KOMATSU PC8000E-6 HYDRAULIC MINING SHOVEL SHOP MANUAL 12089-xE-GB-0 – PDF DOWNLOAD
DESCRIPTION:
KOMATSU PC8000E-6 HYDRAULIC MINING SHOVEL SHOP MANUAL 12089-xE-GB-0 – PDF DOWNLOAD
SERIAL NUMBER 12089 – 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.
TABLE OF CONTENTS:
KOMATSU PC8000E-6 HYDRAULIC MINING SHOVEL SHOP MANUAL 12089-xE-GB-0 – PDF DOWNLOAD
SHOP MANUAL Cover 1
00 FOREWORD 3
1 Foreword 5
1 1 BEFORE READING THIS MANUAL 6
1 2 Contents of this binder 7
1 2 1 Contacting the Service 7
1 2 2 Guarantee 7
1 3 DIVISION OF THE BINDER 8
2 SAFETY 9
2 1 SAFETY INFORMATION 10
2 2 OVERVIEW 11
2 2 1 NORMAL OPERATIONS 11
2 2 2 REGULAR MAINTENANCE 11
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 11
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 11
2 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 12
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 13
2 4 1 UNDERSTANDING THE MACHINE 13
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 13
2 4 2 1 ENSURING SAFE OPERATION 13
2 4 3 PREPARATIONS FOR SAFE OPERATION 13
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 13
2 4 3 2 INSPECTING THE MACHINE 13
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 14
2 4 3 4 KEEP MACHINE CLEAN 14
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 14
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 15
2 4 3 7 IF A PROBLEM IS FOUND 15
2 4 4 FIRE PREVENTION 15
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 15
2 4 4 2 ACTION IF FIRE OCCURS 16
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 17
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 17
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 17
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 17
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 17
2 4 5 4 WORKING IN HIGH PLACES 17
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 18
2 4 5 6 LEAVING THE MACHINE 18
2 4 6 BURN PREVENTION 19
2 4 6 1 Hot coolant 19
2 4 6 2 Hot oil 19
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 19
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 20
2 4 8 1 UNAUTHORIZED MODIFICATION 20
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 20
2 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 21
2 4 10 PRECAUTIONS AT JOBSITE 22
2 4 10 1 VISIBILITY FROM OPERATOR’S SEAT 23
2 4 10 2 CAMERA SYSTEM WITH MONITORS 23
2 4 10 3 ENSURE GOOD VISIBILITY 23
2 4 10 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 23
2 4 10 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 24
2 4 10 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 24
2 4 10 7 WORKING ON LOOSE GROUND 25
2 4 10 8 GAS, DUST, STEAM AND SMOKE 25
2 4 10 9 VENTILATION OF ENCLOSED AREAS 26
2 4 11 STARTING motor 27
2 4 11 1 WARNING TAG 27
2 4 11 2 CHECKS BEFORE STARTING motor 27
2 4 11 3 PRECAUTION WHEN STARTING motor 27
2 4 11 4 PRECAUTION IN COLD AREAS 28
2 4 12 OPERATION 28
2 4 12 1 CHECKS BEFORE OPERATION 28
2 4 12 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 29
2 4 12 3 PRECAUTIONS WHEN travelling 30
2 4 12 4 TRAVELLING ON SLOPES 31
2 4 12 5 OPERATIONS ON SLOPES 32
2 4 12 6 PROHIBITED OPERATIONS 32
2 4 12 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 33
2 4 12 8 PARKING THE MACHINE 33
2 4 12 9 TRANSPORTATION 33
2 5 PRECAUTION FOR MAINTENANCE 34
2 5 1 GENERAL PRECAUTIONS 34
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 35
2 5 1 2 STOP motor FOR MAINTENANCE 36
2 5 1 3 WARNING TAG 37
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 38
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 38
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 39
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 39
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 40
2 5 1 9 NOISE 40
2 5 1 10 WHEN USING A HAMMER 40
2 5 1 11 PROPER TOOLS 41
2 5 1 12 ACCUMULATOR 41
2 5 1 13 PERSONNEL 41
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 42
2 5 2 1 PRECAUTION WHEN WELDING 42
2 5 2 2 BATTERY HANDLING 42
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 43
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 43
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 44
2 5 3 3 REPLACEMENT OF HOSE LINES 44
2 5 3 4 INSPECTION OF HOSE LINES 44
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 45
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 45
2 5 3 7 AIR CONDITIONING MAINTENANCE 45
2 5 3 8 COMPRESSED AIR 46
2 5 3 9 WASTE MATERIALS 46
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 47
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 47
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 47
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 47
2 7 SPECIAL SAFETY EQUIPMENT 48
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 49
2 7 2 OBJECT HANDLING 49
2 7 3 LIGHTING 49
2 7 4 WARNING BEACON 49
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2 7 5 2 INSTRUCTIONS FOR USE 51
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 53
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), 53
2 7 5 5 INSTRUCTIONS FOR USE 55
01 SPECIFICATION 57
PC8000 59
10 STRUCTURE & FUNCTION 67
TOC 69
1 Introduction 81
1 1 Contents of the binder 82
1 2 Foreword 82
1 3 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 84
1 4 Explanation of abbreviations 85
1 5 Diagrams and illustrations in this manual 86
2 SAFETY 89
2 1 SAFETY INFORMATION 90
2 2 OVERVIEW 91
2 2 1 NORMAL OPERATIONS 91
2 2 2 REGULAR MAINTENANCE 91
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 91
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 91
2 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 92
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 93
2 4 1 UNDERSTANDING THE MACHINE 93
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 93
2 4 2 1 ENSURING SAFE OPERATION 93
2 4 3 PREPARATIONS FOR SAFE OPERATION 93
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 93
2 4 3 2 INSPECTING THE MACHINE 93
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 94
2 4 3 4 KEEP MACHINE CLEAN 94
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 94
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 95
2 4 3 7 IF A PROBLEM IS FOUND 95
2 4 4 FIRE PREVENTION 95
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 95
2 4 4 2 ACTION IF FIRE OCCURS 96
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 97
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 97
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 97
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 97
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 97
2 4 5 4 WORKING IN HIGH PLACES 97
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 98
2 4 5 6 LEAVING THE MACHINE 98
2 4 6 BURN PREVENTION 99
2 4 6 1 Hot coolant 99
2 4 6 2 Hot oil 99
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 99
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 100
2 4 8 1 UNAUTHORIZED MODIFICATION 100
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 100
2 4 9 PRECAUTIONS AT JOBSITE 101
2 4 9 1 VISIBILITY FROM OPERATOR’S SEAT 102
2 4 9 2 CAMERA SYSTEM WITH MONITORS 102
2 4 9 3 ENSURE GOOD VISIBILITY 102
2 4 9 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 102
2 4 9 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 103
2 4 9 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 103
2 4 9 7 WORKING ON LOOSE GROUND 104
2 4 9 8 GAS, DUST, STEAM AND SMOKE 104
2 4 9 9 VENTILATION OF ENCLOSED AREAS 105
2 4 10 STARTING ENGINE 106
2 4 10 1 WARNING TAG 106
2 4 10 2 CHECKS BEFORE STARTING ENGINE 106
2 4 10 3 PRECAUTION WHEN STARTING ENGINE 106
2 4 10 4 PRECAUTION IN COLD AREAS 107
2 4 11 OPERATION 107
2 4 11 1 CHECKS BEFORE OPERATION 107
2 4 11 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 108
2 4 11 3 PRECAUTIONS WHEN travelling 109
2 4 11 4 TRAVELLING ON SLOPES 110
2 4 11 5 OPERATIONS ON SLOPES 111
2 4 11 6 PROHIBITED OPERATIONS 111
2 4 11 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 112
2 4 11 8 PARKING THE MACHINE 112
2 4 11 9 TRANSPORTATION 112
2 5 PRECAUTION FOR MAINTENANCE 113
2 5 1 GENERAL PRECAUTIONS 113
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 114
2 5 1 2 STOP ENGINE FOR MAINTENANCE 115
2 5 1 3 WARNING TAG 116
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 117
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 117
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 118
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 118
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 119
2 5 1 9 NOISE 119
2 5 1 10 WHEN USING A HAMMER 119
2 5 1 11 PROPER TOOLS 120
2 5 1 12 ACCUMULATOR 120
2 5 1 13 PERSONNEL 120
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 121
2 5 2 1 PRECAUTION WHEN WELDING 121
2 5 2 2 BATTERY HANDLING 121
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 122
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 122
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 123
2 5 3 3 REPLACEMENT OF HOSE LINES 123
2 5 3 4 INSPECTION OF HOSE LINES 123
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 124
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 124
2 5 3 7 AIR CONDITIONING MAINTENANCE 124
2 5 3 8 COMPRESSED AIR 125
2 5 3 9 WASTE MATERIALS 125
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 126
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 126
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 126
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 126
2 7 SPECIAL SAFETY EQUIPMENT 128
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 129
2 7 2 OBJECT HANDLING 129
2 7 3 LIGHTING 129
2 7 4 WARNING BEACON 129
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 129
