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Komatsu Hydraulic Mining Shovel PC8000E Repair Service Manuals

KoComplete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Mining Shovel PC8000E, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Mining Shovel PC8000E-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.

FAMPC8000-06 – Hydraulic Mining Shovel PC8000 General Assembly Procedure.pdf
GZEAM12058 – Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual.pdf
GZEAM12062 – Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual.pdf
GZEAM12066 – Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual.pdf
Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual (SN12053).pdf
SMPC8000E-6 – Hydraulic Mining Shovel PC8000E-6 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 3,122 pages
File Format: PDF
Language: English

MAIN SECTIONS
FAMPC8000-06 – Hydraulic Mining Shovel PC8000 General Assembly Procedure…2
GZEAM12058 – Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual…160
COVER…160
1. INTRODUCTION…162
1.1 CONTENTS OF THE BINDER…163
1.2 DIVISION OF THE BINDER…164
1.3 DESIGNATED USE OF THE SHOVEL…165
1.4 DELIVERY OF THE SHOVEL…166
1.5 EXPLANATION OF ABBREVIATIONS…167
1.6 TABLE OF CONTENTS…168
2. SAFETY…174
2.1 SAFETY INSTRUCTIONS…175
2.1.1 WARNINGS AND SYMBOLS…175
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL…175
2.1.3 ORGANIZATIONAL MEASURES…176
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…178
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…179
2.1.6 WARNING OF SPECIAL DANGERS…182
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…184
2.1.8 SPECIAL SAFETY EQUIPMENT…184
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…188
3. OPERATION…196
3.1 FOREWORD…197
3.2 CONSTRUCTION OF THE SHOVEL…198
3.2.1 OVERALL VIEW…198
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…199
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…207
3.2.4 EMERGENCY ESCAPE LADDER AT THE OPERATORS CAB PLATFORM…211
3.2.5 EMERGENCY ESCAPE LADDER AT THE SUPERSTRUCTURE PLATFORM…213
3.2.6 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR…215
3.2.7 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE…217
3.2.8 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…219
3.2.9 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…221
3.2.10 ENGINE OIL MANAGEMENT SYSTEM…231
3.3 OPERATORS CAB – CONTROLS…235
3.3.1 HYDRAULIC CONTROL SYSTEM…236
3.3.2 SAFETY CIRCUIT FOR CONTROLS…236
3.3.3 OPERATORS CONSOLE…240
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS…248
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER…250
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…251
3.4.1 INTRODUCTION…252
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM…260
3.4.3 AUTOMATIC DISPLAY OF MESSAGES…264
3.4.4 MENU CONTROL…288
3.4.5 MENU CONTROL LIST…315
3.4.6 FAULT AND INFORMATION MESSAGE LIST…333
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…357
3.5.1 AUXILIARY HEATER FOR OPERATORS CAB…360
3.6 MACHINERY HOUSE…361
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…362
3.6.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE…364
3.6.3 CENTRAL CONTROL AND FILTER PANEL…366
3.6.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO…368
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…369
3.7.1 STANDARD COMPONENTS IN CAB BASE…370
3.7.2 SWITCH BOARD (X2) IN CAB BASE…372
3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE…382
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES…385
3.9 CHECKS BEFORE STARTING THE ENGINES…389
3.10 STARTING THE ENGINES…395
3.10.1 STARTING PROCEDURE…398
3.11 MOVING THE SHOVEL…410
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS…410
3.11.2 TRAVELLING INSTRUCTIONS…413
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…414
3.12.1 SLEWING THE SUPERSTRUCTURE…414
3.13 WORKING WITH THE ATTACHMENT…417
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…417
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…418
3.13.3 BOTTOM DUMP BUCKET…419
3.13.4 DROP BALL OPERATION…420
3.13.5 COMBINED OPERATION CYCLES…423
3.14 WORKING INSTRUCTIONS…425
3.14.1 STABILITY OF THE SHOVEL…425
3.14.2 SHOVEL OPERATION…425
3.15 PARKING THE SHOVEL…428
3.16 STOPPING THE ENGINES…429
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…432
3.17 OPERATION OF THE LUBRICATION SYSTEM…433
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT…433
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…435
3.18 TRANSFER PUMP FOR HYDRAULIC OIL…437
3.18.1 OPERATING THE TRANSFER PUMP…438
3.18.2 TRANSFUSION PROCEDURE…440
3.19 CENTRAL REFILLING SYSTEM…443
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…444
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM…446
3.19.3 RECEIVER PANEL WITH MONITOR BOX…448
3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS…454
3.20 WORK ON THE LOADER ATTACHMENT…455
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL…456
3.21.1 DISASSEMBLING OF THE SHOVEL…456
3.21.2 TRANSPORTATION AND LIFTING…456
3.22 RETRIEVAL PROCEDURE…457
3.23 SHOVEL STORAGE…458
3.23.1 PREPARING FOR STORAGE…458
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD…459
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD…459
3.23.4 PREPARING FOR OPERATION…460
3.24 TROUBLE SHOOTING…461
3.24.1 ENGINE…461
3.24.2 HYDRAULIC SYSTEM…462
3.24.3 FINAL DRIVES AND SWING GEAR…463
3.24.4 CRAWLER TRACKS…463
4. MAINTENANCE…464
4.1 FOREWORD…465
4.2 PRECAUTIONS FOR MAINTENANCE…466
4.3 FLUIDS AND LUBRICANTS…468
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…468
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…469
4.4 FILLING CAPACITIES…471
4.5 STANDARD TORQUE LIST…472
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…473
4.6.1 INITIAL SERVICING…473
4.6.2 PERIODIC SERVICING INTERVALS…473
4.6.3 PERIODIC SERVICING SCHEDULE…474
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES…479
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…480
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM…484
4.6.7 MAINTENANCE OF THE ENGINES…488
4.7 WHEN NECESSARY…489
4.7.1 ENGINE AIR CLEANER MAINTENANCE…490
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…494
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…496
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…500
4.8 EVERY 10 OPERATING HOURS OR DAILY…501
4.8.1 WALK – AROUND INSPECTION…502
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…512
4.8.3 RADIATORS – CHECK COOLANT LEVEL…514
4.8.4 TRACK GROUPS – CLEAN…514
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…515
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL…516
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…520
4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…522
4.9.4 PUMP DISTRIBUTOR GEARS – CHECK OIL LEVEL…524
4.9.5 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…526
4.9.6 MAIN HYDRAULIC OIL COOLER – INSPECT AND CLEAN IF NECESSARY…528
4.9.7 PTO GEAR OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…532
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…533
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…534
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…536
4.10.3 DRIVE SHAFTS – LUBRICATE…536
4.10.4 SIGNAL HORN COMPRESSOR – LUBRICATE…536
4.10.5 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…538
4.10.6 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…538
4.10.7 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER…540
4.10.8 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…542
4.10.9 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL…544
4.10.10 AIR CONDITIONING FOR OPERATORS CAB – CHECK REFRIGERANT LEVEL…546
4.11 EVERY 500 OPERATING HOURS OR QUARTELY…547
4.11.1 BATTERIES – CHECK FLUID LEVEL…548
4.11.2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL…550
4.11.3 DRIVE SHAFT HOUSINGS ON PTO GEARS – CHECK OIL LEVEL…552
4.11.4 FUEL TANK – DRAIN CONDENSATION…554
4.11.5 CRAWLER TRACK – INSPECTION…556
4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION…562
4.11.7 GROUND CABLE OF OPERATORS CAB – CHECK FOR CORRECT CONNECTION…564
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…565
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…566
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…608
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…620
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…622
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…624
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…626
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…628
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…630
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…631
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…632
4.13.2 EMERGENCY ESCAPE LADDERS – INSPECTION…642
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…649
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…650
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…658
4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL…662
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…664
4.15 FIRE PREVENTION…665
4.16 WELD REPAIRS…667
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…670
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…672
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…674
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…676
GZEAM12062 – Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual…683
1. INTRODUCTION…685
1.1 CONTENTS OF THE BINDER…686
1.2 DIVISION OF THE BINDER…687
1.3 DESIGNATED USE OF THE SHOVEL…688
1.4 DELIVERY OF THE SHOVEL…689
1.5 EXPLANATION OF ABBREVIATIONS…690
1.6 TABLE OF CONTENTS…691
2. SAFETY…697
2.1 SAFETY INSTRUCTIONS…698
2.1.1 WARNINGS AND SYMBOLS…698
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL…698
2.1.3 ORGANIZATIONAL MEASURES…699
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…701
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…702
2.1.6 WARNING OF SPECIAL DANGERS…705
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…707
2.1.8 SPECIAL SAFETY EQUIPMENT…707
2.1.9 ELECTROMAGNETIC COMPATIBILITY (EMC)…709
2.1.10 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE…709
2.1.11 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…711
3. OPERATION…719
3.1 FOREWORD…720
3.2 CONSTRUCTION OF THE SHOVEL…721
3.2.1 OVERALL VIEW…721
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…722
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…730
3.2.4 EMERGENCY ESCAPE LADDER AT THE OPERATORS CAB PLATFORM…734
3.2.5 EMERGENCY ESCAPE LADDER AT THE SUPERSTRUCTURE PLATFORM…736
3.2.6 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR…738
3.2.7 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE…740
3.2.8 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…742
3.2.9 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…744
3.2.10 ENGINE OIL MANAGEMENT SYSTEM…754
3.3 OPERATORS CAB – CONTROLS…758
3.3.1 HYDRAULIC CONTROL SYSTEM…759
3.3.2 SAFETY CIRCUIT FOR CONTROLS…759
3.3.3 OPERATORS CONSOLE…763
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS…771
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER…773
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…774
3.4.1 INTRODUCTION…775
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM…783
3.4.3 AUTOMATIC DISPLAY OF MESSAGES…787
3.4.4 MENU CONTROL…811
3.4.5 MENU CONTROL LIST…838
3.4.6 FAULT AND INFORMATION MESSAGE LIST…856
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…880
3.5.1 AUXILIARY HEATER FOR OPERATORS CAB…883
3.6 MACHINERY HOUSE…884
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…885
3.6.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE…887
3.6.3 CENTRAL CONTROL AND FILTER PANEL…889
3.6.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO…891
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…892
3.7.1 STANDARD COMPONENTS IN CAB BASE…893
3.7.2 SWITCH BOARD (X2) IN CAB BASE…895
