Manual Pc 5500.pdf

SHOP 15016-upE-GB-1

Shop Manual

HYDRAULIC EXCAVATOR

PC5500E-6 Serial Number 15016 and up

SHOP XS(*%

SHOP MANUAL

CONTENTS OF SHOP MANUAL

Binder 1 00

FOREWORD

01

SPECIFICATIONS

10

STRUCTURE, FUNCTION

40

TROUBLESHOOTING (WITHOUT CONTENT)

Binder 2 50

ASSEMBLY AND DISASSEMBLY

Table of contents

SHOP MANUAL

SHOP 15016-upE-GB-0

HYDRAULIC EXCAVATOR PC5500E-6

Machine model PC5500E-6

Serial number 15016 and up

00 Foreword

PC3000-6

1

1.1 CONTENTS OF THE BINDER

1.1

CONTENTS OF THE BINDER

Assembled in this file are the Operation- and Maintenance Manuals for your KOMATSU Mining Shovel.

4

INTRODUCTION

INTRODUCTION

1.2

1.2 DIVISION OF THE BINDER

DIVISION OF THE BINDER

Part 1: Operation Manual Part 2: Maintenance Manual Part 3: Depending on the volume of Part 3 a second Binder "Volume 2" is being delivered with the Shovel. This Binder contains the General Assembly Procedure Manual for the Shovel, Specification Booklet, Service Literature for the Power Unit (Diesel Engine or Electric Motor) and for Special Equipment. The Electrical- and Hydraulic Diagrams are attached in the pocket of the front cover. Refer to the -TABLE OF CONTENTS VOLUME 2 BINDERfor details.

Read the Manuals before You Start the Engine. Before operating the machine, familiarize yourself with its instruments and controls. Observe the instructions in these manuals for: ●

your Personal SAFETY

●

Operating SAFETY, and

●

READY an d E FFICIENT P ERFORMANCE KOMATSU Shovel.

of y our

Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses. Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If you have any questions concerning this literature please contact Komatsu Mining Germany GmbH Service Information Department 8151.30 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY

5

1.3 DESIGNATED USE OF THE SHOVEL

1.3

DESIGNATED USE OF THE SHOVEL

This machine h as been ma nufactured in accor dance with advanced and up-to-date technology standards including recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property. The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual. Only trained safety-conscious operators who are fully aware of the risks involved should operate the machine. Any functional disorders, especially those affecting the safety of the machine, should, therefore, be rectified immediately. The hydraulic Shovel is designed exclusively for excavating, i.e. excavation of bulk material and natural soil structure (e.g. earth, clay, sand and stones ashore and off-shore). Observe local and national safety regulations. Special conditions at the worksite require additional safe working precautions, follow your company's safety instructions. Short traveling distances for changing the working site are considered as part of the designated use of the Shovel. Using the Shovel for purposes other than those mentioned above (such as object handling and use as a transport vehicle) is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. WARNING Special use of the Shovel beyond its designated use, e.g. object handling operations, require written agreement from the manufacturer and retrofitment of the Shovel with respective safety related equipment before such special applications are permitted.

6

INTRODUCTION

INTRODUCTION

1.4

1.4 DELIVERY OF THE SHOVEL

DELIVERY OF THE SHOVEL

The Shovel is being delivered disassembled into its main components. For assembling the Shovel refer to the ”General Assembly Procedure Manual” in Volume 2 Service Literature Binder. WARNING ●

●

Improper a ssembling o f t he S hovel can c ause s erious accidents with personal injury or death. Personnel e ntrusted with wor k on the m achine must have read the Assembly Manual, the Operation- and Maintenance Manual and in particular the section on safety before beginning work. Reading the instructions after work has begun is too late. If there are any questions concerning safe assembling procedure, contact your local Komatsu Service Organization.

Prior to first operation, inspect the Shovel thoroughly with the Service Engineer responsible for the erection of the machine. Check all fluid levels according to the Lubrication and Maintenance Schedule. Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee. NOTICE If the Shovel is equipped with a fire suppression system, make sure that the system is ready for operation.

