CONCURRENT OCCURRENCES OF E118 AND E418] COMMUNICATIONS FAILURE ON FRONT ENGINE GP CONTROLLER…1791
N-4 [CONCURRENT OCCURENCES OF E116, E218 AND E418] COMMUNICATIONS FAILURE ON VHMS CONTROLLER…1793
N-5 [E828] NO DISPLAY [OF E116, E117, E118, E218, OR E418] ON MONITOR PANEL, WITH CODE DISPLAYED ONLY ON CGC…1795
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM (GOVERNOR CONTROL SYSTEM) (E MODE)…1796
JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS…1797
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLEHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM…1801
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS…1802
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM)…1810
E-1 POWER SYSTEM ABNORMALITY OF FRONT ENGINE THROTTLE AND PUMP CONTROLLER…1812
E-2 [E308] ABNORMALITY IN FRONT ENGINE CONTROL DIAL INPUT VALUE IS DISPLAYED…1813
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED…1814
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN FRONT ENGINE GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED …1815
E-5 [E306] ABNORMALITY IN FRONT ENGINE FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED…1816
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN FRONT ENGINE BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED…1817
E-7 [E316] ABNORMALITY (STEP-OUT) IN FRONT ENGINE MOTOR IS DISPLAYED…1818
E-8 THE FRONT ENGINE DOES NOT START…1819
E-9 FRONT ENGINE IRREGULAR ROTATION…1822
a) IRREGULAR IDLING SPEED…1822
b) HUNTING…1824
E-10 FRONT ENGINE INSUFFICIENT OUTPUT…1826
E-11 THE FRONT ENGINE DOES NOT STOP…1828
E-12 DEFECTIVE OPERATION OF FRONT ENGINE BATTERY RELAY SYSTEM…1830
E-13 POWER SYSTEM ABNORMALITY OF REAR ENGINE THROTTLE AND PUMP CONTROLLER…1832
E-14 [E508] ABNORMALITY IN REAR ENGINE FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED…1833
E-15 [E517] ABNORMALITY (DISCONNECTION) IN REAR ENGINE MOTOR DRIVE SYSTEM IS DISPLAYED…1834
E-16 [E518] ABNORMALITY (SHORT CIRCUIT) IN REAR ENGINE MOTOR DRIVE SYSTEM IS DISPLAYED…1835
E-17 [E506] ABNORMALITY IN REAR ENGINE FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED…1836
E-18 [E515] ABNORMALITY (SHORT CIRCUIT) IN REAR ENGINE BATTERY RELAY OUTPUT SYTEM IS DISPLAYED…1837
E-19 [E516] ABNORMALITY (STEP-OUT) IN FRONT ENGINE MOTOR IS DISPLAYED…1838
E-20 THE REAR ENGINE DOES NOT START…1839
E-21 REAR ENGINE IRREGULAR ROTATION…1842
a) IRREGULAR IDLING SPEED…1842
b) HUNTING…1844
E-22 REAR ENGINE INSUFFICIENT OUTPUT…1846
E-23 THE REAR ENGINE DOES NOT STOP…1848
E-24 DEFECTIVE OPERATION OF REAR ENGINE BATTERY RELAY SYSTEM…1850
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM (PUMP CONTROL SYSTEM) (C MODE)…1852
JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP CONTROLLER AND HYDRAULIC RELATED PARTS…1853
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…1856
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…1857
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE…1863
C-1 DISPLAY OF ABNORMALITY OF FRONT ENGINE CONTROLLER POWER SUPPLY SYSTEM…1865
C-2 DISPLAY OF [E232] SHORT CIRCUIT OF FRONT PUMP TVC SOLENOID SYSTEM…1866
C-3 DISPLAY OF [E233] DISCONNECTION OF FRONT PUMP TVC SOLENOID SYSTEM…1868
C-4 DISPLAY OF [E203] SHORT CIRCUIT OF SWING HOLD BRAKE SOLENOID SYSTEM…1870
C-5 DISPLAY OF [E213] DISCONNECTION OF SWING HOLD BRAKE SOLENOID SYSTEM…1872
C-6 DISPLAY OF [E201] SHORT CIRCUIT OF CO CANCEL SOLENOID SYSTEM…1874
C-7 DISPLAY OF [E211] DISCONNECTION OF CO CANCEL SOLENOID SYSTEM…1875
C-8 DISPLAY OF [E202] SHORT CIRCUIT OF TRAVEL STRAIGHT SOLENOID SYSTEM…1876
C-9 DISPLAY OF [E212] DISCONNECTION OF TRAVEL STRAIGHT SOLENOID SYSTEM…1877
C-10 DISPLAY OF [E204] SHORT CIRCUIT OF 2-STAGE RELIEF SOLENOID SYSTEM…1878
C-11 DISPLAY OF [E214] DISCONNECTION OF 2-STAGE RELIEF SOLENOID SYSTEM…1879
C-12 DISPLAY OF [E206] SHORT CIRCUIT OF TRAVEL ALARM OUTPUT SYSTEM…1880
C-13 DISPLAY OF [E216] DISCONNECTION OF TRAVEL ALARM OUPUT SYSTEM…1881
C-14 DISPLAY OF [E217] FRONT ENGINE CONTROLLER MODEL SELECTION INPUT ERROR…1882
C-15 DISPLAY OF [E227] ABNORMALITY OF FRONT ENGINE SPEED SENSOR SYSTEM…1884
C-16 DISPLAY OF ABNORMALITY OF MACHINE PUSHUP SOLENOID SYSTEM ( WITH NO DISPLAY OF SERVICE CODE)…1885
C-17 DISPLAY OF ABNORMALITY OF BOOM SHOCKLESS SOLENOID SYSTEM (WITH NO DISPLAY OF SERVICE CODE)…1887
C-18 DISPLAY OF [E221] ABNORMALITY OF GEAR PUMP PRESSURE SENSOR SYSTEM…1890
C-19 DISPLAY OF [E225] ABNORMALITY OF FRONT ENGINE OIL PRESSURE SENSOR SYSTEM…1891
C-20 DISPLAY OF [E226] ABNORMALITY OF FRONT ENGINE SENSOR POWER SUPPLY SYSTEM…1892
C-21 DISPLAY OF [E228] ABNORMALITY OF AUTO-DECEL OUTPUT SYSTEM…1893
C-22 DISPLAY OF ABNORMALITY OF REAR ENGINE CONTROLLER POWER SUPPLY SYSTEM…1894
C-23 DISPLAY OF [E-432] SHORT CIRCUIT OF REAR PUMP TVC SOLENOID SYSTEM…1895
C-24 DISPLAY OF [E433] DISCONNECTION OF REAR PUMP TVC SOLENOID SYSTEM…1897
C-25 DISPLAY OF [E417] REAR ENGINE CONTROLLER MODEL SELECTION INPUT ERROR…1899
C-26 DISPLAY OF [E427] ABNORMALITY OF REAR ENGINE SPEED SENSOR SYSTEM…1901
C-27 DISPLAY OF [E425] ABNORMALITY OF REAR ENGINE OIL PRESSURE SENSOR SYSTEM…1902
C-28 DISPLAY OF [E426] ABNORMALITY OF REAR ENGINE SENSOR POWER SUPPLY SYSTEM…1903
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTOLLER (INMPUT SIGNAL) SYSTEM (F MODE)…1904
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE…1905
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP…1907
F-2 BIT PATTERN 20-(2) R.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP…1908
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP…1909
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP…1910
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP…1911
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP…1912
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP…1913
F-8 BIT PATTERN 21-(2) BUCKET DUMP, SERVICE OIL PRESSURE SWITCH DOES NOT LIGHT UP…1914
F-9 BIT PATTERN 21-(5) L.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP…1915
F-10 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP…1916
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)…1917
TABLE OF FAILURE MODES AND CAUSES…1918
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)…1920
ALL WORK EQUIPMENT, TRAVEL, SWING…1923
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…1923
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…1924
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…1926
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…1928
H-5 AUTO-DECELERATION DOES NOT WORK …1928
WORK EQUIPMENT…1929
