KOMATSU PC8000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 12089-12093 – PDF DOWNLOAD
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DESCRIPTION:
KOMATSU PC8000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 12089-12093 – PDF DOWNLOAD
SAFETY INFORMATION:
- To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed. - The safety information in this manual does not replace any safety rules or laws in your area.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used. - The “Safety Alert Symbol” identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
TABLE OF CONTENTS:
KOMATSU PC8000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 12089-12093 – PDF DOWNLOAD
1 INTRODUCTION 1-1
1 1 CONTENTS OF THE BINDER 1-2
1 2 FOREWORD 1-2
1 3 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION
AND MAINTENANCE OF HYDRAULIC MINING SHOVELS 1-4
1 4 EXPLANATION OF ABBREVIATIONS 1-5
1 5 DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL 1-6
2 SAFETY 2-1
2 1 SAFETY INFORMATION 2-2
2 2 OVERVIEW 2-3
2 2 1 NORMAL OPERATIONS 2-3
2 2 2 REGULAR MAINTENANCE 2-3
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 2-3
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING
AND TRANSPORTATION OF THE EXCAVATOR 2-3
2 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 2-4
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 2-5
2 4 1 UNDERSTANDING THE MACHINE 2-5
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 2-5
2 4 2 1 ENSURING SAFE OPERATION 2-5
2 4 3 PREPARATIONS FOR SAFE OPERATION 2-5
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 2-5
2 4 3 2 INSPECTING THE MACHINE 2-5
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2-6
2 4 3 4 KEEP MACHINE CLEAN 2-6
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 2-6
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2-7
2 4 3 7 IF A PROBLEM IS FOUND 2-7
2 4 4 FIRE PREVENTION 2-7
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 2-7
2 4 4 2 ACTION IF FIRE OCCURS 2-8
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 2-9
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 2-9
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 2-9
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 2-9
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 2-9
2 4 5 4 WORKING IN HIGH PLACES 2-9
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 2-10
2 4 5 6 LEAVING THE MACHINE 2-10
2 4 6 BURN PREVENTION 2-11
2 4 6 1 HOT COOLANT 2-11
2 4 6 2 HOT OIL 2-11
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 2-11
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-12
2 4 8 1 UNAUTHORIZED MODIFICATION 2-12
TOC – 2 PC8000E-6 SM 12089-xE-GB-0
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-12
2 4 9 PRECAUTIONS AT JOBSITE 2-13
2 4 9 1 VISIBILITY FROM OPERATOR’S SEAT 2-14
2 4 9 2 CAMERA SYSTEM WITH MONITORS 2-14
2 4 9 3 ENSURE GOOD VISIBILITY 2-14
