Komatsu PC8000-6 Diesel Hydraulic Mining Shovel Shop Manual PDF

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Komatsu PC8000-6 Diesel Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD

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Komatsu PC8000-6 Diesel Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 1802
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC8000-6 Diesel Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD 

SERIAL NUMBER 12071 and up

SHOP MANUAL COVER 1
00 FOREWORD & SAFETY 5
1 FOREWORD 5
1 1 BEFORE READING THIS MANUAL 6
1 2 DIRECTIONS OF THE MACHINE 7
1 3 SPECIFICATION AND SERIAL PLATE 8
1 3 1 PRODUCT IDENTIFICATION NUMBER 8
1 4 DIVISION OF THE BINDER 9
1 5 DESIGNATED USE OF THE SHOVEL 10
1 6 DELIVERY OF THE SHOVEL 11
1 6 1 SPARE PARTS 11
1 6 2 SERVICE 11
1 7 EXPLANATION OF ABBREVIATIONS 12
1 8 CONTENTS 13
2 SAFETY 19
2 1 SAFETY INFORMATION 20
2 2 OVERVIEW 21
2 2 1 NORMAL OPERATIONS 21
2 2 2 REGULAR MAINTENANCE 21
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 21
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 21
2 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 22
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 23
2 4 1 UNDERSTANDING THE MACHINE 23
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 23
2 4 2 1 ENSURING SAFE OPERATION 23
2 4 3 PREPARATIONS FOR SAFE OPERATION 23
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 23
2 4 3 2 INSPECTING THE MACHINE 23
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 24
2 4 3 4 KEEP MACHINE CLEAN 24
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 24
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 25
2 4 3 7 IF A PROBLEM IS FOUND 25
2 4 4 FIRE PREVENTION 25
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 25
2 4 4 2 ACTION IF FIRE OCCURS 26
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 27
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 27
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 27
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 27
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 27
2 4 5 4 WORKING IN HIGH PLACES 27
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 28
2 4 5 6 LEAVING THE MACHINE 28
2 4 6 BURN PREVENTION 29
2 4 6 1 Hot coolant 29
2 4 6 2 Hot oil 29
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 29
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 30
2 4 8 1 UNAUTHORIZED MODIFICATION 30
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 30
2 4 9 PRECAUTIONS AT JOBSITE 31
2 4 9 1 VISIBILITY FROM OPERATOR’S SEAT 32
2 4 9 2 CAMERA SYSTEM WITH MONITORS 32
2 4 9 3 ENSURE GOOD VISIBILITY 32
2 4 9 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 32
2 4 9 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 33
2 4 9 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 33
2 4 9 7 WORKING ON LOOSE GROUND 34
2 4 9 8 GAS, DUST, STEAM AND SMOKE 34
2 4 9 9 VENTILATION OF ENCLOSED AREAS 35
2 4 10 STARTING ENGINE 36
2 4 10 1 WARNING TAG 36
2 4 10 2 CHECKS BEFORE STARTING ENGINE 36
2 4 10 3 PRECAUTION WHEN STARTING ENGINE 36
2 4 10 4 PRECAUTION IN COLD AREAS 37
2 4 11 OPERATION 37
2 4 11 1 CHECKS BEFORE OPERATION 37
2 4 11 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 38
2 4 11 3 PRECAUTIONS WHEN travelling 39
2 4 11 4 TRAVELLING ON SLOPES 40
2 4 11 5 OPERATIONS ON SLOPES 41
2 4 11 6 PROHIBITED OPERATIONS 41
2 4 11 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 42
2 4 11 8 PARKING THE MACHINE 42
2 4 11 9 TRANSPORTATION 42
2 5 PRECAUTION FOR MAINTENANCE 43
2 5 1 GENERAL PRECAUTIONS 43
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 44
2 5 1 2 STOP ENGINE FOR MAINTENANCE 45
2 5 1 3 WARNING TAG 46
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 47
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 47
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 48
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 48
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 49
2 5 1 9 NOISE 49
2 5 1 10 WHEN USING A HAMMER 49
2 5 1 11 PROPER TOOLS 50
2 5 1 12 ACCUMULATOR 50
2 5 1 13 PERSONNEL 50
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 51
2 5 2 1 PRECAUTION WHEN WELDING 51
2 5 2 2 BATTERY HANDLING 51
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 52
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 52
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 53
2 5 3 3 REPLACEMENT OF HOSE LINES 53
2 5 3 4 INSPECTION OF HOSE LINES 53
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 54
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 54
2 5 3 7 AIR CONDITIONING MAINTENANCE 54
2 5 3 8 COMPRESSED AIR 55
2 5 3 9 WASTE MATERIALS 55
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 56
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 56
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 56
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 56
2 7 SPECIAL SAFETY EQUIPMENT 58
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 59
2 7 2 OBJECT HANDLING 59
2 7 3 LIGHTING 59
2 7 4 WARNING BEACON 59
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 59
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 59
2 7 5 2 INSTRUCTIONS FOR USE 61
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 63
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1), 63
2 7 5 5 INSTRUCTIONS FOR USE 65
2 8 SAFETY WARNING SIGNS 67
2 8 1 LOCATION AND DESCRIPTION OF THE SIGNS 68
01 Specification 81
10 Structure & Function 91
1 Introduction 93
1 1 Contents of the binder 94
1 2 Foreword 94
1 3 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 96
1 4 Explanation of abbreviations 97
1 5 Diagrams and illustrations in this manual 98
2 Specifications 101
2 1 Lifting Gears 102
2 2 Safety hints for sling accessory 104
2 3 Standard Tightening Torque Chart 105
2 4 Conversion Table 106
2 5 Blind plugs 113
2 6 Classification of threads to the nominal width 115
2 7 Plugs and fittings according to ISO 8434-1 / DIN 2353 116
2 8 Sensor Limit Values 117
3 Main assembly groups 121
3 1 General layout 122
3 2 Superstructure 124
3 3 Machine house 126
3 4 Hydraulic oil tank 128
3 5 Hydraulic oil cooler 130
3 6 Fuel tank 132
3 7 Cab support 134
3 8 Operator’s cab 136
3 9 Control blocks 138
3 10 Swing machinery 140
3 10 1 Swing machinery L&S 140
3 10 2 Swing machinery SIEBENHAAR 142
3 11 Undercarriage 144
3 12 Attachments 146
3 12 1 Front Shovel Attachment (FSA) 146
3 12 2 Backhoe Attachment (BHA) 148
4 Drive 151
4 1 Prime drive assembly 152
4 2 Engine mounts 154
4 3 Drive shaft 156
4 4 Flexible coupling 158
4 5 Fan drive and radiator assembly 160
4 5 1 Radiator fan speed adjustment 164
4 6 Pump distributor gearbox (PTO) 168
4 6 1 Pump drive shaft housing / spline lubrication 170
4 6 2 PTO lubrication and cooling 172
4 6 3 Hydraulic pumps – location, drive speed and flow rates 178
4 7 Air filter 180
5 Hydraulic oil tank 183
5 1 General layout 184
5 2 Location of the electric equipment 186
5 3 Suction oil tank with strainers 188
5 4 Return oil collector pipe with strainer 190
5 5 Back pressure valve 192
5 6 Transfer pump 194
5 7 Return and leak oil filter 196
5 8 Breather filter 198
6 Hydraulic oil cooling 201
6 1 Overall view of the hydraulic oil cooling 202
6 2 Function of the hydraulic oil cooling circuit 204
6 2 1 Standard hydraulic oil cooling circuit 204
6 2 2 Additional oil cooling circuit 206
6 3 Adjustment of the back pressure valve 208
6 4 Fan drive – standard oil cooler 210
6 4 1 Two stage cooler fan drive RPM control 210
6 4 2 Fixed displacement pump with variable setting 212
6 4 3 Pressure relief valves 214
6 4 4 Solenoid valves 216