H-6 WORK EQUIPMENT SPEED IS SLOW (BOOM, ARM, BUCKET)…1929
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)…1930
H-8 EXCESSIVE HYDRAULIC DRIFT…1930
H-9 EXCESSIVE TIME LAG…1931
H-10 EXCESSIVE SHOCK WHEN BOOM IS STOPPED (WHEN SHOCKLESS SWITCH IS ON)…1931
H-11 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION…1931
H-12 BOOM RAISE SPEED IS SLOW OR LACKS POWER WHEN HEAVY LIFT SWITCH IS ON …1932
TRAVEL SYSTEM…1933
H-13 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS…1933
H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS…1934
H-15 DEVIATION IS EXCESSIVE WHEN STARTING…1937
H-16 TRAVEL SPEED IS SLOW…1939
H-17 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…1939
SWING SYSTEM…1940
H-18 DOES NOT SWING…1940
H-19 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR…1941
H-20 EXCESSIVE OVERRUN WHEN STOPPING SWING…1942
H-21 EXCESSIVE SHOCK WHEN STOPPING SWING…1943
H-22 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…1943
H-23 EXCESSIVE HYDRAULIC DRIFT OF SWING…1944
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…1945
MONITOR PANEL INDICATIONS AND SYMPTOMS FOUND ON MACHINE IN FAILURE…1946
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM…1948
TROUBLESHOOTING FLOWCHART FOR EACH FAILURE MODE…1950
M-1 [E101] ERROR HISTORY DATA ERROR…1950
[E102] CLOCK DATA ERROR…1950
M-2 [E103] SHORT CIRCUIT IN THE BUZZER OUTPUT CIRCUIT…1951
M-3 [E104] DETECTION OF CLOGGED FRONT ENGINE AIR CLEANER…1952
M-4 [E105] DETECTION OF CLOGGED REAR ENGINE AIR CLEANER…1952
M-5 [E108] DETECTION OF FRONT ENGINE WATER TEMPERATURE OF 105°C…1953
M-6 [E111] DETECTION OF REAR ENGINE WATER TEMPERATURE OF 105°C …1953
M-7 [115] DETECTION OF HYDRAULIC OIL TEMPERATURE OF 100°C …1953
M-8 THE LAMPS ON THE MONITOR PANEL FAILED TO COME ON FOR THREE SECONDS WHEN THE STARTING SWITCH WAS TURNED ON…1954
M-9 THE LAMPS ON THE MONITOR PANEL COME ON WHEN THE STARTING SWITCH IS TURNED ON, BUT DO NOT GO OFF…1956
M-10 THE LAMP FOR A DIFFERENT MACHINE BODY (MODEL) COMES ON WHEN THE STARTING SWITCH IS TRUNED ON…1956
M-11 THE BASIC CHECK ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON …1957
M-12 THE "ENGINE PRE-HEATING MONITOR" TURNS ON THOUGH PRE-HEATING OPERATION IS NOT PERFORMED…1962
M-13 THE BASIC CHECK ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON AND THE ENGINE IS STARTED…1963
M-14 THE CAUTION AND EMERGENCY STOP ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON (THE ENGINE IS STOPPED), BUT THE BATTER…1967
M-15 THE CAUTION AND EMERGENCY STOP ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON AND THE ENGINE IS STARTED, BUT NO ABNO…1971
M-16 THE BUZZER DOES NOT SOUND FOR ONE SECOND WHEN THE STARTING SWITCH IS TURNED ON (THE ENGINE IS STOPPED). THE BUZZER DOES…1979
M-17 THE BUZZER SOUNDS THOUGH THE MONITOR DISPLAYS NO FAILURE…1979
M-18 THE NIGHTLIGHT ON THE MONITOR PANEL DOES NOT COME ON (THE LCD WORKS NORMAL)…1980
M-19 THE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE HIGHER TEMPERTURES…1981
M-20 THE COOLANT TEMPERATURE GAUGE DISPLAYS NOT A SINGLE LEVEL DURING OPERATION…1983
M-21 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE HIGHER TEMPERATURES…1985
M-22 THE HYDRAULIC OIL TEMPERATURE GAUGE DISPLAYS NOT A SINGLE LEVEL DURING OPERATION…1985
M-23 THE FUEL LEVEL GAUGE ALWAYS INDICATES FULL…1986
M-24 THE FUEL LEVEL GAUGE DISPLAYS NOTHING…1986
M-25 THE "SWING LOCK MONITOR" DOES NOT COME ON THOUGH THE SWING LOCK SWITCH IS TURNED ON (LOCK)…1987
M-26 EMERGENCY SWING SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH…1987
M-27 THE SERVICE METER DOES NOT WORK WHILE THE ENGINE IS IN OPERATION. THE CLOCK IS NOT DISPLAYED THOUGH THE STARTING SWITCH…1988
M-28 THE SERVICE METER DOES NOT WORK THOUGH THE CLOCK SWITCH IS PRESSED WITH THE STARTING SWITCH TURNED OFF…1988
M-29 DEFECTIVE FUEL LEVEL SENSOR…1989
M-30 DEFECTIVE TEMPERATURE SENSOR (ENGINE WATER TEMPERATURE, ENGINE OIL TEMPERATURE, PTO OIL TEMPERATURE, AND HYDRAULIC OIL T…1990
M-31 DEFECTIVE ENGINE OIL LEVEL SENSOR…1991
M-32 DEFECTIVE COOLANT LEVEL SENSOR…1992
M-33 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR…1993
TROUBLESHOOTING OF MACHINE CONTROL SYSTEM (V MODE)…1994
CODES DISPLAYED IN FAILURE OCCURRENCES AND DESCRIPTIONS…1996
LIST OF WARNING ITEMS DISPLAYED ON CGC MONITOR…2006
V MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM…2010
TROUBLESHOOTING BY FAILURE MODE…2012
V-1 [E811] FAILURE IN VHMS CONTROLLER POWER SUPPLY SYSTEM…2012
V-2 [E812] FAILURE ON VHMS SENSORE POWER SUPPLY (24 V)…2013
V-3 [E813] FAILURE ON VHMS SENSOR POWER SUPPLY (12 V)…2014
V-4 [E814] FAILURE ON VHMS SENSOR POWER SUPPLY (5 V)…2015
V-5 [E817] VHMS MODEL SELECTION INPUT ERROR…2016
V-6 [E818] VHMS CONNECTORS CONNECTION ERROR…2017
V-7 [E821] VHMS FIRM SYSTEM FAILURE…2018
V-8 [E828] DISCONNECTION ON S-NET BETWEEN VHMS AND MAIN MONITOR…2018
V-9 [E831] VHMS APPLICATION SYSTEM FAILURE…2018
[E832] VHMS LANGUAGE FAILURE…2018
V-10 [E857] FAILURE IN FRONT ENGINE SPEED SENSOR SYSTEM…2019
V-11 [E858] FAILURE IN REAR ENGINE SPEED SENSOR SYSTEM…2020
V-12 [E861] FAILURE IN FRONT ENGINE OIL TEMPERATURE SENSOR SYSTEM…2021
V-13 [E862] FAILURE IN REAR ENGINE OIL TEMPERATURE SENSOR SYSTEM …2022
V-14 [E863] FAILURE IN FRONT PTO OIL TEMPERATURE SENSOR SYSTEM…2023
V-15 [E864] FAILURE IN REAR PTO OIL TEMPERATURE SENSOR SYSTEM…2024
V-16 [E865] FAILURE IN NOS. 1& 2 FRONT PUMPS PRESSURE SENSOR SYSTEM…2025
V-17 [E866] FAILURE IN NOS. 1 & 2 REAR PUMPS PRESSURE SENSOR SYSTEM…2026
V-18 [E867] FAILURE IN NOS. 3 & 4 FRONT PUMPS PRESSURE SENSOR SYSTEM…2027
V-19 [E868] FAILURE IN NOS. 3 & 4 REAR BUMPS PRESSURE SENSOR SYSTEM…2028
V-20 [E871] FAILURE IN FRONT ENGINE WATER TEMPERATURE SENSOR SYSTEM…2029
V-21 [E872] FAILURE IN REAR ENGINE WATER TEMPERATURE SENSOR SYSTEM…2029
V-22 [E873] FAILURE IN HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM…2030
V-23 [E876] ABNORMAL FRONT ENGINE EXHAUST TEMPERATURE SENSOR SYSTEM…2031
V-24 THE VALUE DISPLAYED ON THE FRONT ENGINE EXHAUST TEMPERATURE REAL-TIME MONITOR DOES NOT CORRESPOND WHEN THE TEMPERATURE R…2032
V-25 [E877] ABNORMAL REAR ENGINE EXHAUST TEMPERATURE SENSOR SYSTEM…2033
V-26 THE VALUE DISPLAYED ON THE REAR ENGINE EXHAUST TEMPERATURE REAL-TIME MONITOR DOES NOT CORRESPOND WHEN THE TEMPERATURE RI…2034
V-27 [E878] FAILURE IN SWING PUMP PRESSURE SENSOR SYSTEM…2035
V-28 ABNORMAL ENGINE OIL TEMPERATURE…2036
V-29 [E881] DISPLAY INDICATES DETECTION OF THE FRONT ENGINE OIL TEMPERATURE AT 125°C …2038
[E882] DISPLAY INDICATES DETECTION OF THE REAR ENGINE OIL TEMPERATURE AT 125°C …2038