3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE…905
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES…908
3.9 CHECKS BEFORE STARTING THE ENGINES…912
3.10 STARTING THE ENGINES…918
3.10.1 STARTING PROCEDURE…921
3.11 MOVING THE SHOVEL…933
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS…933
3.11.2 TRAVELLING INSTRUCTIONS…936
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…937
3.12.1 SLEWING THE SUPERSTRUCTURE…937
3.13 WORKING WITH THE ATTACHMENT…940
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…940
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…941
3.13.3 BOTTOM DUMP BUCKET…942
3.13.4 DROP BALL OPERATION…943
3.13.5 COMBINED OPERATION CYCLES…946
3.14 WORKING INSTRUCTIONS…948
3.14.1 STABILITY OF THE SHOVEL…948
3.14.2 SHOVEL OPERATION…948
3.15 PARKING THE SHOVEL…951
3.16 STOPPING THE ENGINES…952
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…955
3.17 OPERATION OF THE LUBRICATION SYSTEM…956
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT…956
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…958
3.18 TRANSFER PUMP FOR HYDRAULIC OIL…960
3.18.1 OPERATING THE TRANSFER PUMP…961
3.18.2 TRANSFUSION PROCEDURE…963
3.19 CENTRAL REFILLING SYSTEM…966
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…967
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM…969
3.19.3 RECEIVER PANEL WITH MONITOR BOX…971
3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS…977
3.20 WORK ON THE LOADER ATTACHMENT…978
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL…979
3.21.1 DISASSEMBLING OF THE SHOVEL…979
3.21.2 TRANSPORTATION AND LIFTING…979
3.22 RETRIEVAL PROCEDURE…980
3.23 SHOVEL STORAGE…981
3.23.1 PREPARING FOR STORAGE…981
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD…982
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD…982
3.23.4 PREPARING FOR OPERATION…983
3.24 TROUBLE SHOOTING…984
3.24.1 ENGINE…984
3.24.2 HYDRAULIC SYSTEM…985
3.24.3 FINAL DRIVES AND SWING GEAR…986
3.24.4 CRAWLER TRACKS…986
4. MAINTENANCE…987
4.1 FOREWORD…988
4.2 PRECAUTIONS FOR MAINTENANCE…989
4.3 FLUIDS AND LUBRICANTS…991
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…991
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…992
4.4 FILLING CAPACITIES…994
4.5 STANDARD TORQUE LIST…995
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…996
4.6.1 INITIAL SERVICING…996
4.6.2 PERIODIC SERVICING INTERVALS…996
4.6.3 PERIODIC SERVICING SCHEDULE…997
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES…1002
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1003
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM…1007
4.6.7 MAINTENANCE OF THE ENGINES…1011
4.7 WHEN NECESSARY…1012
4.7.1 ENGINE AIR CLEANER MAINTENANCE…1013
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…1017
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…1019
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…1023
4.8 EVERY 10 OPERATING HOURS OR DAILY…1024
4.8.1 WALK – AROUND INSPECTION…1025
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…1035
4.8.3 RADIATORS – CHECK COOLANT LEVEL…1037
4.8.4 TRACK GROUPS – CLEAN…1037
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…1038
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL…1039
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…1043
4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…1045
4.9.4 PUMP DISTRIBUTOR GEARS – CHECK OIL LEVEL…1047
4.9.5 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…1049
4.9.6 MAIN HYDRAULIC OIL COOLER – INSPECT AND CLEAN IF NECESSARY…1051
4.9.7 PTO GEAR OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…1055
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…1056
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…1057
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…1059
4.10.3 DRIVE SHAFTS – LUBRICATE…1059
4.10.4 SIGNAL HORN COMPRESSOR – LUBRICATE…1059
4.10.5 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…1061
4.10.6 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…1061
4.10.7 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER…1063
4.10.8 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…1065
4.10.9 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL…1067
4.10.10 AIR CONDITIONING FOR OPERATORS CAB – CHECK REFRIGERANT LEVEL…1069
4.11 EVERY 500 OPERATING HOURS OR QUARTELY…1070
4.11.1 BATTERIES – CHECK FLUID LEVEL…1071
4.11.2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL…1073
4.11.3 DRIVE SHAFT HOUSINGS ON PTO GEARS – CHECK OIL LEVEL…1075
4.11.4 FUEL TANK – DRAIN CONDENSATION…1077
4.11.5 CRAWLER TRACK – INSPECTION…1079
4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION…1085
4.11.7 GROUND CABLE OF OPERATORS CAB – CHECK FOR CORRECT CONNECTION…1087
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…1088
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…1089
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…1131
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…1143
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…1145
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…1147
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…1149
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…1151
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…1153
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…1154
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…1155
4.13.2 EMERGENCY ESCAPE LADDERS – INSPECTION…1165
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…1172
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…1173
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…1181
4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL…1185
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…1187
4.15 FIRE PREVENTION…1188
4.16 WELD REPAIRS…1190
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…1193
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…1195
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…1197
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…1199
GZEAM12066 – Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual…1206
1. INTRODUCTION…1208
1.1 CONTENTS OF THE BINDER…1209
1.2 DIVISION OF THE BINDER…1210
1.3 DESIGNATED USE OF THE SHOVEL…1211
1.4 DELIVERY OF THE SHOVEL…1212
1.5 EXPLANATION OF ABBREVIATIONS…1213
1.6 TABLE OF CONTENTS…1214
2. SAFETY…1220
2.1 SAFETY INSTRUCTIONS…1221
2.1.1 WARNINGS AND SYMBOLS…1221
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL…1221
2.1.3 ORGANIZATIONAL MEASURES…1222
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…1224
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…1225
2.1.6 WARNING OF SPECIAL DANGERS…1228
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…1230
2.1.8 SPECIAL SAFETY EQUIPMENT…1230
2.1.9 ELECTROMAGNETIC COMPATIBILITY (EMC)…1232
2.1.10 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE…1232
2.1.11 VISIBILITY FROM OPERATORS SEAT…1234
2.1.12 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…1236
3. OPERATION…1244
3.1 FOREWORD…1245
3.2 CONSTRUCTION OF THE SHOVEL…1246
3.2.1 OVERALL VIEW WITH BACKHOE ATTACHMENT…1246
3.2.2 OVERALL VIEW WITH BOTTOM DUMP BUCKET ATTACHMENT…1247
3.2.3 SUPERSTRUCTURE…1249
3.2.4 UNDERCARRIAGE…1257
3.2.5 HYDRAULICALLY OPERATED ACCESS LADDER…1259
3.2.6 EMERGENCY ESCAPE LADDER AT THE OPERATORS CAB PLATFORM…1263
3.2.7 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR…1265
3.2.8 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE…1267
3.2.9 FOLDING LADDER INSIDE OF CARBODY…1269
3.2.10 BOOM ACCESS LADDER AND WALKWAY…1271
3.2.11 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…1273
3.2.12 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…1275
3.3 OPERATORS CAB – CONTROLS…1285
3.3.1 HYDRAULIC CONTROL SYSTEM…1286
3.3.2 SAFETY CIRCUIT FOR CONTROLS…1286
3.3.3 OPERATORS CONSOLE…1290
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS…1298
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…1299
3.4.1 INTRODUCTION…1300
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM…1308
3.4.3 AUTOMATIC DISPLAY OF MESSAGES…1312
3.4.4 MENU CONTROL AND SERVICE FUNCTIONS…1336
3.4.5 MENU CONTROL LIST…1363
3.4.6 FAULT AND INFORMATION MESSAGE LIST…1381
3.5 CAMERA SYSTEM WITH MONITORS (SPECIAL EQUIPMENT)…1407
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS…1408
3.6 OPERATING THE HEATERS, VENTILATION AND AIR CONDITIONING…1415
3.6.1 AIR CONDITIONING AND HEATING…1416
3.6.2 A – HEATING…1416
3.6.3 B – COOLING…1416
3.6.4 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…1418
3.7 MACHINERY HOUSE…1419
3.7.1 EMERGENCY MOTOR SHUTDOWN SWITCHES…1420
3.7.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE…1422
3.7.3 CENTRAL CONTROL AND FILTER PANEL…1424
3.7.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO…1426
3.8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE…1427
3.8.1 COMPONENTS IN THE MEDIUM VOLTAGE SWITCH CABINET…1430
3.8.2 SWITCH BOARD (X2) IN CAB BASE…1432
3.8.3 MONITOR AND CONTROL PANEL IN CAB BASE…1440
3.9 HIGH VOLTAGE SWITCH CABINET…1443
3.10 CHECKS BEFORE STARTING THE MOTORS…1445
3.11 STARTING THE MAIN DRIVE MOTORS…1447
3.12 MOVING THE SHOVEL…1454
3.12.1 TRAVEL CONTROL WITH FOOT PEDALS…1454
3.12.2 TRAVELLING INSTRUCTIONS…1457
3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE…1458
3.13.1 SLEWING THE SUPERSTRUCTURE…1458
3.14 WORKING WITH THE ATTACHMENT…1461
3.14.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…1461
3.14.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…1462
3.14.3 BOTTOM DUMP BUCKET…1463
3.14.4 DROP BALL OPERATION…1464
3.14.5 COMBINED OPERATION CYCLES…1467
3.15 WORKING INSTRUCTIONS…1469
3.15.1 STABILITY OF THE SHOVEL…1469
3.15.2 SHOVEL OPERATION…1469
3.16 PARKING THE SHOVEL…1472
3.17 STOPPING THE MAIN DRIVE MOTORS…1473
3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…1476
3.18 OPERATION OF THE LUBRICATION SYSTEM…1477
3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT…1477
3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…1479
3.19 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM (SPECIAL EQUIPMENT)…1481
3.19.1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS…1482
3.19.2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB…1486
3.19.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM:…1486
3.19.4 IN CASE OF FIRE…1488
3.20 TRANSFER PUMP FOR HYDRAULIC OIL…1489
3.20.1 OPERATING THE TRANSFER PUMP…1490
3.20.2 TRANSFUSION PROCEDURE…1492
3.21 CENTRAL REFILLING SYSTEM…1495
3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…1496
3.21.2 RECEIVER PANEL AND MONITOR BOX…1496
3.21.3 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOU….1500
3.22 FOLDING PEDESTAL ON THE OPERATORS CAB…1501
3.23 SERVICE CRANE (SPECIAL EQUIPMENT)…1505
3.23.1 OPERATING THE CRANE…1506
3.24 CABLE DRUM (SPECIAL EQUIPMENT)…1509
3.24.1 OPERATION OF THE CABLE DRUM…1510
3.24.2 TRAVELLING INSTRUCTIONS…1514
3.25 WORK ON THE LOADER ATTACHMENT…1517
3.26 TRANSPORTATION AND LIFTING OF THE SHOVEL…1518
3.26.1 DISASSEMBLING OF THE SHOVEL…1518
3.26.2 TRANSPORTATION AND LIFTING…1518
3.27 RETRIEVAL PROCEDURE…1519
3.28 SHOVEL STORAGE…1520
3.28.1 PREPARING FOR STORAGE…1520
3.28.2 ONE MONTH REPETITIVE SERVICE PERIOD…1520
3.28.3 SIX MONTH REPETITIVE SERVICE PERIOD…1521
3.28.4 PREPARING FOR OPERATION…1521
3.29 TROUBLE SHOOTING…1522
3.29.1 MAIN DRIVE ELECTRIC MOTOR…1522
3.29.2 HYDRAULIC SYSTEM…1523
3.29.3 FINAL DRIVES AND SWING GEAR…1524
3.29.4 CRAWLER TRACKS…1524
4. MAINTENANCE…1526
4.1 FOREWORD…1527
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE…1528
4.3 FLUIDS AND LUBRICANTS…1530
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…1530
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…1531
4.3.3 MAIN DRIVE ELECTRIC MOTORS BEARING LUBRICATION…1532
4.4 FILLING CAPACITIES…1533
4.5 STANDARD TORQUE LIST…1534
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…1535
4.6.1 INITIAL SERVICING…1535
4.6.2 PERIODIC SERVICING INTERVALS…1535
4.6.3 PERIODIC SERVICING SCHEDULE…1536