6 5 Adjustment of the cooler fan drive speed 218
6 5 1 Maximum speed 218
6 5 2 Medium speed 222
6 6 Fan drive – additional oil cooler 224
6 6 1 Function of the additional cooler fan RPM control 225
6 6 2 Adjustment of the additional cooler fan drive speed 225
7 Controlling 227
7 1 General layout 228
7 2 Control and filter panels – location of components 230
7 2 1 Main valve cartridge block 230
7 2 2 Control and filter panels mounted on the PTOs 236
7 3 Pilot pressure supply and adjustments 240
7 3 1 Pilot pressure circuit 241
7 3 2 Checks and adjustments of pilot pressure 244
7 3 3 Remote control valves arrangement 248
7 4 Function of the electro-hydraulic control system 250
7 5 Hand lever (joystick) control 254
7 6 Foot pedal control 256
7 7 Proportional amplifier module, type A 258
7 8 Proportional amplifier module, type B 260
7 9 Ramp time module 262
7 10 Adjustment of amplifier modules 264
7 10 1 General 265
7 10 2 Adjusting the amplifier module, type A 266
7 10 3 Adjusting the amplifier module, type B 268
7 11 Adjusting the ramp time module 270
8 Components 275
8 1 Main control blocks and high pressure filters (FSA) 276
8 2 Distributor manifold – location of restrictor blocks and anti-cavitation valves 280
8 3 Restrictor block with secondary relief valve 282
8 4 Anti-cavitation valve (ACV) block 284
8 4 1 ACV block on control blocks 284
8 4 2 ACV block on top of the manifold 286
8 5 Remote control valves 288
8 6 4/3 Directional solenoid valves 290
8 7 Proportional solenoid valves 292
8 8 High-pressure filter (screen) 294
8 9 CONTROL blocks and valves 296
8 10 Travel brake valve 308
8 11 Pressure reducing valve 310
8 12 4/2 Directional valves 312
8 13 Pressure double stage valve 314
8 14 Hydraulic cylinder 316
9 Main hydraulic pumps and pump regulation 321
9 1 General 322
9 1 1 Layout 323
9 1 2 Pump regulation system (“open sensing system”) 325
9 1 3 Pump regulation system — valve function 327
9 2 Main pumps 329
9 2 1 Pump bearing flushing / lubrication 330
9 2 2 Operating principle 332
9 2 3 Checks / adjustments 348
9 3 Electronic pump regulation system 356
9 3 1 Electronic load limiting control – general 357
9 3 2 Microcontroller RC4-4 358
9 3 3 Checks and adjustments 360
9 4 Hydraulic constant regulation system 368
9 4 1 General 369
9 4 2 X1-pressure adjustment (constant pressure) 370
9 5 Power check (engine performance) 372
9 6 Engine speed sensor (pick-up) 374
9 6 1 General 375
9 6 2 Engine speed sensor (pick-up) adjustment 375
9 7 Energy efficiency 376
9 7 1 General 377
9 7 2 Checks and adjustments 378
10 Operating hydraulics 383
10 1 General 384
10 1 1 Floating function for boom and stick cylinder (FSA) 386
10 2 Hydraulics for the attachment cylinders FSA 388
10 2 1 Electric / hydraulic flowchart “Boom UP” (FSA) 388
10 2 2 Electric / hydraulic flowchart “Boom down” (FSA), Auto-float ON 390
10 2 3 Electric / hydraulic flowchart “Boom down” (FSA), Auto-float OFF 392
10 2 4 Electric / hydraulic flowchart “Stick out” (FSA) 394
10 2 5 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON 396
10 2 6 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF 398
10 2 7 Electric / hydraulic flowchart “Bucket fill” (FSA) 400
10 2 8 Electric / hydraulic flowchart “Bucket dump” (FSA) 402
10 2 9 Electric / hydraulic flowchart “Clam open” (FSA) 404
10 2 10 Electric / hydraulic flowchart “Clam close” (FSA) 406
10 2 11 Checks and adjustments of the main relief valves (MRV), FSA 408
10 2 12 Checks and adjustments of the secondary relief valves (SRV), FSA 410
10 2 12 1 Boom cylinder, piston side (FSA) 410
10 2 12 2 Boom cylinder, piston rod side (FSA) 414
10 2 12 3 Stick cylinder, piston side (FSA) 418
10 2 12 4 Stick cylinder, piston rod side (FSA) 422
10 2 12 5 Bucket cylinder, piston side (FSA) 426
10 2 12 6 Bucket cylinder, piston side (FSA) 430
10 2 12 7 Clam cylinder, piston rod side (FSA), clam open 434
10 2 12 8 Clam cylinder, piston side (FSA), clam close 436
10 2 13 Checks and adjustments of the lowering speed – boom 438
10 2 14 Checks and adjustments of the lowering speed – stick 442
10 2 15 Checks and adjustments of the lowering speed – Bucket 446
10 2 16 Checks and adjustments of the lowering speed – clam 450
10 3 Hydraulics for the slew circuit 452
10 3 1 Slew circuit 452
10 3 2 Slew motor 456
10 3 3 Slew gearbox (L&S) 460
10 3 4 Slew gearbox (SIEBENHAAR) 462
10 3 5 Slew parking brake (L&S) 464
10 3 6 Slew parking brake (SIEBENHAAR) 466
10 3 7 Slew brake valve 468
10 3 8 Electric / hydraulic flowchart “Slew left” 472
10 3 9 Electric / hydraulic flowchart “Slew right” 474
10 3 10 Checks and adjustments for the slew circuit 476
10 3 11 Function check for hydraulic slew brake 480
10 3 12 Function check for the slew parking brake 482
10 4 Hydraulics for the travel circuit 486
10 4 1 Travel circuit 487
10 4 2 Travel motor 490
10 4 3 Rotary joint 492
10 4 4 Travel gearbox 494
10 4 5 Travel parking brake (L&S) 496
10 4 6 Travel parking brake (ZOLLERN) 498
10 4 7 Travel brake valve 500
10 4 8 Electric / hydraulic flowchart “Travel forward” 502
10 4 9 Electric / hydraulic flowchart “Travel backwards” 504
10 4 10 Checks and adjustments for the travel circuit 506
10 4 11 Function check for the travel parking brake 508
11 Hydraulic track tensioning system 511
11 1 General 512
11 2 Functional description 514
11 3 Double-stage valve 518
11 4 Tensioning cylinder 520
11 5 Adjustments / checks 522
12 Access ladder, hydraulically operated 525
12 1 General 526
12 2 Function of the hydraulically operated access ladder 528
12 3 Adjustments / checks 532
13 Central refilling system (service arm) 535
13 1 General 536
13 2 Function 538
14 Hints for reading the hydraulic diagram 541
14 1 General 542
14 2 Hydraulic symbols 544
14 2 1 Lines, unions 545
14 2 2 Components, valves 547
14 2 3 Sensors 547
14 2 4 Valves, valve components 548
14 2 5 Pump, motor, cylinder 552
15 Hints for reading the electric wiring diagram 557
15 1 General 558
15 2 Reference designation of the electrical components 559
15 2 1 Area code 559
15 2 2 Component identifying letter 561
15 3 Graphical symbols 562
15 4 Drawing concept 566
15 5 Cable marking 576
15 6 Table of new and old component designations 577
16 KOMTRAX Plus 613
16 1 General 614
16 2 Specifications for Operators 616
16 2 1 Sequence of Displays 617
16 2 2 Opening Screen 617
16 2 3 Main Gauge Screens 1 to 4 618
16 2 4 Fuel Consumption Screen 622
16 2 5 Failure message History for the Operator 624
16 2 6 Main Gauge Screens – Changing of Time / SMR / Date 626
16 2 7 Maintenance Monitor 627
16 2 8 Settings for Operators 629
16 2 9 Automatic Messages 636
16 3 Tables of all Provided Messages 639
16 3 1 Table of G-Codes 640
16 3 2 Table of C-Codes – Diesel engines QSK60 TIER 2 647
16 3 3 Table of available Instruction Messages 654
16 4 Flow Charts (1-4) VHMS Main Screens 657
16 5 VHMS Service Level 661
16 5 1 Explanation of the Button Symbols (Service Level) 663
16 5 2 Service Menu Select Screen 664
16 5 3 Real Time Menu Select Screen 665
16 5 3 1 Real Time Menu, option: 01 Engine 1 666
16 5 3 2 Real Time Menu, option: 02 Engine 2 667
16 5 3 3 Real Time Menu, option: 03 PTO 1 667
16 5 3 4 Real Time Menu, option: 04 PTO 2 667
16 5 3 5 Real Time Menu, option: 05 Hydraulic 668
16 5 3 6 Real Time Menu, option: 06 Slew 669
16 5 3 7 Real Time Menu, option: 07 Electrical Equipment 670
16 5 3 8 Real Time Menu, option: 08 Emergency Stop 671
16 5 3 9 Real Time Menu, option: 09 Manual Switch 672
16 5 3 10 Real Time Menu, option: 10 Central lUBE System 1 673
16 5 3 11 Real Time Menu, option: 11 Slew Ring Gear Lube System 673