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 129
2 7 5 2 INSTRUCTIONS FOR USE 131
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 133
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1), 133
2 7 5 5 INSTRUCTIONS FOR USE 135
3 Specifications 137
3 1 Lifting Gears 138
3 2 Safety hints for sling accessory 140
3 3 Standard Tightening Torque Chart 141
3 4 Conversion Table 142
3 5 Blind plugs 148
3 6 Classification of threads to the nominal width 150
3 7 Plugs and fittings according to ISO 8434-1 / DIN 2353 151
4 Main assembly groups 153
4 1 General layout 154
4 2 Superstructure 156
4 3 Machine house 160
4 4 Hydraulic oil tank 162
4 5 Hydraulic oil cooler 164
4 6 High voltage switch cabinet 166
4 7 Cab support 172
4 7 1 X2 – Low voltage switch board (location 12) 173
4 7 2 Extra low voltage switch board (location 11) 175
4 8 Slip ring unit 176
4 9 Operator’s cab 180
4 10 Control blocks 182
4 11 Swing machinery 184
4 11 1 Swing machinery L&S 184
4 11 2 Swing machinery SIEBENHAAR 186
4 12 Undercarriage 188
4 13 Attachments 190
4 13 1 Front Shovel Attachment (FSA) 190
4 13 2 Backhoe Attachment (BHA) 192
5 Drive 195
5 1 Electric drive – Safety and operation instruction documents 196
5 2 Prime drive assembly 198
5 3 Electric motors 200
5 3 1 Location of attaching parts 200
5 3 1 1 Motor type plate 201
5 3 1 2 Type plate for the motor bearings 202
5 3 2 Motor bearings & grease equipment 204
5 3 3 Monitoring of the motor bearing temperature 206
5 3 4 Monitoring of the motor winding temperature 207
5 3 5 Junction box for the motor monitoring device 208
5 3 6 Checking of the bearing condition 209
5 3 7 Capacitor assembly 210
5 4 Air-to-air motor cooling system 212
5 5 Initial Start-up procedure 213
5 5 1 Main supply cable 214
5 5 2 Machine configuration (via CoDeSys) 215
5 5 3 Motor protection relay (SPAM 150 C) 220
5 5 4 Motor alignment 222
5 5 5 Motor rotation direction 224
5 5 6 Starting & Re-starting the electric motors 224
5 5 7 Supervision during the first motor running period 225
5 6 Flexible coupling 226
5 6 1 Coupling inspection 227
5 6 2 Coupling replacement 228
5 7 Pump distributor gearbox (PTO) 230
5 7 1 Pump drive shaft housing / spline lubrication 232
5 7 2 PTO lubrication and cooling 234
5 7 2 1 Checks and adjustments 236
5 7 3 Hydraulic pumps – location, drive speed and flow rates 238
6 Hydraulic oil tank 241
6 1 General layout 242
6 2 Location of the electric equipment 244
6 3 Suction oil tank with strainers 246
6 4 Return oil collector pipe with strainer 248
6 5 Back pressure valve 250
6 6 Transfer pump 252
6 7 Return and leak oil filter 254
6 8 Breather filter 256
7 Hydraulic oil cooling 259
7 1 Overall view of the hydraulic oil cooling 260
7 2 Function of the hydraulic oil cooling circuit 262
7 2 1 Standard hydraulic oil cooling circuit 262
7 2 2 Additional oil cooling circuit 264
7 3 Adjustment of the back pressure valve 266
7 4 Fan drive – standard oil cooler 268
7 4 1 Two stage cooler fan drive RPM control 268
7 4 2 Fixed displacement pump with variable setting 270
7 4 3 Pressure relief valves 272
7 4 4 Solenoid valves 274
7 5 Adjustment of the cooler fan drive speed 276
7 5 1 Maximum speed 276
7 5 2 Medium speed 278
7 6 Fan drive – additional oil cooler 280
7 6 1 Function of the additional cooler fan RPM control 281
7 6 2 Adjustment of the additional cooler fan drive speed 281
8 Controlling 283
8 1 General layout 284
8 2 Control and filter panels – location of components 286
8 2 1 Main valve cartridge block 286
8 2 2 Control and filter panels mounted on the PTOs 292
8 3 Pilot pressure supply and adjustments 294
8 3 1 Pilot pressure circuit 295
8 3 2 Checks and adjustments of pilot pressure 298
8 3 3 Remote control valves arrangement 302
8 4 Function of the electro-hydraulic control system 304
8 5 Hand lever (joystick) control 308
8 6 Foot pedal control 310
8 7 Proportional amplifier module, type A 312
8 8 Proportional amplifier module, type B 314
8 9 Ramp time module 316
8 10 Adjustment of amplifier modules 318
8 10 1 General 319
8 10 2 Adjusting the amplifier module, type A 320
8 10 3 Adjusting the amplifier module, type B 322
8 11 Adjusting the ramp time module 324
9 Components 329
9 1 Main control blocks and high pressure filters (FSA) 330
9 2 Distributor manifold – location of restrictor blocks and anti-cavitation valves 334
9 3 Restrictor block with secondary relief valve 336
9 4 Anti-cavitation valve (ACV) block 338
9 4 1 ACV block on control blocks 338
9 4 2 ACV block on top of the manifold 340
9 5 Remote control valves 342
9 6 4/3 Directional solenoid valves 344
9 7 Proportional solenoid valves 346
9 8 High-pressure filter (screen) 348
9 9 CONTROL blocks and valves 350
9 10 Travel brake valve 362
9 11 Pressure reducing valve 364
9 12 4/2 Directional valves 366
9 13 Pressure double stage valve 368
9 14 Hydraulic cylinder 370
10 Main hydraulic pumps and pump regulation 373
10 1 General 374
10 1 1 Layout 374
10 1 2 Pump regulation system (“open sensing system”) 377
10 1 3 Pump regulation system — valve function 378
10 2 Main pumps 380
10 2 1 Pump bearing flushing / lubrication 382
10 2 2 Operating principle 384
10 2 3 Checks / adjustments 400
10 2 3 1 Qmax and Qmin adjustment bolts 402
10 3 Electronic pump regulation system 404
10 3 1 Electronic load limiting control – general 405
10 3 2 Microcontroller RC4-4 406
10 3 3 Signal rectifier module 408
10 3 3 1 Checks and adjustments 410
10 4 Hydraulic constant regulation system (emergency mode) 412
10 4 1 General 413
10 5 Pump regulation system, checks and adjustments 415
10 5 1 Power Check 415
10 5 2 Electronic load limit regulation, XLR basic adjustment 418
10 5 2 1 Method “A” with 24 V supply 420
10 5 2 2 Method “B” with BODAS software 422
10 5 3 Electronic load limit regulation, RC4 function check 426
10 5 4 Hydraulic Control (emergency mode) 428
10 5 5 Pressure cut-off valve 430
10 6 Energy efficiency 432
10 6 1 General 433
10 6 2 Checks and adjustments 434
11 Operating hydraulics 437
11 1 General 438
11 1 1 Floating function for boom and stick cylinder (FSA) 440
11 2 Hydraulics for the attachment cylinders FSA 442
11 2 1 Electric / hydraulic flowchart “Boom UP” (FSA) 442
11 2 2 Electric / hydraulic flowchart “Boom down” (FSA), Auto-float ON 444
11 2 3 Electric / hydraulic flowchart “Boom down” (FSA), Auto-float OFF 446
11 2 4 Electric / hydraulic flowchart “Stick out” (FSA) 448
11 2 5 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON 450
11 2 6 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF 452
11 2 7 Electric / hydraulic flowchart “Bucket fill” (FSA) 454
11 2 8 Electric / hydraulic flowchart “Bucket dump” (FSA) 456
11 2 9 Electric / hydraulic flowchart “Clam open” (FSA) 458
11 2 10 Electric / hydraulic flowchart “Clam close” (FSA) 460
11 2 11 Checks and adjustments of the main relief valves (MRV), FSA 462
11 2 12 Checks and adjustments of the secondary relief valves (SRV), FSA 464
11 2 12 1 Boom cylinder, piston side (FSA) 464
11 2 12 2 Boom cylinder, piston rod side (FSA) 468
11 2 12 3 Stick cylinder, piston side (FSA) 472
11 2 12 4 Stick cylinder, piston rod side (FSA) 476
11 2 12 5 Bucket cylinder, piston side (FSA) 480
11 2 12 6 Bucket cylinder, piston side (FSA) 484
11 2 12 7 Clam cylinder, piston rod side (FSA), clam open 488
11 2 12 8 Clam cylinder, piston side (FSA), clam close 492
11 2 13 Checks and adjustments of the lowering speed – boom 496
11 2 14 Checks and adjustments of the lowering speed – stick 500
11 2 15 Checks and adjustments of the lowering speed – Bucket 504
11 2 16 Checks and adjustments of the lowering speed – clam 508
11 3 Hydraulics for the swing circuit 510
11 3 1 Swing circuit 510
11 3 2 Swing motor 514
11 3 3 Swing gearbox (L&S) 518
11 3 4 Swing gearbox (SIEBENHAAR) 520
11 3 5 Swing parking brake (L&S) 522
11 3 6 Swing parking brake (SIEBENHAAR) 524
11 3 7 Swing brake valve 526
11 3 8 Electric / hydraulic flowchart “Swing left” 530
11 3 9 Electric / hydraulic flowchart “Swing right” 532
11 3 10 Checks and adjustments for the swing circuit 534
11 3 11 Function check for hydraulic swing brake 538
11 3 12 Function check for the swing parking brake 540
11 4 Hydraulics for the travel circuit 544
11 4 1 Travel circuit 545
11 4 2 Travel motor 548
11 4 3 Rotary joint 550
11 4 4 Travel gearbox 552
11 4 5 Travel parking brake (L&S) 554
11 4 6 Travel parking brake (ZOLLERN) 556
11 4 7 Travel brake valve 558
11 4 8 Electric / hydraulic flowchart “Travel forward” 560
11 4 9 Electric / hydraulic flowchart “Travel backwards” 562
11 4 10 Checks and adjustments for the travel circuit 564
11 4 11 Function check for the travel parking brake 566
12 Hydraulic track tensioning system 569
12 1 General 570
12 2 Functional description 572
12 3 Double-stage valve 576
12 4 Tensioning cylinder 578
12 5 Adjustments / checks 580
13 Access ladder, hydraulically operated 583
13 1 General 584
13 2 Function of the hydraulically operated access ladder 586
13 3 Adjustments / checks 590
14 Central refilling system (service arm) 593
14 1 Service arm 594
14 2 Monitoring and control box 596
14 3 Function 598
14 4 Checks and adjustments 600
15 Hints for reading the hydraulic diagram 603
15 1 General 604
15 2 Hydraulic symbols 606
15 2 1 Lines, unions 607
15 2 2 Components, valves 609
15 2 3 Sensors 609
15 2 4 Valves, valve components 610
15 2 5 Pump, motor, cylinder 614
16 Hints for reading the electric wiring diagram 619
16 1 General 620
16 2 Reference code of the electrical components 621
16 2 1 Area code 621
16 2 2 Component identifying letter 623
16 3 Graphical symbols 624
16 4 Drawing concept 628