V-30 [E883] FRONT ENGINE OIL PRESSURE DROP…2039
V-31 [E884] REAR ENGINE OIL PRESSURE DROP…2039
V-32 ABNORMAL PTO OIL TEMPERATURE…2040
V-33 [E885] DISPLAY INDICATES DETECTION OF THE FRONT ENGINE PTO OIL TEMPERATURE AT 125°C…2042
[E886] DISPLAY INDICATES DETECTION OF THE REAR ENGINE PTO OIL TEMPERATURE AT 125°C …2042
V-34 ABNORMAL GEAR PUMP PRESSURE IS DISPLAYED…2043
V-35 [E887] ABNORMAL GEAR PUMP PRESSURE IS DISPLAYED…2043
V-36 [E888] EXCESSIVE EXHAUST GAS TEMPERATURE OF FRONT ENGINE …2044
V-37 [E898] EXCESSIVE EXHAUST GAS TEMPERATURE OF REAR ENGINE…2044
V-38 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 AND 2 FRONT PUMPS…2045
V-39 [E891] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 & 2 FRONT PUMPS…2045
V-40 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 AND 2 REAR PUMPS…2046
V-41 [E892] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 AND 2 REAR PUMPS…2046
V-42 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 FRONT PUMPS…2047
V-43 [E893] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 FRONT PUMPS…2047
V-44 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 REAR PUMPS…2048
V-45 [E894] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 REAR PUMPS…2048
V-46 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR THE SWING PUMP…2049
V-47 [E895] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR THE SWING PUMP…2049
V-48 FAILURE IN GEAR PUMP PRESSURE SENSOR SYSTEM…2050
V-49 FAILURE IN PRESSURE SENSOR SYSTEM FOR NOS. 1,2,3, & 4 PUMPS AND SWING PUMP…2051
TROUBLESHOOTING OF BOTTOM CYLINDER CONTROL SYSTEM (LE, LH MODE) [LOADING SHOVEL SPECIFICATION]…2052
LE-1 DEFECTIVE OPERATION OF BOTTOM CYLINDER…2053
A) BOTTOM CLOSING SIDE…2053
B) BOTTOM OPENING SIDE…2053
LH-1 DEFECTIVE OPERATION OF BOTTOM CYLINDER…2055
TROUBLESHOOTING OF WORK EQUIPMENT AUTOMATIC CONTROL SYSTEM (W, L MODE) [LOADING SHOVEL SPECIFICATION]…2056
ABNORMALITY JUDGEMENT STANDARDS FOR SELF-DIAGNOSTIC SYSTEM…2057
TROUBLESHOOTING…2058
W-1 IN ARC DIGGING MODE (AUTO LEVEL DIGGING SWITCH OFF), HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION IS CARRIED OUT…2061
W-2 IN HORIZONTAL DIGGING MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING…2062
A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"…2062
B) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "NORMAL DISPLAY"…2066
W-3 IN HORIZONTAL DIGGING MODE (BUCKET ANGLE REVISE SWITCH OFF), BUCKET ANGLE COMPENSATION IS CARRIED OUT…2067
W-4 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT HORIZONTAL DIGGING BUT DOES NOT CARRY OUT BUCKET ANGL…2068
A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"…2068
B) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "NORMAL DISPLAY"…2069
W-5 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT BUCKET ANGLE COMPENSATION BUT DOES NOT CARRY OUT HORI…2071
A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"…2071
B) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "NORMAL DISPLAY"…2071
W-6 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATIO MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION…2072
A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"…2072
L-1 IMPOSSIBLE TO CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION…2076
30 DISASSEMBLY AND ASSEMBLY…2077
METHOD OF USING MANUAL…2079
PRECAUTIONS WHEN CARRYING OUT OPERATION…2081
SPECIAL TOOL LIST…2083
FUEL INJECTION PUMP ASSEMBLY…2088
REMOVAL AND INSTALLATION…2088
NOZZLE HOLDER ASSEMBLY…2089
REMOVAL…2089
INSTALLATION…2090
TURBOCHARGER ASSEMBLY…2091
REMOVAL AND INSTALLATION…2091
CYLINDER HEAD ASSEMBLY…2092
REMOVAL…2092
INSTALLATION…2096
HYDRAULIC COOLER, AFTERCOOLER ASSEMBLY…2099
REMOVAL AND INSTALLATION…2099
FAN GUARD, RADIATOR, HYDRAULIC COOLER ASSEMBLY…2100
REMOVAL…2100
INSTALLATION…2101
AFTERCOOLER CORE…2102
REMOVAL AND INSTALLATION…2102
ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY…2103
REMOVAL…2103
INSTALLATION…2107
PTO ASSEMBLY…2108
REMOVAL…2108
INSTALLATION…2111
DISASSEMBLY…2112
ASSEMBLY…2113
CENTER SWIVEL JOINT ASSEMBLY…2116
REMOVAL AND INSTALLATION…2116
DISASSEMBLY AND ASSEMBLY…2117
TRAVEL MOTOR ASSEMBLY…2118
REMOVAL AND INSTALLATION…2118
TRAVEL MOTOR BRAKE VALVE ASSEMBLY…2119
REMOVAL AND INSTALLATION…2119
TRAVEL MOTOR ASSEMBLY…2120
DISASSEMBLY…2120
ASSEMBLY…2124
FINAL DRIVE ASSEMBLY…2130
DISASSEMBLY…2130
ASSEMBLY…2134
SWING MOTOR ASSEMBLY…2141
REMOVAL AND INSTALLATION…2141
DISASSEMBLY…2142
ASSEMBLY…2145
REVOLVING FRAME ASSEMBLY…2150
REMOVAL AND INSTALLATION…2150
SWING CIRCLE ASSEMBLY…2151
REMOVAL AND INSTALLATION…2151
SWING MACHINERY ASSEMBLY…2152
REMOVAL AND INSTALLATION…2152
DISASSEMBLY …2153
ASSEMBLY…2158
IDLER CUSHION CYLINDER ASSEMBLY…2163
REMOVAL AND INSTALLATION…2163
DISASSEMBLY AND ASSEMBLY…2164
IDLER ADJUSTMENT CYLINDER ASSEMBLY…2165
DISASSEMBLY AND ASSEMBLY…2165
TRACK ROLLER ASSEMBLY…2166
REMOVAL AND INSTALLATION…2166
CARRIER ROLLER ASSEMBLY…2167
REMOVAL AND INSTALLATION…2167
TRACK SHOE ASSEMBLY…2168
REMOVAL…2168
INSTALLLATION…2169
CONTROL, PTO LUBRICATION PUMP ASSEMBLY…2170
REMOVAL AND INSTALLATION…2170
SWING PUMP ASSEMBLY…2171
REMOVAL AND INSTALLATION…2171
DISASSEMBLY…2172
ASSEMBLY…2179
NO. 1, 3 PUMP ASSEMBLY…2191
REMOVAL AND INSTALLATION…2191
NO. 2, 4 PUMP ASSEMBLY…2192
REMOVAL…2192
INSTALLATION…2193
HYDAULIC PUMP ASSEMBLY…2194
DISASSEMBLY…2194
ASSEMBLY…2204
PILOT RELIEF VALVE ASSEMBLY…2219
REMOVAL AND INSTALLATION…2219
DISASSEMBLY AND ASSEMBLY…2220
MAIN RELIEF VALVE ASSEMBLY (FOR SWING)…2221
DISASSEMBLY AND ASSEMBLY…2221
MAIN RELIEF VALVE ASSEMBLY (FOR WORK EQUIPMENT, TRAVEL)…2222
DISASSEMBLY AND ASSEMBLY…2222
SWING CONTROL VALVE ASSEMBLY…2223
REMOVAL AND INSTALLATION…2223
DISASSEMBLY AND ASSEMBLY…2224
V1, V3 CONTROL VALVE ASSEMBLY…2226
REMOVAL AND INSTALLATION…2226
V2, V4 CONTROL VALVE ASSEMBLY…2227
REMOVAL AND INSTALLATION…2227
CONTROL VALVE ASSEMBLY…2228
DISASSEMBLY…2228
ASSEMBLY…2230
CO, NC VALVE ASSEMBLY…2232
REMOVAL AND INSTALLATION…2232
SERVO VALVE ASSEMBLY…2233
REMOVAL AND INSTALLATION…2233
TVC VALVE ASSEMBLY…2234
REMOVAL AND INSTALLATION…2234
PPC VALVE ASSEMBLY (FOR TRAVEL)…2235
REMOVAL AND INSTALLATION…2235
DISASSEMBLY AND ASSEMBLY…2236
PPC VALVE ASSEMBLY (FOR WORK EQUIPMENT, SWING)…2237
REMOVAL AND INSTALLATION0…2237
DISASSEMBLY AND ASSEMBLY…2238
BOOM CYLINDER ASSEMBLY (BACKHOE)…2239
BACK HOE…2239
REMOVAL…2239
INSTALLATION…2240
LOADING SHOVEL…2241
REMOVAL…2241
INSTALLATION…2242
ARM CYLINDER ASSEMBLY …2243
(BACK HOE)…2243
REMOVAL…2243
INSTALLATION…2244
(LOADING SHOVEL)…2245