16 5 3 12 Real Time Menu, option: 12 Central Lube System 2 674
16 5 3 13 Real Time Menu, option: 13 Windscreen Wiper 674
16 5 3 14 Real Time Menu, option: 14 Ladder 675
16 5 3 15 Real Time Menu, option: 15 Service Arm 676
16 5 3 16 Real Time Menu, option: 16 Pilot Control 677
16 5 3 17 Real Time Menu, option: 17 Other Items 678
16 5 3 18 Real Time Menu, option: 18 Output Signals 679
16 5 3 19 Output Signals with deactivated MTC-Evaluation 682
16 5 4 PM-Clinic 684
16 5 4 1 General 684
16 5 4 2 Power Check 685
16 5 5 Serial/GCC No Setting 686
16 5 6 Memory Clear 687
16 5 6 1 Input Memory Clear ID 687
16 5 6 2 Memory Clear Screen 688
16 5 7 Failure History 689
16 5 8 Maintenance Monitor 690
16 5 9 Snapshot 691
16 5 10 Settings 692
16 5 10 1 Central Lubrication System (CLS 1), screen 1/10 692
16 5 10 2 Swing Lubrication System (SLS), screen 2/10 693
16 5 10 3 Central Lubrication System (CLS 2), screen 3/10 694
16 5 10 4 Qmin – Qmax – Setting, screen 4/10 695
16 5 10 5 Other Settings 1/2, screen 5/10 695
16 5 10 6 Other Settings 2/2, screen 6/10 697
16 5 10 7 Shutdown Bypass ON/OFF 700
16 6 Interface-Connection VHMS-Controller 704
16 6 1 VHMS-Controller 705
16 7 Wiring of the VHMS-Controller 706
16 8 Global Layout of the MTC Control System 710
16 8 1 MTC (Master Turbo Controller) 712
16 8 1 1 MTC-Flowchart 712
16 8 1 2 MTC Features 712
16 8 1 3 MTC-Firmware and Software 713
16 8 1 4 View onto the MTC unit and its Connectors (exemplary) 714
16 9 Global Layout of the Internal CAN bus 716
16 9 1 General Information about a CAN bus System 716
16 9 1 1 General CAN bus description 717
16 9 1 2 CAN bus troubleshooting 717
16 9 1 3 Can bus wiring 718
16 9 1 4 CAN bus End Resistor 720
16 10 The Nodes in the CAN bus System 722
16 10 1 Global Layout 722
16 10 2 Introduction 723
16 10 2 1 ICN-V Node Features 723
16 10 2 2 ICN-D Node Features 725
16 10 3 Node DIP-Switches 726
16 10 4 Node Box 727
16 10 5 Node Locations on the Machine 730
16 10 5 1 Node & Location Chart 731
16 10 5 2 Exemplary View onto Location 11 (Cab base) 732
17 Lubrication system 735
17 1 General overview (SLS & CLS 1 / 2) 736
17 1 1 General description 737
17 2 Basic function of the lubrication systems 738
17 3 Central lubrication system (CLS 1 & 2) 740
17 3 1 General information on the CLS (CLS 1 / 2) 741
17 4 Slew ring lubrication system (SLS) 744
17 4 1 General information on the SLS 746
17 5 Lubrication cycle 747
17 5 1 Operation and control 747
17 5 2 Lubrication cycle – components 748
17 5 3 Lubrication cycle – processing 750
17 5 4 Time segments & switch points of a lubrication cycle 751
17 5 5 Lubrication modes 752
17 5 5 1 Automatic lubrication mode 752
17 5 5 2 Manual lubrication mode 752
17 5 5 3 VHMS service mode 752
17 6 Hydraulically driven lube pump 754
17 6 1 Adjustment of lube pump speed & working pressure 756
17 6 1 1 Stroke speed adjustment 757
17 6 1 2 Working pressure adjustment 758
17 7 Lubricant injectors 760
17 7 1 Tightening torques for fittings at grease injectors 761
17 7 2 Description 761
17 7 3 Adjustment of the lubricant output 762
17 7 4 Operation principle of lubricant injectors 764
17 7 4 1 Function description 765
17 7 5 Connection of one or more injectors 766
17 8 Vent valve 768
17 8 1 Description 769
17 9 End-line switch 770
17 9 1 Description 771
17 9 2 CLS end-line switch adjustment 772
17 9 3 SLS end-line switch adjustment 774
17 10 In-line filter 776
17 10 1 Description 777
17 10 2 Maintenance procedure 777
17 11 Lubricant level sensor 778
17 11 1 Description 779
17 11 1 1 LEDs at the sonar sensor 780
17 12 Commissioning 782
17 12 1 Commissioning of the CLS 1 & CLS 2 lubrication systems 782
17 12 2 Fine adjustment 783
17 12 3 Commissioning of the SLS lubrication system 784
40 Troubleshooting 787
2 Introduction & General Information for Troubleshooting 789
2 1 Overview 790
2 1 1 General advice when using troubleshooting charts 790
2 2 General Precautions 791
2 3 Preparations For Work 792
2 4 Precautions During Work 792
2 5 Precautions When Carrying Out Any Operation 793
2 5 1 Precautions when carrying out removal work 793
2 5 2 Precautions when carrying out installation work 793
2 5 3 Precautions when completing the operation 794
2 6 Fundamental Requirements for Troubleshooting 795
2 6 1 Technical documentation 795
2 6 2 Tools 795
2 6 2 1 Reference Guide for Deutsch Removal Tools 798
2 6 3 Personnel 799
2 7 Points To Remember When Trouble- shooting 799
2 8 Sequence Of Events In Troubleshooting 801
2 9 Checks Before Troubleshooting 802
2 10 Handling Of Electric Equipment And Hydraulic Components 803
2 10 1 Points to remember when handling electric equipment 803
2 10 2 Points To Remember When Handling Hydraulic Equipment 806
2 11 General working procedures 808
2 11 1 Air Bleeding of Various Hydraulic Parts 808
2 11 2 Air bleeding from the hydraulic pumps 808
2 11 3 Air bleeding from hydraulic cylinders 808
2 12 Cylinder bypass test 809
2 13 Information about MTC & Nodes 810
2 13 1 Outline of the MTC and its connector locations 810
2 13 1 1 View onto the MTC connectors* LH & RH 810
2 13 1 2 General description of the MTC 810
2 13 1 3 Information about the LED indications at the MTC 811
2 13 2 Information about the ICN-D node 811
2 13 2 1 View onto an ICN-D node without wiring 812
2 13 2 2 View onto the Status LEDs at the ICN-D node 813
2 13 2 3 General information on the LED control 813
2 13 3 Information about the ICN-V node 815
2 13 3 1 View onto an ICN-V node 815
2 13 3 2 View onto an open ICN-V node and its DIP-switches 816
2 13 4 DIP switches at the ICN-D and ICN-V nodes 817
2 14 Basics about “How to crimp” 818
2 14 1 Stripping a wire for use with the HDT 48 crimp tool 818
2 14 2 View onto the Deutsch crimp tool HDT 48 818
2 14 3 Adjustment of the wire size at the Deutsch crimp tool HDT 48 819
2 14 3 1 Wire cross section units in mm2 and AWG 819
2 14 4 Crimping instructions (for Deutsch crimp tool HDT 48) 820
2 15 Cable Shielding 821
2 16 KOMTRAX Plus vs VHMS 821
3 Mounting Locations and Connector Types 823
3 1 Component Location 824
3 1 1 View onto the Superstructure 824
3 1 2 Location of Engine Electrical Parts (1) 826
3 1 3 Location of Engine Electrical Parts (2) 828
3 1 4 Location of Engine Remote Oil Tank Sensors 830
3 1 5 Location of Hydraulic Components (1) 832
3 1 6 Location of Hydraulic Components (2) 834
3 1 7 Control and Filter Panels Mounted on the PTOs 836
3 1 8 Location of the Remote Control Valves 840
3 1 9 Hydraulic Oil Tank – Location of Electrical Components 842
3 1 10 View onto the CLS1/2 & SLS Lubrication Station and the Lubrication Cycle Components 844
3 1 11 Exemplary View onto the Electrical Components in the Cab Base 846
3 1 12 Exemplary View onto the X2 Board in the Cab Base 848
3 1 13 Batteries, Battery Main Switches & Safety Switch for Maintenance 850
3 1 14 Hydraulically Operated Access Ladder 852
3 1 15 Service Arm 854
3 2 Connector Types Overview 856
4 Standard Value Table for Electrical Components 861
5 References for Troubleshooting (CAN Bus & Node Outputs) 873
5 1 CAN-Bus trouble or Node Output Trouble 874
5 1 1 Trouble CAN-BUS or CAN-Hardware (G00308) 875
5 1 2 Trouble output short-circuit (G00043) 876
5 2 Sequence of the CAN nodes at the CAN bus 878
5 3 Troubleshooting for Relay Monitored Node Outputs 879
5 3 1 Relay Check 879
G00107 – Trouble slew parking brake control 56K250a 880
G00109 – Trouble slew parking brake control 56K250b 880
View onto the CoDeSys HMI Visualization screen for trouble code G00107 882
Wiring Diagram (56K250a & 56K250b) for trouble code G00107 883
5 3 2 Output Check 884
G00108 – Trouble slew parking brake control Output to 56K250a 885