16 5 Cable marking 638
17 KOMTRAX Plus & MTC control system 639
17 1 General 640
17 2 Specifications for operators 643
17 2 1 Sequence of displays 644
17 2 2 Opening screen 644
17 2 3 Main gauge screens 1 to 3 645
17 2 4 Energy consumption screen 648
17 2 5 Failure message history for the operator 650
17 2 6 Main gauge screens – Changing of Time / SMR / Date 652
17 2 7 Maintenance monitor 653
17 2 8 Settings for operator 655
17 2 9 Automatic messages 662
17 3 Tables of all provided messages 665
17 3 1 Table of G-Codes 666
17 3 2 Table of available Instruction Messages 674
17 4 Flow charts (1-4) of KOMTRAX Plus main screens 677
17 5 KOMTRAX Plus service level 682
17 5 1 Explanation of the button symbols (Service Level) 684
17 5 2 Service Menu Select Screen 685
17 5 3 Real Time Menu Select Screen 686
17 5 3 1 Real Time Menu, option: 01 Motor 1 687
17 5 3 2 Real Time Menu, option: 02 Motor 2 687
17 5 3 3 Real Time Menu, option: 03 PTO 1 688
17 5 3 4 Real Time Menu, option: 04 PTO 2 688
17 5 3 5 Real Time Menu, option: 05 Hydraulic 689
17 5 3 6 Real Time Menu, option: 06 Slew 690
17 5 3 7 Real Time Menu, option: 07 Electrical Equipment 691
17 5 3 8 Real Time Menu, option: 08 Emergency Stop 692
17 5 3 9 Real Time Menu, option: 09 Heater 693
17 5 3 10 Real Time Menu, option: 10 Manual Switch 694
17 5 3 11 Real Time Menu, option: 11 Central lUBE System 1 695
17 5 3 12 Real Time Menu, option: 12 Slew Ring Gear Lube System 696
17 5 3 13 Real Time Menu, option: 13 Central Lube System 2 697
17 5 3 14 Real Time Menu, option: 14 Cable Drum 698
17 5 3 15 Real Time Menu, option: 15 Windscreen Wiper 699
17 5 3 16 Real Time Menu, option: 16 Ladder 700
17 5 3 17 Real Time Menu, option: 17 Service Arm 701
17 5 3 18 Real Time Menu, option: 18 Pilot Control 702
17 5 3 19 Real Time Menu, option: 19 Other Items 703
17 5 3 20 Real Time Menu, option: 20 Output Signals 704
17 5 3 21 Output signals with deactivated MTC evaluation 707
17 5 4 PM-Clinic 709
17 5 4 1 General 709
17 5 4 2 Power Check 710
17 5 5 Serial/GCC no setting 711
17 5 6 Memory Clear 712
17 5 6 1 Input Memory Clear ID 712
17 5 6 2 Memory Clear screen 713
17 5 7 Failure History 714
17 5 8 Maintenance Monitor 715
17 5 9 Snapshot 716
17 5 10 Settings 717
17 5 10 1 Central Lubrication System (CLS 1), screen 1/12 717
17 5 10 2 Swing Lubrication System (SLS), screen 2/12 718
17 5 10 3 Central Lubrication System (CLS 2), screen 3/12 719
17 5 10 4 Qmin – Qmax setting, screen 4/12 720
17 5 10 5 Other Settings 1/2, screen 5/12 720
17 5 10 6 Other Settings 2/2, screen 6/12 722
17 5 10 7 Shutdown Bypass ON/OFF 725
17 6 Interface-Connection KOMTRAX Plus controller 728
17 6 1 KOMTRAX Plus controller 729
17 7 Wiring of the KOMTRAX Plus controller 730
17 8 MTC control system global layout 734
17 8 1 MTC (Master Turbo Controller) 736
17 8 1 1 MTC flowchart 736
17 8 1 2 MTC features 736
17 8 1 3 MTC firmware and software 737
17 8 1 4 View onto the MTC unit and its connectors 738
17 9 Global layout of the internal CAN bus 740
17 9 1 General information on a CAN bus system 740
17 9 1 1 General CAN bus description 741
17 9 1 2 CAN bus troubleshooting 741
17 9 1 3 Can bus wiring 742
17 9 1 4 CAN bus end resistor 744
17 10 The nodes in the CAN bus system 746
17 10 1 Global layout 746
17 10 2 Introduction 748
17 10 2 1 ICN-V features 748
17 10 2 2 ICN-D features 750
17 10 3 Node DIP-switches 751
17 10 4 Node box 752
17 10 5 Node locations on the machine 754
17 10 5 1 Node & location chart 755
17 10 5 2 Exemplary view onto the CAN bus control components in a cab base 756
18 Lubrication system 759
18 1 General overview (SLS & CLS 1 / 2) 760
18 1 1 General description 761
18 2 Basic function of the lubrication systems 762
18 3 Central lubrication system (CLS 1 & 2) 764
18 3 1 General information on the CLS (CLS 1 / 2) 766
18 3 1 1 Manual lube activation 766
18 4 Swing circle lubrication system (SLS) 768
18 4 1 General information on the SLS 770
18 4 1 1 Manual lube activation 770
18 5 Lubrication cycle 771
18 5 1 Operation and control 771
18 5 2 Lubrication cycle – components 772
18 5 3 Lubrication cycle – processing 774
18 5 4 Time segments & switch points of a lubrication cycle 775
18 5 5 Lubrication modes 776
18 5 5 1 Automatic lubrication mode 776
18 5 5 2 Manual lubrication mode 776
18 5 5 3 VHMS service mode 776
18 6 Hydraulically driven lube pump 778
18 6 1 Adjustment of lube pump speed & working pressure 780
18 6 1 1 Stroke speed adjustment 781
18 6 1 2 Working pressure adjustment 782
18 7 Lubricant injectors 784
18 7 1 Tightening torques for fittings at grease injectors 785
18 7 2 Injector type description 786
18 7 3 Adjustment of the lubricant output 786
18 7 4 Operation principle of lubricant injectors 788
18 7 4 1 Function description 789
18 7 5 Connection of one or more injectors 790
18 8 Vent valve 792
18 8 1 Description 793
18 9 End-line switch 794
18 9 1 Description 795
18 9 2 CLS end-line switch adjustment 796
18 9 3 SLS end-line switch adjustment 798
18 10 In-line filter 800
18 10 1 Description 801
18 10 2 Maintenance procedure 801
18 11 Lubricant level sensor 802
18 11 1 Description 803
18 11 1 1 LEDs at the sonar sensor 804
18 11 2 Binary type lubricant level sensor 806
18 11 3 Description 807
18 11 3 1 Adjustment 807
18 12 Commissioning 808
18 12 1 Commissioning of the CLS 1 & CLS 2 lubrication systems 808
18 12 2 Fine adjustment 809
18 12 3 Commissioning of the SLS lubrication system 810
19 Deep temperature equipment (option) 813
19 1 General information 814
19 1 1 Introduction 814
19 1 2 Deep temperature components overview 814
19 1 3 Power supply preconditions for preheating 815
19 1 4 Power requirements for preheating systems 816
19 2 Preheating procedure 817
19 2 1 Global flow chart of the preheating procedure 817
19 2 2 Starting the preheating procedure 818
19 2 3 Preheating of operator’s cab and Diesel engine [coolant system] 819
19 2 4 Preheating of lubricants and superstructure (Diesel) [electric system] 820
19 3 Constant heating of travel motors (TTT equipment below-40°C only) 821
19 4 Component location 822
19 4 1 Electric heating elements for hydraulic & batteries [electric machine] 822
19 4 2 Electric heating elements for hydraulics [Diesel machine] 824
19 4 3 Electric heating elements for engines & batteries [Diesel machine] 826
19 5 Components of TT equipment 828
19 5 1 Preheating components on a Diesel machine 828
19 5 2 Preheating components on an electric machine 829
19 5 3 Exemplary Wiring Diagrams for preheating systems 830
19 5 3 1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 830
19 5 3 2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 831
19 5 3 3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 832
19 5 3 4 Wiring diagram “Suction Oil Manifold Preheating” 833
19 5 3 5 Wiring diagram “PTO Preheating” 834
19 5 3 6 Wiring diagram “Battery heater pads” 835
20 Cable drum (optional equipment) 837
20 1 General layout 838
20 1 1 Long type cable drum 838
20 1 2 short type cable drum 839
20 1 2 1 Parts installed in the undercarriage 840
20 2 Service switch 841
20 3 Drive system 842
20 3 1 Drive motor 843
20 4 Drum Body 844
20 4 1 Slip ring assembly 845
20 4 2 Checks and adjustments 845
20 5 High voltage interlock system 846
20 6 Cable guide drive mechanism 848
20 6 1 Proximity switches on the cable guide drive mechanism 850
20 6 2 Checks and adjustments 852
20 7 Travel motion control 856
20 8 Arrangement of the Slew Angle Sensor 858
20 8 1 Slew Angle Sensor 60B059 in the Wiring Diagram 859
40 TROUBLESHOOTING 861
TOC 863
1 SAFETY 883
1 1 SAFETY INFORMATION 884
1 2 OVERVIEW 885
1 2 1 NORMAL OPERATIONS 885
1 2 2 REGULAR MAINTENANCE 885
1 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 885
1 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 885
1 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 886
1 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 887
1 4 1 UNDERSTANDING THE MACHINE 887
1 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 887
1 4 2 1 ENSURING SAFE OPERATION 887
1 4 3 PREPARATIONS FOR SAFE OPERATION 887
1 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 887
1 4 3 2 INSPECTING THE MACHINE 887
1 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 888
1 4 3 4 KEEP MACHINE CLEAN 888
1 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 888
1 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 889
1 4 3 7 IF A PROBLEM IS FOUND 889
1 4 4 FIRE PREVENTION 889
1 4 4 1 PRECAUTIONS TO PREVENT FIRE 889
1 4 4 2 ACTION IF FIRE OCCURS 890
1 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 891
1 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 891
1 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 891
1 4 5 2 NO JUMPING ON OR OFF THE MACHINE 891
1 4 5 3 NO PEOPLE ON THE ATTACHMENT 891
1 4 5 4 WORKING IN HIGH PLACES 891
1 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 892
1 4 5 6 LEAVING THE MACHINE 892
1 4 6 BURN PREVENTION 893
1 4 6 1 Hot coolant 893
1 4 6 2 Hot oil 893
1 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 893
1 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 894
1 4 8 1 UNAUTHORIZED MODIFICATION 894
1 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 894
1 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 895
1 4 10 PRECAUTIONS AT JOBSITE 896
1 4 10 1 VISIBILITY FROM OPERATOR’S SEAT 897
1 4 10 2 CAMERA SYSTEM WITH MONITORS 897
1 4 10 3 ENSURE GOOD VISIBILITY 897
1 4 10 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 897
1 4 10 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 898
1 4 10 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 898