REMOVAL…2245
INSTALLATION…2246
BUCKET CYLINDER ASSEMBLY …2247
(BACK HOE)…2247
REMOVAL…2247
INSTALLATION…2248
(LOADING SHOVEL)…2249
REMOVAL…2249
INSTALLATION…2250
BOTTOM DUMP CYLINDER ASSEMBLY…2251
(LOADING SHOVEL)…2251
REMOVAL…2251
INSTALLATION…2252
HYDRAULIC CYLINDER ASSEMBLY …2253
(BACK HOE)…2253
DISASSEMBLY…2253
ASSEMBLY…2259
(LOADING SHOVEL)…2263
DISASSEMBLY…2263
ASSEMBLY…2265
BUCKET ASSEMBLY …2268
(BACK HOE)…2268
REMOVAL…2268
INSTALLATION…2269
(LOADING SHOVEL)…2270
REMOVAL…2270
INSTALLATION…2271
ARM ASSEMBLY …2272
(BACK HOE)…2272
REMOVAL…2272
INSTALLATION…2273
(LOADING SHOVEL)…2274
REMOVAL…2274
INSTALLATION…2275
BOOM ASSEMBLY…2280
(BACKHOE)…2280
REMOVAL…2280
INSTALLATION…2281
(LOADING SHOVEL)…2282
REMOVAL…2282
INSTALLATION…2283
COUNTERWEIGHT ASSEMBLY…2284
REMOVAL AND INSTALLATION…2284
OPERATOR'S CAB ASSEMBLY…2285
REMOVAL…2285
INSTALLATION…2286
40 MAINTENANCE STANDARD…2287
PTO…2288
SWING MACHINERY…2289
FINAL DRIVE…2291
IDLER…2292
TRACK ROLLER…2294
CARRIER ROLLER…2295
TRACK SHOE…2296
HYDRAULIC PUMP…2300
SWING PUMP…2301
CONTROL AND PTO LUBRICATION PUMP…2302
CONTROL VALVE…2303
SWING CONTROL VALVE…2310
SWING MOTOR…2311
TRAVEL MOTOR…2312
TRAVEL BRAKE VALVE…2313
CENTER SWIVEL JOINT…2314
PILOT RELIEF VALVE…2315
PPC VALVE…2316
SOLENOID VALVE…2318
HYDRAULIC CYLINDER…2319
WORK EQUIPMENT…2323
DIMENSIONS OF WORK EQUIPMENT…2327
90 OTHERS…2331
HYDRAULIC CIRCUIT DIAGRAM (BACK HOE)…2332
HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)…2338
ELECTRIC CIRCUIT DIAGRAM (1/5)…2342
ELECTRIC CIRCUIT DIAGRAM (2/5)…2347
ELECTRIC CIRCUIT DIAGRAM (3/5)…2352
ELECTRIC CIRCUIT DIAGRAM (4/5)…2357
ELECTRIC CIRCUIT DIAGRAM (5/5)…2362
SEBM027708 – Hydraulic Excavator PC1800-6 Shop Manual…2368
COVER…2368
CONTENTS…2369
01 GENERAL…2398
SPECIFICATION DRAWINGS…2399
SPECIFICATIONS…2401
WEIGHT TABLE…2405
FUEL, COOLANT AND LUBRICANTS…2409
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…2411
PTO…2412
PTO LUBRICATION SYSTEM…2414
POWER TRAIN…2415
SWING MACHINERY…2417
SWING CIRCLE…2419
FINAL DRIVE…2420
SPROCKET…2422
IDLER…2424
HIC SYSTEM…2426
TRACK ROLLER…2428
CARRIER ROLLER…2429
TRACK SHOE…2430
HYDRAULIC COMPONENT LAYOUT…2434
HYDRAULIC TANK…2436
HYDRAULIC PUMP…2437
SWING PUMP…2464
CONTROL AND PTO LUBRICATING PUMP…2469
LINE OIL FILTER…2471
PILOT OIL FILTER…2471
RETURN OIL FILTER…2472
DRAIN OIL FILTER…2473
ELECTRONIC OLSS…2474
CONTROL VALVE…2476
SWING CONTROL VALVE…2492
SWING MOTOR…2495
CENTER SWIVEL JOINT…2498
TRAVEL MOTOR…2499
TRAVEL BRAKE VALVE…2501
PILOT RELIEF VALVE…2503
SAFETY LOCK VALVE…2505
ACCUMULATOR…2507
PPC VALVE…2508
SOLENOID VALVE…2514
HYDRAULIC CYLINDER…2516
AIR SYSTEM…2520
AIR GOVERNOR…2521
AIR TANK…2521
AUTO-DRAIN VALVE…2521
SAFETY VALVE…2522
SOLENOID VALVE (FOR LUBRICATION, HORN)…2522
GREASE PUMP…2523
GREASING SYSTEM…2525
WORK EQUIPMENT…2532
DIMENSIONS OF WORK EQUIPMENT…2536
ENGINE CONTROL…2540
MACHINE CONTROL SYSTEM…2546
ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM…2570
MONITOR SYSTEM…2576
20 TESTING AND ADJUSTING…2592
STANDARD VALUE TABLE FOR ENGINE…2593
STANDARD VALUE TABLE FOR CHASSIS…2594
TESTING AND ADJUSTING…2602
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…2603
MEASUREMENT OF ENGINE SPEED…2605
MEASUREMENT OF AIR BOOST PRESSURE (BOOST PRESSURE)…2606
MEASUREMENT OF EXHAUST GAS TEMPERATURE…2607
MEASUREMENT OF EXHAUST GAS COLOR…2607
ADJUSTMENT OF VALVE CLEARANCE…2609
MEASUREMENT OF COMPRESSION PRESSURE…2610
MEASUREMENT OF BLOW-BY PRESSURE…2610
MEASUREMENT OF ENGINE OIL PRESSURE…2611
HANDLING OF FUEL SYSTEM EQUIPMENT…2612
REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT…2612
MEASUREMENT OF FUEL PRESSURE…2613
AIR BLEEDING FROM FUEL CIRCUIT…2614
INSPECTION OF LEAKAGE FROM FUEL SYSTEM…2616
ADJUSTMENT OF ENGINE SPEED SENSOR…2617
INSPECTION AND ADJUSTMENT OF FAN BELT TENSION…2618
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…2619
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…2620
INSPECTION OF SWING CIRCLE BEARING CLEARANCE…2621
REMAINING PRESSURE RELIEF FROM HIC CIRCUIT…2622
GAS FILLING IN HIC CIRCUIT ACCUMULATOR…2622
BLEEDING AIR FROM AND FILLING PRESSURIZED OIL IN HIC CIRCUIT…2624
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION…2625
INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT OIL PRESSURES…2626
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE…2631
INSPECTION AND ADJUSTMENT OF PISTON PUMP CONTROL OIL PRESSURE…2632
INSPECTION OF SERVO PISTON STROKE…2639
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE…2640
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE…2642
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE…2644
INSPECTION AND ADJUSTMENT OF TRAVEL DEIEATION…2645
INSPECTION OF WORK EQUIPMENT HYDRAULIC DRIFT CAUSE PORTION…2647
INSPECTION OF OIL LEAKAGE…2648
REMAINING PRESSURE RELIEF FROM HYDRAULIC CIRCUIT…2651
AIR BLEEDING FROM EACH COMPONENT…2652
TESTING AND ADJUSTING HYDRAULIC AUTO GREASE SYSTEM…2657
SPECIAL FUNCTION OF MACHINE MONITOR…2661
FUNCTION AMD OPERATION OF CGC MONITOR…2681
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT…2716
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER…2717
SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER…2731
TESTING AND ADJUSTING DEVICES RELATED TO VHMS…2748
ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)…2751
TROUBLESHOOTING…2769
POINTS TO REMEMBER WHEN TROUBLESHOOTING…2770
SEQUENCE OF EVENTS IN TROUBLESHOOTING…2771
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…2772
CHECKS BEFORE TROUBLESHOOTING…2780
CLASSIFICATION AND PROCEDURE OF TROUBLESHOOTING…2781
CONNECTOR ARRANGMENT DIAGRAM AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM…2785
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…2813
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…2848
TROUBLESHOOTING AT DISPLAY OF FAILURE CODE OR ERROR CODE [CODE DISPLAY MODE]…2852
INFORMATION IN TROUBLESHOOTING TABLE…2855
FAILURE CODE [6014NX]…2857
FAILURE CODE [7@HAKA]…2859
FAILURE CODE [7@HAKB]…2860
FAILURE CODE [7@HAZL]…2861
FAILURE CODE [7@HBKA]…2862
FAILURE CODE [7@HBKB]…2863
FAILURE CODE [7@HBZL]…2864
FAILURE CODE [7@HCKA]…2865
FAILURE CODE [7@HCKB]…2866
FAILURE CODE [7@HCZL]…2867
FAILURE CODE [7@HDKA]…2868
FAILURE CODE [7@HDKB]…2869
FAILURE CODE [7@HDZL]…2870
FAILURE CODE [A000N1] OR ERROR CODE [E922]…2871
FAILURE CODE [a000N1] OR ERROR CODE [EA22]…2872
FAILURE CODE [AA10NX] OR ERROR CODE [104]…2873
FAILURE CODE [aA10NX] OR ERROR CODE [105]…2874
FAILURE CODE [ABOOKE]…2875
FAILURE CODE [aBOOKE]…2876