4.6.4 MAINTENANCE OF THE MAIN DRIVE ELECTRIC MOTORS…1540
4.6.5 REPLACEMENT OF HYDRAULIC HOSE LINES…1542
4.6.6 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1543
4.7 WHEN NECESSARY…1545
4.7.1 SWING CIRCLE TOOTHING LUBRICATION…1546
4.7.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…1548
4.7.3 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…1552
4.8 EVERY 10 OPERATING HOURS OR DAILY…1553
4.8.1 WALK – AROUND INSPECTION…1554
4.8.2 CLEANING THE TRACK GROUPS…1562
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…1563
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL…1564
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…1568
4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…1570
4.9.4 PUMP DISTRIBUTOR GEARS – CHECK OIL LEVEL…1572
4.9.5 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…1574
4.9.6 MAIN HYDRAULIC OIL COOLER – INSPECT AND CLEAN IF NECESSARY…1576
4.9.7 PTO GEAR OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…1580
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…1581
4.10.1 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…1582
4.10.2 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…1582
4.10.3 SIGNAL HORN COMPRESSOR – LUBRICATE…1582
4.10.4 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER…1584
4.10.5 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…1586
4.10.6 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL…1588
4.10.7 AIR CONDITIONING FOR OPERATORS CAB – VERSION "KYSOR"…1590
4.10.8 AIR CONDITIONING FOR ELECTRICAL SWITCH CABINETS – CHECK REFRIGERANT LEVEL…1592
4.11 EVERY 500 OPERATING HOURS OR MONTHLY…1595
4.11.1 BATTERIES – CHECK FLUID LEVEL…1596
4.11.2 DRIVE SHAFT HOUSINGS ON PTO GEARS – CHECK OIL LEVEL…1598
4.11.3 CRAWLER TRACK – INSPECTION…1600
4.11.4 GROUND CABLE OF OPERATORS CAB – CHECK FOR CORRECT CONNECTION…1606
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…1607
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…1608
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…1654
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…1666
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…1668
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…1670
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…1672
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…1674
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…1676
4.12.9 SLIP RING UNIT – LUBRICATE…1678
4.12.10 SERVICE CRANE – LUBRICATE…1678
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…1679
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…1680
4.13.2 EMERGENCY ESCAPE LADDERS – INSPECTION…1690
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…1695
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…1696
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…1704
4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL…1708
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…1710
4.15 FIRE PREVENTION…1711
4.16 WELD REPAIRS…1713
4.16.1 GENERAL PROTECTIVE MEASURES…1714
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…1716
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…1718
4.16.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…1720
4.16.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…1720
Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual (SN12053)…1728
COVER…1728
1. INTRODUCTION…1730
1.1 CONTENTS OF THE BINDER…1731
1.2 DIVISION OF THE BINDER…1732
1.3 DESIGNATED USE OF THE SHOVEL…1733
1.4 DELIVERY OF THE SHOVEL…1734
1.5 EXPLANATION OF ABBREVIATIONS…1735
1.6 TABLE OF CONTENTS…1736
2. SAFETY…1742
2.1 SAFETY INSTRUCTIONS…1743
2.1.1 WARNINGS AND SYMBOLS…1743
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL…1743
2.1.3 ORGANIZATIONAL MEASURES…1744
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…1746
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…1747
2.1.6 WARNING OF SPECIAL DANGERS…1750
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…1752
2.1.8 SPECIAL SAFETY EQUIPMENT…1752
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…1756
3. OPERATION…1764
3.1 FOREWORD…1765
3.2 CONSTRUCTION OF THE SHOVEL…1766
3.2.1 OVERALL VIEW…1766
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…1767
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…1775
3.2.4 EMERGENCY ESCAPE LADDER AT THE OPERATORS CAB PLATFORM…1779
3.2.5 EMERGENCY ESCAPE LADDER AT THE SUPERSTRUCTURE PLATFORM…1781
3.2.6 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR…1783
3.2.7 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE…1785
3.2.8 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…1787
3.2.9 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…1789
3.2.10 ENGINE OIL MANAGEMENT SYSTEM…1799
3.3 OPERATORS CAB – CONTROLS…1803
3.3.1 HYDRAULIC CONTROL SYSTEM…1804
3.3.2 SAFETY CIRCUIT FOR CONTROLS…1804
3.3.3 OPERATORS CONSOLE…1808
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS…1816
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER…1818
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…1819
3.4.1 INTRODUCTION…1820
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM…1828
3.4.3 AUTOMATIC DISPLAY OF MESSAGES…1832
3.4.4 MENU CONTROL…1856
3.4.5 MENU CONTROL LIST…1883
3.4.6 FAULT AND INFORMATION MESSAGE LIST…1901
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…1925
3.5.1 AUXILIARY HEATER FOR OPERATORS CAB…1928
3.6 MACHINERY HOUSE…1929
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…1930
3.6.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE…1932
3.6.3 CENTRAL CONTROL AND FILTER PANEL…1934
3.6.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO…1936
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…1937
3.7.1 STANDARD COMPONENTS IN CAB BASE…1938
3.7.2 SWITCH BOARD (X2) IN CAB BASE…1940
3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE…1950
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES…1953
3.9 CHECKS BEFORE STARTING THE ENGINES…1957
3.10 STARTING THE ENGINES…1963
3.10.1 STARTING PROCEDURE…1966
3.11 MOVING THE SHOVEL…1974
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS…1974
3.11.2 TRAVELLING INSTRUCTIONS…1977
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…1978
3.12.1 SLEWING THE SUPERSTRUCTURE…1978
3.13 WORKING WITH THE ATTACHMENT…1981
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…1981
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…1982
3.13.3 BOTTOM DUMP BUCKET…1983
3.13.4 DROP BALL OPERATION…1984
3.13.5 COMBINED OPERATION CYCLES…1987
3.14 WORKING INSTRUCTIONS…1989
3.14.1 STABILITY OF THE SHOVEL…1989
3.14.2 SHOVEL OPERATION…1989
3.15 PARKING THE SHOVEL…1992
3.16 STOPPING THE ENGINES…1993
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…1996
3.17 OPERATION OF THE LUBRICATION SYSTEM…1997
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT…1997
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…1999
3.18 TRANSFER PUMP FOR HYDRAULIC OIL…2001
3.18.1 OPERATING THE TRANSFER PUMP…2002
3.18.2 TRANSFUSION PROCEDURE…2004
3.19 CENTRAL REFILLING SYSTEM…2007
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…2008
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM…2010
3.19.3 RECEIVER PANEL WITH MONITOR BOX…2012
3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS…2018
3.20 WORK ON THE LOADER ATTACHMENT…2019
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL…2020
3.21.1 DISASSEMBLING OF THE SHOVEL…2020
3.21.2 TRANSPORTATION AND LIFTING…2020
3.22 RETRIEVAL PROCEDURE…2021
3.23 SHOVEL STORAGE…2022
3.23.1 PREPARING FOR STORAGE…2022
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD…2023
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD…2023
3.23.4 PREPARING FOR OPERATION…2024
3.24 TROUBLE SHOOTING…2025
3.24.1 ENGINE…2025
3.24.2 HYDRAULIC SYSTEM…2026
3.24.3 FINAL DRIVES AND SWING GEAR…2027
3.24.4 CRAWLER TRACKS…2027
4. MAINTENANCE…2028
4.1 FOREWORD…2029
4.2 PRECAUTIONS FOR MAINTENANCE…2030
4.3 FLUIDS AND LUBRICANTS…2032
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…2032
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…2033
4.4 FILLING CAPACITIES…2035
4.5 STANDARD TORQUE LIST…2036
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…2037
4.6.1 INITIAL SERVICING…2037
4.6.2 PERIODIC SERVICING INTERVALS…2037
4.6.3 PERIODIC SERVICING SCHEDULE…2038
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES…2043
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2044
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM…2048
4.6.7 MAINTENANCE OF THE ENGINES…2052
4.7 WHEN NECESSARY…2053
4.7.1 ENGINE AIR CLEANER MAINTENANCE…2054
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…2058
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…2060
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…2064
4.8 EVERY 10 OPERATING HOURS OR DAILY…2065
4.8.1 WALK – AROUND INSPECTION…2066
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…2076
4.8.3 RADIATORS – CHECK COOLANT LEVEL…2078
4.8.4 TRACK GROUPS – CLEAN…2078
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…2079
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL…2080
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…2082
4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL…2084
4.9.4 PUMP DISTRIBUTOR GEARS – CHECK OIL LEVEL…2086
4.9.5 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…2088
4.9.6 MAIN HYDRAULIC OIL COOLER – INSPECT AND CLEAN IF NECESSARY…2090
4.9.7 PTO GEAR OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…2094
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…2095
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…2096
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…2098
4.10.3 DRIVE SHAFTS – LUBRICATE…2098
4.10.4 SIGNAL HORN COMPRESSOR – LUBRICATE…2098
4.10.5 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…2100
4.10.6 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…2100
4.10.7 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER…2102
4.10.8 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…2104
4.10.9 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL…2106
4.10.10 AIR CONDITIONING FOR OPERATORS CAB – CHECK REFRIGERANT LEVEL…2108
4.11 EVERY 500 OPERATING HOURS OR QUARTELY…2109
4.11.1 BATTERIES – CHECK FLUID LEVEL…2110
4.11.2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL…2112
4.11.3 DRIVE SHAFT HOUSINGS ON PTO GEARS – CHECK OIL LEVEL…2114
4.11.4 FUEL TANK – DRAIN CONDENSATION…2116
4.11.5 CRAWLER TRACK – INSPECTION…2118
4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION…2124
4.11.7 GROUND CABLE OF OPERATORS CAB – CHECK FOR CORRECT CONNECTION…2126
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…2127
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…2128
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…2170
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…2182
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…2184
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…2186
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…2188
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…2190
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…2192
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…2193
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…2194
4.13.2 EMERGENCY ESCAPE LADDERS – INSPECTION…2204
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…2211
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…2212
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…2216
4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL…2220
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…2222
4.15 FIRE PREVENTION…2223
4.16 WELD REPAIRS…2225
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…2228
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…2230
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…2232
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…2234
SMPC8000E-6 – Hydraulic Mining Shovel PC8000E-6 Shop Manual…2241