2 4 9 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 2-14
2 4 9 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2-15
2 4 9 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 2-15
2 4 9 7 WORKING ON LOOSE GROUND 2-16
2 4 9 8 GAS, DUST, STEAM AND SMOKE 2-16
2 4 9 9 VENTILATION OF ENCLOSED AREAS 2-17
2 4 10 STARTING ENGINE 2-18
2 4 10 1 WARNING TAG 2-18
2 4 10 2 CHECKS BEFORE STARTING ENGINE 2-18
2 4 10 3 PRECAUTION WHEN STARTING ENGINE 2-18
2 4 10 4 PRECAUTION IN COLD AREAS 2-19
2 4 11 OPERATION 2-19
2 4 11 1 CHECKS BEFORE OPERATION 2-19
2 4 11 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 2-20
2 4 11 3 PRECAUTIONS WHEN TRAVELLING 2-21
2 4 11 4 TRAVELLING ON SLOPES 2-22
2 4 11 5 OPERATIONS ON SLOPES 2-23
2 4 11 6 PROHIBITED OPERATIONS 2-23
2 4 11 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 2-24
2 4 11 8 PARKING THE MACHINE 2-24
2 4 11 9 TRANSPORTATION 2-24
2 5 PRECAUTION FOR MAINTENANCE 2-25
2 5 1 GENERAL PRECAUTIONS 2-25
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL –
BASIC RESPONSIBILITIES 2-26
2 5 1 2 STOP ENGINE FOR MAINTENANCE 2-27
2 5 1 3 WARNING TAG 2-28
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 2-29
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 2-29
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 2-30
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 2-30
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 2-31
2 5 1 9 NOISE 2-31
2 5 1 10 WHEN USING A HAMMER 2-31
2 5 1 11 PROPER TOOLS 2-32
2 5 1 12 ACCUMULATOR 2-32
2 5 1 13 PERSONNEL 2-32
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-33
2 5 2 1 PRECAUTION WHEN WELDING 2-33
2 5 2 2 BATTERY HANDLING 2-33
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 2-34
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 2-34
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 2-35
2 5 3 3 REPLACEMENT OF HOSE LINES 2-35
2 5 3 4 INSPECTION OF HOSE LINES 2-35
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2-36
SM 12089-xE-GB-0 PC8000E-6 TOC – 3
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 2-36
2 5 3 7 AIR CONDITIONING MAINTENANCE 2-36
2 5 3 8 COMPRESSED AIR 2-37
2 5 3 9 WASTE MATERIALS 2-37
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 2-38
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 2-38
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 2-38
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 2-38
2 7 SPECIAL SAFETY EQUIPMENT 2-40
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 2-41
2 7 2 OBJECT HANDLING 2-41
2 7 3 LIGHTING 2-41
2 7 4 WARNING BEACON 2-41
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 2-41
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361
(EUROPEAN STANDARD) 2-41
2 7 5 2 INSTRUCTIONS FOR USE 2-43
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 2-45
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS
AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), 2-45