FAILURE CODE [ADOOL2] OR ERROR CODE [E979]…2877
FAILURE CODE [aD00L2] OR ERROR CODE [EA79]…2878
FAILURE CODE [AD00MA] OR ERROR CODE [E97A]…2879
FAILURE CODE [aD00MA] OR ERROR CODE [EA7A]…2879
FAILURE CODE [AD10L3] OR ERROR CODE [E97b]…2880
FAILURE CODE [aD10L3] OR ERROR CODE [EA7b]…2882
FAILURE CODE [AD10MA] OR ERROR CODE [E97d]…2884
FAILURE CODE [aD10MA] OR ERROR CODE [EA7d]…2884
FAILURE CODE [AD10MB] OR ERROR CODE [E97C]…2885
FAILURE CODE [aD10MB] OR ERROR CODE [EA7C]…2885
FAILURE CODE [AD11KA] OR ERROR CODE [E974]…2886
FAILURE CODE [aD11KA] OR ERROR CODE [EA74]…2887
FAILURE CODE [AD11KB] OR ERROR CODE [E970]…2888
FAILURE CODE [aD11KB] OR ERROR CODE [EA70]…2889
FAILURE CODE [AD51KA] OR ERROR CODE [E975]…2890
FAILURE CODE [aD51KA] OR ERROR CODE [EA75]…2891
FAILURE CODE [AD51KB] OR ERROR CODE [E971]…2892
FAILURE CODE [aD51KB] OR ERROR CODE [EA71]…2893
FAILURE CODE [ADA1KA] OR ERROR CODE [E981]…2894
FAILURE CODE [aDA1KA] OR ERROR CODE [EA81]…2895
FAILURE CODE [ADAZKB] OR ERROR CODE [E98A]…2896
FAILURE CODE [aDAZKB] OR ERROR CODE [EA8A]…2898
FAILURE CODE [ADB1KA] OR ERROR CODE [E982]…2900
FAILURE CODE [aDB1KA] OR ERROR CODE [EA82]…2901
FAILURE CODE [ADC1KA] OR ERROR CODE [E983]…2902
FAILURE CODE [aDC1KA] OR ERROR CODE [EA83]…2903
FAILURE CODE [ADD1KA] OR ERROR CODE [E984]…2904
FAILURE CODE [aDD1KA] OR ERROR CODE [EA84]…2905
FAILURE CODE [ADDZKB] OR ERROR CODE [E98b]…2906
FAILURE CODE [aDDZKB] OR ERROR CODE [EA8b]…2908
FAILURE CODE [ADE1KA] OR ERROR CODE [E985]…2910
FAILURE CODE [aDE1KA] OR ERROR CODE [EA85]…2911
FAILURE CODE [ADF1KA] OR ERROR CODE [E986]…2912
FAILURE CODE [aDF1KA] OR ERROR CODE [EA86]…2913
FAILURE CODE [B@BAZG] OR ERROR CODE [E924]…2914
FAILURE CODE [b@BAZG] OR ERROR CODE [EA24]…2915
FAILURE CODE [B@BAZK]…2916
FAILURE CODE [b@BAZK]…2917
FAILURE CODE [B@BCNS] OR ERROR CODE [108]…2918
FAILURE CODE [b@BCNS] OR ERROR CODE [111]…2919
FAILURE CODE [B@BCZK]…2920
FAILURE CODE [b@BCZK]…2922
FAILURE CODE [B@CBNS]…2924
FAILURE CODE [b@CBNS]…2925
FAILURE CODE [B@HANS] OR ERROR CODE [115]…2926
FAILURE CODE [B@HAZK]…2927
FAILURE CODE [D11OKB]…2928
FAILURE CODE [D163KB]…2929
FAILURE CODE [D194KZ]…2930
FAILURE CODE [D195KB]…2931
FAILURE CODE [D1D0KB] OR ERROR CODE [E957]…2932
FAILURE CODE [d1D0KB] OR ERROR CODE [EA57]…2934
FAILURE CODE [DA20KT] OR ERROR CODE [101]…2936
FAILURE CODE [DA2SKA]…2937
FAILURE CODE [DA2SKQ]…2939
FAILURE CODE [DA80MA]…2941
FAILURE CODE [DAB0KR] OR ERROR CODE [118]…2942
FAILURE CODE [DB20KT] OR ERROR CODE [E980]…2944
FAILURE CODE [dB20KT] OR ERROR CODE [EA80]…2945
FAILURE CODE [DB22KK] OR ERROR CODE [E956]…2946
FAILURE CODE [dB22KK] OR ERROR CODE [EA56]…2948
FAILURE CODE [DB29KQ] OR ERROR CODE [E920]…2950
FAILURE CODE [dB29KQ] OR ERROR CODE [EA20]…2951
FAILURE CODE [DB2AMA] OR ERROR CODE [E95A]…2952
FAILURE CODE [bB2AMA] OR ERROR CODE [EA5A]…2952
FAILURE CODE [DB2RMC] OR ERROR CODE [E935]…2953
FAILURE CODE [dB2RMC] OR ERROR CODE [EA35]…2955
FAILURE CODE [DB2SMC] OR ERROR CODE [E955]…2957
FAILURE CODE [dB2SMC] OR ERROR CODE [EA55]…2959
FAILURE CODE [DBB0KK]…2961
FAILURE CODE [DBB0KM]…2962
FAILURE CODE [DBB0KP]…2963
FAILURE CODE [DBB0KQ]…2965
FAILURE CODE [DBB0KR] OR ERROR CODE [116]…2967
FAILURE CODE [DBB0KT]…2969
FAILURE CODE [DBBQKR]…2970
FAILURE CODE [DD11KB] OR ERROR CODE [E954]…2972
FAILURE CODE [dD11KB] OR ERROR CODE [EA54]…2974
FAILURE CODE [DDE2L6] OR ERROR CODE [E936]…2976
FAILURE CODE [dDE2L6] OR ERROR CODE [EA36]…2978
FAILURE CODE [DGE4KX] OR ERROR CODE [E93d]…2980
FAILURE CODE [dGE4KX] OR ERROR CODE [EA3d]…2981
FAILURE CODE [DGT4KA]…2982
FAILURE CODE [dGT4KA]…2984
FAILURE CODE [DGT4KB]…2986
FAILURE CODE [dGT4KB]…2988
FAILURE CODE [DGT5KA]…2990
FAILURE CODE [dGT5KA]…2992
FAILURE CODE [DGT5KB]…2994
FAILURE CODE [dGT5KB]…2996
FAILURE CODE [DH30KX] OR ERROR CODE [E93C]…2998
FAILURE CODE [dH30KX] OR ERROR CODE [EA3C]…2999
FAILURE CODE [DH40KX] OR ERROR CODE [E977]…3000
FAILURE CODE [dH40KX] OR ERROR CODE [EA77]…3001
FAILURE CODE [DHE4KB]…3002
FAILURE CODE [dHE4KB]…3003
FAILURE CODE [DHE4KY]…3004
FAILURE CODE [dHE4KY]…3005
FAILURE CODE [DHE5KB]…3006
FAILURE CODE [dHE5KB]…3007
FAILURE CODE [DHE5KY]…3008
FAILURE CODE [dHE5KY]…3009
FAILURE CODE [DK10KX] OR ERROR CODE [E931]…3010
FAILURE CODE [dK10KX] OR ERROR CODE [EA31]…3011
FAILURE CODE [DLE2MA]…3012
FAILURE CODE [dLE2MA]…3013
FAILURE CODE [DLE3LC] OR ERROR CODE [E91b]…3014
FAILURE CODE [dLE3LC] OR ERROR CODE [EA1b]…3015
FAILURE CODE [DLH1LC] OR ERROR CODE [E91C]…3016
FAILURE CODE [dLH1LC] OR ERROR CODE [EA1C]…3017
FAILURE CODE [DPA0KR]…3018
FAILURE CODE [DV00KY] OR ERROR CODE [102]…3019
FAILURE CODE [DV20KB]…3020
FAILURE CODE [DW42KZ]…3021
FAILURE CODE [DW45KA]…3022
FAILURE CODE [DW45KB]…3024
FAILURE CODE [DW48KA]…3026
FAILURE CODE [DW48KB]…3027
FAILURE CODE [DW91KA]…3028
FAILURE CODE [DW91KB]…3029
FAILURE CODE [DWK0KA]…3030
FAILURE CODE [DWK0KB]…3031
FAILURE CODE [DXA0KA]…3032
FAILURE CODE [dXA0KA]…3034
FAILURE CODE [DXA0KB]…3036
FAILURE CODE [dXA0KB]…3038
FAILURE CODE [F@BBZL]…3040
FAILURE CODE [f@BBZL]…3040
FAILURE CODE [F@BVL6]…3041
FAILURE CODE [f@BVL6]…3041
FAILURE CODE [F@BYNR]…3042
FAILURE CODE [f@BYNR]…3043
FAILURE CODE [F@BYNS]…3044
FAILURE CODE [f@BYNS]…3045
FAILURE CODE [F@BZNR]…3046
FAILURE CODE [f@BZNR]…3047
FAILURE CODE [F@BZNS]…3048
FAILURE CODE [f@BZNS]…3049
FAILURE CODE [F@HCKA]…3050
FAILURE CODE [F@HCKB]…3051
FAILURE CODE [F@HCZL]…3052
FAILURE CODE [J100KA]…3053
FAILURE CODE [J100KB]…3054
FAILURE CODE [J100L6]…3055
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…3056
INFORMATION CONTAINED IN THE TROUBLESHOOTING LIST…3057
E-1 ENGINE DOESN'T START UP…3058
E-2 PREHEATING DOES NOT WORK…3063
E-3 AUTOMATIC-DECELERATOR DOES NOT WORK…3066
E-4 BOOM SHOCK-LESS FUNCTION DOES NOT OPERATE NORMALLY…3067
E-5 MACHINE PUSHUP FUNCTION DOES NOT WORK NORMALLY…3070
E-6 TRAVEL ALARM IS NOT SOUNDED…3072
E-7 ALL THE MACHINE MONITOR LAMPS DO NOT COME ON FOR 3 SECONDS AFTER THE STARTING SWITCH IS TURNED ON…3073
E-8 WHEN THE STARTING SWITCH IS TURNED ON ,MACHINE MONITOR LAMPS ALL STAYED LIGHTED UP AND DO NOT GO OUT…3075
E-9 MACHINE MONITOR LAMPS WHICH IS LIGHTED UP WHEN THE STARTING SWITCH IS TURNED ON, DO NOT EXACTLY REPRESENT THE MACHINE OPERATING STATUS…3075
E-10 A BASIC CHECK ITEM FLASHES ON THE MACHINE MONITOR WHILE THE STARTING SWITCH IS TURNED ON…3076
E-11 WHILE THE ENGINE IS IN OPERATION, A CAUTION ITEM FLASHES ON THE MACHINE MONITOR…3077
E-12 WHILE THE ENGINE IS IN OPERATION, AN EMERGENCY STOP ITEM FLASHES ON THE MACHINE MONITOR…3079