G00110 – Trouble slew parking brake control Output to 56K250b 885
View onto the CoDeSys HMI Visualization screen for trouble code G00108 887
Wiring Diagram (56K250a & 56K250b) for trouble code G00108 888
6 Tables for Testing and Troubleshooting 891
6 1 Index of Tables in this section 892
6 2 Test Value Table for Temperature Sensors (PT100) g Centigrade – Volt 893
6 3 Test Value Table for Temperature Sensors (PT100) g Centigrade – Ohm 894
6 4 Table of Trouble Codes (G-Codes) 895
6 5 Table of Instruction Messages 902
6 6 Table of Binary Codes 905
6 6 1 Table of Add-On Binary Codes for G00308 907
6 7 Binary Output Signals on the KOMTRAX Plus Monitor 908
6 8 Tables of Symptom Codes 911
6 8 1 Symptoms of the Engines and Related Electrical Systems 911
6 8 2 Symptoms of the Hydraulic System 911
6 8 3 Symptoms of the Mechanical System 912
6 8 4 SYMPTOMS OF ADDITIONAL SYSTEMS 912
6 9 Power Supply 913
6 10 Cable colour identification 913
6 11 Sensor Limit Values 914
7 Troubleshooting by Trouble Code 917
G00001 – Trouble Shut-Off (gate) valve 918
View onto the gap of proximity switch 40B031 920
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR 921
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor 921
Wiring Diagram (40B031) for trouble code G00001 (Trouble Shut-Off (gate) valve) 922
G00002 – Test speed 1800 1/min engine 1 923
G00006 – Test speed 1800 1/min engine 2 923
Wiring Diagram (11S041-1 & 11S041-2) for trouble codes G00002 & G00006 924
G00003 – Trouble pump controller 925
G00005 – Low hydraulic oil level 931
Wiring Diagram, oil level label, and defined position of the attachment (G00005) 933
G00006 – Test speed 1800 1/min engine 2 934
G00007 – Trouble hydraulic oil level 934
Wiring Diagram (40B004) and the defined position of the attachment (G00007) 935
G00012 – Central lubrication system grease level too low 936
G00013 – Slew ring gear lubr system grease level too low 936
G00202 – Attachment lubrication system grease level too low 936
Wiring Diagram (62B108 / 62B109 / 62B173) for trouble codes G00012 / G00013 / G00202 940
Wiring Diagram (junction box) for trouble codes G00012 / G00013 / G00202 941
G00020 – Trouble Shut-Off (gate) valve (Start blocked) 942
View onto the gap of proximity switch 40B031 (G00020) 944
Wiring Diagram (40B031) for trouble code G00020 (Main gate valve closed) 945
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR 946
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor 946
G00031 – Set engine to low idle 947
Wiring Diagram (20S030) for trouble code G00031 948
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR 948
G00032 – Trouble starter 949
Wiring Diagram (Cold Start Signal Engine 1 & 2) for trouble code G00032 950
Wiring Diagram (“Engine running” signals) for trouble code G00032 951
G00033 – Trouble KOMTRAX Plus controller 952
G00034 – Trouble KOMTRAX Plus display 953
G00035 – Trouble totally loss gear oil (PTO 1) 954
G00036 – Trouble totally loss gear oil (PTO 2) 954
View onto the location of sensor 57B175-1 at PTO 1 (G00035) 956
Input signal (analog) of the gear oil sensors 57B175-1/-2 on the REAL TIME MONITOR 957
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor 957
Wiring Diagram (57B175-1/-2) for trouble codes G00035 & G00036 958
G00037 – Trouble monitoring, engine 2 speed too low 959
G00038 – Trouble monitoring, engine 2 speed too high 959
G00039 – Actuate engine speed selector switch 959
G00043 – Trouble output short-circuit 960
G00048 – Trouble emergency safety circuit 961
Wiring Diagram (11K044a) for trouble code G00048 961
G00053 – Reset emergency safety circuit 962
G00054 – Monitoring idle position cut off 963
Wiring Diagram (11K032) for trouble code G00054 964
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054) 965
Exemplary view onto the KOMTRAX Plus Failure History (G00054) 965
G00060 – Fire in the power house 966
Wiring Diagram (fire alarm) for trouble code G00060 968
Wiring Diagram (10B350 in the safety circuit) for G00060 969
G00061 – Trouble monitoring, engine 1 speed too low 970
G00037 – Trouble monitoring, engine 2 speed too low 970
Input signal (analog) of 51K003b-1 & 51K003b-2 on the REAL TIME MONITOR 972
Wrong signal of the engine 2 speed converter on the REAL TIME MONITOR 972
Wiring Diagram (engine speed) for trouble codes G00061 & G00037 973
G00062 – Trouble monitoring, engine 1 speed too high 974
G00038 – Trouble monitoring, engine 2 speed too high 974
Wiring Diagram (engine speed) for trouble codes G00062 & G00038 975
G00063 – Trouble monitoring hydraulic oil temp 976
Wiring Diagram (59B015) for trouble code G00063 977
G00064 – Trouble monitoring hydraulic oil level 978
Wiring Diagram (40B004) for trouble code G00064 980
G00065 – Very low hydraulic oil level 981
View onto the hydraulic oil level label 981
G00066 – Trouble hydraulic oil temperature 982
Hydraulic oil temperature table 983
Wiring Diagram (57K506a-1/57K506b-1 & 57K506a-2/57K506b-2) and location for G00066 984
G00067 – Trouble battery voltage too high 985
Wiring Diagram (11T080) and component location for G00067 986
Input signal of 11T080 on the REAL TIME MONITOR for G00067 986
G00068 – Trouble gear lubrication (PTO 2) 987
G00069 – Trouble monitoring oil temperature gear (PTO 1) 988
G00083 – Trouble monitoring oil temperature gear (PTO 2) 988
Input of 57B049-1 on the REAL TIME MONITOR (G00069) 989
Gear oil temperature (PTO 1 & PTO 2) on the Main Gauge Screen 989
Wiring Diagram (57B049-1 & 57B049-2) and component location (G00069 & G00083) 990
G00070 – Trouble oil temperature gear (PTO 1) 991
G00084 – Trouble oil temperature gear (PTO 2) 991
Location of the PTO gear oil level dipstick & temperature sensors 57B049-1/57B049-2 994
G00071 – Trouble gear lubrication (PTO 1) 995
G00068 – Trouble gear lubrication (PTO 2) 995
Wiring Diagram (57B017-1 & 57B017-2) for trouble codes G00071 & G00068 996
G00081 – Trouble lubrication system 997
Operation cycles of the lubrication systems 999
Wiring Diagram (11K050) for trouble code G00081 1000
G00083 – Trouble monitoring oil temperature gear (PTO 2) 1001
G00084 – Trouble oil temperature gear (PTO 2) 1001
G00086 – SHUTDOWN 1001
G00087 – Stop all movements for low idle 1002
G00090 – Trouble power supply 1003
G00099 – Trouble power supply 1003
Wiring Diagram (stabilized power supply) for G00090 & G00099 1004
G00091 – Pilot control cut out 1005
View onto the lock lever and the cover of 20S105 (G00091) 1006
G00092 – Emergency shut-down at access ladder 1007
G00093 – Emergency shut-down at valve block 1007
G00094 – Emergency shut-down at hydraulic control panel 1007
G00095 – Emergency shut-down in cabin 1007
Wiring Diagram (emergency switches) for G00092~G00095 1008
G00096 – Pilot control cut out 1009
Wiring Diagram (20S094) for trouble code G00096 1010
G00099 – Trouble power supply 1011
G00100 – Maintenance Safety Switch 1011
Wiring Diagram (50S058) for trouble code G00100 1012
G00103 – Faulty switch 20M004 1013
Wiring Diagram 1 (windscreen wiper) for trouble code G00103 1015
Wiring Diagram 2 (windscreen wiper) for trouble code G00103 1016
G00104 – Trouble battery current 1017
Wiring Diagram (battery current) for trouble code G00104 1019
G00105 – Trouble battery charging current too low 1020
Wiring Diagram (11T080) for trouble code G00105 1021
G00107 – Trouble slew parking brake control 56K250a 1022
G00109 – Trouble slew parking brake control 56K250b 1022
View onto the CoDeSys HMI Visualization screen for trouble code G00107 1024
Wiring Diagram (56K250a & 56K250b) for trouble code G00107 1025
G00108 – Trouble slew parking brake control Output to 56K250a 1026