2 7 5 5 INSTRUCTIONS FOR USE 2-47
3 SPECIFICATIONS 3-1
3 1 LIFTING GEARS 3-2
3 2 SAFETY HINTS FOR SLING ACCESSORY 3-4
3 3 STANDARD TIGHTENING TORQUE CHART 3-5
3 4 CONVERSION TABLE 3-6
3 5 BLIND PLUGS 3-12
3 6 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH 3-14
3 7 PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353 3-15
4 MAIN ASSEMBLY GROUPS 4-1
4 1 GENERAL LAYOUT 4-2
4 2 SUPERSTRUCTURE 4-4
4 3 MACHINE HOUSE 4-8
4 4 HYDRAULIC OIL TANK 4-10
4 5 HYDRAULIC OIL COOLER 4-12
4 6 HIGH VOLTAGE SWITCH CABINET 4-14
4 7 CAB SUPPORT 4-20
4 7 1 X2 – LOW VOLTAGE SWITCH BOARD (LOCATION 12) 4-21
4 7 2 EXTRA LOW VOLTAGE SWITCH BOARD (LOCATION 11) 4-23
4 8 SLIP RING UNIT 4-24
4 9 OPERATOR’S CAB 4-28
4 10 CONTROL BLOCKS 4-30
4 11 SWING MACHINERY 4-32
4 11 1 SWING MACHINERY L&S 4-32
TOC – 4 PC8000E-6 SM 12089-xE-GB-0
4 11 2 SWING MACHINERY SIEBENHAAR 4-34
4 12 UNDERCARRIAGE 4-36
4 13 ATTACHMENTS 4-38
4 13 1 FRONT SHOVEL ATTACHMENT (FSA) 4-38
4 13 2 BACKHOE ATTACHMENT (BHA) 4-40
5 DRIVE 5-1
5 1 ELECTRIC DRIVE – SAFETY AND OPERATION INSTRUCTION DOCUMENTS 5-2
5 2 PRIME DRIVE ASSEMBLY 5-4
5 3 ELECTRIC MOTORS 5-6
5 3 1 LOCATION OF ATTACHING PARTS 5-6
5 3 1 1 MOTOR TYPE PLATE 5-7
5 3 1 2 TYPE PLATE FOR THE MOTOR BEARINGS 5-8
5 3 2 MOTOR BEARINGS & GREASE EQUIPMENT 5-10
5 3 3 MONITORING OF THE MOTOR BEARING TEMPERATURE 5-12
5 3 4 MONITORING OF THE MOTOR WINDING TEMPERATURE 5-13
5 3 5 JUNCTION BOX FOR THE MOTOR MONITORING DEVICE 5-14
5 3 6 CHECKING OF THE BEARING CONDITION 5-15
5 3 7 CAPACITOR ASSEMBLY 5-16
5 4 AIR-TO-AIR MOTOR COOLING SYSTEM 5-18
5 5 INITIAL START-UP PROCEDURE 5-19
5 5 1 MAIN SUPPLY CABLE 5-20
5 5 2 MACHINE CONFIGURATION (VIA CODESYS) 5-21
5 5 3 MOTOR PROTECTION RELAY (SPAM 150 C) 5-26
5 5 4 MOTOR ALIGNMENT 5-28
5 5 5 MOTOR ROTATION DIRECTION 5-30
5 5 6 STARTING & RE-STARTING THE ELECTRIC MOTORS 5-30
5 5 7 SUPERVISION DURING THE FIRST MOTOR RUNNING PERIOD 5-31
5 6 FLEXIBLE COUPLING 5-32
5 6 1 COUPLING INSPECTION 5-33
5 6 2 COUPLING REPLACEMENT 5-34
5 7 PUMP DISTRIBUTOR GEARBOX (PTO) 5-36
5 7 1 PUMP DRIVE SHAFT HOUSING / SPLINE LUBRICATION 5-38
5 7 2 PTO LUBRICATION AND COOLING 5-40
5 7 2 1 CHECKS AND ADJUSTMENTS 5-42
5 7 3 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES 5-44
6 HYDRAULIC OIL TANK 6-1
6 1 GENERAL LAYOUT 6-2
6 2 LOCATION OF THE ELECTRIC EQUIPMENT 6-4
6 3 SUCTION OIL TANK WITH STRAINERS 6-6
6 4 RETURN OIL COLLECTOR PIPE WITH STRAINER 6-8
6 5 BACK PRESSURE VALVE 6-10
6 6 TRANSFER PUMP 6-12
6 7 RETURN AND LEAK OIL FILTER 6-14
6 8 BREATHER FILTER 6-16
SM 12089-xE-GB-0 PC8000E-6 TOC – 5
7 HYDRAULIC OIL COOLING 7-1
7 1 OVERALL VIEW OF THE HYDRAULIC OIL COOLING 7-2
7 2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT 7-4
7 2 1 STANDARD HYDRAULIC OIL COOLING CIRCUIT 7-4
7 2 2 ADDITIONAL OIL COOLING CIRCUIT 7-6
7 3 ADJUSTMENT OF THE BACK PRESSURE VALVE 7-8
7 4 FAN DRIVE – STANDARD OIL COOLER 7-10