E-13 WARM-UP MONITOR UNINTENDED COMES ON OR FLASHES ON THE MACHINE MONITOR THOUGH THE WARM-UP OPERATION IS NOT TURNED ON…3081
E-14 SWING LOCK MONITOR DOES NOT COME ON…3083
E-15 ENGINE WATER TEMPERATURE GAUGE IS NOT CORRECT…3085
E-16 DISPLAY OF THE MACHINE MONITOR'S HYDRAULIC OIL TEMPERATURE GAUGE IS NOT CORRECT…3087
E-17 DISPLAY OF FUEL GAUGE IS NOT CORRECT…3088
E-18 ALARM BUZZER OF THE MACHINE MONITOR DOES NOT WORK NORMALLY…3089
E-19 CLOCK AND SERVICE METER ARE NOT CORRECTLY DISPLAYED…3091
E-20 BIT DISPLAY FOR BOOM RAISE IS NOT CORRECTLY DISPLAYED…3092
E-21 BIT DISPLAY FOR BOOM LOWER IS NOT CORRECTLY DISPLAYED…3093
E-22 BIT DISPLAY FOR ARM IN IS NOT CORRECTLY DISPLAYED…3094
E-23 BIT DISPLAY FOR ARM OUT IS NOT CORRECTLY DISPLAYED…3095
E-24 BIT DISPLAY FOR BUCKET CURL IS NOT CORRECTLY DISPLAYED…3096
E-25 BIT DISPLAY FOR BUCKET DUMP IS NOT CORRECTLY DISPLAYED…3097
E-26 BIT DISPLAY FOR SWING IS NOT CORRECTLY DISPLAYED…3098
E-27 BIT DISPLAY FOR LH TRAVEL IS NOT CORRECTLY DISPLAYED…3100
E-28 BIT DISPLAY FOR RH TRAVEL IS NOT CORRECTLY DISPLAYED…3102
E-29 BIT DISPLAY FOR THE SERVICE IS NOT CORRECTLY DISPLAYED…3104
E-30 BIT DISPLAY FOR BOTTOM OPEN, CLOSE IS NOT CORRECTLY DISPLAYED…3105
E-31 AIR CONDITIONER DOES NOT WORK…3107
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…3109
TABLE OF FAILURE MODES AND CAUSES…3110
PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC SYSTEM…3112
HOW TO READ THE TROUBLESHOOTING FLOW…3117
H-1. SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…3118
H-2. THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…3119
H-3. NO WORK EQUIPMENT, TRAVEL, SWING MOVE…3121
H-4. ABNORMAL NOISE GENERATED (AROUND PUMP)…3123
H-5. WORK EQUIPMENT SPEED IS SLOW (BOOM, ARM, BUCKET)…3124
H-6. WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)…3125
H-7. EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)…3125
H-8. EXCESSIVE TIME LAG…3126
H-9. EXCESSIVE SHOCK WHEN BOOM IS STOPPED (WHEN SHOCKLESS SWITCH IS ON)…3126
H-10. DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION…3126
H-11. WHEN HEAVY LIFT IS ON, BOOM RAISE SPEED IS SLOW OR LACKS POWER…3127
H-12. TRAVEL DEVIATION IS EXCESSIVE DRUING COMPOUND OPERATIONS…3128
H-13. MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS…3129
H-14. DEVIATION IS EXCESSIVE WHEN STARTING …3132
H-15. TRAVEL SPEED IS SLOW…3134
H-16. TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…3134
H-17. DOES NOT SWING…3135
H-18. SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR…3136
H-19. EXCESSIVE OVERRUN WHEN STOPPING SWING…3137
H-20. EXCESSIVE SHOCK WHEN STOPPING SWING…3138
H-21. EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…3138
H-22. EXCESSIVE HYDRAULIC DRIFT OF SWING…3139
TROUBLESHOOTING OF WORK EQUIPMENT AUTOMATIC CONTROL SYSTEM (W-MODE) [LOADING SHOVEL]…3140
METHOD OF USING TROUBLESHOOTING FLOWCHART…3141
ABNORMALITY JUDGEMENT STANDARDS FOR SELF-DIAGNOSTIC SYSTEM…3142
TROUBLESHOOTING…3143
W-1. IN ARC DIGGING MODE (AUTO LEVEL DIGGING SWITCH OFF), HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION IS CARRIED OUT…3146
W-2. IN HORIZONTAL DIGGING MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING…3147
W-3. IN HORIZONTAL DIGGING MODE (BUCKET ANGLE REVISE SWITCH OFF),BUCKET ANGLE COMPENSATION IS CARRIED OUT…3154
W-4. IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT HORIZONTAL DIGGING BUT DOES NOT CARRY OUT BUCKET ANGLE COMPENSATION…3155
W-5. IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT BUCKET ANGLE COMPENSATION BUT DOES NOT CARRY OUT HORIZONTAL DIGGING…3158
W-6. IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION…3160
W-7. IMPOSSIBLE TO CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION…3167
30 DISASSEMBLY AND ASSEMBLY…3168
METHOD OF USING MANUAL…3170
PRECAUTIONS WHEN CARRYING OUT OPERATION…3172
SPECIAL TOOL LIST…3174
SKETCHES OF SPECIAL TOOLS…3177
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP…3180
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY…3183
REMOVAL AND INSTALLATION OF NOZZLE TIP…3186
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…3188
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…3190
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…3195
REMOVAL AND INSTALLATION OF FUEL COOLER ASSEMBLY…3200
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY…3201
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY…3202
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…3203
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY…3204
REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY…3206
REMOVAL AND INSTALLATION OF PTO ASSEMBLY…3210
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY…3213
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…3215
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…3217
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY…3218
REMOVAL AND INSTALLATION OF TRAVEL MOTOR BRAKE VALVE ASSEMBLY…3219
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY…3220
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMLY…3228
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…3229
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…3230
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY…3231
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY …3232
REMOVAL AND INSTALLATION OF IDLER CUSHION CYLINDER ASSEMBLY…3240
DISASSEMBLY AND ASSEMBLY OF IDLER CUSHION CYLINDER ASSEMBLY…3241
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY…3242
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY…3243
REMOVAL AND INSTALLATION OF FRONT IDLER ASSEMBLY…3245
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…3246
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY…3248
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…3249
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY…3251
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…3252
REMOVAL AND INSTALLATION OF CONTROL・PTO LUBRICATION PUMP ASSEMBLY…3254
REMOVAL AND INSTALLATION OF SWING PUMP ASSEMBLY…3255
REMOVAL AND INSTALLATION OF NO.1, 3 PUMP ASSEMBLY…3256
REMOVAL AND INSTALLATION OF NO.2, 4 PUMP ASSEMBLY…3257
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY…3258
REMOVAL AND INSTALLATION OF PILOT RELIEF VALVE ASSEMBLY…3259
DISASSEMBLY AND ASSEMBLY OF PILOT RELIEF VALVE ASSEMBLY…3260
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (FOR SWING)…3261
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (FOR WORK EQUIPMENT, TRAVEL)…3262
REMOVAL AND INSTALLATION OF SWING CONTROL VALVE ASSEMBLY…3263