G00110 – Trouble slew parking brake control Output to 56K250b 1026
View onto the CoDeSys HMI Visualization screen for trouble code G00108 1028
Wiring Diagram (56K250a & 56K250b) for trouble code G00108 1029
G00109 – Trouble slew parking brake control 56K250b 1030
G00110 – Trouble slew parking brake control Output to 56K250b 1030
G00111 – Trouble travel parking brake control 56K251a 1031
G00113 – Trouble travel parking brake control 56K251b 1031
56K251a & 56K251b (relay check) on the REAL TIME MONITOR (G00111 & G00113) 1031
G00112 – Trouble travel parking brake control Output to 56K251a 1032
G00114 – Trouble travel parking brake control Output to 56K251b 1032
56K251a & 56K251b (output check) on the REAL TIME MONITOR (G00112 & G00114) 1032
G00113 – Trouble travel parking brake control 56K251b 1033
G00114 – Trouble travel parking brake control Output to 56K251b 1033
G00115 – Trouble slew hydraulic brake control 56K252a 1034
G00117 – Trouble slew hydraulic brake control 56K252b 1034
56K252a & 56K252b (relay check) on the REAL TIME MONITOR (G00115 & G00117) 1034
G00116 – Trouble slew hydraulic brake control Output to 56K252a 1035
G00118 – Trouble slew hydraulic brake control Output to 56K252b 1035
56K252a & 56K252b (output check) on the REAL TIME MONITOR (G00116 & G00118) 1035
G00117 – Trouble slew hydraulic brake control 56K252b 1036
G00118 – Trouble slew hydraulic brake control Output to 56K252b 1036
G00140 – Trouble monitoring X1-1 pressure 1037
G00139 – Trouble monitoring X1-2 pressure 1037
Wiring Diagram (57B085-1 & 57B085-2) for trouble codes G00140 & G00139 1039
G00141 – Trouble monitoring X2 pressure 1040
Wiring Diagram (57B086) for trouble code G00141 1042
G00147 – Trouble monitoring gear lubrication (PTO 1) 1043
G00150 – Trouble monitoring gear lubrication (PTO 2) 1043
Wiring Diagram (57B017-1 & 57B017-2) for trouble codes G00147 & G00150 1046
G00148 – Trouble monitoring fuel level 1047
Wiring Diagram (31B063) and component location for G00148 1049
G00150 – Trouble monitoring gear lubrication (PTO 2) 1049
G00151 – Trouble monitoring gear (PTO) oil filter 1 1050
G00193 – Trouble monitoring gear (PTO) oil filter 2 1050
Wiring Diagram (57B027-1/-2) and location for trouble codes G00151 & G00193 1053
G00154 – Trouble monitoring return oil filter 1054
Wiring Diagram (40B163) for trouble code G00154 1056
G00155 – Trouble monitoring leak oil filter 1057
Wiring Diagram (40B164) for trouble code G00155 1059
G00159 – Trouble monitoring breather filter 1060
Wiring Diagram (40B024) for trouble code G00159 1062
G00160 – Trouble monitoring engine air cleaner 1 1063
G00197 – Trouble monitoring engine air cleaner 2 1063
Wiring Diagram (52B018-1/-2 & 52B019-1/-2) for trouble codes G00160 & G00197 1066
G00161 – Trouble monitoring battery voltage 1067
Wiring Diagram (11T080) for trouble code G00161 1069
G00162 – Trouble monitoring charging-/discharging current 1070
Wiring Diagram (battery charging current) for trouble code G00162 1072
G00164 – Trouble air cleaner 1 1073
G00198 – Trouble air cleaner 2 1073
View onto the engine air cleaners (G00164 & G00198) 1074
G00165 – Trouble breather filter hydraulic oil tank 1075
Sight glass, hydraulic oil temperature information, and defined positions (G00165) 1076
G00166 – Trouble oil filter gear (PTO 1) 1078
G00191 – Trouble oil filter gear (PTO 2) 1078
View onto the PTO 1/2 gear oil filter with pressure sensor 57B027-1/-2 (G00166/G00191) 1079
G00169 – Trouble return oil filter hydraulic oil tank 1080
G00170 – Trouble leak oil filter hydraulic oil tank 1081
G00176 – Trouble battery voltage too low 1082
Wiring Diagram (batteries) for trouble code G00176 1084
G00177 – Trouble battery charging circuit 1085
Wiring Diagram (measuring points 1-4) for trouble code G00177 1086
G00178 – Trouble battery charging current too high 1087
Wiring Diagram (51T017) for trouble code G00178 1088
G00179 – Trouble control pressure X1-1 1089
G00182 – Trouble control pressure X1-2 1089
View onto the valve cartridge block (G00179) 1090
G00180 – Trouble pilot pressure X2 too low 1091
Valve cartridge block with X2 pressure sensor 57B086 & M1 2 1092
G00181 – Trouble pilot pressure X2 too high 1093
Valve cartridge block with X2 pressure sensor 57B086 & M1 2 1094
G00182 – Trouble control pressure X1-2 1094
G00184 – Central lubrication system empty 1095
G00187 – Slew ring gear lubrication system empty 1095
G00201 – Attachment lubrication system empty 1095
Grease level (CLS 1 & SLS & CLS 2) on the REAL TIME MONITOR 1096
G00185 – Trouble central lubrication system 1097
G00188 – Trouble slew ring gear lubrication system 1097
G00203 – Trouble attachment lubrication system 1097
Allocation of vent valves and end-of-line switches 1098
Action chart for lube cycles 1099
View onto the vent valve (62Q507a – 62Q509a – 62Q642a) 1100
Wiring Diagram (60B043/62B046/80B043) for trouble codes G00185/G00188/G00203 1101
G00186 – Trouble central lubrication system 1102
G00189 – Trouble slew ring gear lubrication system 1102
G00204 – Trouble attachment lubrication system 1102
Allocation of vent valves 1102
Action chart for lube cycles 1103
View onto the vent valve (62Q507a – 62Q509a – 62Q642a) 1104
G00187 – Slew ring gear lubrication system empty 1105
G00188 – Trouble slew ring gear lubrication system 1105
G00189 – Trouble slew ring gear lubrication system 1105
G00191 – Trouble oil filter gear (PTO 2) 1105
G00193 – Trouble monitoring gear (PTO) oil filter 2 1105
G00197 – Trouble monitoring engine air cleaner 2 1105
G00198 – Trouble air cleaner 2 1105
G00201 – Attachment lubrication system empty 1105
G00202 – Attachment lubrication system grease level too low 1105
G00203 – Trouble attachment lubrication system 1105
G00204 – Trouble attachment lubrication system 1105
G00207 – Engine remote oil tank 1 empty 1106
G00208 – Engine remote oil tank 2 empty 1106
G00216 – Trouble software not compatible 1107
G00218 – Switch off all motors for running transfer pump 1109
G00219 – Return oil tank empty 1110
Sensor 40B068 (return oil level) on the REAL TIME MONITOR 1110
G00220 – Trouble transfer pump motor overheated 1111
Wiring Diagram (transfer pump) for trouble code G00220 1112
G00223 – Trouble starter control 51K001a-1 1113
G00225 – Trouble starter control 51K001b-1 1113
G00227 – Trouble starter control 51K001a-2 1113
G00229 – Trouble starter control 51K001b-2 1113
51K001a-1/-2 & 51K001b-1/-2 (relay check) on the REAL TIME MONITOR 1113
G00224 – Trouble starter control Output to 51K001a-1 1114
G00226 – Trouble starter control Output to 51K001b-1 1114
G00228 – Trouble starter control Output to 51K001a-2 1114
G00230 – Trouble starter control Output to 51K001b-2 1114
51K001a-1/-2 & 51K001b-1/-2 (output check) on the REAL TIME MONITOR 1114
G00225 – Trouble starter control 51K001b-1 1115
G00226 – Trouble starter control Output to 51K001b-1 1115
G00227 – Trouble starter control 51K001a-2 1115
G00228 – Trouble starter control Output to 51K001a-2 1115
G00229 – Trouble starter control 51K001b-2 1115
G00230 – Trouble starter control Output to 51K001b-2 1115
G00231 – Trouble pilot control lever 20S019 1116
G00232 – Trouble pilot control lever 20S020 1116
Wiring Diagram (20S019) for trouble code G00231 1117
Wiring Diagram (20S020) for trouble code G00232 1118
G00233 – Trouble pilot control 11Q045 1119
Wiring Diagram (11Q045) for trouble code G00233 1120
G00234 – Trouble pilot control 11K111a 1121
G00236 – Trouble pilot control 11K111b 1121
11K111a & 11K111b (relay check) on the REAL TIME MONITOR (G00234 & G00236) 1121
G00235 – Trouble pilot control Output to 11K111a 1122