7 4 1 TWO STAGE COOLER FAN DRIVE RPM CONTROL 7-10
7 4 2 FIXED DISPLACEMENT PUMP WITH VARIABLE SETTING 7-12
7 4 3 PRESSURE RELIEF VALVES 7-14
7 4 4 SOLENOID VALVES 7-16
7 5 ADJUSTMENT OF THE COOLER FAN DRIVE SPEED 7-18
7 5 1 MAXIMUM SPEED 7-18
7 5 2 MEDIUM SPEED 7-20
7 6 FAN DRIVE – ADDITIONAL OIL COOLER 7-22
7 6 1 FUNCTION OF THE ADDITIONAL COOLER FAN RPM CONTROL 7-23
7 6 2 ADJUSTMENT OF THE ADDITIONAL COOLER FAN DRIVE SPEED 7-23
8 CONTROLLING 8-1
8 1 GENERAL LAYOUT 8-2
8 2 CONTROL AND FILTER PANELS – LOCATION OF COMPONENTS 8-4
8 2 1 MAIN VALVE CARTRIDGE BLOCK 8-4
8 2 2 CONTROL AND FILTER PANELS MOUNTED ON THE PTOS 8-10
8 3 PILOT PRESSURE SUPPLY AND ADJUSTMENTS 8-12
8 3 1 PILOT PRESSURE CIRCUIT 8-13
8 3 2 CHECKS AND ADJUSTMENTS OF PILOT PRESSURE 8-16
8 3 3 REMOTE CONTROL VALVES ARRANGEMENT 8-20
8 4 FUNCTION OF THE ELECTRO-HYDRAULIC CONTROL SYSTEM 8-22
8 5 HAND LEVER (JOYSTICK) CONTROL 8-26
8 6 FOOT PEDAL CONTROL 8-28
8 7 PROPORTIONAL AMPLIFIER MODULE, TYPE A 8-30
8 8 PROPORTIONAL AMPLIFIER MODULE, TYPE B 8-32
8 9 RAMP TIME MODULE 8-34
8 10 ADJUSTMENT OF AMPLIFIER MODULES 8-36
8 10 1 GENERAL 8-37
8 10 2 ADJUSTING THE AMPLIFIER MODULE, TYPE A 8-38
8 10 3 ADJUSTING THE AMPLIFIER MODULE, TYPE B 8-40
8 11 ADJUSTING THE RAMP TIME MODULE 8-42
9 COMPONENTS 9-1
9 1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTERS (FSA) 9-2
9 2 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS
AND ANTI-CAVITATION VALVES 9-6
9 3 RESTRICTOR BLOCK WITH SECONDARY RELIEF VALVE 9-8
9 4 ANTI-CAVITATION VALVE (ACV) BLOCK 9-10
9 4 1 ACV BLOCK ON CONTROL BLOCKS 9-10
TOC – 6 PC8000E-6 SM 12089-xE-GB-0
9 4 2 ACV BLOCK ON TOP OF THE MANIFOLD 9-12
9 5 REMOTE CONTROL VALVES 9-14
9 6 4/3 DIRECTIONAL SOLENOID VALVES 9-16
9 7 PROPORTIONAL SOLENOID VALVES 9-18
9 8 HIGH-PRESSURE FILTER (SCREEN) 9-20
9 9 CONTROL BLOCKS AND VALVES 9-22
9 10 TRAVEL BRAKE VALVE 9-34
9 11 PRESSURE REDUCING VALVE 9-36
9 12 4/2 DIRECTIONAL VALVES 9-38
9 13 PRESSURE DOUBLE STAGE VALVE 9-40
9 14 HYDRAULIC CYLINDER 9-42
10 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 10-1
10 1 GENERAL 10-2
10 1 1 LAYOUT 10-2
10 1 2 PUMP REGULATION SYSTEM (“OPEN SENSING SYSTEM”) 10-5
10 1 3 PUMP REGULATION SYSTEM — VALVE FUNCTION 10-6
10 2 MAIN PUMPS 10-8
10 2 1 PUMP BEARING FLUSHING / LUBRICATION 10-10
10 2 2 OPERATING PRINCIPLE 10-12
10 2 3 CHECKS / ADJUSTMENTS 10-28
10 2 3 1 QMAX AND QMIN ADJUSTMENT BOLTS 10-30
10 3 ELECTRONIC PUMP REGULATION SYSTEM 10-32
10 3 1 ELECTRONIC LOAD LIMITING CONTROL – GENERAL 10-33
10 3 2 MICROCONTROLLER RC4-4 10-34
10 3 3 SIGNAL RECTIFIER MODULE 10-36
10 3 3 1 CHECKS AND ADJUSTMENTS 10-38
10 4 HYDRAULIC CONSTANT REGULATION SYSTEM (EMERGENCY MODE) 10-40
10 4 1 GENERAL 10-41
10 5 PUMP REGULATION SYSTEM, CHECKS AND ADJUSTMENTS 10-43
10 5 1 POWER CHECK 10-43
10 5 2 ELECTRONIC LOAD LIMIT REGULATION, XLR BASIC ADJUSTMENT 10-46
10 5 2 1 METHOD “A” WITH 24 V SUPPLY 10-48
10 5 2 2 METHOD “B” WITH BODAS SOFTWARE 10-50