1 4 10 7 WORKING ON LOOSE GROUND 899
1 4 10 8 GAS, DUST, STEAM AND SMOKE 899
1 4 10 9 VENTILATION OF ENCLOSED AREAS 900
1 4 11 STARTING motor 901
1 4 11 1 WARNING TAG 901
1 4 11 2 CHECKS BEFORE STARTING motor 901
1 4 11 3 PRECAUTION WHEN STARTING motor 901
1 4 11 4 PRECAUTION IN COLD AREAS 902
1 4 12 OPERATION 902
1 4 12 1 CHECKS BEFORE OPERATION 902
1 4 12 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 903
1 4 12 3 PRECAUTIONS WHEN travelling 904
1 4 12 4 TRAVELLING ON SLOPES 905
1 4 12 5 OPERATIONS ON SLOPES 906
1 4 12 6 PROHIBITED OPERATIONS 906
1 4 12 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 907
1 4 12 8 PARKING THE MACHINE 907
1 4 12 9 TRANSPORTATION 907
1 5 PRECAUTION FOR MAINTENANCE 908
1 5 1 GENERAL PRECAUTIONS 908
1 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 909
1 5 1 2 STOP motor FOR MAINTENANCE 910
1 5 1 3 WARNING TAG 911
1 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 912
1 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 912
1 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 913
1 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 913
1 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 914
1 5 1 9 NOISE 914
1 5 1 10 WHEN USING A HAMMER 914
1 5 1 11 PROPER TOOLS 915
1 5 1 12 ACCUMULATOR 915
1 5 1 13 PERSONNEL 915
1 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 916
1 5 2 1 PRECAUTION WHEN WELDING 916
1 5 2 2 BATTERY HANDLING 916
1 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 917
1 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 917
1 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 918
1 5 3 3 REPLACEMENT OF HOSE LINES 918
1 5 3 4 INSPECTION OF HOSE LINES 918
1 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 919
1 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 919
1 5 3 7 AIR CONDITIONING MAINTENANCE 919
1 5 3 8 COMPRESSED AIR 920
1 5 3 9 WASTE MATERIALS 920
1 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 921
1 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 921
1 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 921
1 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 921
1 7 SPECIAL SAFETY EQUIPMENT 922
1 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 923
1 7 2 OBJECT HANDLING 923
1 7 3 LIGHTING 923
1 7 4 WARNING BEACON 923
1 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 923
1 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 923
1 7 5 2 INSTRUCTIONS FOR USE 925
1 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 927
1 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), 927
1 7 5 5 INSTRUCTIONS FOR USE 929
2 Introduction & General Information for Troubleshooting 931
2 1 Overview 932
2 1 1 General advice when using troubleshooting charts 932
2 2 General Precautions 933
2 3 Preparations For Work 934
2 4 Precautions During Work 934
2 5 Precautions When Carrying Out Any Operation 935
2 5 1 Precautions when carrying out removal work 935
2 5 2 Precautions when carrying out installation work 935
2 5 3 Precautions when completing the operation 936
2 6 Fundamental Requirements for Trouble shooting 937
2 6 1 Technical documentation 937
2 6 2 Tools 937
2 6 2 1 Reference Guide for Deutsch Removal Tools 941
2 6 3 Personnel 942
2 7 Points To Remember When Trouble- shooting 942
2 8 Sequence Of Events In Troubleshooting 944
2 9 Checks Before Troubleshooting 945
2 10 Handling Of Electric Equipment And Hydraulic Components 946
2 10 1 Points to remember when handling electric equipment 946
2 10 2 Points To Remember When Handling Hydraulic Equipment 949
2 11 General working procedures 951
2 11 1 Air Bleeding of Various Hydraulic Parts 951
2 11 2 Air bleeding from the hydraulic pumps 951
2 11 3 Air bleeding from hydraulic cylinders 951
2 12 Cylinder bypass test 952
2 13 Information about MTC & Nodes 953
2 13 1 Outline of the MTC and its connector locations 953
2 13 1 1 View onto the MTC connectors* LH & RH 953
2 13 1 2 General description of the MTC 953
2 13 1 3 Information about the LED indications at the MTC 954
2 13 2 Information about the ICN-D node 954
2 13 2 1 View onto an ICN-D node without wiring 955
2 13 2 2 View onto the Status LEDs at the ICN-D node 956
2 13 2 3 General information on the LED control 956
2 13 3 Information about the ICN-V node 958
2 13 3 1 View onto an ICN-V node 958
2 13 3 2 View onto an open ICN-V node and its DIP-switches 959
2 13 4 DIP switches at the ICN-D and ICN-V nodes 960
2 14 Basics about “How to crimp” 961
2 14 1 Stripping a wire for use with the HDT 48 crimp tool 961
2 14 2 View onto the Deutsch crimp tool HDT 48 961
2 14 3 Adjustment of the wire size at the Deutsch crimp tool HDT 48 962
2 14 3 1 Wire cross section units in mm2 and AWG 962
2 14 4 Crimping instructions (for Deutsch crimp tool HDT 48) 963
2 15 Cable Shielding 964
3 Mounting Locations and Connector Types 965
3 1 Component Location (exemplarily) 966
3 1 1 Side View onto the Excavator 966
3 1 2 Side view onto the Superstructure 968
3 1 3 Top View onto the Superstructure 970
3 1 4 Side View onto the Machine House 972
3 2 Slip ring unit & Rotary joint 974
3 2 1 Slip Ring Unit in Detail 976
3 3 General Layout of the Cable Drum 978
3 3 1 Proximity Switches on the Cable Guide Drive 979
3 4 Capacitors 980
3 5 High Voltage Switch Cabinet – View 1 982
3 5 1 High Voltage Switch Cabinet – View 2 984
3 6 Cab Support 986
3 6 1 Low voltage switch board – location 11 – view 1 988
3 6 2 Low voltage switch board – location 11 – view 2 990
3 6 3 Switch cabinet for power breakers 992
3 7 Mounting plate for instruments 994
3 8 Medium Voltage Switch Board – Location 12 – view 1 996
3 8 1 Medium Voltage Switch Board – Location 12 – view 2 998
3 9 Arrangement of the Slew Angle Sensor 1000
3 9 1 Slew Angle Sensor 60B059 in the Wiring Diagram 1001
3 10 Location of the Control Blocks 1002
3 11 Control and filter panels – location of components 1004
3 12 Location of the Suction Oil tank with strainers 1006
3 13 Arrangement of the Remote Control Valves 1008
3 14 Hydraulic Oil Tank – Location of the Electrical Components 1010
3 15 General Overview on SLS & CLS1/2 1012
3 16 Batteries, Battery Main Switches & Safety Switch for Maintenance 1014
3 17 Hydraulically operated access ladder 1016
3 18 Service arm 1018
3 19 Connector Types Overview 1020
3 19 1 Connector (10-pole) for ICN-D nodes (Phoenix Contact) 1023
3 19 2 Connector for ICN-V nodes (55 pins) 1024
4 Standard Value Table for Electrical Components 1025
5 References for Troubleshooting (CAN Bus & Node Outputs) 1043
5 1 CAN-Bus Trouble or Node Output Trouble 1044
5 1 1 Trouble CAN-BUS or CAN-Hardware (G00308) 1045
5 1 2 Trouble output short-circuit (G00043) 1046
5 2 Sequence of the CAN nodes at the CAN bus 1048
5 3 Troubleshooting for Relay Monitored Node Outputs 1049
5 3 1 Relay Check 1049
G00107 – Trouble slew parking brake control 56K250a 1050
View onto the CoDeSys HMI Visualization screen for message G00107 1052
Wiring Diagram (56K250a & 56K250b) for message G00107 1053
5 3 2 Output Check 1054
G00108 – Trouble slew parking brake control Output to 56K250a 1055
View onto the CoDeSys HMI Visualization screen for message G00108 1057
Wiring Diagram (56K250a & 56K250b) for message G00108 1058
6 Tables for Testing and Troubleshooting 1059
6 1 Index of Tables in this section 1060
6 2 Test Value Table for Temperature Sensors (PT100) g Centigrade – Volt 1061
6 3 Test Value Table for Temperature Sensors (PT100) g Centigrade – Ohm 1062
6 4 Table of G-Codes 1063
6 4 1 Monitoring-codes without readout 1070
6 5 Table of Instruction Messages 1071
6 6 Table of Binary Codes 1074
6 6 1 Table of Add-On Binary Codes for G00308 1076
6 7 Binary Output Signals on the KOMTRAX Plus Monitor 1077
6 8 Tables of Symptom Codes 1080
6 8 1 Symptoms of the E-Motors and Related parts 1080
6 8 2 Symptoms of the Hydraulic System 1080
6 8 3 Symptoms of the Mechanical System 1081
6 8 4 SYMPTOMS OF ADDITIONAL SYSTEMS 1081
6 9 Power Supply 1082
6 10 Cable colour identification 1082
7 Troubleshooting by Trouble Code 1083
G00001 – Trouble Shut-Off (gate) valve 1084
View onto the gap of proximity switch 40B031 1086
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR 1087
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor 1087
Wiring Diagram (40B031) for message G00001 (Trouble Shut-Off (gate) valve) 1088
G00003 – Trouble pump controller 1089
G00005 – Low hydraulic oil level 1098
Wiring Diagram, oil level label, and defined position of the attachment (G00005) 1100
G00007 – Trouble hydraulic oil level 1101
Hydraulic oil level at defined position of the attachment 1102
Wiring Diagram for 40B004 (message G00007) 1103
G00012 (Sonar) – Central lubrication system grease level too low 1104
G00013 (Sonar) – Slew ring gear lubr system grease level too low 1104
Wiring Diagram (62B108 / 62B109 / 62B173) for G00012 / G00013 / G00202 (sonar) 1108
Wiring Diagram (junction box for sonar sensors) for G00012 / G00013 / G00202 1109
G00012 (Binary) – Central lubrication system grease level too low 1110
G00013 (Binary) – Slew ring gear lubr system grease level too low 1110
Wiring Diagram (binary grease level sensors) for G00012 / G00013 / G00202 1113
Wiring Diagram (junction box for binary sensors) for G00012 / G00013 / G00202 1114
G00020 – Trouble Shut-Off (gate) valve (Start blocked) 1115
View onto the gap of proximity switch 40B031 (G00020) 1117
Wiring Diagram (40B031) for message G00020 (Main gate valve closed) 1118
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR 1119
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor 1119
G00033 – Trouble KOMTRAX Plus controller 1120