PRODUCT DETAILS:
Total Pages: 3,122 pages
File Format: PDF
Language: English

Komatsu Hydraulic Mining Shovel PC8000E Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 11, 2025 by admin

Komatsu Hydraulic Mining Shovel PC5500 Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Mining Shovel PC5500, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Mining Shovel PC5500 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.

SMPC550015011 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015018 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015019 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015022 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015023 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015025 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015027 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015032 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015035 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015038 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015039 – Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
PC5500615025SM – Hydraulic Shovel PC5500-6 Electrical & Hydraulic Diagrams.pdf
FAMPC5500-04 – Hydraulic Mining Shovel PC5500 General Assembly Procedure.pdf
Hydraulic Excavator PC5500 Service Manual (SN15014&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15016&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15017&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15031&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15046&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15050&up).pdf
GZEAM15066 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15012&15013).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15014).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15016).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15027).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15028&15029&15030).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15032&15039).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15033).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15035&up).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15036).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15038).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15040).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15041).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15044).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15045&up).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15049&up).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15050).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15052).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15060&15062).pdf
OMPC550015011 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015018 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015019 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015022 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015023 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015025 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015027 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015032 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015035 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015038 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015039 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf

Total Pages: 27,543 pages
File Format: PDF
Language: English

MAIN SECTIONS
FAMPC5500-04 – Hydraulic Mining Shovel PC5500 General Assembly Procedure…..5
Cover…..5
Contents…..13
1. Assembly of the Undercarriage (Z 24016a, Z 24018a) …..25
1.1 Assembly …..25
2. Assembly of the Cable Reel Unit (Z21885) …..37
3. Assembly of the Superstructure Platform onto the Undercarriage (Z21886) …..39
4. Assembly of the Prime Drive Unit to the Superstructure Platform (Z 21887) …..41
4. a Mounting of the hydraulic access ladder (Z21136) …..43
5. Assembly of the Boom Cylinders and the Stick Cylinder to the Boom (Z 21888a; Z 21941, Z 21944) …..47
5.a. Assembly of the Boom (Z21889a) …..49
6. Assembly of the Counterweight (Z21891b) …..51
7. Mounting of the Fuel Tank (Z 21892) or Main Switch Cabinet for Electrical Driven Unit…..53
8. Mounting of the Cab Base (Z 21893) …..55
9. Mounting of the Cab with Support Frame (Z 21894) …..57
10. Mounting of the High Pressure Hoses (Z 21896) and the Hydraulic Oil Tank (Z 21897) …..59
11. Mounting of the Hydraulic Oil Cooler (Z 21895) …..65
12. Mounting of the Hand Rails, Cat Walks, Steps and the Grease Barrel Crane* (Z 21901) …..71
13. Mounting of Cable transfer to the Operators Cab (Z22937) …..73
13a. Installation of Hydraulic Hoses to the Attachment and Rotary Joint …..75
14. Checking of direction motor rotation Z 22644a …..77
15. Connection of Electric Cables …..79
16. Filling the Hydraulic System (Z25026) …..83
17. Pre-checks prior Initial Start-up …..85
17.1 General …..85
17.2 Only with Electric Drive …..87
17.3 Initial Start up …..87
18. Assembly of the Stick to the Boom: Z 21890 …..89
19. Mounting of the Stick Cylinders to the Stick (Z 21903) …..91
20. Assembly of the Bullclam Bucket to the Stick: Z 21904 …..93
21. Mounting of the Pin Seals (Z 21906) …..97
22. Putting the Lubrication System into operation (Z25022) …..99
23. Checks and Adjustments Prior Commissioning …..101
Metric standard thread …..103
Metric fine thread …..105
GZEAM15066 – Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual…..109
1. INTRODUCTION…..111
1.1 CONTENTS OF THE BINDER…..112
1.2 DIVISION OF THE BINDER…..113
1.3 DESIGNATED USE OF THE SHOVEL…..114
1.4 DELIVERY OF THE SHOVEL…..115
1.5 EXPLANATION OF ABBREVIATIONS…..116
1.6 TABLE OF CONTENTS…..117
2. SAFETY…..123
2.1 SAFETY INSTRUCTIONS…..124
2.1.1 WARNINGS AND SYMBOLS…..124
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL…..124
2.1.3 ORGANIZATIONAL MEASURES…..125
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…..127
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…..128
2.1.6 WARNING OF SPECIAL DANGERS…..131
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…..133
2.1.8 SPECIAL SAFETY EQUIPMENT…..133
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…..137
3. OPERATION…..145
3.1 FOREWORD…..146
3.2 CONSTRUCTION OF THE SHOVEL…..147
3.2.1 OVERALL VIEW…..147
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…..148
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…..154
3.2.4 EMERGENCY ESCAPE LADDER…..158
3.2.5 BOOM ACCESS LADDER AND WALKWAY…..160
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…..162
3.2.7 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…..164
3.2.8 ENGINE OIL MANAGEMENT SYSTEM…..174
3.3 OPERATORS CAB – CONTROLS…..178
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…..178
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…..182
3.3.3 OPERATORS CONSOLE…..187
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS…..195
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER…..197
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS HEALTH MONITOR…..198
3.4.1 SEQUENCE OF DISPLAYS…..199
3.4.2 OPENING SCREEN…..199
3.4.3 MAIN GAUGE SCREENS 1 TO 4…..200
3.4.4 FUEL CONSUMPTION SCREEN…..207
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR…..208
3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE…..208
3.4.7 MAINTENANCE MONITOR…..209
3.4.8 SETTINGS FOR OPERATOR…..210
3.4.9 AUTOMATIC MESSAGES…..215
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM…..220
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES…..231
3.5 CAMERA SYSTEM WITH MONITORS…..234
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS…..235
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…..242
3.6.1 AUXILIARY HEATER FOR OPERATORS CAB…..247
3.7 MACHINERY HOUSE…..248
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…..249
3.7.2 SAFETY SWITCH FOR MAINTENANCE…..251
3.7.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT…..253
3.8 ELECTRICAL EQUIPMENT IN CAB BASE…..254
3.8.1 STANDARD COMPONENTS IN CAB BASE…..255
3.8.2 SWITCH BOARD (X2) IN CAB BASE…..257
3.8.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE…..267
3.9 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES…..270
3.10 CHECKS BEFORE STARTING THE ENGINES…..276
3.11 STARTING THE ENGINES…..282
3.11.1 STARTING PROCEDURE…..285
3.11.2 ENGINE WARM-UP…..293
3.11.3 HYDRAULIC OIL WARM-UP…..293
3.12 MOVING THE SHOVEL…..295
3.12.1 TRAVEL CONTROL WITH FOOT PEDALS…..295
3.12.2 TRAVELLING INSTRUCTIONS…..298
3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE…..299
3.13.1 SLEWING THE SUPERSTRUCTURE…..299
3.14 WORKING WITH THE ATTACHMENT…..302
3.14.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…..302
3.14.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…..303
3.14.3 BOTTOM DUMP BUCKET…..304
3.14.4 DROP BALL OPERATION…..305
3.14.5 COMBINED OPERATION CYCLES…..308
3.15 WORKING INSTRUCTIONS…..310
3.15.1 STABILITY OF THE SHOVEL…..310
3.15.2 SHOVEL OPERATION…..310
3.16 PARKING THE SHOVEL…..313
3.17 STOPPING THE ENGINES…..314
3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…..317
3.18 OPERATION OF THE LUBRICATION SYSTEM…..318
3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT…..318
3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM -SLS-…..320
3.19 FIRE DETECTION AND SUPPRESSION SYSTEM…..322
3.19.1 HIGH LEVEL ALARM FIRE…..327
3.19.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…..327
3.19.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS…..327
3.19.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S……329
3.19.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER……331
3.20 TRANSFER PUMP FOR HYDRAULIC OIL…..332
3.20.1 OPERATING THE TRANSFER PUMP…..333
3.20.2 FUNCTIONS OF THE TRANSFER PUMP…..335
3.21 CENTRAL REFILLING SYSTEM…..338
3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…..339
3.21.2 OPERATING THE HYDRAULIC SERVICE ARM…..341
3.21.3 RECEIVER PANEL WITH MONITOR BOX…..343
3.21.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS…..349
3.22 WORK ON THE LOADER ATTACHMENT…..350
3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL…..351
3.23.1 DISASSEMBLING OF THE SHOVEL…..351
3.23.2 TRANSPORTATION AND LIFTING…..351
3.24 RETRIEVAL PROCEDURE…..352
3.25 SHOVEL STORAGE…..353
3.25.1 PREPARING FOR STORAGE…..353
3.25.2 ONE MONTH REPETITIVE SERVICE PERIOD…..354
3.25.3 SIX MONTH REPETITIVE SERVICE PERIOD…..354
3.25.4 PREPARING FOR OPERATION…..355
3.26 TROUBLE SHOOTING…..356
3.26.1 ENGINE…..356
3.26.2 HYDRAULIC SYSTEM…..357
3.26.3 FINAL DRIVES AND SWING GEAR…..358
3.26.4 CRAWLER TRACKS…..358
4. MAINTENANCE…..359
4.1 FOREWORD…..360
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE…..361
4.3 FLUIDS AND LUBRICANTS…..363
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…..363
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…..364
4.4 FILLING CAPACITIES…..366
4.5 STANDARD TORQUE LIST…..367
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…..368
4.6.1 INITIAL SERVICING…..368
4.6.2 PERIODIC SERVICING INTERVALS…..368
4.6.3 PERIODIC SERVICING SCHEDULE…..369
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES…..374
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..375
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM…..379
4.6.7 MAINTENANCE OF THE ENGINES…..383
4.6.8 ENGINE FUEL FILTER LOCATION…..385
4.7 WHEN NECESSARY…..388
4.7.1 ENGINE AIR CLEANER MAINTENANCE…..389
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…..393
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…..395
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…..399
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER…..401
4.8 EVERY 10 OPERATING HOURS OR DAILY…..402
4.8.1 WALK – AROUND INSPECTION…..403
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…..413
4.8.3 RADIATORS – CHECK COOLANT LEVEL…..415
4.8.4 TRACK GROUPS – CLEAN…..415
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…..416
4.9.1 SWING GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..417
4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS…..423
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL…..429
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…..433
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…..435
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…..436
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…..437
4.10.2 SIGNAL HORN COMPRESSOR – LUBRICATE…..439
4.10.3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..439
4.10.4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..439
4.10.5 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER…..441
4.10.6 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…..443
4.10.7 AIR CONDITIONING FOR OPERATORS CAB – CHECK REFRIGERANT LEVEL…..447
4.10.8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…..449
4.11 EVERY 500 OPERATING HOURS OR QUARTERLY…..450
4.11.1 BATTERIES – CHECK FLUID LEVEL…..451
4.11.2 FUEL TANK – DRAIN CONDENSATION…..453
4.11.3 CRAWLER TRACK – INSPECTION…..455
4.11.4 GROUND CABLES OF ENGINE AND ALTERNATOR – CHECK FOR CORRECT CONNECTION…..461
4.11.5 GROUND CABLE OF OPERATORS CAB – CHECK FOR CORRECT CONNECTION…..463
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…..464
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…..465
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…..523
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…..537
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…..539
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…..541
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…..543
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…..545
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…..547
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…..548
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…..549
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…..561
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…..562
4.14.1 SWING GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…..563
4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL…..571
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…..575
4.15 FIRE PREVENTION…..578
4.16 WELD REPAIRS…..580
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…..583
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…..585
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…..587
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…..589
Hydraulic Excavator PC5500 Service Manual (SN15014&up)…..597
Hydraulic Excavator PC5500 Service Manual (SN15016&up)…..1034
PC5500-6-E_Sec_7-0_rev1.pdf…..0
8.pdf…..0
Example for ESR 1:…..1276
Example for ESR 2:…..1276
Example for ESR 3:…..1276
Example for ESR 2:…..1276
SET 1…..1302
Hydraulic Excavator PC5500 Service Manual (SN15017&up)…..1662
PC5500-6_Sec_Appendix_rev1.pdf…..0
2. MC7 Fault Code, Diagnostic…..2296
…..2296
Blink…..2296
High Speed 2…..2296
Hydraulic Excavator PC5500 Service Manual (SN15031&up)…..2298
Contents and 00_Foreworda_15031.pdf…..2298
…..2308
PC5500-6-D_Sec_1-0_rev4.pdf…..2316
PC5500-6-D_Sec_1-0_rev4.pdf…..2316
Leerseite.pdf…..2345
PC5500-6-D_Sec_4-0_rev3.pdf…..2396
PC5500-6-D_Sec_4-0_rev3.pdf…..2396
Leerseite.pdf…..2419
PC5500-6-D_Sec_5-0_rev3.pdf…..2420
PC5500-6-D_Sec_5-0_rev3.pdf…..2420
Leerseite.pdf…..2467
PC5500-6-D_Sec_6-0_rev1.pdf…..2468
PC5500-6-D_Sec_7-0_rev5c.pdf…..2512
PC5500-6_Sec_8-0_rev1.pdf…..2592
PC5500-6-D_Sec_8-1_rev3.pdf…..2600
PC5500-6-D_Sec_8-2_rev4.pdf…..2706
PC5500-6-D_Sec_8-3_rev2.pdf…..2744
PC5500-6-D_Sec_9-0_rev0.pdf…..2768
PC5500-6-D_Sec_10-0_rev1.pdf…..2786
PC5500-6-D_Sec_10-0_rev1.pdf…..2786
Leerseite.pdf…..2793
PC5500-6-D_Sec_11-0_rev0.pdf…..2794
PC5500-6_Sec_12-0_rev3.pdf…..2800