G00237 – Trouble pilot control Output to 11K111b 1122
11K111a & 11K111b (output check) on the REAL TIME MONITOR (G00235 & G00237) 1122
G00236 – Trouble pilot control 11K111b 1123
G00237 – Trouble pilot control Output to 11K111b 1123
G00238 – Trouble supply by key switch 11Q044 1124
Input signal of 11Q044 on the REAL TIME MONITOR (G00238) 1124
Wiring Diagram (11Q044) for trouble code G00238 1125
G00240 – Trouble hydraulic oil temperature 1126
G00242 – Engine 1 already running 1127
G00248 – Engine 2 already running 1127
G00243 – Fill up fuel tank 1128
G00245 – Engine shutdown from ground 1129
Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245) 1130
G00246 – Hydraulic oil temperature 1131
G00248 – Engine 2 already running 1131
G00252 – Emergency shut-down at access ladder 1132
G00253 – Emergency shut-down at valve block 1132
G00254 – Emergency shut-down at hydraulic control panel 1132
G00255 – Emergency shut-down in cabin 1132
Wiring Diagram (emergency switches) for trouble codes G00252~G00255 1133
G00257 – Hydraulic oil temperature 1134
G00261 – Maintenance Safety Switch 1135
Wiring Diagram (50S058) for trouble code G00261 1136
G00262 – Trouble screen at hydr cooler entry clogged 1137
40B166 and 40B165 on the REAL TIME MONITOR (05 Hydraulic) 1137
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262) 1138
Wiring Diagram (40B166 & 40B165) for trouble code G00262 1139
G00308 – Trouble CAN-Bus or CAN-Hardware 1140
G00309 – Trouble ladder up 56K253a 1143
G00311 – Trouble ladder up redundant 56K253b 1143
56K253a & 56K253b (relay check) on the REAL TIME MONITOR (G00309 & G00311) 1143
G00310 – Trouble ladder up Output to 56K253a 1144
G00312 – Trouble ladder up redundant Output to 56K253b 1144
56K253a & 56K253b (output check) on the REAL TIME MONITOR (G00310 & G00312) 1144
G00313 – Trouble ladder down 56K254a 1145
G00315 – Trouble ladder down redundant 56K254b 1145
56K254a & 56K254b (relay check) on the REAL TIME MONITOR (G00313 & G00315) 1145
G00314 – Trouble ladder down Output to 56K254a 1146
G00316 – Trouble ladder down redundant Output to 56K254b 1146
56K254a & 56K254b (output check) on the REAL TIME MONITOR (G00314 & G00316) 1146
G00317 – Trouble service arm up 56K255a 1147
G00319 – Trouble service arm up redundant 56K255b 1147
56K255a & 56K255b (relay check) on the REAL TIME MONITOR (G00317 & G00319) 1147
G00318 – Trouble service arm up Output to 56K255a 1148
G00320 – Trouble service arm up redundant Output to 56K255b 1148
56K255a & 56K255b (output check) on the REAL TIME MONITOR (G00318 & G00320) 1148
G00321 – Trouble service arm down 56K256a 1149
G00323 – Trouble service arm down redundant 56K256b 1149
56K256a & 56K256b (relay check) on the REAL TIME MONITOR (G00321 & G00323) 1149
G00322 – Trouble service arm down Output to 56K256a 1150
G00324 – Trouble service arm down redundant Output to 56K256b 1150
56K256a & 56K256b (output check) on the REAL TIME MONITOR (G00322 & G00324) 1150
G00325 – Trouble service arm Input 1151
G00326 – Trouble ladder Input 1151
G00327 – Trouble parking brake Input 1151
G00328 – Trouble start Input 1151
G00330 – Trouble pilot control 11Q111 1154
Wiring Diagram (11Q111/11K126) for trouble code G00330 1156
G00331 – Automatic after_running engine 1 1157
G00332 – Automatic after_running engine 2 1157
G00333 – Trouble battery charger relay 1158
Wiring Diagram (11Q122) for trouble code G00333 1159
G00351 – Engine 1 running 1160
G00349 – Engine 2 running 1160
G00352 – Engine 1 standstill 1160
G00350 – Engine 2 standstill 1160
G00417 – Communication failure PLC [MTC] <=> KOMTRAX Plus controller 1161
G00420 – Connector sel error 1162
G00421 – Farm sys error 1163
G00422 – Can-net sys (J1939) 1164
G00423 – Application sys error 1165
G00425 – Settings impossible to take over into the PLC [MTC] 1166
Wiring Diagram overview for G00425: KOMTRAX Plus monitor → KOMTRAX Plus controller → MTC 1167
G00491 – Communication failure MH800 <=> KOMTRAX Plus controller 1168
Wiring Diagram overview for G00491: MH800 <=> KOMTRAX Plus controller 1169
8 Troubleshooting by Symptoms 1171
8 1 Symptoms of the Engines and Related Electrical Systems 1172
SEL001 – Engine does not start (engine does not rotate) 1172
Wiring Diagram 1 (starter batteries) for trouble code SEL001 1174
Wiring Diagram 2 (engine 1 start) for trouble code SEL001 1176
Wiring Diagram 3 (engine 2 start) for trouble code SEL001 1178
Wiring Diagram 4 (engine start & stop buttons) for trouble code SEL001 1180
Wiring Diagram 5 (engine start relays) for trouble code SEL001 1182
SEL002 – Engine stops while in operation 1184
View onto the water separators and fuel filters (SEL002) 1186
View onto fuel filters, shut-off solenoid valves, and fuel piping (SEL002) 1187
SEL003 – Engine speed is hunting during boom-up movement 1188
SEL004 – Engine does not stop 1189
SEL005 – Engine lacks output (no power) 1190
Judgment Table for SEL005 1191
SEL006 – Exhaust smoke is black 1192
Judgment Table for SEL006 1193
SEL007 – Oil consumption is excessive 1194
Judgment Table for SEL007 1195
SEL008 – Oil becomes contaminated quickly 1196
Judgment Table for SEL008 1197
SEL009 – Fuel consumption is excessive 1198
Judgment Table for SEL009 1199
SEL010 – Oil is in engine coolant 1200
Judgment Table for SEL010 1201
SEL011 – Oil level rises 1202
Judgment Table for SEL011 1203
SEL012 – Coolant temperature becomes too high (overheating) 1204
Judgment Table for SEL012 1205
8 2 Symptoms of the Hydraulic System 1206
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 1206
SHY002 – Engine speed sharply drops or engine stalls too much 1208
SHY003 – No work equipment, travel or swing movement 1210
SHY004 – Work equipment has too much hydraulic drift 1211
SHY005 – Work equipment has big time lag 1213
SHY006 – Machine deviates during travel movement 1214
SHY007 – Hydraulic system has lack of power (Energy Efficiency) 1215
SHY008 – Machine does not swing 1217
SHY009 – Swing acceleration is poor 1218
SHY010 – Excessive overrun when stopping swing 1220
SHY011 – Floating system without function 1222
SHY012 – Abnormal noise coming from SRV or MRV 1223
SHY013 – Track tensioning system without function 1224
SHY014 – Ladder does not move, or slow movement 1225
SHY015 – Refilling arm does not move, or slow movement 1227
SHY016 – The hydraulic driven grease pump does not move 1229
SHY017 – Trouble pump bearing lubrication 1231
SHY018 – Abnormal track chain movement during digging 1232
SHY019 – Swing parking brake without function 1233
SHY020 – Travel parking brake without function 1234
8 3 Symptoms of the Mechanical System 1235
SME001 – Abnormal noise is made 1235
Judgment Table for SME001 1236
SME002 – Abnormal noise around the PTOs / hydraulic pumps 1237
SME003 – Vibration is excessive (engine mountings) 1239
Judgment Table for SME003 1240
SME004 – Vibration is excessive (engine torsion) 1241
SME005 – There is a big shock when stopping swing 1242
SME006 – There is a big abnormal noise when moving/stopping swing 1243
SME007 – Fan hub bearing noise is abnormal 1245
SME008 – Abnormal noise coming from a travel gearbox 1246
SME009 – Abnormal noise coming from the work equipment (lack of grease) 1248
SME010 – Abnormal idler movement 1250
SME011 – Leak at the PTO shaft seal 1251
8 4 Symptoms of Additional Systems 1253
SAD001 – Air conditioner does not work 1253
View onto the A/C unit (SAD001) 1254
SAD002 – Air conditioner compressor clutch is burnt 1255
View onto the A/C compressor and its mounting (SAD002) 1256
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) 1257
SAD004 – Travel alarm does not sound 1258
Wiring Diagram (60P140) for trouble code SAD004 1259