G00034 – Trouble KOMTRAX Plus Display 1121
G00035 – Trouble totally loss gear oil (PTO 1) 1122
G00036 – Trouble totally loss gear oil (PTO 2) 1122
Location of sensors 57B175-1/-2 at PTO-1/-2 (G00035 & G00036) 1124
Input signal (analog) of the gear oil sensors 57B175-1/-2 on the REAL TIME MONITOR 1125
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor 1125
Exemplary Wiring Diagram (57B175-1/-2) for messages G00035 & G00036 1126
G00043 – Trouble output short-circuit 1127
G00046 – Reverse travel cut out bypassed by horn 1128
G00047 – Travel cut out by cable drum 1129
Temperature sensor 91B979 and module 91B980 for message G00047 1130
Cable drum temperature on the REAL TIME MONITOR for message G00047 1131
G00048 – Trouble emergency safety circuit 1132
Wiring Diagram (11K044a) for message G00048 1133
G00049 – Trouble cab heating 1 1134
Wiring Diagram for cab heater 1 – location 20 – below operator’s seat 1135
Wiring Diagram for cab heater 1 – location 12 (LV board) – overheating protection control 1136
Wiring Diagram for cab heater 1 – location 12 – blower control & after-run 1137
Wiring Diagram for cab heating – location 12 – 3 step heater regulation 1138
G00050 – Trouble cab heating 2 1139
Wiring Diagram for cab heater 2 – location 20 – at the cab wall 1140
Wiring Diagram for cab heater 2 – location 12 (LV board) – overheating protection control 1141
Wiring Diagram for cab heater 2 – location 12 – blower control & after-run 1142
Wiring Diagram for cab heater 1 & 2 – location 12 – 3 step heater regulation 1143
G00053 – Reset emergency safety circuit 1144
G00054 – Monitoring idle position cut off 1145
Wiring Diagram (11K032) for message G00054 1146
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054) 1147
Exemplary view onto the KOMTRAX Plus Failure History (G00054) 1147
G00055 – Trouble monitoring cable drum motor temperature 1148
Wiring Diagram (91B979 & 91B980) for message G00055 1149
G00059 – Fire in the switch cabinet 1150
Wiring Diagram 1 (temperature sensors) for message G00059 1152
Wiring Diagram 2 (activation unit in the cab) for message G00059 1153
Wiring Diagram 3 (12K403a & 12K403b) for message G00059 1154
Wiring Diagram 4 (pilot line interruption) for message G00059 1155
G00060 – Fire in the power house 1156
Wiring Diagram 1 (fire warning system) for message G00060 1157
Wiring Diagram 2 (fire warning system) for message G00060 1158
Wiring Diagram 3 (fire warning system) for message G00060 1159
G00063 – Trouble monitoring hydraulic oil temp 1160
Wiring Diagram (59B015) and REAL TIME MONITOR for message G00063 1161
G00064 – Trouble monitoring hydraulic oil level 1162
Wiring Diagram (40B004) for message G00064 1164
G00065 – Very low hydraulic oil level 1165
View onto the hydraulic oil level label 1165
G00066 – Trouble hydraulic oil temperature 1166
Hydraulic oil temperature table 1167
Wiring Diagram (57K506a-1/57K506b-1 & 57K506a-2/57K506b-2) and location for G00066 1168
G00067 – Trouble battery voltage too high 1169
Wiring Diagram (11T080) and component location at the X2 board 1170
Wiring Diagram (13T002 & 13T004) for message G00067 1171
Input signal of 11T080 on the REAL TIME MONITOR for message G00067 1172
G00068 – Trouble gear lubrication (PTO 2) 1172
G00069 – Trouble monitoring oil temperature gear (PTO 1) 1173
Input signal of 57B049-1 on the REAL TIME MONITOR (G00069) 1174
Gear oil temperature (PTO 1 & PTO 2) on the Main Gauge Screen 1174
Wiring Diagram (57B049-1 & 57B049-2) and component location (G00069 & G00083) 1175
G00070 – Trouble oil temperature gear (PTO 1) 1176
Location of the PTO gear oil level dipstick & temperature sensor 57B049-1/-2 1179
G00071 – Trouble gear lubrication (PTO 1) 1180
Wiring Diagram (57B017-1 & 57B017-2) for messages G00071 & G00068 1181
Input signal of 57B017-1 on the REAL TIME MONITOR for message G00071 1181
G00081 – Trouble lubrication system 1182
Operation cycles of the lubrication systems 1184
Wiring Diagram (11K050) for message G00081 1185
G00083 – Trouble monitoring oil temperature gear (PTO 2) 1186
G00084 – Trouble oil temperature gear (PTO 2) 1186
G00086 – SHUTDOWN 1186
G00090 – Trouble power supply 1187
Wiring Diagram (stabilized power supply) for messages G00090 & G00099 1188
Wiring Diagram (battery chargers) for messages G00090 & G00099 1189
G00091 – Pilot control cut out 1190
View onto the lock lever and the cover of 20S105 (G00091) 1191
G00092 – Emergency shut-down at access ladder 1192
G00093 – Emergency shut-down at valve block 1192
G00094 – Emergency shut-down at hydraulic control panel 1192
G00095 – Emergency shut-down in cabin 1192
Wiring Diagram (emergency switches) for G00092~G00095 & G00097 1194
G00096 – Pilot control cut out 1195
Wiring Diagram (20S094) for message G00096 1196
G00097 – Emergency shut-down at counterweight 1196
G00099 – Trouble power supply 1196
G00100 – Maintenance Safety Switch 1197
Wiring Diagram (50S058) for message G00100 1198
G00103 – Faulty switch 20M004 1199
Wiring Diagram 1 (windscreen wiper) for message G00103 1201
Wiring Diagram 2 (windscreen wiper) for message G00103 1202
G00107 – Trouble slew parking brake control 56K250a 1203
View onto the CoDeSys HMI Visualization screen for message G00107 1205
Wiring Diagram (56K250a & 56K250b) for message G00107 1206
G00108 – Trouble slew parking brake control Output to 56K250a 1207
View onto the CoDeSys HMI Visualization screen for message G00108 1209
Wiring Diagram (56K250a & 56K250b) for message G00108 1210
G00109 – Trouble slew parking brake control 56K250b 1211
G00110 – Trouble slew parking brake control Output to 56K250b 1211
G00111 – Trouble travel parking brake control 56K251a 1212
56K251a & 56K251b (relay check) on the REAL TIME MONITOR (G00111 & G00113) 1212
G00112 – Trouble travel parking brake control Output to 56K251a 1213
56K251a & 56K251b (output check) on the REAL TIME MONITOR (G00112 & G00114) 1213
G00113 – Trouble travel parking brake control 56K251b 1214
G00114 – Trouble travel parking brake control Output to 56K251b 1214
G00115 – Trouble slew hydraulic brake control 56K252a 1215
56K252a & 56K252b (relay check) on the REAL TIME MONITOR (G00115 & G00117) 1215
G00116 – Trouble slew hydraulic brake control Output to 56K252a 1216
56K252a & 56K252b (output check) on the REAL TIME MONITOR (G00116 & G00118) 1216
G00117 – Trouble slew hydraulic brake control 56K252b 1217
G00118 – Trouble slew hydraulic brake control Output to 56K252b 1217
G00119 – Trouble cable drum wind up control 91K257a 1218
91K257a & 91K257b (relay check) on the REAL TIME MONITOR (G00119 & G00121) 1218
G00120 – Trouble cable drum wind up control Output to 91K257a 1219
91K257a & 91K257b (output check) on the REAL TIME MONITOR (G00120 & G00122) 1219
G00121 – Trouble cable drum wind up control 91K257b 1220
G00122 – Trouble cable drum wind up control Output to 91K257b 1220
G00123 – Trouble cable drum unwind control 91K258a 1221
91K258a & 91K258b (relay check) on the REAL TIME MONITOR (G00123 & G00125) 1221
G00124 – Trouble cable drum wind up control Output to 91K258a 1222
91K258a & 91K258b (output check) on the REAL TIME MONITOR (G00124 & G00126) 1222
G00125 – Trouble cable drum unwind control 91K258b 1223
G00126 – Trouble cable drum wind up control Output to 91K258b 1223
G00127 – Trouble cable drum torque control 91K259a 1224
91K259a & 91K259b (relay check) on the REAL TIME MONITOR (G00127 & G00129) 1224
G00128 – Trouble cable drum torque control Output to 91K259a 1225
91K259a & 91K259b (output check) on the REAL TIME MONITOR (G00128 & G00130) 1225
G00129 – Trouble cable drum torque control 91K259b 1226
G00130 – Trouble cable drum torque control Output to 91K259b 1226
G00139 – Trouble monitoring X1-2 pressure 1227
G00140 – Trouble monitoring X1-1 pressure 1227
Wiring Diagram (57B085-1 & 57B085-2) for messages G00139 & G00140 1229
G00141 – Trouble monitoring X2 pressure 1230
Wiring Diagram (57B086) for message G00141 1232
G00147 – Trouble monitoring gear lubrication (PTO 1) 1233
G00150 – Trouble monitoring gear lubrication (PTO 2) 1233
Wiring Diagram (57B017-1 & 57B017-2) for messages G00147 & G00150 1236
G00151 – Trouble monitoring gear (PTO) oil filter 1 1237
Wiring Diagram (57B027-1/-2) and location for messages G00151 & G00193 1240
G00154 – Trouble monitoring return oil filter 1241
Wiring Diagram (40B163) for message G00154 1243
G00155 – Trouble monitoring leak oil filter 1244
Wiring Diagram (40B164) for message G00155 1246
G00159 – Trouble monitoring breather filter 1247
Wiring Diagram (40B024) for message G00159 1249
G00161 – Trouble monitoring battery voltage 1250
Wiring Diagram (11T080) and component location for message G00161 1252
G00165 – Trouble breather filter hydraulic oil tank 1253
Sight glass, hydraulic oil temperature information, and defined positions (G00165) 1254
G00166 – Trouble oil filter gear (PTO 1) 1256
Location of the PTO 1/2 gear oil filters with pressure sensors 57B027-1 & 57B027-2 1257
G00169 – Trouble return oil filter hydraulic oil tank 1258
G00170 – Trouble leak oil filter hydraulic oil tank 1259
G00176 – Trouble battery voltage too low 1260
Input signal of 11T080 on the REAL TIME MONITOR for message G00176 1261
Wiring Diagram (11T080) and component location at the X2 board 1262
Wiring Diagram (13T002 & 13T004) for message G00176 1263
G00179 – Trouble control pressure X1-1 1264
View onto the valve cartridge block for X1 pressure adjustment 1265
G00180 – Trouble pilot pressure X2 too low 1266
Valve cartridge block with X2 pressure sensor 57B086 & M1 2 1267
G00181 – Trouble pilot pressure X2 too high 1268
Control and filter panel 1 with X2 pressure sensor 57B086 & M3 1269