PC5500-6_Sec_13_0_rev0neu.pdf…..2817
PC5500-6-D_Sec_14-0_rev2.doc…..2832
PC5500-6-D_Sec_15-0_rev1.pdf…..2890
PC5500-6-D_Sec_Appendix_rev1.pdf…..2946
PC5500-6-D_Sec_Appendix_rev0.pdf…..2946
PC5500_6_FS.PDF…..2964
MC7_Flashcode.doc…..2982
Hydraulic Excavator PC5500 Service Manual (SN15046&up)…..2984
Contents and 00_Foreworda_15046.pdf…..2984
PC5500-6-D_Sec_1-0_rev4.pdf…..3002
PC5500-6-D_Sec_1-0_rev4.pdf…..3002
Leerseite.pdf…..3031
PC5500-6-D_Sec_2-0_rev3.pdf…..3032
PC5500-6-D_Sec_3-0_rev2.pdf…..3066
PC5500-6-D_Sec_4-0_rev4a.pdf…..3082
PC5500-6-D_Sec_5-0_rev4.pdf…..3106
PC5500-6-D_Sec_6-0_rev3.pdf…..3154
PC5500-6-D_Sec_7-0_rev5d.pdf…..3198
PC5500-6_Sec_8-0_rev1.pdf…..3278
PC5500-6-D_Sec_8-1_rev3.pdf…..3286
PC5500-6-D_Sec_8-2_rev4.pdf…..3392
PC5500-6-D_Sec_8-3_rev2.pdf…..3430
PC5500-6-D_Sec_9-0_rev0.pdf…..3454
PC5500-6-D_Sec_10-0_rev1.pdf…..3472
PC5500-6-D_Sec_10-0_rev1.pdf…..3472
Leerseite.pdf…..3479
PC5500-6-D_Sec_11-0_rev0.pdf…..3480
PC5500-6_Sec_12-0_rev3.pdf…..3486
PC5500-6_Sec_13_0_rev0neu.pdf…..3502
PC5500-6-D_Sec_15-0_rev1.pdf…..3576
PC5500-6_Sec_Appendix_rev2.pdf…..0
PC5500-6-D_Sec_Appendix_rev1 Code.pdf…..0
MC7_Flashcode.doc…..3652
Hydraulic Excavator PC5500 Service Manual (SN15050&up)…..3654
Contents and 00_Foreworda15050.pdf…..3654
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15012&15013)…..4312
COVER…..4312
1. INTRODUCTION…..4314
1.1 CONTENTS OF THE BINDER…..4315
1.2 DIVISION OF THE BINDER…..4316
1.3 DESIGNATED USE OF THE SHOVEL…..4317
1.4 DELIVERY OF THE SHOVEL…..4318
1.5 EXPLANATION OF ABBREVATIONS…..4319
1.6 TABLE OF CONTENTS…..4320
2. SAFETY…..4326
2.1 SAFETY INSTRUCTIONS…..4327
2.1.1 WARNINGS AND SYMBOLS…..4327
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC EXCAVATOR…..4327
2.1.3 ORGANIZATIONAL MEASURES…..4328
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…..4330
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…..4331
2.1.6 WARNING OF SPECIAL DANGERS…..4334
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…..4336
2.1.8 SPECIAL SAFETY EQUIPMENT…..4336
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…..4340
3. OPERATION…..4348
3.1 FOREWORD…..4349
3.2 CONSTRUCTION OF THE SHOVEL…..4350
3.2.1 OVERALL VIEW…..4350
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…..4351
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…..4357
3.2.4 EMERGENCY ESCAPE LADDER…..4361
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…..4363
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…..4365
3.2.7 ENGINE OIL MANAGEMENT SYSTEM…..4373
3.3 OPERATORS CAB – CONTROLS…..4377
3.3.1 HYDRAULIC CONTROL SYSTEM…..4378
3.3.2 SAFETY CIRCUIT FOR CONTROLS…..4378
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…..4391
3.4.1 OPERATING THE ELECTRONIC MONITORING SYSTEM…..4400
3.4.2 MENU CONTROL CHART…..4449
3.4.3 FAULT AND INFORMATION MESSAGE LIST…..4469
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…..4493
3.5.1 A – HEATING…..4494
3.5.2 B – COOLING…..4494
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…..4494
3.6 POWER HOUSE…..4495
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…..4496
3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT…..4498
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…..4499
3.7.1 STANDARD COMPONENTS IN CAB BASE…..4500
3.7.2 SWITCH BOARD (X2) IN CAB BASE…..4502
3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE…..4510
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES…..4513
3.9 GENERATOR SET…..4519
3.9.1 OPERATING THE GENERATOR SET…..4522
3.10 CHECKS BEFORE STARTING THE ENGINES…..4525
3.11 STARTING THE ENGINES…..4531
3.11.1 COLD SEASON STARTING…..4532
3.11.2 STARTING PROCEDURE…..4538
3.12 MOVING THE SHOVEL…..4552
3.12.1 TRAVEL CONTROL WITH FOOT PEDALS…..4552
3.12.2 TRAVELLING INSTRUCTIONS…..4555
3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE…..4556
3.13.1 SLEWING THE SUPERSTRUCTURE…..4556
3.14 WORKING WITH THE ATTACHMENT…..4559
3.14.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…..4559
3.14.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…..4560
3.14.3 BOTTOM DUMP BUCKET…..4561
3.14.4 DROP BALL OPERATION…..4562
3.14.5 COMBINED OPERATION CYCLES…..4565
3.15 WORKING INSTRUCTIONS…..4567
3.15.1 STABILITY OF THE SHOVEL…..4567
3.15.2 SHOVEL OPERATION…..4567
3.16 PARKING THE SHOVEL…..4570
3.17 STOPPING THE ENGINES…..4571
3.18 OPERATION OF THE LUBRICATION SYSTEM…..4575
3.18.1 CENTRAL LUBRICATION SYSTEM CLS…..4575
3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…..4577
3.19 FIRE DETECTION AND SUPPRESSION SYSTEM…..4579
3.19.1 HIGH LEVEL ALARM FIRE…..4582
3.19.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVES…..4582
3.19.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM…..4582
3.19.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S……4584
3.19.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER……4586
3.20 TRANSFER PUMP FOR HYDRAULIC OIL…..4587
3.20.1 OPERATING THE TRANSFER PUMP…..4588
3.20.2 FUNCTIONS OF THE TRANSFER PUMP…..4590
3.21 CENTRAL REFILLING SYSTEM…..4593
3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…..4594
3.21.2 OPERATING THE HYDRAULIC SERVICE ARM…..4596
3.21.3 RECEIVER PANEL WITH MONITOR BOX…..4598
3.21.4 CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATION SYSTEM…..4604
3.22 WORK ON THE LOADER ATTACHMENT…..4605
3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL…..4606
3.23.1 DISASSEMBLING OF THE SHOVEL…..4606
3.23.2 TRANSPORTATION AND LIFTING…..4606
3.24 RETRIEVAL PROCEDURE…..4607
3.25 SHOVEL STORAGE…..4608
3.25.1 PREPARING FOR STORAGE…..4608
3.25.2 ONE MONTH REPETITIVE SERVICE PERIOD…..4609
3.25.3 SIX MONTH REPETITIVE SERVICE PERIOD…..4609
3.25.4 PREPARING FOR OPERATION…..4610
3.26 TROUBLE SHOOTING…..4611
3.26.1 ENGINE…..4611
3.26.2 HYDRAULIC SYSTEM…..4612
3.26.3 FINAL DRIVES AND SWING GEAR…..4613
3.26.4 CRAWLER TRACKS…..4613
4. MAINTENANCE…..4614
4.1 FOREWORD…..4615
4.2 PRECAUTIONS FOR MAINTENANCE…..4616
4.3 FUEL AND LUBRICANTS…..4617
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…..4617
4.3.2 FUEL AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…..4618
4.4 FILLING CAPACITIES…..4620
4.5 STANDARD TORQUE LIST…..4621
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…..4622
4.6.1 INITIAL SERVICING…..4622
4.6.2 PERIODIC SERVICING INTERVALS…..4622
4.6.3 PERIODIC SERVICING SCHEDULE…..4623
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM…..4630
4.6.5 MAINTENANCE OF THE ENGINES…..4634
4.7 WHEN NECESSARY…..4635
4.7.1 ENGINE AIR CLEANER MAINTENANCE…..4636
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…..4640
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…..4642
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…..4646
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER…..4648
4.8 EVERY 10 OPERATING HOURS OR DAILY…..4649
4.8.1 VISUAL INSPECTIONS…..4650
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…..4658
4.8.3 RADIATORS – CHECK COOLANT LEVEL…..4660
4.8.4 TRACK GROUPS – CLEAN…..4660
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…..4661
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..4662
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..4664
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL…..4670
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…..4674
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…..4676
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…..4677
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…..4678
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…..4680
4.10.3 SIGNAL HORN COMPRESSOR – LUBRICATE…..4680
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..4680
4.10.5 RADIATOR FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..4680
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…..4682
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…..4684
4.11 EVERY 500 OPERATING HOURS OR MONTHLY…..4685
4.11.1 BATTERIES – CHECK FLUID LEVEL…..4686
4.11.2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL…..4688
4.11.3 FUEL TANK – DRAIN CONDENSATION…..4690
4.11.4 CRAWLER TRACK – INSPECTION…..4692
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…..4697
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…..4698
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…..4752
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…..4766
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…..4768
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…..4770
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…..4772
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…..4773
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…..4774
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…..4786
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…..4787
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…..4788
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…..4792
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…..4798
4.15 FIRE PREVENTION…..4801
4.16 REPAIR WELDINGS…..4803
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…..4806
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…..4808
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…..4810
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE…..4812
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15014)…..4819
COVER…..4819
1. INTRODUCTION…..4821
1.1 CONTENTS OF THE BINDER…..4822
1.2 DIVISION OF THE BINDER…..4823
1.3 DESIGNATED USE OF THE EXCAVATOR…..4824
1.4 DELIVERY OF THE EXCAVATOR…..4825
1.5 EXPLANATION OF ABBREVATIONS…..4826
1.6 TABLE OF CONTENTS…..4827
2. SAFETY…..4833
2.1 SAFETY INSTRUCTIONS…..4834
2.1.1 WARNINGS AND SYMBOLS…..4834
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC EXCAVATOR…..4834
2.1.3 ORGANIZATIONAL MEASURES…..4835
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…..4837
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…..4838
2.1.6 WARNING OF SPECIAL DANGERS…..4841
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…..4843
2.1.8 SPECIAL SAFETY EQUIPMENT…..4843
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…..4847
3. OPERATION…..4855
3.1 FOREWORD…..4856
3.2 CONSTRUCTION OF THE EXCAVATOR…..4857
3.2.1 OVERALL VIEW…..4857
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…..4858
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…..4864
3.2.4 EMERGENCY ESCAPE LADDER…..4868
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…..4870
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…..4872
3.2.7 Engine Oil Management System…..4880
3.3 OPERATORS CAB – CONTROLS…..4884
3.3.1 HYDRAULIC CONTROL SYSTEM…..4885
3.3.2 SAFETY CIRCUIT FOR CONTROLS…..4885
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…..4898
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…..5000
3.5.1 A – HEATING…..5000
3.5.2 B – COOLING…..5001
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…..5001
3.6 POWER HOUSE…..5002
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…..5003
3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT…..5005
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…..5006
3.7.1 SWITCH BOARD (X2) IN CAB BASE…..5009
3.8 CHECKS BEFORE STARTING THE ENGINES…..5022
3.9 STARTING THE ENGINES…..5028
3.9.1 STARTING PROCEDURE…..5031
3.10 MOVING THE EXCAVATOR…..5039
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS…..5039
3.10.2 TRAVELLING INSTRUCTIONS…..5042
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE…..5043
3.11.1 SLEWING THE SUPERSTRUCTURE…..5043
3.12 WORKING WITH THE ATTACHMENT…..5046
3.12.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…..5046
3.12.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…..5047
3.12.3 BOTTOM DUMP BUCKET…..5048
3.12.4 DROP BALL OPERATION…..5049
3.12.5 COMBINED OPERATION CYCLES…..5052
3.13 WORKING INSTRUCTIONS…..5054
3.13.1 STABILITY OF THE EXCAVATOR…..5054
3.13.2 EXCAVATOR OPERATION…..5054
3.14 PARKING THE EXCAVATOR…..5057
3.15 STOPPING THE ENGINES…..5058
3.16 OPERATION OF THE LUBRICATION SYSTEM…..5062
3.16.1 CENTRAL LUBRICATION SYSTEM CLS…..5062
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…..5064
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM…..5066
3.17.1 HIGH LEVEL ALARM FIRE…..5069
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…..5069
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM…..5069
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S……5071
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER……5073
3.18 CENTRAL REFILLING SYSTEM…..5074
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…..5075
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM…..5077
3.18.3 RECEIVER PANEL WITH MONITOR BOX…..5079
3.18.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATIO……5085
3.19 WORK ON THE LOADER ATTACHMENT…..5086
3.20 TRANSPORTATION AND LIFTING OF THE EXCAVATOR…..5087
3.20.1 DISASSEMBLING OF THE EXCAVATOR…..5087
3.20.2 TRANSPORTATION AND LIFTING…..5087
3.21 RETRIEVAL PROCEDURE…..5088
3.22 EXCAVATOR STORAGE…..5089
3.22.1 PREPARING FOR STORAGE…..5089
3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD…..5090
3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD…..5090
3.22.4 PREPARING FOR OPERATION…..5091
3.23 TROUBLE SHOOTING…..5092
3.23.1 ENGINE…..5092
3.23.2 HYDRAULIC SYSTEM…..5093
3.23.3 FINAL DRIVES AND SWING GEAR…..5094
3.23.4 CRAWLER TRACKS…..5094
4. MAINTENANCE…..5095
4.1 FOREWORD…..5096
4.2 PRECAUTIONS FOR MAINTENANCE…..5097
4.3 FUEL AND LUBRICANTS…..5099
4.4 FILLING CAPACITIES…..5101
4.5 STANDARD TORQUE LIST…..5102
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…..5103
4.6.1 INITIAL SERVICING…..5103
4.6.2 PERIODIC SERVICING INTERVALS…..5103
4.6.3 PERIODIC SERVICING SCHEDULE…..5104
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM…..5111
4.6.5 MAINTENANCE OF THE ENGINES…..5115
4.7 WHEN NECESSARY…..5116
4.7.1 ENGINE AIR CLEANER MAINTENANCE…..5117
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…..5121
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…..5123
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…..5127
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER…..5129
4.8 EVERY 10 OPERATING HOURS OR DAILY…..5130
4.8.1 VISUAL INSPECTIONS…..5131
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…..5139
4.8.3 RADIATORS – CHECK COOLANT LEVEL…..5141
4.8.4 TRACK GROUPS – CLEAN…..5141
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…..5142
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..5143
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..5145
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL…..5151
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…..5155
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…..5157
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…..5158
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…..5159
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…..5161
4.10.3 SIGNAL HORN COMPRESSOR – LUBRICATE…..5161
4.10.4 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..5161
4.10.5 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..5161
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…..5163
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…..5165
4.11 EVERY 500 OPERATING HOURS OR MONTHLY…..5166
4.11.1 BATTERIES – CHECK FLUID LEVEL…..5167
4.11.2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL…..5169
4.11.3 FUEL TANK – DRAIN CONDENSATION…..5171
4.11.4 CRAWLER TRACK – INSPECTION…..5173
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…..5178
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…..5179
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…..5229
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…..5243
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…..5245