10 5 3 ELECTRONIC LOAD LIMIT REGULATION, RC4 FUNCTION CHECK 10-54
10 5 4 HYDRAULIC CONTROL (EMERGENCY MODE) 10-56
10 5 5 PRESSURE CUT-OFF VALVE 10-58
10 6 ENERGY EFFICIENCY 10-60
10 6 1 GENERAL 10-61
10 6 2 CHECKS AND ADJUSTMENTS 10-62
11 OPERATING HYDRAULICS 11-1
11 1 GENERAL 11-2
11 1 1 FLOATING FUNCTION FOR BOOM AND STICK CYLINDER (FSA) 11-4
11 2 HYDRAULICS FOR THE ATTACHMENT CYLINDERS FSA 11-6
11 2 1 ELECTRIC / HYDRAULIC FLOWCHART “BOOM UP” (FSA) 11-6
SM 12089-xE-GB-0 PC8000E-6 TOC – 7
11 2 2 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (FSA), AUTO-FLOAT ON 11-8
11 2 3 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (FSA), AUTO-FLOAT OFF 11-10
11 2 4 ELECTRIC / HYDRAULIC FLOWCHART “STICK OUT” (FSA) 11-12
11 2 5 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (FSA), AUTO-FLOAT ON 11-14
11 2 6 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (FSA), AUTO-FLOAT OFF 11-16
11 2 7 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET FILL” (FSA) 11-18
11 2 8 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET DUMP” (FSA) 11-20
11 2 9 ELECTRIC / HYDRAULIC FLOWCHART “CLAM OPEN” (FSA) 11-22
11 2 10 ELECTRIC / HYDRAULIC FLOWCHART “CLAM CLOSE” (FSA) 11-24
11 2 11 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV), FSA 11-26
11 2 12 CHECKS AND ADJUSTMENTS OF THE SECONDARY RELIEF VALVES (SRV), FSA 11-28
11 2 12 1 BOOM CYLINDER, PISTON SIDE (FSA) 11-28
11 2 12 2 BOOM CYLINDER, PISTON ROD SIDE (FSA) 11-32
11 2 12 3 STICK CYLINDER, PISTON SIDE (FSA) 11-36
11 2 12 4 STICK CYLINDER, PISTON ROD SIDE (FSA) 11-40
11 2 12 5 BUCKET CYLINDER, PISTON SIDE (FSA) 11-44
11 2 12 6 BUCKET CYLINDER, PISTON SIDE (FSA) 11-48
11 2 12 7 CLAM CYLINDER, PISTON ROD SIDE (FSA), CLAM OPEN 11-52
11 2 12 8 CLAM CYLINDER, PISTON SIDE (FSA), CLAM CLOSE 11-56
11 2 13 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – BOOM 11-60
11 2 14 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – STICK 11-64
11 2 15 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – BUCKET 11-68
11 2 16 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – CLAM 11-72
11 3 HYDRAULICS FOR THE SWING CIRCUIT 11-74
11 3 1 SWING CIRCUIT 11-74
11 3 2 SWING MOTOR 11-78
11 3 3 SWING GEARBOX (L&S) 11-82
11 3 4 SWING GEARBOX (SIEBENHAAR) 11-84
11 3 5 SWING PARKING BRAKE (L&S) 11-86
11 3 6 SWING PARKING BRAKE (SIEBENHAAR) 11-88
11 3 7 SWING BRAKE VALVE 11-90
11 3 8 ELECTRIC / HYDRAULIC FLOWCHART “SWING LEFT” 11-94
11 3 9 ELECTRIC / HYDRAULIC FLOWCHART “SWING RIGHT” 11-96
11 3 10 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT 11-98
11 3 11 FUNCTION CHECK FOR HYDRAULIC SWING BRAKE 11-102
11 3 12 FUNCTION CHECK FOR THE SWING PARKING BRAKE 11-104
11 4 HYDRAULICS FOR THE TRAVEL CIRCUIT 11-108
11 4 1 TRAVEL CIRCUIT 11-109
11 4 2 TRAVEL MOTOR 11-112
11 4 3 ROTARY JOINT 11-114
11 4 4 TRAVEL GEARBOX 11-116
11 4 5 TRAVEL PARKING BRAKE (L&S) 11-118