G00182 – Trouble control pressure X1-2 1269
G00184 (Sonar) – Central lubrication system empty 1270
Grease level (sonar, CLS 1 & SLS & CLS 2) on the REAL TIME MONITOR 1271
G00184 (Binary) – Central lubrication system empty 1272
G00185 – Trouble central lubrication system 1274
Allocation of vent valves and end-of-line switches 1275
Action chart for lube cycles 1276
View onto the vent valve (62Q507a – 62Q509a – 62Q642a) 1277
Wiring Diagram (60B043/62B046/80B043) for messages G00185/G00188/G00203 1278
G00186 – Trouble central lubrication system 1279
Allocation of vent valves 1279
Action chart for lube cycles 1280
View onto the vent valve (62Q507a – 62Q509a – 62Q642a) 1281
G00187 – Slew ring gear lubrication system empty 1282
G00188 – Trouble slew ring gear lubrication system 1282
G00189 – Trouble slew ring gear lubrication system 1282
G00191 – Trouble oil filter gear (PTO 2) 1282
G00193 – Trouble monitoring gear (PTO) oil filter 2 1282
G00201 – Attachment lubrication system empty 1282
G00202 (Sonar) – Attachment lubrication system grease level too low 1282
G00203 – Trouble attachment lubrication system 1282
G00204 – Trouble attachment lubrication system 1282
G00210 – Trouble electric motor 1 winding temperature 1283
G00211 – Trouble electric motor 2 winding temperature 1283
Wiring Diagram (motor winding temp monitoring – motor 1) for G00210 1284
Wiring Diagram (motor winding temp monitoring – motor 2) for G00211 1285
REAL TIME MONITOR for motor winding temperature, G00210 & G00211 1286
G00212 – Trouble electric motor 1 bearing temperature 1287
G00213 – Trouble electric motor 2 bearing temperature 1287
REAL TIME MONITOR for motor bearing temperature, G00212 & G00213 1288
Wiring Diagram (motor bearing temperature – motor 1 & 2), G00212 & G00213 1289
G00214 – Trouble transformer 1 temperature 1290
G00215 – Trouble transformer 2 temperature 1290
Wiring Diagram (temperature control for transformer A), message G00214 1291
REAL TIME MONITOR (net-line voltage & transformer temperature) for G00214 & 215 1292
G00216 – Trouble software not compatible 1293
G00218 – Switch off all motors for running transfer pump 1295
G00219 – Return oil tank empty 1296
Sensor 40B068 (return oil level) on the REAL TIME MONITOR 1296
G00220 – Trouble transfer pump motor overheated 1297
Wiring Diagram (transfer pump) for message G00220 1298
G00231 – Trouble pilot control lever 20S019 1299
G00232 – Trouble pilot control lever 20S020 1299
Wiring Diagram (20S019) for message G00231 1300
Wiring Diagram (20S020) for message G00232 1301
G00233 – Trouble pilot control 11Q045 1302
Wiring Diagram (11Q045) for message G00233 1303
G00234 – Trouble pilot control 11K111a 1304
11K111a & 11K111b (relay check) on the REAL TIME MONITOR (G00234 & G00236) 1304
G00235 – Trouble pilot control Output to 11K111a 1305
11K111a & 11K111b (output check) on the REAL TIME MONITOR (G00235 & G00237) 1305
G00236 – Trouble pilot control 11K111b 1306
G00237 – Trouble pilot control Output to 11K111b 1306
G00238 – Trouble supply by key switch 11Q044 1307
Input signal of 11Q044 on the REAL TIME MONITOR (G00238) 1307
Wiring Diagram (11Q044) for message G00238 1308
G00239 – Trouble electrical matter 1309
Wiring Diagram (12K403a/b) for message G00239 1310
G00240 – Trouble hydraulic oil temperature 1311
Hydraulic Oil Temperature Table 1312
G00241 – Motor 1 already running 1313
G00244 – Motor shutdown from ground 1314
Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00244) 1315
G00246 – Hydraulic oil temperature 1316
G00250 – Electric motor 2 already running 1316
G00252 – Emergency shut-down at access ladder 1317
G00253 – Emergency shut-down at valve block 1317
G00254 – Emergency shut-down at hydraulic control panel 1317
G00255 – Emergency shut-down in cabin 1317
Wiring Diagram (emergency switches) for G00252~G00255 & G00258 & G00355 1319
G00256 – Operator warning system 1320
G00257 – Hydraulic oil temperature 1321
Hydraulic Oil Temperature Table 1322
G00258 – Emergency shut-down at counterweight 1323
G00261 – Maintenance Safety Switch 1323
Wiring Diagram (50S058 and safety line) for message G00261 1324
G00262 – Trouble screen at hydr cooler entry clogged 1325
40B166 and 40B165 on the REAL TIME MONITOR (05 Hydraulic) 1325
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262) 1326
Wiring Diagram (40B166 & 40B165) for message G00262 1327
G00263 – Trouble monitoring motor 1 bearing temperature 1328
G00264 – Trouble monitoring motor 2 bearing temperature 1328
View onto the terminal box at motor side 1329
Wiring Diagram (motor bearing temperature – motor 1 & 2), G00263 & G00264 1330
G00265 – Trouble monitoring emergency voltage 1331
Wiring Diagram (12T082) for message G00265 1333
G00266 – Trouble emergency voltage too high 1334
Wiring Diagram (12T082) for message G00266 1335
Wiring Diagram (13T003) for message G00266 1336
Input signal of 12T082 on the REAL TIME MONITOR for message G00266 1337
G00267 – Trouble emergency voltage too low 1338
Wiring Diagram (12T082) for message G00267 1339
Wiring Diagram (13T003) for message G00267 1340
Input signal of 12T082 on the REAL TIME MONITOR for message G00267 1341
G00274 – Trouble monitoring motor 1 winding temperature 1342
G00276 – Trouble monitoring motor 2 winding temperature 1342
View onto the terminal box at motor side 1343
Wiring Diagram (motor winding temp monitoring – motor 1) for G00274 1344
Wiring Diagram (motor winding temp monitoring – motor 2) for G00276 1345
G00277 – Trouble high voltage capacitor 1 1346
Wiring Diagram (capacitor pressure monitoring) for G00277 & G00303 1347
Capacitor pressure (motor 1) on the REAL TIME MONITOR for message G00277 1347
G00278 – Earth fault tripped 1348
G00281 – Ground leakage tripped 1349
Wiring Diagram (12F431) for message G00281 1350
Wiring Diagram (continued) for message G00281 1351
G00285 – Trouble motor 1 1352
G00286 – Trouble motor 2 1352
Wiring Diagram (motor protection relays & node inputs) for message G00285/286 1354
Wiring Diagram (motor protection relay motor 1) for message G00285 1355
Wiring Diagram (motor protection relay motor 2) for message G00286 1356
G00287 – Trouble 3 phase current rotation direction 1357
Wiring Diagram (phase sequence monitoring) for message G00287 1358
Phase sequence relay on the REAL TIME MONITOR for message G00287 1359
G00288 – Trouble restart motor 1, temperature too high 1360
G00289 – Trouble restart motor 2, temperature too high 1360
G00290 – Trouble motor main relay 1 1361
Wiring Diagram (32Q701-1/-2) for messages G00290 & G00306 1362
Wiring Diagram (32Q701-1/-2 & nodes) for messages G00290 & G00306 1363
Wiring Diagram (safety circuit) for messages G00290 & G00306 1364
G00291 – Reverse travel cut out by cable drum 1365
Wiring Diagram (91B904a, 91B911, 91B919) for message G00291 1366
G00292 – Reverse travel left track cut out by cable drum 1367
G00293 – Reverse travel right track cut out by cable drum 1367
Wiring Diagram (diagonal cable pull) for messages G00292 & G00293 1368
G00294 – Forward travel cut out by cable drum 1369
Wiring Diagram (91B912 & 91B913, optional 91B914 & 91B915) for message G00294 1370
Wiring Diagram (91B904b) for message G00294 1371
G00295 – Trouble temperature cab base 1372
Cab base temperature on the REAL TIME MONITOR (G00295) 1372
Wiring Diagram (10B001) for message G00295 1373
G00296 – Trouble temperature high voltage cabinet 1374
HV-cabinet temperature on the REAL TIME MONITOR (G00296) 1374
G00301 – Trouble high voltage supply was interrupted 1375
Motor voltage (12T431-3) on the REAL TIME MONITOR (G00301) 1375
Wiring Diagram (12T431) for message G00301 1376
Wiring Diagram (continued) for message G00301 1377
G00303 – Trouble high voltage capacitor 2 1378
G00304 – Start Motor 1 blocked 1378
G00305 – Start Motor 2 blocked 1378
G00306 – Trouble motor main relay 2 1379
G00307 – Attention ! Cable drum ! 1379
G00308 – Trouble CAN-Bus or CAN-Hardware 1380
G00309 – Trouble ladder up 56K253a 1383
56K253a & 56K253b (relay check) on the REAL TIME MONITOR (G00309 & G00311) 1383
G00310 – Trouble ladder up Output to 56K253a 1384
56K253a & 56K253b (output check) on the REAL TIME MONITOR (G00310 & G00312) 1384
G00311 – Trouble ladder up redundant 56K253b 1385
G00312 – Trouble ladder up redundant Output to 56K253b 1385
G00313 – Trouble ladder down 56K254a 1386
56K254a & 56K254b (relay check) on the REAL TIME MONITOR (G00313 & G00315) 1386
G00314 – Trouble ladder down Output to 56K254a 1387
56K254a & 56K254b (output check) on the REAL TIME MONITOR (G00314 & G00316) 1387
G00315 – Trouble ladder down redundant 56K254b 1388
G00316 – Trouble ladder down redundant Output to 56K254b 1388
G00317 – Trouble service arm up 56K255a 1389
56K255a & 56K255b (relay check) on the REAL TIME MONITOR (G00317 & G00319) 1389
G00318 – Trouble service arm up Output to 56K255a 1390
56K255a & 56K255b (output check) on the REAL TIME MONITOR (G00318 & G00320) 1390
G00319 – Trouble service arm up redundant 56K255b 1391
G00320 – Trouble service arm up redundant Output to 56K255b 1391
G00321 – Trouble service arm down 56K256a 1392
56K256a & 56K256b (relay check) on the REAL TIME MONITOR (G00321 & G00323) 1392
G00322 – Trouble service arm down Output to 56K256a 1393
56K256a & 56K256b (output check) on the REAL TIME MONITOR (G00322 & G00324) 1393
G00323 – Trouble service arm down redundant 56K256b 1394
G00324 – Trouble service arm down redundant Output to 56K256 1394
G00325 – Trouble service arm Input 1395
G00326 – Trouble ladder Input 1395
G00327 – Trouble parking brake Input 1395
G00328 – Trouble start Input 1395
G00329 – Protection switch tripped 1398