DISASSEMBLY AND ASSEMBLY OF SWING CONTROL VALVE ASSEMBLY…3264
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…3266
REMOVAL AND INSTALLATION OF CO, NC VALVE ASSEMBLY…3270
REMOVAL AND INSTALLATION OF SERVO VALVE ASSEMBLY…3271
REMOVAL AND INSTALLATION OF TVC VALVE ASSEMBLY…3272
REMOVAL AND INSTALLATION OF PPC VALVE ASSEMBLY (FOR TRAVEL)…3273
DISASSEMBLY AND ASSEMBLY OF PPC VALVE ASSEMBLY (FOR TRAVEL)…3274
REMOVAL AND INSTALLATION OF PPC VALVE ASSEMBLY (FOR WORK EQUIPMENT, SWING)…3275
DISASSEMBLY AND ASSEMBLY OF PPC VALVE ASSEMBLY (FOR WORK EQUIPMENT, SWING)…3276
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY…3277
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY…3279
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY…3281
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY…3282
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY…3283
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY…3284
REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY…3285
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…3287
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…3294
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY…3298
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY…3299
REMOVAL AND INSTALLATION OF ARM ASSEMBLY…3301
REMOVAL AND INSTALLATION OF ARM ASSEMBLY…3302
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY…3304
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY…3306
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY …3308
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY…3309
REMOVAL AND INSTALLATION OF VHMS CONTROLLER…3311
90 OTHERS…3313
LOCATIONS OF CONNECTORS (WHOLE MACHINE-1/12)…3314
LOCATIONS OF CONNECTORS (WHOLE MACHINE-2/12)…3315
LOCATIONS OF CONNECTORS (WHOLE MACHINE-3/12)…3316
LOCATIONS OF CONNECTORS (WHOLE MACHINE-4/12)…3317
LOCATIONS OF CONNECTORS (WHOLE MACHINE-5/12)…3318
LOCATIONS OF CONNECTORS (WHOLE MACHINE-6/12)…3319
LOCATIONS OF CONNECTORS (WHOLE MACHINE-7/12)…3320
LOCATIONS OF CONNECTORS (WHOLE MACHINE-8/12)…3321
LOCATIONS OF CONNECTORS (WHOLE MACHINE-9/12)…3322
LOCATIONS OF CONNECTORS (WHOLE MACHINE-10/12)…3323
LOCATIONS OF CONNECTORS (WHOLE MACHINE-11/12)…3324
LOCATIONS OF CONNECTORS (WHOLE MACHINE-12/12)…3325
LOCATIONS OF CONNECTORS (AROUND CONTROL)…3326
LOCATIONS OF CONNECTORS (OPERATOR'S CAB-1/2)…3327
LOCATIONS OF CONNECTORS (OPERATOR'S CAB-2/2)…3328
LOCATIONS OF CONNECTORS (AROUND LADDER)…3329
LOCATIONS OF CONNECTORS (RELATED TO AUTO GREASE SYSTEM)…3330
LOCATIONS OF CONNECTORS (FRONT ENGINE)…3331
LOCATIONS OF CONNECTORS (REAR ENGINE)…3332
HYDRAULIC CIRCUIT DIAGRAM (BACK HOE)…3333
HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)…3335
ELECTRICAL CIRCUIT DIAGRAM (1/7)…3337
ELECTRICAL CIRCUIT DIAGRAM (2/7)…3338
ELECTRICAL CIRCUIT DIAGRAM (3/7)…3339
ELECTRICAL CIRCUIT DIAGRAM (4/7)…3340
ELECTRICAL CIRCUIT DIAGRAM (5/7)…3341
ELECTRICAL CIRCUIT DIAGRAM (6/7)…3342
ELECTRICAL CIRCUIT DIAGRAM (7/7)…3343
TEN00051-00 – Hydraulic Excavator GALEO PC1800-6 Operation & Maintenance Manual…3344
COVER…3344
FOREWORD…3345
FOREWORD…3346
SAFETY INFORMATION…3349
INTRODUCTION…3351
DIRECTIONS OF MACHINE…3351
PRODUCT INFORMATION…3352
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…3352
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…3352
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…3353
SERVICE METER LOCATION…3353
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…3354
CONTENTS…3355
SAFETY…3359
SAFETY INFORMATION…3360
POSITION FOR ATTACHING SAFETY LABELS…3362
POSITION FOR ATTACHING SAFETY LABELS…3363
SAFETY LABELS…3364
SAFETY INFORMATION…3368
SAFETY RULES…3368
IF ABNORMALITIES ARE FOUND…3368
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…3368
FIRE EXTINGUISHER AND FIRST AID KIT…3368
SAFETY EQUIPMENT…3369
KEEP MACHINE CLEAN…3369
KEEP OPERATOR'S COMPARTMENT CLEAN…3369
LEAVING OPERATOR'S SEAT WITH LOCK…3369
HANDRAILS AND STEPS…3370
MOUNTING AND DISMOUNTING…3371
NO PERSONS ON ATTACHMENTS…3371
BURN PREVENTION…3371
FIRE PREVENTION AND EXPLOSION PREVENTION…3372
ACTION IF FIRE OCCURS…3373
WINDSHIELD WASHER FLUID…3373
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…3373
ATTACHMENT INSTALLATION…3373
ATTACHMENT COMBINATIONS…3374
CAB WINDOW GLASSES…3374
UNAUTHORIZED MODIFICATIONS…3374
SAFETY AT JOBSITE…3374
WORKING ON LOOSE GROUND…3375
DISTANCE TO HIGH VOLTAGE CABLES…3375
ENSURE GOOD VISIBILITY…3375
VENTILATION FOR ENCLOSED AREA…3376
SIGNALMAN’S SIGNAL AND SIGNS…3376
EMERGENCY EXIT FROM OPERATOR’S CAB…3376
ASBESTOS DUST HAZARD PREVENTION…3376
SAFETY MACHINE OPERATION…3377
STARTING ENGINE…3377
CHECKS BEFORE STARTING ENGINE…3377
SAFETY RULES FOR STARTING ENGINE…3378
STARTING ENGINE IN COLD WEATHER…3378
OPERATION…3379
CHECKS AFTER STARTING ENGINE…3379
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…3379
SAFETY RULES FOR TRAVELING…3380
TRAVELING ON SLOPES…3381
OPERATIONS ON SLOPES…3382
PROHIBITED OPERATIONS…3382
OPERATIONS ON SNOW…3384
PARKING MACHINE…3384
TRANSPORTATION…3385
SHIPPING THE MACHINE…3385
BATTERY…3386
BATTERY HAZARD PREVENTION…3386
STARTING ENGINE WITH BOOSTER CABLES…3387
TOWING…3388
SAFETY RULES FOR TOWING…3388
LIFTING OBJECTS WITH BUCKET…3389
SAFETY RULES FOR LIFTING OBJECTS…3389
SAFETY MAINTENANCE INFORMATION…3390
WARNING TAG…3390
KEEP WORK PLACE CLEAN AND TIDY…3390
APPOINT LEADER WHEN WORKING WITH OTHERS…3390
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…3391
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…3392
PROPER TOOLS…3392
ACCUMULATOR…3393
PERSONNEL…3393
ATTACHMENTS…3393
WORK UNDER THE MACHINE…3393
NOISE…3394
WHEN USING HAMMER…3394
WELDING WORKS…3394
REMOVING BATTERY TERMINALS…3394
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…3395
DO NOT DISASSEMBLE RECOIL SPRINGS…3395
SAFETY RULES FOR HIGH-PRESSURE OIL…3395
PRECAUTION FOR HIGH FUEL PRESSURE…3396
SAFETY HANDLING HIGH-PRESSURE HOSES…3396
PRECAUTION FOR HIGH VOLTAGE…3396
WASTE MATERIALS…3396
AIR CONDITIONER MAINTENANCE…3397
COMPRESSED AIR…3397
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3397
OPERATION…3399
GENERAL VIEW…3400
GENERAL VIEW OF MACHINE…3400
GENERAL VIEW OF CONTROLS AND GAUGES…3401
EXPLANATION OF COMPONENTS…3403
MACHINE MONITOR…3403
CGC MONITOR…3417
SWITCHES…3455
LAMP…3466
CONTROL LEVERS, PEDALS…3470
DOOR LOCK…3474
POCKET…3474
EMERGENCY ESCAPE HAMMER…3474
EMERGENCY ESCAPE LADDER…3475
FIRE EXTINGUISHER…3475
CAP, COVER WITH LOCK…3476
ASHTRAY…3476
HANDLING AIR CONDITIONER…3477
RADIO…3485
FUSE…3489