11 4 6 TRAVEL PARKING BRAKE (ZOLLERN) 11-120
11 4 7 TRAVEL BRAKE VALVE 11-122
11 4 8 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL FORWARD” 11-124
11 4 9 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL BACKWARDS” 11-126
11 4 10 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT 11-128
11 4 11 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE 11-130
TOC – 8 PC8000E-6 SM 12089-xE-GB-0
12 HYDRAULIC TRACK TENSIONING SYSTEM 12-1
12 1 GENERAL 12-2
12 2 FUNCTIONAL DESCRIPTION 12-4
12 3 DOUBLE-STAGE VALVE 12-8
12 4 TENSIONING CYLINDER 12-10
12 5 ADJUSTMENTS / CHECKS 12-12
13 ACCESS LADDER, HYDRAULICALLY OPERATED 13-1
13 1 GENERAL 13-2
13 2 FUNCTION OF THE HYDRAULICALLY OPERATED ACCESS LADDER 13-4
13 3 ADJUSTMENTS / CHECKS 13-8
14 CENTRAL REFILLING SYSTEM (SERVICE ARM) 14-1
14 1 SERVICE ARM 14-2
14 2 MONITORING AND CONTROL BOX 14-4
14 3 FUNCTION 14-6
14 4 CHECKS AND ADJUSTMENTS 14-8
15 HINTS FOR READING THE HYDRAULIC DIAGRAM 15-1
15 1 GENERAL 15-2
15 2 HYDRAULIC SYMBOLS 15-4
15 2 1 LINES, UNIONS 15-5
15 2 2 COMPONENTS, VALVES 15-7
15 2 3 SENSORS 15-7
15 2 4 VALVES, VALVE COMPONENTS 15-8
15 2 5 PUMP, MOTOR, CYLINDER 15-12
16 HINTS FOR READING THE ELECTRIC WIRING DIAGRAM 16-1
16 1 GENERAL 16-2
16 2 REFERENCE CODE OF THE ELECTRICAL COMPONENTS 16-3
16 2 1 AREA CODE 16-3
16 2 2 COMPONENT IDENTIFYING LETTER 16-5
16 3 GRAPHICAL SYMBOLS 16-6
16 4 DRAWING CONCEPT 16-10
16 5 CABLE MARKING 16-20
17 KOMTRAX PLUS & MTC CONTROL SYSTEM 17-1
17 1 GENERAL 17-2
17 2 SPECIFICATIONS FOR OPERATORS 17-5
17 2 1 SEQUENCE OF DISPLAYS 17-6
17 2 2 OPENING SCREEN 17-6
17 2 3 MAIN GAUGE SCREENS 1 TO 3 17-7
17 2 4 ENERGY CONSUMPTION SCREEN 17-10
17 2 5 FAILURE MESSAGE HISTORY FOR THE OPERATOR 17-12
17 2 6 MAIN GAUGE SCREENS – CHANGING OF TIME / SMR / DATE 17-14
SM 12089-xE-GB-0 PC8000E-6 TOC – 9
17 2 7 MAINTENANCE MONITOR 17-15
17 2 8 SETTINGS FOR OPERATOR 17-17
17 2 9 AUTOMATIC MESSAGES 17-24
17 3 TABLES OF ALL PROVIDED MESSAGES 17-27
17 3 1 TABLE OF G-CODES 17-28
17 3 2 TABLE OF AVAILABLE INSTRUCTION MESSAGES 17-36
17 4 FLOW CHARTS (1-4) OF KOMTRAX PLUS MAIN SCREENS 17-39
17 5 KOMTRAX PLUS SERVICE LEVEL 17-44
17 5 1 EXPLANATION OF THE BUTTON SYMBOLS (SERVICE LEVEL) 17-46
17 5 2 SERVICE MENU SELECT SCREEN 17-47
17 5 3 REAL TIME MENU SELECT SCREEN 17-48
17 5 3 1 REAL TIME MENU, OPTION: 01 MOTOR 1 17-49
17 5 3 2 REAL TIME MENU, OPTION: 02 MOTOR 2 17-49
17 5 3 3 REAL TIME MENU, OPTION: 03 PTO 1 17-50
17 5 3 4 REAL TIME MENU, OPTION: 04 PTO 2 17-50
17 5 3 5 REAL TIME MENU, OPTION: 05 HYDRAULIC 17-51
17 5 3 6 REAL TIME MENU, OPTION: 06 SLEW 17-52
17 5 3 7 REAL TIME MENU, OPTION: 07 ELECTRICAL EQUIPMENT 17-53
17 5 3 8 REAL TIME MENU, OPTION: 08 EMERGENCY STOP 17-54
17 5 3 9 REAL TIME MENU, OPTION: 09 HEATER 17-55
17 5 3 10 REAL TIME MENU, OPTION: 10 MANUAL SWITCH 17-56
17 5 3 11 REAL TIME MENU, OPTION: 11 CENTRAL LUBE SYSTEM 1 17-57
17 5 3 12 REAL TIME MENU, OPTION: 12 SLEW RING GEAR LUBE SYSTEM 17-58