Additional protection switches on the REAL TIME MONITOR (G00329) 1398
G00330 – Trouble pilot control 11Q111 1399
Wiring Diagram (11Q111/11K126) for message G00330 1401
G00334 -Trouble cab heater contactor 1402
Wiring Diagram for cab heating – 3 step heater regulation 1403
Wiring Diagram – additional cab heater at the cab wall 1404
Wiring Diagram – additional cab heater at the cab wall 1405
G00335 -Trouble cab heater safety relay 1406
Wiring Diagram (heater safety relays) for message G00335 1408
G00337 – Trouble motor on control 12K408a-1 1409
12K408a-1/-2 & 12K408b-1/-2 (relay check) on the REAL TIME MONITOR 1409
G00338 – Trouble motor on control Output to 12K408a-1 1410
12K408a-1/-2 & 12K408b-1/-2 (output check) on the REAL TIME MONITOR 1410
G00339 – Trouble motor on control 12K408b-1 1411
G00340 – Trouble motor on control Output to 12K408b-1 1411
G00341 – Trouble motor on control 12K408a-2 1411
G00342 – Trouble motor on control Output to 12K408a-2 1411
G00343 – Trouble motor on control 12K408b-2 1411
G00344 – Trouble motor on control Output to 12K408b-2 1411
G00345 – E-Motor 2 running 1412
G00346 – E-Motor 2 standstill 1412
G00347 – E-Motor 1 running 1413
G00348 – E-Motor 1 standstill 1413
G00354 – Emergency shut-down cable drum 1413
G00355 – Emergency shut-down cable drum 1413
G00417 – Communication failure PLC [MTC] <=> KOMTRAX Plus controller 1414
G00420 – Connector sel error 1415
G00421 – Farm sys error 1416
G00423 – Application sys error 1417
G00425 – Settings impossible to take over into the PLC [MTC] 1418
Wiring Diagram: KOMTRAX Plus monitor → KOMTRAX Plus controller → MTC 1419
G00491 – Communication failure MH800 <=> KOMTRAX Plus controller 1420
Wiring Diagram overview: MH800 <=> KOMTRAX Plus controller 1421
8 Troubleshooting by Symptoms 1423
8 1 Symptoms of the E-motors and related parts 1424
SEM001 – Starting the E-motor(s) is not possible 1424
Wiring Diagram (batteries and lock lever switch) for SEM001 1425
SEM002 – Stopping the E-motor(s) is not possible 1426
Wiring Diagram (motor stop switches) for SEM002 1427
SEM003 – E-motor has excessive vibration 1428
View onto the coupling for SEM003 1429
SEM004 – Abnormal noise coming from the E-motor(s) 1430
SEM005 – E-motor lacks output (low power) 1431
View onto the PM CLINIC sheet (power check) for SEM005 1432
SEM006 – Air-to-Air motor cooling system not sufficient 1433
Exemplary view onto the Air-to-Air motor cooling system for SEM006 1434
SEM007 – Motor shuts down during start 1435
Motor 1 – Signal flow from bottom to top (SEM007) 1436
Motor 2 – Signal flow from bottom to top (SEM007) 1437
Motor 1/2 – Signal flow from bottom to top continued (SEM007) 1438
Wiring Diagram – Motor 1 & 2 and capacitors (SEM007) 1439
SEM008 – Substation main circuit breaker tripped 1440
Net-line supply overview (SEM008) 1441
Electric energy consumption (SEM008) 1442
Motor current overview (SEM008) 1443
8 2 Symptoms of the Hydraulic System 1444
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 1444
SHY002 – No work equipment, travel or swing movement 1446
SHY003 – Work equipment has too much hydraulic drift 1447
SHY004 – Work equipment has big time lag 1448
SHY005 – Machine deviates during travel movement 1449
SHY006 – Machine does not swing 1450
SHY007 – Swing acceleration is poor 1451
SHY008 – Excessive overrun when stopping swing 1453
SHY009 – Floating system without function 1455
SHY010 – Abnormal noise coming from SRV or MRV 1456
SHY011 – Track tensioning system without function 1457
Track tensioning – overview (SHY011) 1458
SHY012 – Ladder does not move, or slow movement 1459
SHY013 – The hydraulic driven grease pump does not move 1461
SHY014 – Trouble pump bearing lubrication 1463
SHY015 – Abnormal track chain movement during digging 1464
SHY016 – Swing parking brake without function 1465
SHY017 – Travel parking brake without function 1466
8 3 Symptoms of the Mechanical System 1467
SME001 – Abnormal noise around the PTO / hydraulic pumps 1467
SME002 – There is a big shock when stopping swing 1469
SME003 – There is a big abnormal noise when moving/stopping swing 1470
SME004 – Abnormal noise coming from a travel gearbox 1472
SME005 – Abnormal noise coming from the work equipment (lack of grease) 1474
SME006 – Abnormal idler movement 1476
SME007 – Leak at the PTO shaft seal 1477
8 4 Symptoms of Additional Systems 1479
SAD001 – Air conditioner for the cabin does not work 1479
Exemplary view onto A/C test tools & A/C filling and service station 1480
Wiring Diagram – Cab heater control unit 20S026a (SAD001) 1481
Wiring Diagram – Air conditioner cab (SAD001) 1482
SAD002 – Air conditioner LV cabinet does not work 1483
Exemplary view onto A/C test tools & A/C filling and service station 1484
Wiring Diagram – Compressor drive LV switch cabinet (SAD002) 1485
Wiring Diagram – Air conditioner LV switch cabinet (SAD002) 1486
SAD003 – Air conditioner HV cabinet does not work 1487
Exemplary view onto A/C test tools & A/C filling and service station 1488
Wiring Diagram – Compressor drive HV switch cabinet (SAD003) 1489
Wiring Diagram – Air conditioner HV switch cabinet (SAD003) 1490
50 DISASSEMBLY & ASSEMBLY 1491
Overview 1493
TOC 1495
1 Introduction 1505
1 1 Contents of the binder 1506
1 2 Foreword 1507
1 2 1 Service 1508
2 Safety 1509
2 1 General information 1510
2 1 1 Method of using this manual 1510
2 2 Safety instructions 1512
2 2 1 General precautions 1512
2 2 2 Preparations before work 1514
2 2 3 Precautions during work 1515
2 2 3 1 Precautions with high pressure oil 1517
2 2 4 Warning of special dangers 1518
2 2 4 1 Electrical energy 1518
2 2 4 2 Gas, dust, steam and smoke 1519
2 2 4 3 Noise 1519
2 2 4 4 Oil, grease and other chemical substances 1519
2 2 4 5 Hydraulic, air conditioning and pneumatic equipment 1520
2 2 4 6 Heat 1520
2 2 4 7 Height 1520
2 2 5 Special safety equipment 1523
2 2 5 1 Safety harness in conformity with EN 361 (European standard) 1523
2 2 5 2 Instructions for use 1525
2 2 5 3 Recommendations for use of the holding hooks and hold-back hooks of the safety harness 1527
2 2 5 4 Instructions for using the fall absorber 1529
2 2 6 Safety hints for hydraulic hose installation 1530
2 2 7 Safety hints for Lifting heavy parts 1533
2 2 8 Safety hints for Wire ropes 1533
2 2 9 Safety hints for Sling accessory 1535
2 3 Grounding procedure of the high voltage system 1536
2 4 Explanation of abbreviations 1539
3 Superstructure 1541
3 1 Superstructure overview 1542
3 2 service crane (optional) 1545
3 2 1 Removal of the service crane 1545
3 2 2 Replacement of the service crane 1547
3 3 Engine house roof 1548
3 3 1 Removal of the roof plates 1548
3 3 2 Replacement of the roof plates 1554
3 3 3 front roof section 1555
3 3 3 1 Removal of the front roof plates 1555
3 3 3 2 Replacement of the front roof plates 1558
3 4 Batteries 1559
3 4 1 Removal of the batteries 1559
3 4 2 Replacement of the batteries 1561
3 5 Electric motors 1562
3 5 1 Removal of the front electric motor (Motor 1) 1562
3 5 2 Replacement of the front electric motor (motor 1) 1566
3 5 3 Removal of the rear electric motor (motor 2) 1568
3 5 4 Replacement of the rear electric motor (motor 2) 1568
3 5 5 Final alignment of the electric motors 1569
3 5 6 Capacitor assemblies 1572
3 5 6 1 Removal of the capacitor assembly (Motor 1) 1573
3 5 6 2 Replacement of the capacitor assembly (Motor 1) 1575
3 5 6 3 Removal of the capacitor assembly (Motor 2) 1575
3 5 6 4 Replacement of the capacitor assembly (Motor 2) 1575
3 6 Flexible coupling 1576
3 6 1 Vulkan coupling assembly 1576
3 6 1 1 Removal of the Vulkan coupling 1577
3 6 1 2 Replacement of the Vulkan coupling 1579
3 7 PTO 1580
3 7 1 Main pumps 1580
3 7 1 1 Removal of main pumps 1582
3 7 1 2 Replacement of main pumps 1585
3 7 2 PTO oil pumps (auxiliary pumps) 1587
3 7 2 1 Removal of the PTO oil pumps (auxiliary pumps) 1587
3 7 2 2 Replacement of the PTO oil pumps (auxiliary pumps) 1587
3 7 3 Pump distributor gearbox (PTO) 1588
3 7 3 1 Removal of the pump distributor gearbox (PTO) 1590
3 7 3 2 Replacement of the pump distributor gearbox (PTO) 1594
3 8 Hydraulics 1595
3 8 1 Hydraulic cooler fan drive pumps 1595
3 8 1 1 Removal of the hydraulic cooler fan drive pumps 1596
3 8 1 2 Replacement of the hydraulic cooler fan drive pumps 1598
3 8 2 Additional hydraulic oil cooler assembly 1599
3 8 2 1 Removal of the Additional hydraulic oil cooler fan assembly 1602
3 8 2 2 Replacement of Additional hydraulic oil cooler fan assembly 1605
3 8 2 3 Removal of Additional hydraulic oil cooler fans and motors 1606
3 8 2 4 Replacement of Additional hydraulic oil cooler fans and motors 1607
3 8 2 5 Removal of the Additional hydraulic oil coolers 1608
3 8 2 6 Replacement of the Additional hydraulic oil coolers 1611
3 8 2 7 Removal of the Additional hydraulic oil cooler assembly 1612
3 8 2 8 Replacement of Additional hydraulic oil cooler assembly 1614
3 8 3 Hydraulic oil cooler assembly 1616
3 8 3 1 Removal of the hydraulic oil cooler fan assemblies 1620
3 8 3 2 Replacement of hydraulic oil cooler fan assemblies 1624
3 8 3 3 Removal of the hydraulic oil cooler fan and motor 1626
3 8 3 4 Replacement of hydraulic oil cooler fan and motor 1628
3 8 3 5 Removal of the hydraulic oil coolers 1630
3 8 3 6 Replacement of the hydraulic oil coolers 1634
3 8 3 7 Removal of the hydraulic oil cooler assembly 1636
3 8 3 8 Replacement of the hydraulic oil cooler assembly 1640
3 8 4 Pilot oil pump (gear pump) 1641
3 8 4 1 Removal of the pilot oil pump 1641
3 8 4 2 Replacement of the pilot oil pump 1643
3 8 5 Main gate valve 1644
3 8 5 1 Removal of the main gate valve 1644