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…..5247
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…..5249
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…..5250
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…..5251
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…..5263
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…..5264
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…..5265
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…..5269
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…..5275
4.15 FIRE PREVENTION…..5278
4.16 REPAIR WELDINGS…..5280
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…..5283
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…..5285
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…..5287
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE…..5289
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15016)…..5296
COVER…..5296
1. INTRODUCTION…..5298
1.1 CONTENTS OF THE BINDER…..5299
1.2 DIVISION OF THE BINDER…..5300
1.3 DESIGNATED USE OF THE SHOVEL…..5301
1.4 DELIVERY OF THE SHOVEL…..5302
1.5 EXPLANATION OF ABBREVATIONS…..5303
1.6 TABLE OF CONTENTS…..5304
2. SAFETY…..5310
2.1 SAFETY INSTRUCTIONS…..5311
2.1.1 WARNINGS AND SYMBOLS…..5311
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL…..5311
2.1.3 ORGANIZATIONAL MEASURES…..5312
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…..5314
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…..5315
2.1.6 WARNING OF SPECIAL DANGERS…..5318
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…..5320
2.1.8 SPECIAL SAFETY EQUIPMENT…..5320
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…..5324
3. OPERATION…..5332
3.1 FOREWORD…..5333
3.2 CONSTRUCTION OF THE SHOVEL…..5334
3.2.1 OVERALL VIEW…..5334
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…..5335
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…..5341
3.2.4 EMERGENCY ESCAPE LADDER…..5345
3.2.5 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…..5347
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…..5349
3.3 OPERATORS CAB – CONTROLS…..5357
3.3.1 HYDRAULIC CONTROL SYSTEM…..5358
3.3.2 SAFETY CIRCUIT FOR CONTROLS…..5358
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…..5371
3.4.1 OPERATING THE ELECTRONIC MONITORING SYSTEM…..5380
3.4.2 MENU CONTROL CHART…..5429
3.4.3 FAULT AND INFORMATION MESSAGE LIST…..5447
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…..5470
3.6 POWER HOUSE…..5471
3.6.1 EMERGENCY MOTOR SHUTDOWN SWITCHES…..5472
3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT…..5474
3.7 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE…..5475
3.7.1 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET…..5476
3.7.2 SWITCH BOARD (X2) IN CAB BASE…..5478
3.7.3 MONITOR AND CONTROL PANEL IN CAB BASE…..5484
3.7.4 SWITCH BOARD – MEDIUM VOLTAGE…..5486
3.8 HIGH VOLTAGE SWITCH CABINET…..5487
3.9 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS…..5489
3.10 STARTING THE MAIN DRIVE MOTORS…..5493
3.11 MOVING THE SHOVEL…..5500
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS…..5500
3.11.2 TRAVELLING INSTRUCTIONS…..5503
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…..5504
3.12.1 SLEWING THE SUPERSTRUCTURE…..5504
3.13 WORKING WITH THE ATTACHMENT…..5507
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…..5507
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…..5508
3.13.3 BOTTOM DUMP BUCKET…..5509
3.13.4 DROP BALL OPERATION…..5510
3.13.5 COMBINED OPERATION CYCLES…..5513
3.14 WORKING INSTRUCTIONS…..5515
3.14.1 STABILITY OF THE SHOVEL…..5515
3.14.2 SHOVEL OPERATION…..5515
3.15 PARKING THE SHOVEL…..5518
3.16 STOPPING THE MAIN DRIVE MOTORS…..5519
3.17 OPERATION OF THE LUBRICATION SYSTEM…..5523
3.17.1 CENTRAL LUBRICATION SYSTEM CLS…..5523
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…..5525
3.18 TRANSFER PUMP FOR HYDRAULIC OIL…..5527
3.18.1 OPERATING THE TRANSFER PUMP…..5528
3.18.2 FUNCTIONS OF THE TRANSFER PUMP…..5530
3.19 CENTRAL REFILLING SYSTEM…..5533
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…..5534
3.19.2 CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATION SYSTEM…..5538
3.20 CABLE DRUM…..5539
3.20.1 CABLE DRUM OPERATION…..5540
3.20.2 TRAVELLING INSTRUCTIONS…..5542
3.21 SERVICE CRANE…..5545
3.21.1 OPERATING THE SERVICE CRANE…..5546
3.22 WORK ON THE LOADER ATTACHMENT…..5549
3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL…..5550
3.23.1 DISASSEMBLING OF THE SHOVEL…..5550
3.23.2 TRANSPORTATION AND LIFTING…..5550
3.24 RETRIEVAL PROCEDURE…..5551
3.25 SHOVEL STORAGE…..5552
3.25.1 PREPARING FOR STORAGE…..5552
3.25.2 ONE MONTH REPETITIVE SERVICE PERIOD…..5552
3.25.3 SIX MONTH REPETITIVE SERVICE PERIOD…..5553
3.25.4 PREPARING FOR OPERATION…..5553
3.26 TROUBLE SHOOTING…..5554
3.26.1 MAIN DRIVE MOTOR…..5554
3.26.2 HYDRAULIC SYSTEM…..5555
3.26.3 FINAL DRIVES AND SWING GEAR…..5556
3.26.4 CRAWLER TRACKS…..5556
4. MAINTENANCE…..5558
4.1 FOREWORD…..5559
4.2 PRECAUTIONS FOR MAINTENANCE…..5560
4.3 LUBRICANTS…..5561
4.3.1 LUBRICANTS FOR MODERATE AND HOT CLIMATES…..5561
4.4 FILLING CAPACITIES…..5565
4.5 STANDARD TORQUE LIST…..5566
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…..5567
4.6.1 INITIAL SERVICING…..5567
4.6.2 PERIODIC SERVICING INTERVALS…..5567
4.6.3 PERIODIC SERVICING SCHEDULE…..5568
4.6.4 MAINTENANCE OF THE MAIN DRIVE MOTORS…..5572
4.7 WHEN NECESSARY…..5575
4.7.1 SWING CIRCLE TOOTHING LUBRICATION…..5576
4.7.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…..5578
4.7.3 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…..5582
4.8 EVERY 10 OPERATING HOURS OR DAILY…..5583
4.8.1 VISUAL INSPECTIONS…..5584
4.8.2 TRACK GROUPS – CLEAN…..5592
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…..5593
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..5594
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..5596
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL…..5602
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…..5606
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…..5608
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…..5609
4.10.1 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE…..5610
4.10.2 SIGNAL HORN COMPRESSOR – LUBRICATE…..5610
4.10.3 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..5610
4.10.4 RADIATOR FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSIO……5610
4.10.5 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…..5612
4.10.6 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…..5614
4.10.7 AIR CONDITIONING FOR OPERATORS CAB AND SWITCH CABINETS…..5616
4.10.8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…..5620
4.11 EVERY 500 OPERATING HOURS OR MONTHLY…..5621
4.11.1 BATTERIES – CHECK FLUID LEVEL…..5622
4.11.2 CRAWLER TRACK – INSPECTION…..5624
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…..5629
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…..5630
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…..5678
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…..5692
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…..5694
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…..5696
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…..5698
4.12.7 SLIP RING UNIT – LUBRICATE…..5700
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…..5701
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…..5702
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…..5714
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…..5715
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…..5716
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL…..5720
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…..5726
4.15 FIRE PREVENTION…..5729
4.16 REPAIR WELDINGS…..5731
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…..5734
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…..5736
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…..5738
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE…..5738
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15027)…..5745
COVER…..5745
1. INTRODUCTION…..5747
1.1 CONTENTS OF THE BINDER…..5748
1.2 DIVISION OF THE BINDER…..5749
1.3 DESIGNATED USE OF THE SHOVEL…..5750
1.4 DELIVERY OF THE SHOVEL…..5751
1.5 EXPLANATION OF ABBREVIATIONS…..5752
1.6 TABLE OF CONTENTS…..5753
2. SAFETY…..5759
2.1 SAFETY INSTRUCTIONS…..5760
2.1.1 WARNINGS AND SYMBOLS…..5760
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL…..5760
2.1.3 ORGANIZATIONAL MEASURES…..5761
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…..5763
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…..5764
2.1.6 WARNING OF SPECIAL DANGERS…..5767
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…..5769
2.1.8 SPECIAL SAFETY EQUIPMENT…..5769
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…..5773
3. OPERATION…..5781
3.1 FOREWORD…..5782
3.2 CONSTRUCTION OF THE SHOVEL…..5783
3.2.1 OVERALL VIEW…..5783
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…..5784
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…..5790
3.2.4 EMERGENCY ESCAPE LADDER…..5794
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…..5796
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…..5798
3.2.7 ENGINE OIL MANAGEMENT SYSTEM…..5806
3.3 OPERATORS CAB – CONTROLS…..5814
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…..5814
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…..5818
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…..5832
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…..5936
3.5.1 A – HEATING…..5936
3.5.2 B – COOLING…..5937
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…..5937
3.6 POWER HOUSE…..5938
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…..5939
3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT…..5941
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…..5942
3.7.1 SWITCH BOARD (X2) IN CAB BASE…..5945
3.8 CHECKS BEFORE STARTING THE ENGINES…..5958
3.9 STARTING THE ENGINES…..5964
3.9.1 STARTING PROCEDURE…..5967
3.10 MOVING THE SHOVEL…..5975
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS…..5975
3.10.2 TRAVELLING INSTRUCTIONS…..5978
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE…..5979
3.11.1 SLEWING THE SUPERSTRUCTURE…..5979
3.12 WORKING WITH THE ATTACHMENT…..5982
3.12.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…..5982
3.12.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…..5983
3.12.3 BOTTOM DUMP BUCKET…..5984
3.12.4 DROP BALL OPERATION…..5985
3.12.5 COMBINED OPERATION CYCLES…..5988
3.13 WORKING INSTRUCTIONS…..5990
3.13.1 STABILITY OF THE SHOVEL…..5990
3.13.2 SHOVEL OPERATION…..5990
3.14 PARKING THE SHOVEL…..5993
3.15 STOPPING THE ENGINES…..5994
3.16 OPERATION OF THE LUBRICATION SYSTEM…..5998
3.16.1 CENTRAL LUBRICATION SYSTEM CLS…..5998
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…..6000
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM…..6002
3.17.1 HIGH LEVEL ALARM FIRE…..6005
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…..6005
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM…..6005
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S……6007
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER……6009
3.18 CENTRAL REFILLING SYSTEM…..6010
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…..6011
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM…..6013
3.18.3 RECEIVER PANEL WITH MONITOR BOX…..6015
3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS…..6021
3.19 SERVICE CRANE…..6022
3.19.1 OPERATING THE CRANE…..6023
3.20 WORK ON THE LOADER ATTACHMENT…..6026
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL…..6027
3.21.1 DISASSEMBLING OF THE SHOVEL…..6027
3.21.2 TRANSPORTATION AND LIFTING…..6027
3.22 RETRIEVAL PROCEDURE…..6028
3.23 SHOVEL STORAGE…..6029
3.23.1 PREPARING FOR STORAGE…..6029
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD…..6030
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD…..6030
3.23.4 PREPARING FOR OPERATION…..6031
3.24 TROUBLE SHOOTING…..6032
3.24.1 ENGINE…..6032
3.24.2 HYDRAULIC SYSTEM…..6033
3.24.3 FINAL DRIVES AND SWING GEAR…..6034
3.24.4 CRAWLER TRACKS…..6034
4. MAINTENANCE…..6035
4.1 FOREWORD…..6036
4.2 PRECAUTIONS FOR MAINTENANCE…..6037
4.3 FUEL AND LUBRICANTS…..6039
4.4 FILLING CAPACITIES…..6041
4.5 STANDARD TORQUE LIST…..6042
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…..6043
4.6.1 INITIAL SERVICING…..6043
4.6.2 PERIODIC SERVICING INTERVALS…..6043
4.6.3 PERIODIC SERVICING SCHEDULE…..6044
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM…..6051
4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL…..6053
4.6.6 MAINTENANCE OF THE ENGINES…..6055
4.6.7 ENGINE FUEL FILTER LOCATIONS…..6057
4.7 WHEN NECESSARY…..6058
4.7.1 ENGINE AIR CLEANER MAINTENANCE…..6059
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…..6063
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…..6065
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…..6069
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER…..6071
4.8 EVERY 10 OPERATING HOURS OR DAILY…..6072
4.8.1 WALK – AROUND INSPECTION…..6073
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…..6081
4.8.3 RADIATORS – CHECK COOLANT LEVEL…..6083
4.8.4 TRACK GROUPS – CLEAN…..6083
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…..6084
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..6085
4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS…..6089
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL…..6095
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…..6099
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…..6101
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…..6102
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…..6103
4.10.2 SIGNAL HORN COMPRESSOR – LUBRICATE…..6105
4.10.3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..6105
4.10.4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..6105
4.10.5 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER…..6107
4.10.6 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…..6109
4.10.7 AIR CONDITIONING FOR OPERATORS CAB – CHECK REFRIGERANT LEVEL…..6111
4.11 EVERY 500 OPERATING HOURS OR QUARTERLY…..6112
4.11.1 BATTERIES – CHECK FLUID LEVEL…..6113
4.11.2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL…..6115
4.11.3 FUEL TANK – DRAIN CONDENSATION…..6117
4.11.4 CRAWLER TRACK – INSPECTION…..6119
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…..6124
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…..6125
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…..6183
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…..6197
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…..6199
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…..6201
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…..6203
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…..6205
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…..6207
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…..6208
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…..6209
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…..6221
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…..6222
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…..6223
4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL…..6231
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…..6235
4.15 FIRE PREVENTION…..6238
4.16 WELD REPAIRS…..6240
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…..6243
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…..6245
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…..6247
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE…..6249
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15028&15029&15030)…..6256
COVER…..6256