17 5 3 13 REAL TIME MENU, OPTION: 13 CENTRAL LUBE SYSTEM 2 17-59
17 5 3 14 REAL TIME MENU, OPTION: 14 CABLE DRUM 17-60
17 5 3 15 REAL TIME MENU, OPTION: 15 WINDSCREEN WIPER 17-61
17 5 3 16 REAL TIME MENU, OPTION: 16 LADDER 17-62
17 5 3 17 REAL TIME MENU, OPTION: 17 SERVICE ARM 17-63
17 5 3 18 REAL TIME MENU, OPTION: 18 PILOT CONTROL 17-64
17 5 3 19 REAL TIME MENU, OPTION: 19 OTHER ITEMS 17-65
17 5 3 20 REAL TIME MENU, OPTION: 20 OUTPUT SIGNALS 17-66
17 5 3 21 OUTPUT SIGNALS WITH DEACTIVATED MTC EVALUATION 17-69
17 5 4 PM-CLINIC 17-71
17 5 4 1 GENERAL 17-71
17 5 4 2 POWER CHECK 17-72
17 5 5 SERIAL/GCC NO SETTING 17-73
17 5 6 MEMORY CLEAR 17-74
17 5 6 1 INPUT MEMORY CLEAR ID 17-74
17 5 6 2 MEMORY CLEAR SCREEN 17-75
17 5 7 FAILURE HISTORY 17-76
17 5 8 MAINTENANCE MONITOR 17-77
17 5 9 SNAPSHOT 17-78
17 5 10 SETTINGS 17-79
17 5 10 1 CENTRAL LUBRICATION SYSTEM (CLS 1), SCREEN 1/12 17-79
17 5 10 2 SWING LUBRICATION SYSTEM (SLS), SCREEN 2/12 17-80
17 5 10 3 CENTRAL LUBRICATION SYSTEM (CLS 2), SCREEN 3/12 17-81
17 5 10 4 QMIN – QMAX SETTING, SCREEN 4/12 17-82
17 5 10 5 OTHER SETTINGS 1/2, SCREEN 5/12 17-82
17 5 10 6 OTHER SETTINGS 2/2, SCREEN 6/12 17-84
17 5 10 7 SHUTDOWN BYPASS ON/OFF 17-87
TOC – 10 PC8000E-6 SM 12089-xE-GB-0
17 6 INTERFACE-CONNECTION KOMTRAX PLUS CONTROLLER 17-90
17 6 1 KOMTRAX PLUS CONTROLLER 17-91
17 7 WIRING OF THE KOMTRAX PLUS CONTROLLER 17-92
17 8 MTC CONTROL SYSTEM GLOBAL LAYOUT 17-96
17 8 1 MTC (MASTER TURBO CONTROLLER) 17-98
17 8 1 1 MTC FLOWCHART 17-98
17 8 1 2 MTC FEATURES 17-98
17 8 1 3 MTC FIRMWARE AND SOFTWARE 17-99
17 8 1 4 VIEW ONTO THE MTC UNIT AND ITS CONNECTORS 17-100
17 9 GLOBAL LAYOUT OF THE INTERNAL CAN BUS 17-102
17 9 1 GENERAL INFORMATION ON A CAN BUS SYSTEM 17-102
17 9 1 1 GENERAL CAN BUS DESCRIPTION 17-103
17 9 1 2 CAN BUS TROUBLESHOOTING 17-103
17 9 1 3 CAN BUS WIRING 17-104
17 9 1 4 CAN BUS END RESISTOR 17-106
17 10THE NODES IN THE CAN BUS SYSTEM 17-108
17 10 1 GLOBAL LAYOUT 17-108
17 10 2 INTRODUCTION 17-110
17 10 2 1 ICN-V FEATURES 17-110
17 10 2 2 ICN-D FEATURES 17-112
17 10 3 NODE DIP-SWITCHES 17-113
17 10 4 NODE BOX 17-114
17 10 5 NODE LOCATIONS ON THE MACHINE 17-116
17 10 5 1 NODE & LOCATION CHART 17-117
17 10 5 2 EXEMPLARY VIEW ONTO THE CAN BUS CONTROL COMPONENTS
IN A CAB BASE 17-118
18 LUBRICATION SYSTEM 18-1
18 1 GENERAL OVERVIEW (SLS & CLS1/2) 18-2
18 1 1 GENERAL DESCRIPTION 18-3
18 2 BASIC FUNCTION OF THE LUBRICATION SYSTEMS 18-4
18 3 CENTRAL LUBRICATION SYSTEM (CLS 1&2) 18-6
18 3 1 GENERAL INFORMATION ON THE CLS (CLS1/2) 18-8
18 3 1 1 MANUAL LUBE ACTIVATION 18-8
18 4 SWING CIRCLE LUBRICATION SYSTEM (SLS) 18-10
18 4 1 GENERAL INFORMATION ON THE SLS 18-12
18 4 1 1 MANUAL LUBE ACTIVATION 18-12
18 5 LUBRICATION CYCLE 18-13
18 5 1 OPERATION AND CONTROL 18-13
18 5 2 LUBRICATION CYCLE – COMPONENTS 18-14
18 5 3 LUBRICATION CYCLE – PROCESSING 18-16