CIRCUIT BREAKER…3490
CONTROLLER (COMPUTER)…3493
TOOLBOX…3494
HANDLING GREASE PUMP AND GREASE GUN…3494
HANDLING ACCUMULATOR…3498
ORBCOMM CONTROLLER…3499
MACHINE OPERATIONS AND CONTROLS…3500
BEFORE STARTING ENGINE…3500
STARTING ENGINE…3521
AFTER STARTING ENGINE…3526
IN COLD AREAS…3530
STOPPING THE ENGINE…3533
CHECK AFTER SHUT OFF ENGINE…3536
MACHINE OPERATION…3537
STEERING THE MACHINE…3541
SWINGING…3543
WORK EQUIPMENT CONTROLS AND OPERATIONS…3544
HANDLING WORKING MODE…3545
PROHIBITED OPERATIONS…3546
GENERAL OPERATION INFORMATION…3548
TRAVELING ON SLOPES…3549
ESCAPE FROM MUD…3551
RECOMMENDED APPLICATIONS…3552
REPLACEMENT AND INVERSION OF BUCKET…3553
PARKING MACHINE…3555
CHECK AFTER FINISHING WORK…3556
LOCKING…3557
TRANSPORTATION…3558
PRECAUTIONS FOR TRANSPORTATION…3558
LIFTING MACHINE…3559
PARTS FOR TRANSPORT…3559
COLD WEATHER OPERATION…3560
COLD WEATHER OPERATION INFORMATION…3560
AFTER DAILY WORK COMPLETION…3562
AFTER COLD WEATHER SEASON…3562
LONG TERM STORAGE…3563
BEFORE STORAGE…3563
DURING STORAGE…3563
AFTER STORAGE…3564
TROUBLESHOOTING…3565
RUNNING OUT OF FUEL…3565
PHENOMENA THAT ARE NOT FAILURES…3566
TOWING THE MACHINE…3567
PRECAUTIONS ON PARTICULAR JOBSITES…3567
DISCHARGED BATTERY…3568
OTHER TROUBLE…3572
MAINTENANCE…3577
MAINTENANCE INFORMATION…3578
LUBRICANTS, COOLANT AND FILTERS…3581
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3581
ELECTRIC SYSTEM MAINTENANCE…3584
WEAR PARTS LIST…3585
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…3586
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…3586
TIGHTENING TORQUE SPECIFICATIONS…3590
TIGHTENING TORQUE LIST…3590
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3591
SAFETY CRITICAL PARTS…3592
MAINTENANCE SCHEDULE…3594
MAINTENANCE SCHEDULE CHART…3594
MAINTENANCE PROCEDURE…3597
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…3597
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER…3658
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…3597
CHANGE OIL IN SWING MACHINERY CASE…3667
CHANGE OIL IN PTO CASE…3669
CHANGE OIL IN FINAL DRIVE CASE…3671
WHEN REQUIRED…3598
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…3598
CLEAN INSIDE OF COOLING SYSTEM…3601
CHECK AND TIGHTEN TRACK SHOE BOLTS…3605
CHECK AND ADJUST TRACK TENSION…3606
CHECK ELECTRICAL INTAKE AIR HEATER…3609
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…3610
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…3613
ADJUST BUCKET CLEARANCE…3614
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…3615
CHECK AND ADJUST AIR CONDITIONER…3616
CLEANING, REMOVING DIRT FROM LINE FILTER…3617
REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER…3618
GREASE LADDER…3619
INSPECT SEALANT AROUND ENGINE COOLING SYSTEM…3620
CHECK FOR LOOSE AFTERCOOLER HOSE CLAMPS…3621
PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT…3621
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…3629
CHECK BEFORE STARTING…3631
EVERY 10 HOURS MAINTENANCE…3632
LUBRICATING…3632
EVERY 100 HOURS MAINTENANCE…3636
CHECK OIL LEVEL IN SWING MACHINERY CASE…3636
EVERY 250 HOURS MAINTENANCE…3637
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…3637
CHECK LEVEL OF BATTERY ELECTROLYTE…3638
REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER…3640
CHECK, WASH FUEL STRAINER…3641
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS…3642
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…3643
CHECK ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…3645
EVERY 500 HOURS MAINTENANCE…3647
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…3647
REPLACE FUEL FILTER CARTRIDGE…3650
CLEAN PILOT FILTER STRAINER…3652
CLEAN HYDRAULIC FILTER STRAINER FOR AUTO GREASING DRIVE…3652
CHANGE HYDRAULIC FILTER ELEMENT…3653
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTER COOLER FINS…3654
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM…3656
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER…3658
CHECK, REPLACE, ADJUST FAN BELT…3659
CHECK, REPLACE HYDRAULIC PUMP DRAIN FILTER CARTRIDGE…3660
REPLACING SWING MOTOR DRAIN FILTER CARTRIDGE…3661
REPLACING TRAVEL MOTOR DRAIN FILTER CARTRIDGE…3662
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE…3663
EVERY 1000 HOURS MAINTENANCE…3665
REPLACE FUEL FILTER CARTRIDGE…3665
CHANGE OIL IN SWING MACHINERY CASE…3667
CHANGE OIL IN PTO CASE…3669
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…3669
REPLACE CORROSION RESISTOR CARTRIDGE…3670
INSPECTION OF WELDED STRUCTURE AFTER INITIAL 4000 HOURS SERVICE…3670
GREASING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY…3670
EVERY 2000 HOURS MAINTENANCE…3671
CHANGE OIL IN FINAL DRIVE CASE…3671
CHANGE OIL IN HYDRAULIC TANK, WASH STRAINER…3672
CHECK SWING PINION GREASE LEVEL, ADD GREASE…3675
CLEAN ENGINE BREATHER…3675
CLEAN, CHECK TURBOCHARGER…3675
CHECK ALTERNATOR AND STARTING MOTOR…3675
CHECK ENGINE VALVE CLEARANCES, ADJUST…3676
CHECK INJECTOR…3676
EVERY 4000 HOURS MAINTENENCE…3677
CHECK WATER PUMP…3677
CHECK VIBRATION DAMPER…3677
CHECK FAN PULLEY AND TENSION PULLEY…3677
REPLACE INJECTOR NOZZLE ASSEMBLY…3677
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…3678
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…3679
CHECK, ADJUST AIR COMPRESSOR…3679
CHECK WELDED STRUCTURE…3680
EVERY 5000 HOURS MAINTENANCE…3683
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…3683
EVERY 8000 HOURS MAINTENANCE…3686
REPLACE HIGH-PRESSURE PIPING CLAMP…3686
REPLACE FUEL SPRAY PREVENTION CAP…3686
SPECIFICATIONS…3687
SPECIFICATIONS…3688
ATTACHMENTS AND OPTIONS…3691
GENERAL PRECAUTIONS…3692
PRECAUTIONS RELATED TO SAFETY…3692
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…3694
ATTACHMENT GUIDE…3695
COMBINATIONS OF WORK EQUIPMENT…3695
PROTECTIVE GUARD…3696
AUTO GREASING SYSTEM…3697
LOADING SHOVEL…3701
GENERAL VIEW…3702
GENERAL VIEW OF MACHINE…3702
GENERAL VIEW OF CONTROLS AND GAUGES…3703
EXPLANATION OF COMPONENTS…3704
SWITCHES…3704
CONTROL BOX…3705
OPERATIONS…3706
OPERATION OF WORK EQUIPMENT…3706
PRECAUTIONS DURING OPERATION…3708
EXCAVATOR WORK…3712
PRECAUTIONS WHEN DISASSEMBLING MACHINE…3713
RELEASING PRESSURE…3713
TROUBLESHOOTING…3714
WORK EQUIPMENT AUTOMATIC CONTROL CONTROLLER…3714
TRANSPORTATION…3715
MACHINE CONFIGURATION FOR TRANSPORT…3715
MAINTENANCE SCHEDULE…3716
EVERY 10 HOURS MAINTENANCE…3716
SPECIFICATION…3725
COMBINATION OF WORK EQUIPMENT…3727
COMBINATION OF WORK EQUIPMENT…3727
INDEX…3729

Komatsu Hydraulic Excavator PC1800 Workshop Service Repair Manuals

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