1. INTRODUCTION…..6258
1.1 CONTENTS OF THE BINDER…..6259
1.2 DIVISION OF THE BINDER…..6260
1.3 DESIGNATED USE OF THE SHOVEL…..6261
1.4 DELIVERY OF THE SHOVEL…..6262
1.5 EXPLANATION OF ABBREVIATIONS…..6263
1.6 TABLE OF CONTENTS…..6264
2. SAFETY…..6270
2.1 SAFETY INSTRUCTIONS…..6271
2.1.1 WARNINGS AND SYMBOLS…..6271
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL…..6271
2.1.3 ORGANIZATIONAL MEASURES…..6272
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…..6274
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…..6275
2.1.6 WARNING OF SPECIAL DANGERS…..6278
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…..6280
2.1.8 SPECIAL SAFETY EQUIPMENT…..6280
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…..6284
3. OPERATION…..6292
3.1 FOREWORD…..6293
3.2 CONSTRUCTION OF THE SHOVEL…..6294
3.2.1 OVERALL VIEW…..6294
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…..6295
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…..6301
3.2.4 EMERGENCY ESCAPE LADDER…..6305
3.2.5 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…..6307
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…..6309
3.3 OPERATORS CAB – CONTROLS…..6319
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…..6319
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…..6323
3.3.3 OPERATORS CONSOLE…..6328
3.3.4 CONTROL UNITS FOR FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM…..6338
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…..6339
3.4.1 INTRODUCTION…..6340
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM…..6348
3.4.3 AUTOMATIC DISPLAY OF MESSAGES…..6352
3.4.4 MENU CONTROL AND SERVICE FUNCTIONS…..6376
3.4.5 MENU CONTROL LIST…..6401
3.4.6 FAULT AND INFORMATION MESSAGE LIST…..6418
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…..6443
3.5.1 A – HEATING…..6443
3.5.2 B – COOLING…..6444
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…..6444
3.6 MACHINERY HOUSE…..6445
3.6.1 EMERGENCY MOTOR SHUTDOWN SWITCHES…..6446
3.6.2 SAFETY SWITCH FOR MAINTENANCE…..6448
3.6.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT…..6450
3.7 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE…..6451
3.7.1 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET…..6452
3.7.2 SWITCH BOARD (X2) IN CAB BASE…..6454
3.7.3 MONITOR AND CONTROL PANEL IN CAB BASE…..6464
3.7.4 SWITCH BOARD – MEDIUM VOLTAGE…..6466
3.8 HIGH VOLTAGE SWITCH CABINET…..6467
3.9 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS…..6469
3.10 STARTING THE MAIN DRIVE MOTORS…..6473
3.11 MOVING THE SHOVEL…..6480
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS…..6480
3.11.2 TRAVELLING INSTRUCTIONS…..6483
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…..6484
3.12.1 SLEWING THE SUPERSTRUCTURE…..6484
3.13 WORKING WITH THE ATTACHMENT…..6487
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…..6487
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…..6488
3.13.3 BOTTOM DUMP BUCKET…..6489
3.13.4 DROP BALL OPERATION…..6490
3.13.5 COMBINED OPERATION CYCLES…..6493
3.14 WORKING INSTRUCTIONS…..6495
3.14.1 STABILITY OF THE SHOVEL…..6495
3.14.2 SHOVEL OPERATION…..6495
3.15 PARKING THE SHOVEL…..6498
3.16 STOPPING THE MAIN DRIVE MOTORS…..6499
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…..6502
3.17 OPERATION OF THE LUBRICATION SYSTEM…..6503
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT…..6503
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…..6505
3.18 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM…..6507
3.18.1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS…..6508
3.18.2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB…..6512
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM:…..6512
3.18.4 IN CASE OF FIRE…..6514
3.19 TRANSFER PUMP FOR HYDRAULIC OIL…..6515
3.19.1 OPERATING THE TRANSFER PUMP…..6516
3.19.2 FUNCTIONS OF THE TRANSFER PUMP…..6518
3.20 CENTRAL REFILLING SYSTEM…..6521
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…..6522
3.20.2 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS…..6526
3.21 CABLE DRUM…..6527
3.21.1 OPERATION OF THE CABLE DRUM…..6528
3.21.2 TRAVELLING INSTRUCTIONS…..6532
3.22 SERVICE CRANE (SPECIAL EQUIPMENT)…..6535
3.22.1 OPERATING THE CRANE…..6536
3.23 WORK ON THE LOADER ATTACHMENT…..6539
3.24 TRANSPORTATION AND LIFTING OF THE SHOVEL…..6540
3.24.1 DISASSEMBLING OF THE SHOVEL…..6540
3.24.2 TRANSPORTATION AND LIFTING…..6540
3.25 RETRIEVAL PROCEDURE…..6541
3.26 SHOVEL STORAGE…..6542
3.26.1 PREPARING FOR STORAGE…..6542
3.26.2 ONE MONTH REPETITIVE SERVICE PERIOD…..6542
3.26.3 SIX MONTH REPETITIVE SERVICE PERIOD…..6543
3.26.4 PREPARING FOR OPERATION…..6543
3.27 TROUBLE SHOOTING…..6544
3.27.1 MAIN DRIVE ELECTRIC MOTOR…..6544
3.27.2 HYDRAULIC SYSTEM…..6545
3.27.3 FINAL DRIVES AND SWING GEAR…..6546
3.27.4 CRAWLER TRACKS…..6546
4. MAINTENANCE…..6548
4.1 FOREWORD…..6549
4.2 PRECAUTIONS FOR MAINTENANCE…..6550
4.3 FUEL AND LUBRICANTS…..6552
4.4 FILLING CAPACITIES…..6556
4.5 STANDARD TORQUE LIST…..6557
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…..6558
4.6.1 INITIAL SERVICING…..6558
4.6.2 PERIODIC SERVICING INTERVALS…..6558
4.6.3 PERIODIC SERVICING SCHEDULE…..6559
4.6.4 MAINTENANCE OF THE MAIN DRIVE MOTORS…..6562
4.7 WHEN NECESSARY…..6565
4.7.1 SWING CIRCLE TOOTHING LUBRICATION…..6566
4.7.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…..6568
4.7.3 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…..6572
4.8 EVERY 10 OPERATING HOURS OR DAILY…..6573
4.8.1 WALK – AROUND INSPECTION…..6574
4.8.2 TRACK GROUPS – CLEAN…..6584
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…..6585
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..6586
4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS…..6590
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL…..6596
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…..6600
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…..6602
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…..6603
4.10.1 SIGNAL HORN COMPRESSOR – LUBRICATE…..6604
4.10.2 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..6604
4.10.3 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSION ONLY)…..6604
4.10.4 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER…..6606
4.10.5 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…..6608
4.10.6 AIR CONDITIONING FOR OPERATORS CAB AND SWITCH CABINETS…..6610
4.10.7 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…..6614
4.11 EVERY 500 OPERATING HOURS OR QUARTERLY…..6615
4.11.1 BATTERIES – CHECK FLUID LEVEL…..6616
4.11.2 CRAWLER TRACK – INSPECTION…..6618
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…..6623
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…..6624
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…..6680
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…..6694
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…..6696
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…..6698
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…..6700
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…..6702
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…..6704
4.12.9 SLIP RING UNIT – LUBRICATE…..6706
4.13 EVERY 2000 OPERATING HOURS OR YEARLY…..6707
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…..6708
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION…..6720
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…..6721
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…..6722
4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL…..6730
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…..6734
4.15 FIRE PREVENTION…..6737
4.16 WELD REPAIRS…..6739
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…..6742
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…..6744
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE…..6746
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE…..6746
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15032&15039)…..6753
COVER…..6753
1. INTRODUCTION…..6755
1.1 CONTENTS OF THE BINDER…..6756
1.2 DIVISION OF THE BINDER…..6757
1.3 DESIGNATED USE OF THE SHOVEL…..6758
1.4 DELIVERY OF THE SHOVEL…..6759
1.5 EXPLANATION OF ABBREVIATIONS…..6760
1.6 TABLE OF CONTENTS…..6761
2. SAFETY…..6767
2.1 SAFETY INSTRUCTIONS…..6768
2.1.1 WARNINGS AND SYMBOLS…..6768
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL…..6768
2.1.3 ORGANIZATIONAL MEASURES…..6769
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…..6771
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES…..6772
2.1.6 WARNING OF SPECIAL DANGERS…..6775
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING…..6777
2.1.8 SPECIAL SAFETY EQUIPMENT…..6777
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…..6781
3. OPERATION…..6789
3.1 FOREWORD…..6790
3.2 CONSTRUCTION OF THE SHOVEL…..6791
3.2.1 OVERALL VIEW…..6791
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…..6792
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER…..6798
3.2.4 EMERGENCY ESCAPE LADDER…..6802
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…..6804
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)…..6806
3.2.7 ENGINE OIL MANAGEMENT SYSTEM…..6816
3.3 OPERATORS CAB – CONTROLS…..6824
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…..6824
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…..6828
3.3.3 OPERATORS CONSOLE…..6833
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING…..6841
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS…..6844
3.4.1 INTRODUCTION…..6845
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM…..6853
3.4.3 AUTOMATIC DISPLAY OF MESSAGES…..6857
3.4.4 MENU CONTROL AND SERVICE FUNCTIONS…..6881
3.4.5 MENU CONTROL LIST…..6906
3.4.6 FAULT AND INFORMATION MESSAGE LIST…..6924
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…..6948
3.5.1 A – HEATING…..6949
3.5.2 B – COOLING…..6949
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING…..6949
3.5.4 AUXILIARY HEATER FOR OPERATORS CAB…..6951
3.6 MACHINERY HOUSE…..6952
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…..6953
3.6.2 SAFETY SWITCH FOR MAINTENANCE…..6955
3.6.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT…..6957
3.7 ELECTRICAL EQUIPMENT IN CAB BASE…..6958
3.7.1 STANDARD COMPONENTS IN CAB BASE…..6959
3.7.2 SWITCH BOARD (X2) IN CAB BASE…..6961
3.7.3 CENSE ENGINE MONITORING SYSTEM…..6967
3.7.4 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE…..6973
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES…..6976
3.9 CHECKS BEFORE STARTING THE ENGINES…..6982
3.10 STARTING THE ENGINES…..6988
3.10.1 STARTING PROCEDURE…..6991
3.11 MOVING THE SHOVEL…..6999
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS…..6999
3.11.2 TRAVELLING INSTRUCTIONS…..7002
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…..7003
3.12.1 SLEWING THE SUPERSTRUCTURE…..7003
3.13 WORKING WITH THE ATTACHMENT…..7006
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM…..7006
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM…..7007
3.13.3 BOTTOM DUMP BUCKET…..7008
3.13.4 DROP BALL OPERATION…..7009
3.13.5 COMBINED OPERATION CYCLES…..7012
3.14 WORKING INSTRUCTIONS…..7014
3.14.1 STABILITY OF THE SHOVEL…..7014
3.14.2 SHOVEL OPERATION…..7014
3.15 PARKING THE SHOVEL…..7017
3.16 STOPPING THE ENGINES…..7018
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…..7021
3.17 OPERATION OF THE LUBRICATION SYSTEM…..7022
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT…..7022
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS…..7024
3.18 FIRE DETECTION AND SUPPRESSION SYSTEM…..7026
3.18.1 HIGH LEVEL ALARM FIRE…..7029
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…..7029
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM…..7029
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S……7031
3.18.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER……7033
3.19 TRANSFER PUMP FOR HYDRAULIC OIL…..7034
3.19.1 OPERATING THE TRANSFER PUMP…..7035
3.19.2 FUNCTIONS OF THE TRANSFER PUMP…..7037
3.20 CENTRAL REFILLING SYSTEM…..7040
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…..7041
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM…..7043
3.20.3 RECEIVER PANEL WITH MONITOR BOX…..7045
3.20.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS…..7051
3.21 SERVICE CRANE (SPECIAL EQUIPMENT)…..7052
3.21.1 OPERATING THE CRANE…..7053
3.22 WORK ON THE LOADER ATTACHMENT…..7056
3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL…..7057
3.23.1 DISASSEMBLING OF THE SHOVEL…..7057
3.23.2 TRANSPORTATION AND LIFTING…..7057
3.24 RETRIEVAL PROCEDURE…..7058
3.25 SHOVEL STORAGE…..7059
3.25.1 PREPARING FOR STORAGE…..7059
3.25.2 ONE MONTH REPETITIVE SERVICE PERIOD…..7060
3.25.3 SIX MONTH REPETITIVE SERVICE PERIOD…..7060
3.25.4 PREPARING FOR OPERATION…..7061
3.26 TROUBLE SHOOTING…..7062
3.26.1 ENGINE…..7062
3.26.2 HYDRAULIC SYSTEM…..7063
3.26.3 FINAL DRIVES AND SWING GEAR…..7064
3.26.4 CRAWLER TRACKS…..7064
4. MAINTENANCE…..7065
4.1 FOREWORD…..7066
4.2 PRECAUTIONS FOR MAINTENANCE…..7067
4.3 FUEL AND LUBRICANTS…..7069
4.4 FILLING CAPACITIES…..7071
4.5 STANDARD TORQUE LIST…..7072
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…..7073
4.6.1 INITIAL SERVICING…..7073
4.6.2 PERIODIC SERVICING INTERVALS…..7073
4.6.3 PERIODIC SERVICING SCHEDULE…..7074
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM…..7081
4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL…..7083
4.6.6 MAINTENANCE OF THE ENGINES…..7085
4.6.7 ENGINE FUEL FILTER LOCATIONS…..7087
4.7 WHEN NECESSARY…..7088
4.7.1 ENGINE AIR CLEANER MAINTENANCE…..7089
4.7.2 SWING CIRCLE TOOTHING LUBRICATION…..7093
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…..7095
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…..7099
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER…..7101
4.8 EVERY 10 OPERATING HOURS OR DAILY…..7102
4.8.1 WALK – AROUND INSPECTION…..7103
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER…..7111
4.8.3 RADIATORS – CHECK COOLANT LEVEL…..7113
4.8.4 TRACK GROUPS – CLEAN…..7113
4.9 EVERY 50 OPERATING HOURS OR WEEKLY…..7114
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…..7115
4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS…..7119
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL…..7125
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR…..7129
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY…..7131
4.10 EVERY 250 OPERATING HOURS OR MONTHLY…..7132
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…..7133
4.10.2 SIGNAL HORN COMPRESSOR – LUBRICATE…..7135
4.10.3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..7135
4.10.4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…..7135
4.10.5 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER…..7137
4.10.6 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…..7139
4.10.7 AIR CONDITIONING FOR OPERATORS CAB – CHECK REFRIGERANT LEVEL…..7141
4.10.8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…..7143
4.11 EVERY 500 OPERATING HOURS OR QUARTERLY…..7144
4.11.1 BATTERIES – CHECK FLUID LEVEL…..7145
4.11.2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL…..7147
4.11.3 FUEL TANK – DRAIN CONDENSATION…..7149
4.11.4 CRAWLER TRACK – INSPECTION…..7151
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…..7156
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…..7157
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE…..7215
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…..7229
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…..7231
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…..7233
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE…..7235
4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…..7237
4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…..7239