3 8 5 2 Replacement of the main gate valve 1645
3 8 6 Hydraulic oil reservoir 1646
3 8 6 1 Removal of the hydraulic oil reservoir 1648
3 8 6 2 Replacement of the hydraulic oil reservoir 1651
3 8 7 Main control valve blocks 1653
3 8 7 1 Removal of the main control valve blocks 1654
3 8 7 2 Replacement of the main control valve blocks 1657
3 8 8 Main relief valves (MRV) 1658
3 8 8 1 Removal of the MRV on the main control valve block 1658
3 8 8 2 Replacement of the MRV on the main control valve block 1659
3 8 9 Service line relief valves (SRV) 1660
3 8 9 1 Removal of the SRV on the manifold 1660
3 8 9 2 Replacement of the SRV on the manifold 1662
3 8 9 3 Removal of the SRV on the main control valve block 1663
3 8 9 4 Replacement of the SRV on the main control valve blocks 1665
3 8 10 Anti-cavitation valves (ACV) 1666
3 8 10 1 Removal of the ACV on the manifold 1667
3 8 10 2 Replacement of the ACV on the manifold 1671
3 8 10 3 Removal of the ACV on the main control valve blocks 1672
3 8 10 4 Replacement of the ACV on the main control valve blocks 1673
3 8 11 Throttle check valves 1674
3 8 11 1 Removal of the throttle check valves on the manifold 1678
3 8 11 2 Replacement of the throttle check valves on the manifold 1680
3 8 12 Manifold 1681
3 8 12 1 Removal of the manifold 1681
3 8 12 2 Replacement of the manifold 1683
3 9 Slew system 1685
3 9 1 Slew gear 1685
3 9 1 1 Removal of the Slew gear 1688
3 9 1 2 Replacement of the slew gear 1691
3 9 2 Swing motor 1694
3 9 2 1 Removal of the swing motor 1695
3 9 2 2 Replacement of the swing motor 1698
3 9 3 Slew parking brake 1701
3 9 3 1 Removal/disassembly of the slew parking brake (L&S) 1703
3 9 3 2 Replacement/assembly of the slew parking brake (L&S) 1706
3 9 3 3 Removal of the slew parking brake (Siebenhaar) 1709
3 9 3 4 replacement of the slew parking brake (Siebenhaar) 1712
3 9 4 Dynamic slew brake 1716
3 9 4 1 Removal of the slew brake valve 1719
3 9 4 2 Replacement of the slew brake valve 1721
3 9 5 swing circle 1722
3 9 5 1 Removal of the swing circle 1724
3 9 5 2 Replacement of the swing circle 1727
3 10 Lubrication system 1732
3 10 1 Swing circle lubrication pinion (dummy wheel) 1732
3 10 1 1 Removal of the lubrication pinion assembly 1734
3 10 1 2 Replacement of the lubrication pinion assembly 1736
3 10 2 Lubrication pump station 1738
3 10 2 1 Removal of the lubrication pump station 1742
3 10 2 2 Replacement of the lubrication pump station 1744
3 10 2 3 Removal of the lubrication pump 1745
3 10 2 4 Replacement of the lubricating pump 1747
3 11 Operator’s cab 1748
3 11 1 Removal of the operator’s cab 1751
3 11 2 Replacement of the operator’s cab 1756
3 11 3 Viscous cab-mounts 1758
3 11 3 1 Removal of the viscous cab-mounts 1758
3 11 3 2 replacement of the viscous cab-mounts 1760
3 11 4 Front window (windscreen) 1762
3 11 4 1 Removal of the front window 1762
3 11 4 2 Replacement of the front window 1763
3 11 5 Operator’s seat 1764
3 11 5 1 Removal of the operator’s seat 1764
3 11 5 2 Replacement of the operator’s seat 1765
3 11 6 ECS 1766
3 11 6 1 Removal of the ECS text display 1766
3 11 6 2 Replacement of the ECS text display 1766
3 12 Cab base (medium voltage switch cabinet) 1767
3 12 1 Removal of the cab base 1767
3 12 2 Replacement of the cab base 1770
3 12 3 Pump controller 1773
3 12 3 1 Removal of the pump controller 1773
3 12 3 2 Replacement of the pump controller 1774
3 13 Access ladder 1776
3 13 1 Removal of the access ladder 1779
3 13 2 Replacement of the access ladder 1783
3 13 3 Removal of the access ladder cylinder 1785
3 13 4 Replacement of the access ladder cylinder 1787
3 14 Counterweight 1788
3 14 1 Removal of the counterweight 1788
3 14 2 Replacement of the counterweight 1791
3 15 Superstructure lifting 1792
3 15 1 Lift the superstructure (platform, PN 910 605 40 only) 1792
3 15 2 Dump the superstructure (platform, PN 910 605 40 only) 1795
3 15 3 Remove the superstructure from the undercarriage 1796
3 15 4 Install the superstructure onto the undercarriage 1801
3 16 High voltage switch cabinet 1805
3 16 1 Removal of the high voltage switch cabinet 1806
3 16 2 Replacement of the high voltage switch cabinet 1810
3 17 Slip ring unit 1812
3 17 1 Removal of the slip ring unit 1813
3 17 2 Replacement of the slip ring unit 1817
4 Undercarriage 1819
4 1 Undercarriage overview 1820
4 2 Travel system 1822
4 2 1 Track group 1822
4 2 1 1 Changing of the track group 1822
4 2 2 Sprocket 1827
4 2 2 1 Removal of the sprocket assembly 1827
4 2 2 2 Replacement of the sprocket assembly 1832
4 2 3 Guide wheels (idlers) 1834
4 2 3 1 Removal of the guide wheel assembly 1834
4 2 3 2 Replacement of the guide wheel assembly 1836
4 2 4 Track tensioning accumulators 1837
4 2 4 1 Removal of the low pressure accumulators 1837
4 2 4 2 Replacement of the low pressure accumulators 1839
4 2 4 3 Removal of the high pressure accumulators 1840
4 2 4 4 Replacement of the high pressure accumulators 1841
4 2 5 Track tensioning valve block 1842
4 2 5 1 Removal of the track tensioning valve block 1842
4 2 5 2 Replacement of the track tensioning valve block 1844
4 2 6 Track tensioning cylinders 1845
4 2 6 1 Removal of the track tensioning cylinders 1845
4 2 6 2 Replacement of the track tensioning cylinders 1847
4 2 7 Substitute the Hydraulic hoses of the track tensioning system 1849
4 2 7 1 Substitute the hydraulic hoses inside the car body 1851
4 2 7 2 Substitute the hydraulic hose between car body and crawler frame 1851
4 2 7 3 Substitute the hydraulic hoses inside the crawler frame 1853
4 2 7 4 Subsequent work 1854
4 2 8 Travel brake valve block (overspeed valve) 1855
4 2 8 1 Removal of the travel brake valve block 1858
4 2 8 2 Replacement of the travel brake valve block 1860
4 2 9 Travel motor 1861
4 2 9 1 Removal of the travel motors 1861
4 2 9 2 Replacement of the travel motors 1863
4 2 10 Travel parking brake 1864
4 2 10 1 Removal of the travel parking brake 1866
4 2 10 2 Replacement of the travel parking brake 1869
4 2 11 Travel gearbox 1875
4 2 11 1 Removal of the travel gearbox 1876
4 2 11 2 Replacement of the travel gearbox 1879
4 2 12 Carrier roller 1881
4 2 12 1 Removal of the carrier roller assembly 1881
4 2 12 2 Replacement of the carrier roller assembly 1884
4 2 13 Track roller 1885
4 2 13 1 Removal of the track roller assembly 1885
4 2 13 2 Replacement of the track roller assembly 1887
4 3 Car body 1888
4 3 1 Removal of the car body and the crawler carriers (type with mounting pins) 1888
4 3 2 Replacement of the car body and the crawler carriers (type with mounting pins) 1892
4 3 3 Removal of the car body and the crawler carriers (type with bolted connection) 1896
4 3 4 Replacement of the car body and the crawler carriers (type with bolted connection) 1899
4 3 4 1 Tightening torque for the crawler carrier mounting bolts 1902
4 3 5 Rotary joint 1906
4 3 5 1 Removal of the rotary joint 1908
4 3 5 2 Replacement of the rotary joint 1911
4 4 Cable drum assembly 1912
4 4 1 Removal of the cable drum assembly 1913
4 4 2 Replacement of the cable drum assembly 1915
5 Attachment 1917
5 1 Face Shovel (FSA) 1918
5 1 1 FSA Overview 1918
5 1 2 Using the installation tools for hydraulic cylinders 1919
5 1 3 Boom 1920
5 1 3 1 Removal of the boom 1920
5 1 3 2 Replacement of the boom 1925
5 1 3 3 Removal of the boom cylinders 1930
5 1 3 4 Replacement of the boom cylinders 1935
5 1 4 Stick 1938
5 1 4 1 Removal of the stick 1938
5 1 4 2 Replacement of the stick 1942
5 1 4 3 Removal of the stick cylinders 1946
5 1 4 4 Replacement of the stick cylinders 1951
5 1 5 Bull clam bucket 1954
5 1 5 1 Removal of the bull clam bucket 1956
5 1 5 2 Replacement of the bull clam bucket 1960
5 1 5 3 Removal of the bucket cylinders 1962
5 1 5 4 Replacement of the bucket cylinders 1967
5 1 5 5 Removal of the clam cylinders 1972
5 1 5 6 Replacement of the clam cylinders 1976
5 1 6 Ground engaging tools (GET) 1980
5 1 6 1 Removal and replacement of the GET 1982
5 1 7 Hydraulic hoses at the face shovel attachment 1984
5 1 7 1 Substitute the boom arc hoses 1984
5 1 7 2 Substitute the boom cylinder hoses 1988
5 1 7 3 Substitute the stick arc hoses 1992
5 1 7 4 Substitute the stick cylinder hoses 1998
5 1 7 5 Substitute the bucket cylinder hoses 2002
5 1 7 6 Substitute the clam cylinder hoses 2008
5 2 Metering valves (grease injectors) at the attachment 2016
5 2 1 Check the operation of the metering valves (grease injectors) 2017
5 2 2 Removal of the metering valves (grease injectors) 2018
5 2 3 Replacement of the metering valves (grease injectors) 2019
5 3 Cylinder bypass test 2020
6 Service information 2023
6 1 Fluids and lubricants 2024
6 2 Filling capacities 2025
6 3 Work instructions 2026
6 3 1 Remove / install the crawler carrier 2026
6 4 Weight tables 2027
6 4 1 Superstructure 2027
6 4 1 1 Undercarriage 2030
6 4 1 2 Face shovel attachment (FSA) 2031
6 5 Torque charts according to ISO 2032
6 5 1 Metric standard thread 2032
6 5 2 Metric fine thread 2033
6 5 3 SAE flange connections 2034
6 6 Blind plugs 2036
6 6 1 Dummy plates for SAE-flanges 2036
6 6 2 Classification of threads to the nominal width 2038
6 6 3 Plugs and fittings according to EN ISO 84 34-1 2039
6 7 Conversion table 2040
6 7 1 Method of using the conversion table 2040
6 7 2 Millimeter – Inch & Kilogram – Pound 2041
6 7 3 Liter – U S Gallon & Liter – U K Gallon 2042
6 7 4 Nm- ft lb 2043
6 7 5 Bar – PSI – kPa – MPa 2044
6 7 6 Basic Values in Ohm according to DIN 4376 / IEC 751 2045
6 7 7 Temperature 2046
6 8 Tools 2047
6 8 1 Standard tool case 2047
6 8 2 Used special tools (overview) 2049
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