50 Assembly & Disassembly 1261
1 Introduction 1263
1 1 Contents of the binder 1264
1 2 Foreword 1265
1 2 1 Service 1266
2 Safety and standards 1267
2 1 Safety instructions 1268
2 1 1 Method of using this manual 1268
2 1 2 General precautions 1270
2 1 3 Preparations for work 1271
2 1 4 Precautions during work 1273
2 1 5 Warning of special dangers 1274
2 1 5 1 Electrical energy 1274
2 1 5 2 Gas, dust, steam and smoke 1275
2 1 5 3 Hydraulic, air conditioning and pneumatic equipment 1276
2 1 5 4 Noise 1276
2 1 5 5 Heat 1277
2 1 5 6 Oil, grease and other chemical substances 1277
2 1 5 7 Height 1277
2 1 6 Special safety equipment 1279
2 1 6 1 Safety harness in conformity with EN 361 (European standard) 1279
2 1 6 2 Instructions for use 1281
2 1 6 3 Recommendations for use of the holding hooks and hold-back hooks of the safety harness 1283
2 1 6 4 Instructions for using the fall absorber 1285
2 1 7 Safety hints for hydraulic hose installation 1286
2 1 8 Safety hints for Lifting heavy parts 1289
2 1 9 Safety hints for Wire ropes 1289
2 1 10 Safety hints for Sling accessory 1291
2 1 11 Weight tables 1292
2 1 11 1 Superstructure 1292
2 1 11 2 Undercarriage 1295
2 1 11 3 Face shovel attachment (FSA) 1296
2 2 Torque charts according to DIN 1297
2 2 1 Metric standard thread 1297
2 2 2 Metric fine thread 1298
2 2 3 Cummins motor torques – metric 1299
2 2 4 Cummins motor torques – U S customary 1299
2 2 5 SAE flange connections 1300
2 3 Blind plugs 1301
2 3 1 Dummy plates for SAE–flanges 1301
2 3 2 Classification of threads to the nominal width 1303
2 3 3 Plugs and fittings according to DIN 2353 1304
2 4 Conversion table 1305
2 4 1 Method of using the conversion table 1305
2 4 2 Millimeter – Inch & Kilogram – Pound 1306
2 4 3 Liter – U S Gallon & Liter – U K Gallon 1307
2 4 4 Nm- ft lb 1308
2 4 5 Bar – PSI / PSI – Bar 1309
2 4 6 Basic Values in Ohm according to DIN 43 76 1310
2 4 7 Temperature 1311
2 5 Tools 1312
2 5 1 Standard tool case 1312
2 6 Explanation of Abbreviations 1314
3 Superstructure 1315
3 1 Superstructure overview 1316
3 2 Special preparatory work 1319
3 2 1 Preparatory work at the engine house 1319
3 2 2 Preparatory works at the front roof section 1327
3 3 Diesel engine 1330
3 3 1 Removal of the diesel engines 1330
3 3 1 1 Removal of the Front diesel engine (engine 1) 1330
3 3 1 2 Replacement of the Front diesel engine (engine 1) 1336
3 3 1 3 Removal of the rear diesel engine (engine 2) 1339
3 3 1 4 Replacement of the rear diesel engine (engine 2) 1339
3 3 2 Engine torque support and engine/PTO mounts 1340
3 3 2 1 Flexible mounts 1341
3 3 2 2 Torque support 1343
3 3 3 Alternator 1344
3 3 3 1 Removal of the alternator 1344
3 3 3 2 Replacement of the alternator 1345
3 3 4 Starter system 1346
3 3 4 1 Removal of the starter motor 1346
3 3 4 2 Replacement of the starter motor 1347
3 3 5 Batteries 1347
3 3 5 1 Removal of the batteries 1347
3 3 5 2 Replacement of the batteries 1349
3 4 Radiators (engine coolant) 1350
3 4 1 Radiator fan Drive Motor 1351
3 4 1 1 Removal of the Hydraulic Fan Motor 1351
3 4 1 2 Replacement of the Hydraulic Fan Motor 1353
3 4 2 Radiator fan 1354
3 4 2 1 Removal of the radiator fan assembly 1354
3 4 2 2 Replacement of the radiator fan assembly 1356
3 4 2 3 Removal of the radiator fan 1357
3 4 2 4 Replacement of the radiator fan 1358
3 4 3 Radiator assembly 1359
3 4 3 1 Removal of the radiator assembly and the fuel cooler 1359
3 4 3 2 Replacement of the radiator assembly and the fuel cooler 1362
3 4 4 Radiator fan drive pump 1363
3 4 4 1 Removal of the radiator fan drive pump 1363
3 4 4 2 Replacement of the radiator fan drive pump 1365
3 5 Torsion type coupling 1366
3 5 1 Geislinger coupling 1366
3 5 1 1 Removal of the Geislinger coupling 1367
3 5 1 2 Replacement of the Geislinger coupling 1371
3 6 PTO 1372
3 6 1 Main pumps 1372
3 6 1 1 Removal of main pumps 1374
3 6 1 2 Replacement of main pumps 1377
3 6 2 PTO oil pumps (auxiliary pumps) 1378
3 6 2 1 Removal of the PTO oil pumps (auxiliary pumps) 1379
3 6 2 2 Replacement of the PTO oil pumps (auxiliary pumps) 1379
3 6 3 Pump distributor gearbox (PTO) 1380
3 6 3 1 Removal of the pump distributor gearbox (PTO) 1382
3 6 3 2 Replacement of the pump distributor gearbox (PTO) 1386
3 7 Hydraulics 1387
3 7 1 Hydraulic cooler fan drive pumps 1387
3 7 1 1 Removal of the hydraulic cooler fan drive pumps 1388
3 7 1 2 Replacement of the hydraulic cooler fan drive pumps 1390
3 7 2 Additional hydraulic oil cooler assembly 1391
3 7 2 1 Removal of the Additional hydraulic oil cooler fan assembly 1394
3 7 2 2 Replacement of Additional hydraulic oil cooler fan assembly 1397
3 7 2 3 Removal of Additional hydraulic oil cooler fans and motors 1398
3 7 2 4 Replacement of Additional hydraulic oil cooler fans and motors 1399
3 7 2 5 Removal of the Additional hydraulic oil coolers 1400
3 7 2 6 Replacement of the Additional hydraulic oil coolers 1403
3 7 2 7 Removal of the Additional hydraulic oil cooler assembly 1404
3 7 2 8 Replacement of Additional hydraulic oil cooler assembly 1406
3 7 3 Hydraulic oil cooler assembly 1407
3 7 3 1 Removal of the hydraulic oil cooler fan assemblies 1410
3 7 3 2 Replacement of hydraulic oil cooler fan assemblies 1414
3 7 3 3 Removal of the hydraulic oil cooler fan and motor 1416
3 7 3 4 Replacement of hydraulic oil cooler fan and motor 1418
3 7 3 5 Removal of the hydraulic oil coolers 1420
3 7 3 6 Replacement of the hydraulic oil coolers 1424
3 7 3 7 Removal of the hydraulic oil cooler assembly 1426
3 7 3 8 Replacement of the hydraulic oil cooler assembly 1430
3 7 4 Pilot oil pump (gear pump) 1431
3 7 4 1 Removal of the pilot oil pump 1431
3 7 4 2 Replacement of the pilot oil pump 1433
3 7 5 Main gate valve 1434
3 7 5 1 Removal of the main gate valve 1434
3 7 5 2 Replacement of the main gate valve 1435
3 7 6 Hydraulic oil reservoir 1436
3 7 6 1 Removal of the hydraulic oil reservoir 1438
3 7 6 2 Replacement of the hydraulic oil reservoir 1441
3 7 7 Main control valve blocks 1443
3 7 7 1 Removal of the main control valve blocks 1444
3 7 7 2 Replacement of the main control valve blocks 1447
3 7 8 Main relief valves (MRV) 1448
3 7 8 1 Removal of the MRV on the main control valve block 1448
3 7 8 2 Replacement of the MRV on the main control valve block 1449
3 7 9 Service line relief valves (SRV) 1450
3 7 9 1 Removal of the SRV on the manifold 1450
3 7 9 2 Replacement of the SRV on the manifold 1452
3 7 9 3 Removal of the SRV on the main control valve block 1453
3 7 9 4 Replacement of the SRV on the main control valve blocks 1455
3 7 10 Anti-cavitation valves (ACV) 1456
3 7 10 1 Removal of the ACV on the manifold 1457
3 7 10 2 Replacement of the ACV on the manifold 1461
3 7 10 3 Removal of the ACV on the main control valve blocks 1462
3 7 10 4 Replacement of the ACV on the main control valve blocks 1463
3 7 11 Throttle check valves 1464
3 7 11 1 Removal of the throttle check valves on the manifold 1468
3 7 11 2 Replacement of the throttle check valves on the manifold 1470
3 7 12 Manifold 1471
3 7 12 1 Removal of the manifold 1471
3 7 12 2 Replacement of the manifold 1473
3 8 Slew system 1475
3 8 1 Slew gear 1475
3 8 1 1 Removal of the Slew gear 1478
3 8 1 2 Replacement of the slew gear 1481
3 8 2 Swing motor 1484
3 8 2 1 Removal of the swing motor 1485
3 8 2 2 Replacement of the swing motor 1488
3 8 3 Slew parking brake 1491
3 8 3 1 Removal/disassembly of the slew parking brake (L&S) 1493
3 8 3 2 Replacement/assembly of the slew parking brake (L&S) 1496
3 8 3 3 Removal of the slew parking brake (Siebenhaar) 1499
3 8 3 4 replacement of the slew parking brake (Siebenhaar) 1502