18 5 4 TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE 18-17
18 5 5 LUBRICATION MODES 18-18
18 5 5 1 AUTOMATIC LUBRICATION MODE 18-18
18 5 5 2 MANUAL LUBRICATION MODE 18-18
18 5 5 3 VHMS SERVICE MODE 18-18
18 6 HYDRAULICALLY DRIVEN LUBE PUMP 18-20
18 6 1 ADJUSTMENT OF LUBE PUMP SPEED & WORKING PRESSURE 18-22
SM 12089-xE-GB-0 PC8000E-6 TOC – 11
18 6 1 1 STROKE SPEED ADJUSTMENT 18-23
18 6 1 2 WORKING PRESSURE ADJUSTMENT 18-24
18 7 LUBRICANT INJECTORS 18-26
18 7 1 TIGHTENING TORQUES FOR FITTINGS AT GREASE INJECTORS 18-27
18 7 2 INJECTOR TYPE DESCRIPTION 18-28
18 7 3 ADJUSTMENT OF THE LUBRICANT OUTPUT 18-28
18 7 4 OPERATION PRINCIPLE OF LUBRICANT INJECTORS 18-30
18 7 4 1 FUNCTION DESCRIPTION 18-31
18 7 5 CONNECTION OF ONE OR MORE INJECTORS 18-32
18 8 VENT VALVE 18-34
18 8 1 DESCRIPTION 18-35
18 9 END-LINE SWITCH 18-36
18 9 1 DESCRIPTION 18-37
18 9 2 CLS END-LINE SWITCH ADJUSTMENT 18-38
18 9 3 SLS END-LINE SWITCH ADJUSTMENT 18-40
18 10IN-LINE FILTER 18-42
18 10 1 DESCRIPTION 18-43
18 10 2 MAINTENANCE PROCEDURE 18-43
18 11LUBRICANT LEVEL SENSOR 18-44
18 11 1 DESCRIPTION 18-45
18 11 1 1 LEDS AT THE SONAR SENSOR 18-46
18 12COMMISSIONING 18-48
18 12 1 COMMISSIONING OF THE CLS1 & CLS2 LUBRICATION SYSTEMS 18-48
18 12 2 FINE ADJUSTMENT 18-49
18 12 3 COMMISSIONING OF THE SLS LUBRICATION SYSTEM 18-50
19 DEEP TEMPERATURE EQUIPMENT (OPTION) 19-1
19 1 GENERAL INFORMATION 19-2
19 1 1 INTRODUCTION 19-2
19 1 2 DEEP TEMPERATURE COMPONENTS OVERVIEW 19-2
19 1 3 POWER SUPPLY PRECONDITIONS FOR PREHEATING 19-3
19 1 4 POWER REQUIREMENTS FOR PREHEATING SYSTEMS 19-4
19 2 PREHEATING PROCEDURE 19-5
19 2 1 GLOBAL FLOW CHART OF THE PREHEATING PROCEDURE 19-5
19 2 2 STARTING THE PREHEATING PROCEDURE 19-6
19 2 3 PREHEATING OF OPERATOR’S CAB AND DIESEL ENGINE
[COOLANT SYSTEM] 19-7
19 2 4 PREHEATING OF LUBRICANTS AND SUPERSTRUCTURE (DIESEL)
[ELECTRIC SYSTEM] 19-8
19 3 CONSTANT HEATING OF TRAVEL MOTORS (TTT EQUIPMENT BELOW-40°C ONLY) 19-9
19 4 COMPONENT LOCATION 19-10
19 4 1 ELECTRIC HEATING ELEMENTS FOR HYDRAULIC & BATTERIES
[ELECTRIC MACHINE] 19-10
19 4 2 ELECTRIC HEATING ELEMENTS FOR HYDRAULICS
[DIESEL MACHINE] 19-12
19 4 3 ELECTRIC HEATING ELEMENTS FOR ENGINES & BATTERIES
[DIESEL MACHINE] 19-14
19 5 COMPONENTS OF TT EQUIPMENT 19-16
TOC – 12 PC8000E-6 SM 12089-xE-GB-0
19 5 1 PREHEATING COMPONENTS ON A DIESEL MACHINE 19-16
19 5 2 PREHEATING COMPONENTS ON AN ELECTRIC MACHINE 19-17
19 5 3 EXEMPLARY WIRING DIAGRAMS FOR PREHEATING SYSTEMS 19-18
19 5 3 1 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 1 OF 3 19-18
19 5 3 2 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 2 OF 3 19-19
19 5 3 3 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 3 OF 3 19-20
19 5 3 4 WIRING DIAGRAM “SUCTION OIL MANIFOLD PREHEATING” 19-21
19 5 3 5 WIRING DIAGRAM “PTO PREHEATING” 19-22
19 5 3 6 WIRING DIAGRAM “BATTERY HEATER PADS” 19-23
Introduction
SM
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