Komatsu Hydraulic Mining Shovel PC5500 Repair Service Manuals

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Posted on June 10, 2025 by admin

Komatsu Hydraulic Mining Excavator PC4000 Repair Service Manuals

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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

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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
FLOWCHART 942 107 40 …9511
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SMPC40008172 – Hydraulic Mining Shovel PC4000-6 Shop Manual…9663
COVER…9663
CONTENTS…9665
TABLE OF CONTENTS…9665
SAFETY…9666
FOREWARD…9669
HOISTING INSTRUCTIONS…9670
STANDARD TIGHTENING TORQUE…9672
CONVERSION TABLE…9673
1.0 MAIN ASSEMBLY GROUPS…9680
1.0 MAIN ASSEMBLY GROUPS – GENERAL LAY OUT…9682
1. GENERAL LAY OUT – LEGEND FOR ILLUSTRATION\…9682
1.1 SUPERSTRUCTURE – LEGEND FOR ILLUSTRATION…9684
1.1.1 MACHINE HOUSE – LEGEND FOR ILLUSTRATION…9686
1.1.2 HYDRAULIC OIL RESERVOIR – LEGEND FOR ILLUSTRATION…9688
1.1.3 HYDRAULIC OIL COOLER – LEGEND FOR ILLUSTRATION…9690
1.1.4 FUEL TANK (FUEL RESERVOIR) – LEGEND FOR ILLUSTRATION…9692
1.1.5 COUNTERWEIGHT – LEGEND FOR ILLUSTRATION…9694
1.1.6 CAB SUPPORT – LEGEND FOR ILLUSTRATION…9696
1.1.7 OPERATOR'S CAB – LEGEND FOR ILLUSTRATION…9698
1.1.8 CONTROL BLOCKS – LEGEND FOR ILLUSTRATION…9700
1.1.9 SWING GEARS – LEGEND FOR ILLUSTRATION…9702
1.2 UNDER CARRIAGE – LEGEND FOR ILLUSTRATION…9704
1.3 ATTACHMENT – LEGEND FOR ILLUSTRATION…9706
1.3.1 BACKHOE ATTACHMENT (BHA) – LEGEND FOR ILLUSTRATION…9706
1.3.2 FRONT SHOVEL ATTACHMENT – LEGEND FOR ILLUSTRATION…9708
2.0 PRIME DRIVE ASSEMBLY…9709
2.0 PRIME DRIVE ASSEMBLY – GENERAL LAY OUT…9709
2.0 PRIME DRIVE ASSEMBLY – LEGEND FOR ILLUSTRATION…9711
2.1 ENGINE AND PTO MOUNT…9713
2.2 COUPLING…9717
2.2 COUPLING LEGEND FOR ILLUSTRATION…9717
2.3 AIR FILTER…9719
2.3 AIR FILTER – LEGEND FOR ILLUSTRATION…9719
2.4 FAN DRIVE AND RADIATOR ASSEMBLY…9721
2.4 FAN DRIVE AND RADIATOR ASSEMBLY – LEGEND FOR ILLUSTRATION…9721
2.5 RADIATOR FAN DRIVE SPEED ADJUSTMENT…9725
2.6 PUMP DISTRIBUTOR GEARBOX (PTO)…9729
2.7 PUMP-SPLINE LUBRICATION…9731
2.8 PTO LUBRICATION AND COOLING…9733
2.8 PTO LUBRICATION AND COOLING – LEGEND OF ILLUSTRATION…9733
2.9 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES…9737
3.0 HYDRAULIC OIL RESERVOIR…9738
3.0 HYDRAULIC OIL RESERVOIR GENERAL LAYOUT…9738
3.1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS ETC…9742
3.2 SUCTION OIL TANK WITH STRAINERS…9744
3.3 RETURN OIL COLLECTOR TUBE WITH STRAINER…9746
3.4 BACK PRESSURE VALVE…9748
3.5 TRANSFER PUMP (OPTIONAL EQUIPMENT)…9750
3.6 RETURN AND LEAK OIL FILTER…9752
3.7 BREATHER FILTER…9754
4.0 HYDRAULIC OIL COOLING…9755
4.1 GENERAL…9757
4.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT…9759
4.3 ADJUSTMENT OF THE BACK PRESSURE VALVE…9761
4.4 FAN DRIVE (TWO STAGE COOLER FAN PRM CONTROL)…9763
4.5 PRESSURE RELIEF VALVES AND SOLENOID VALVE…9765
4.6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING…9769
5.0 CONTROLLING…9770
5.0 GENERAL LAYOUT – LEGEND FOR ILLUSTRATIONS…9772
5.1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS (VALVES, SWITCHES, SENSORS ETC)…9774
5.2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS…9778
5.3 REMOTE CONTROL VALVES ARRANGEMENT…9784
5.4 FUNCTION PRINCIPLEOF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL…9786
5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK)…9790
5.6 POTENTIOMETER CONTROL (PEDAL)…9792
5.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A…9794
5.8 PROPORTIONAL AMPLIFIER MODULE, TYPE B…9796
5.9 RAMP TIME MODULE…9798
5.10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)…9800
5.11 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION…9802
5.12 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION…9806
5.13 ADJUSTING THE RAMP TIME MODULE…9810
6.0 COMPONENTS…9815
6.1 HYDRAULIC…9815
6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER – FRONT SHOVEL ATTACHMENT…9817
6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACK HOE ATTACHMENT…9819
6.1.3 DISTRIBUTOR MAINFOLD – LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES – FRONT SHOVEL ATTACHMENT…9821
6.1.4 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES – BACKHOE ATTACHMENT…9823
6.1.5 SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM FRONT SHOVEL ATTACHMENT…9825
6.1.6 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE…9827
6.1.7 ANTI CAVITATION VALVE BLOCK…9829
6.1.8 REMOTE CONTROL VALVE…9831
6.1.9 DIRECTIONAL SOLENOID VALVES (THREE POSITIONS / 4-WAY)…9833
6.1.10 PROPORTIONAL SOLENOID VALVE…9835
6.1.11 HIGH PRESSURE FILTER…9837
6.1.12 CONTROL BLOCKS AND VALVES…9839
6.1.13 TRAVEL BRAKE VALVE…9851
6.1.14 PRESSURE REDUCING VALVE…9853
6.1.15 DIRECTIONAL SOLENOID VALVES (TWO POSITIONS / 4-WAYS)…9855
6.1.16 PRESSURE INCREASING VALVE…9857
7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM…9858
7.0 GENERAL LAYOUT (HYDRAULIC ONLY)…9860
7.0 GENERAL LAYOUG (PUMP REGULATION SYSTEM)…9862
7.1 MAIN PUMPS…9868
7.1.1 LOCATION OF PUMPS…9868
7.1.2 PUMP BEARING FLUSHING / LUBRICATION…9870
7.1.3 OPERATING PRINCIPLES…9872
7.1.4 CHECKS / ADJUSTMENTS…9888
7.2 ELECTRONIC PUMP REGULATION SYSTEM…9898
7.2.1 ELECTRONIC LOAD LIMITING CONTROL – GENERAL…9898
7.2.2 MICROCONTROLLER MC7…9900
7.2.3 CHECKS AND ADJUSTMENTS…9902
METHOD A X1 PRESSURE WITH 24V SUPPLY…9904
METHOD B – WITH ELECTRONIC SERVICE TOOL…9906
LANGUAGE SELECTION…9906
EXCAVATOR TYPE SELECTION…9910
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT…9914
METHOD C – WITH A LAPTOP COMPUTER…9918
STARTING THE PROGRAM…9918
LANGUAGE SELECTION…9922
EXCAVATOR TYPE SELECTION…9924
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT…9926
7.3 HYDRAULIC CONSTANT REGULATION SYSTEM…9928
7.3.1 GENERAL…9928
7.3.2 X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE)…9930
7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)…9932
8.0 OPERATING HYDRAULIC…9933
OPERATING HYDRAULIC – GENERAL…9935
8.1 HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA…9938
8.1.1 ELECTRIC/HYDRAULIC FLOWCHART "BOOM RAISING"…9940
8.1.2 ELECTRIC/HYDRAULIC FLOWCHART "BOOM LOWERING"…9944
8.1.3 ELECTRIC/HYDRAULIC FLOWCHART "STICK EXTENDING"…9948
8.1.4 ELECTRIC/HYDRAULIC FLOWCHART "STICK RETRACTING"…9952
8.1.5 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET FILLING"…9956
8.1.6 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET EMPTYING"…9960
8.1.7 ELECTRIC/HYDRAULIC FLOWCHART "CLAM OPENING"…9964
8.1.8 ELECTRIC/HYDRAULIC FLOWCHARG "CLAM CLOSING"…9966
8.1.9 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES …9968
8.1.10 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES…9972
Boom cylinder “Piston side” FSA +BHA…9974
Boom cylinder “Piston rod side” FSA +BHA…9976
Stick cylinder “Piston side” FSA…9980
Stick cylinder “Piston side” BHA…9984
Stick cylinder “Piston rod side” FSA…9988
Stick cylinder “Piston rod side” BHA…9992
Bucket cylinder “Piston side” FSA…9996
Bucket cylinder “Piston side” BHA…10000
Bucket cylinder “Piston rod side” FSA…10004
Bucket cylinder “Piston rod side” BHA…10008
Clam cylinder “Piston rod side” FSA…10012
Clam cylinder “Piston side” FSA…10014
8.1.11 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED…10016
Boom cylinder FSA…10018
Boom cylinder BHA…10022
Stick cylinder BHA…10028
Bucket cylinder FSA…10030
Bucket cylinder BHA…10032
Clam cylinder BHA…10034
8.2 HYDRAULIC FOR THE SWING CIRCUIT…10035
8.2.1 SWING CIRCUIT…10037
8.2.2 SWING MOTOR…10041
8.2.3 SWING GEAR BOX…10045
8.2.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE)…10047
8.2.5 SWING BRAKE VALVE…10049
8.2.6 ELECTRIC/HYDRAULIC FLOWCHART "SWING LEFT"…10053
8.2.7 ELECTRIC/HYDRAULIC FLOWCHART "SWING RIGHT"…10055
8.2.8 SWING MONITORING SYSTEM…10057
8.2.9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT…10061
8.2.10 FUNCTION FOR THE SWING PARKING BRAKE…10067
8.3 HYDRAULIC FOR THE SWING CIRCUIT…10068
8.3.1 TRAVEL CIRCUIT…10070
8.3.2 TRAVEL MOTOR…10074
8.3.3 ROTARY DISTRIBUTOR…10076
8.3.4 TRAVEL GEAR…10078
8.3.5 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)…10080
8.3.6 TRAVEL BRAKE VALVE…10082
8.3.7 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING FORWARD"…10084
8.3.8 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING BACKWARD"…10086
8.3.9 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT…10088
8.3.10 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE…10090
9.0 HYDRAULIC TRACK TENSIONING SYSTEM…10091
9.0 GENERAL…10093
9.1 FUNCTIONAL DESCRIPTION…10095
9.2 PRESSURE INCREASING VALVE…10099
9.3 TENSIONING CYLINDER…10101
9.4 ADJUSTMENTS / CHECKS…10103
9.5 FUNCTIONAL TEST…10107
10.0 ACCESS LADDER HYDRAULIC OPERAGED…10108
10.0 GENERAL…10110
10.1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER…10112
11.0 HYDRAULIC OPERATED REFILLING ARM…10115
11.0 GENERAL…10117
11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM…10119
12.0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM…10120
12.0 GENERAL…10121
12.1 LEGEND FOR THE CIRCUIT DIAGRAM…10122
12.2 HOW TO READ THE CIRCUIT DIAGRAM…10130
13.0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM…10131
13.1 DESIGNATION OF ELECTRICAL DEVICES…10133
13.2 SYMBOLS…10135
13.3 GENERAL INFORMATION…10139
13.4 READING A CIRCUIT DIAGRAM…10143
13.5 COMPONENT LIST…10147
14.0 VEHICLE HEALTH MONITORING SYSTEM…10293
DATA FLOW CONTROL OF VHMS…10294
GENERAL…10295
14.1 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR OPERATORS…10272
14.1.1 GRAPHIC FLOW CHART…10274
14.1.2 INITIALIZATION SCREEN (NO. 0.0)…10276
14.1.3 OPERATOR INFORMATION SCREEN ( NO. 1.1)…10276
14.1.4 MONITORING SCREENS…10278
STANDARD MONITOR 1 (NO. 1.2)…10278
EXPANSION MONITOR 2 (NO.1.3)…10278
EXPANSION MONITOR 3 (NO. 1.4)…10278
14.1.5 BRIGHTNESS AND CONTRAST SETTING SCREEN (NO. 1.2.1)…10280
14.1.6 FUEL CONSUMPTION SCREEN (NO. 1.2.2)…10282
14.1.7 SETTINGS FOR OPERATOR, SCREEN (NO. 1.2.3)…10284
14.1.8 MAINTENANCE MONITOR (NO. 1.2.4)…10286
14.1.9 FAILURE MESSAGE ( NO. 1.2.5)…10290
14.1.10 AUTOMATIC MESSAGES…10292
14.2 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR SERVICEMEN…10213
14.2.1 GRAPHIC FLOW CHART…10215
14.2.2 SERVICE ID SETUP SCREEN (NO. 2.0)…10217
14.2.3 SERVICE MENU SELECT SCREEN (NO. 3.1)…10219
14.2.4 REAL TIME MENU SELECT SCREEN (NO. 4.1.1)…10221
ENGINE 5.1.1 – 5.1.4…10221
TRANSMISSION 5.2.1…10223
HYDRAULIC 5.3.1 – 5.4.2…10225
ELECTRICAL EQUIPMENT 5.4.1 – 5.4.2…10227
EMERGENCY STOP 5.5.1…10229
MANUAL SWITCH 5.6.1 – 5.6.3…10231
CENTRAL LUBRICATION SYSTEM 5.7.1 – 5.7.2…10233
SWING LUBRICATION SYSTEM 5.8.1 – 5.8.2…10235
OTHER ITEMS 5.9.1 – 5.9.3…10237
OUTPUT SIGNALS 5.10.1 – 5.10.6…10239
14.2.5 PM-CLINIC…10241
PM CLINIC GENERAL – 4.2.1 – 4.2.2…10241
PM CLINIC POWER CHECK – 4.2.3 – 4.2.5…10243
14.2.6 SERIAL NO. SETTING …10245
MACHINE 4.3.1…10245
ENGINE 4.3.2…10247
14.2.7 MEMORY CLEAR…10249
INPUT ID 4.3.2…10249
MEMORY CLEAR 4.4.1…10251
14.2.8 MAINTENANCE MONITOR – MAINTENANCE ACKNOWLEDGEMENT – 4.5 – 4.5.1…10253
14.2.9 FAILURE HISTORY – 4.6…10255
14.2.10 SNAPSHOT TRIGGER- 4.7…10257
14.2.11 SETTINGS…10259
CENTRAL LUBRICATION SYSTEM 4.8.1…10259
SWING LUBRICATION SYSTEM 4.8.2…10261
OTHER SETTINGS 1/2…10263
LANGUAGE…10264
OPERATING HOURS…10264
DATE…10264
TIME…10265
GMT REFERENCE…10265
OTHER SETTINGS 2/2…10267
OIL VISCOSITY HYDRAULIC…10267
OIL VISCOSITY GEAR…10267
MESSAGES ON/OFF…10269
PLC-AUTOM. ON/OFF…10269
SHUT DOWN ON.OFF 4.8.5 – 4.8.10…10271
14.4 WIRING OF THE MAIN COMPONENTS…10200
14.4.1 WIRING OF THE ENGINE…10204
14.4.2 WIRING OF THE VHMS CONTROLLER…10206
14.4.3 WIRING OF THE CGC MONITOR…10210
14.4.4 WIRING OF THE PLC…10212
15.0 LUBRICATION SYSTEMS…10300
15.1 HYDRAULICALLY DRIVEN LUBE PUMP…10300
FUNCTION…10306
ADJUSTMENTS…10310
15.2 ONE LINE SYSTEM WITH HYDRAULICALLY DRIVEN "PUMP MASTER III" PUMP…10312
FUNCTION…10314
ELECTRICAL FUNCTION…10318
SONAR SENSOR FOR GREASE LEVEL…10322
ADJUSTMENTS…10324
END LINE SWITCH…10324
INJECTORS…10326
15.3 PINION TYPE SYSTEM WITH HYDRAULIC DRIVEN "POWER MASTER III" PUMP…10328
FUNCTION…10331
ELECTRICAL FUNCTION…10334
LUBRICANT LEVEL…10338
ADJUSTMENTS…10340
END OF LINE SWITCH SETTING…10340
INJECTORS…10342
15.4 COMPONENTS…10344
HYDRAULICALLY DRIVEN "POWER MASTER III" LUBE PUMP…10346
LUBRICANT INJECTORS…10350
END-OF-LINE SWITCH…10356
FILTER…10358
VENT VALVE…10360
FLOWCHART 942 107 40 …10370
FLOWCHART 942 107 40 PAGE 1 OF 70…10370
…
ELECTRICAL PLAN 942 106 40 PAGE 73 OF 73…10521

Komatsu Hydraulic Mining Shovel PC4000 Repair Service Manuals

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

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