3 8 4 Dynamic slew brake 1506
3 8 4 1 Removal of the slew brake valve 1509
3 8 4 2 Replacement of the slew brake valve 1511
3 8 5 swing circle 1512
3 8 5 1 Removal of the swing circle 1514
3 8 5 2 Replacement of the swing circle 1517
3 9 Lubrication system 1522
3 9 1 Swing circle lubrication pinion (dummy wheel) 1522
3 9 1 1 Removal of the lubrication pinion assembly 1524
3 9 1 2 Replacement of the lubrication pinion assembly 1526
3 9 2 Lubrication pump station 1528
3 9 2 1 Removal of the lubrication pump station 1530
3 9 2 2 Replacement of the lubrication pump station 1532
3 9 2 3 Removal of the lubrication pump 1533
3 9 2 4 Replacement of the lubricating pump 1535
3 10 Operator’s cab 1536
3 10 1 Removal of the operator’s cab 1539
3 10 2 Replacement of the operator’s cab 1544
3 10 3 Viscous cab-mounts 1546
3 10 3 1 Removal of the viscous cab-mounts 1546
3 10 3 2 replacement of the viscous cab-mounts 1548
3 10 4 Front window (windscreen) 1550
3 10 4 1 Removal of the front window 1550
3 10 4 2 Replacement of the front window 1551
3 10 5 Operator’s seat 1552
3 10 5 1 Removal of the operator’s seat 1552
3 10 5 2 Replacement of the operator’s seat 1553
3 10 6 ECS 1554
3 10 6 1 Removal of the ECS text display 1554
3 10 6 2 Replacement of the ECS text display 1554
3 11 Cab base 1555
3 11 1 Removal of the cab base 1555
3 11 2 Replacement of the cab base 1558
3 11 3 Pump controller 1560
3 11 3 1 Removal of the pump controller RC4 1560
3 11 3 2 Replacement of the pump controller RC4 1560
3 12 Access ladder 1562
3 12 1 Removal of the access ladder 1565
3 12 2 Replacement of the access ladder 1569
3 12 3 Removal of the access ladder cylinder 1571
3 12 4 Replacement of the access ladder cylinder 1573
3 13 Counterweight 1574
3 13 1 Removal of the counterweight 1574
3 13 2 Replacement of the counterweight 1577
3 14 Superstructure lifting 1578
3 14 1 Lift the superstructure (platform, PN 910 605 40 only) 1578
3 14 2 Dump the superstructure (platform, PN 910 605 40 only) 1581
3 14 3 Remove the superstructure from the undercarriage 1582
3 14 4 Install the superstructure onto the undercarriage 1585
3 15 Fuel tank 1590
3 15 1 Removal of the fuel tank 1591
3 15 2 Replacement of the fuel tank 1594
4 Undercarriage 1597
4 1 Travel system 1598
4 1 1 Track group 1598
4 1 1 1 Changing of the track group 1598
4 1 2 Sprocket 1603
4 1 2 1 Removal of the sprocket assembly 1603
4 1 2 2 Replacement of the sprocket assembly 1608
4 1 3 Guide wheels (idlers) 1610
4 1 3 1 Removal of the guide wheel assembly 1610
4 1 3 2 Replacement of the guide wheel assembly 1612
4 1 4 Track tensioning accumulators 1613
4 1 4 1 Removal of the low pressure accumulators 1613
4 1 4 2 Replacement of the low pressure accumulators 1615
4 1 4 3 Removal of the high pressure accumulators 1616
4 1 4 4 Replacement of the high pressure accumulators 1617
4 1 5 Track tensioning valve block 1618
4 1 5 1 Removal of the track tensioning valve block 1618
4 1 5 2 Replacement of the track tensioning valve block 1620
4 1 6 Track tensioning cylinders 1621
4 1 6 1 Removal of the track tensioning cylinders 1621
4 1 6 2 Replacement of the track tensioning cylinders 1623
4 1 7 Substitute the Hydraulic hoses of the track tensioning system 1625
4 1 7 1 Substitute the hydraulic hoses inside the car body 1627
4 1 7 2 Substitute the hydraulic hose between car body and crawler frame 1627
4 1 7 3 Substitute the hydraulic hoses inside the crawler frame 1629
4 1 7 4 Subsequent work 1630
4 1 8 Travel brake valve block (overspeed valve) 1631
4 1 8 1 Removal of the travel brake valve block 1634
4 1 8 2 Replacement of the travel brake valve block 1636
4 1 9 Travel motor 1637
4 1 9 1 Removal of the travel motors 1637
4 1 9 2 Replacement of the travel motors 1639
4 1 10 Travel parking brake 1640
4 1 10 1 Removal of the travel parking brake 1642
4 1 10 2 Replacement of the travel parking brake 1645
4 1 11 Travel gearbox 1651
4 1 11 1 Removal of the travel gearbox 1652
4 1 11 2 Replacement of the travel gearbox 1655
4 1 12 Carrier roller 1657
4 1 12 1 Removal of the carrier roller assembly 1657
4 1 12 2 Replacement of the carrier roller assembly 1660
4 1 13 Track roller 1661
4 1 13 1 Removal of the track roller assembly 1661
4 1 13 2 Replacement of the track roller assembly 1663
4 2 Car body 1664
4 2 1 Removal of the car body and the crawler carriers (type with mounting pins) 1664
4 2 2 Replacement of the car body and the crawler carriers (type with mounting pins) 1668
4 2 3 Removal of the car body and the crawler carriers (type with bolted connection) 1672
4 2 4 Replacement of the car body and the crawler carriers (type with bolted connection) 1675
4 2 4 1 Tightening torque for the crawler carrier mounting bolts 1678
4 2 5 Rotary joint 1682
4 2 5 1 Removal of the rotary joint 1683
4 2 5 2 Replacement of the rotary joint 1686
5 Attachment 1687
5 1 Face Shovel (FSA) 1688
5 1 1 Using the installation tools for hydraulic cylinders 1689
5 1 2 Boom 1690
5 1 2 1 Removal of the boom 1690
5 1 2 2 Replacement of the boom 1695
5 1 2 3 Removal of the boom cylinders 1700
5 1 2 4 Replacement of the boom cylinders 1705
5 1 3 Stick 1708
5 1 3 1 Removal of the stick 1708
5 1 3 2 Replacement of the stick 1712
5 1 3 3 Removal of the stick cylinders 1714
5 1 3 4 Replacement of the stick cylinders 1719
5 1 4 Bull clam bucket 1722
5 1 4 1 Removal of the bull clam bucket 1724
5 1 4 2 Replacement of the bull clam bucket 1728
5 1 4 3 Removal of the bucket cylinders 1730
5 1 4 4 Replacement of the bucket cylinders 1735
5 1 4 5 Removal of the clam cylinders 1740
5 1 4 6 Replacement of the clam cylinders 1745
5 1 5 Ground engaging tools (GET) 1748
5 1 5 1 Removal and replacement of the GET 1750
5 1 6 Hydraulic hoses at the face shovel attachment 1752
5 1 6 1 Substitute the boom arc hoses 1752
5 1 6 2 Substitute the boom cylinder hoses 1756
5 1 6 3 Substitute the stick arc hoses 1760
5 1 6 4 Substitute the stick cylinder hoses 1766
5 1 6 5 Substitute the bucket cylinder hoses 1770
5 1 6 6 Substitute the clam cylinder hoses 1776
5 2 Metering valves (grease injectors) at the attachment 1784
5 2 1 Check the operation of the metering valves (grease injectors) 1785
5 2 2 Removal of the metering valves (grease injectors) 1786
5 2 3 Replacement of the metering valves (grease injectors) 1787
5 3 Cylinder bypass test 1788
6 Service information 1791
6 1 Fluids and lubricants 1792
6 1 1 Lubricants for operation in moderate and hot climates 1792
6 1 2 Lubricants for operation in cold and arctic climates 1794
6 2 Filling capacities 1795
6 3 Work Instructions 1796
6 3 1 Remove / install the crawler carrier 1796
6 4 Used special tools (overview) 1797
7 Tools catalogue 1799
8 Parts & Service News 1801

DESCRIPTION:

Komatsu PC8000-6 Diesel Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD 

SERIAL NUMBER 12071 and up

BEFORE READING THIS MANUAL:

• This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
• Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death.
  Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used.
• Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you or others engage in prohibited uses or actions described in this manual. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death.
• If you sell the machine, be sure to give this manual to the new owner together with the machine.
  This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ).
• The explanations, values, and illustrations in this manual have been prepared based on the latest information
  available as of the date of publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.

S.V 28/12/24