SPARE PARTS For your spare part orders refer to the Parts Catalogue. In order to keep your Shovel in first-class operating condition use only genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee.

SERVICE For all questions related to your Shovel please contact your local Service Center. In all your written or phoned inquiries please indicate the model and serial number of your Shovel.

7

1.5 EXPLANATION OF ABBREVIATIONS

1.5

EXPLANATION OF ABBREVIATIONS

ABB

Definition

A

Ampere

AC

Alternating Current

API

American Petroleum Institute

cSt

Centistoke

°C

Degree Celsius

CENSE

Engine Monitoring System

CLS

Central Lubrication System

DC

Direct Current

DIN

German Institute for Standardization

EBL

Electronic Bucket Levelling System

ECM

Electronic Control Module (Engine)

FGPS

Front Guard Protective Structure

FOPS

Falling-Object Protective Structure

GL

Gear Lubricant

h

hours of operation

HPF

High Pressure Filter (Hydraulic Oil)

HT

High Tension

LED

Light Emitting Diode

LT

Low Tension

N

Newton

Nm

Newton meter

QSK

Type of Engine Fuel System

PLC

Programmable Logic Controller

PM

Planned Maintenance

ppm

parts per million

PTO

Power Take-Off (Pump Distributor Gear)

SLS

Swing circle pinion Lubrication System

V

Volt

VHMS

Vehicle Health Monitoring System

1/min

Revolutions Per Minute (RPM)

8

INTRODUCTION

SAFETY

2 SAFETY

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS INJURY OR DEATH. Please read and make sure that you fully understand the precautions described in this section and the safety labels on the machine. When operating or servicing the machine, always follow these precaution strictly.

2 -1

SAFETY

CONTENTS 2.1

SAFETY INFORMATION ................................................................................................................... 2-3

2.2

OVERVIEW......................................................................................................................................... 2.2.1 NORMAL OPERATIONS ....................................................................................................... 2.2.2 REGULAR MAINTENANCE................................................................................................... 2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................... 2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR.........................................................................

2-4 2-4 2-4 2-4 2-4

2.3

SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB. .............................................................. 2-5

2.4

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................... 2-6 2.4.1 UNDERSTANDING THE MACHINE ...................................................................................... 2-6 2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................... 2-6 2.4.2.1 ENSURING SAFE OPERATION............................................................................ 2-6 2.4.3 PREPARATIONS FOR SAFE OPERATION.......................................................................... 2-6 2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT........................ 2-6 2.4.3.2 INSPECTING THE MACHINE................................................................................ 2-6 2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.................. 2-7 2.4.3.4 KEEP MACHINE CLEAN ....................................................................................... 2-7 2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT ................................... 2-7 2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ........................................ 2-8 2.4.3.7 IF A PROBLEM IS FOUND .................................................................................... 2-8 2.4.4 FIRE PREVENTION............................................................................................................... 2-8 2.4.4.1 PRECAUTIONS TO PREVENT FIRE .................................................................... 2-8 2.4.4.2 ACTION IF FIRE OCCURS.................................................................................... 2-9 2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB................................................. 2-10 2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 2-10 2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ....................................... 2-10 2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE............................................................................................................. 2-10 2.4.6.2 NO JUMPING ON OR OFF THE MACHINE ........................................................ 2-10 2.4.6.3 NO PEOPLE ON THE ATTACHMENT ................................................................ 2-10 2.4.6.4 WORKING IN HIGH PLACES .............................................................................. 2-10 2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK ...................................................... 2-11 2.4.6.6 LEAVING THE MACHINE .................................................................................... 2-11 2.4.7 BURN PREVENTION........................................................................................................... 2-11 2.4.7.1 HOT COOLANT .................................................................................................. 2-11 2.4.7.2 HOT OIL .............................................................................................................. 2-12 2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .......................................... 2-12 2.4.8.1 UNAUTHORIZED MODIFICATION...................................................................... 2-12 2.4.9 PRECAUTIONS AT JOBSITE.............................................................................................. 2-14 2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT ............................................................. 2-15 2.4.9.2 CAMERA SYSTEM WITH MONITORS................................................................ 2-15 2.4.9.3 ENSURE GOOD VISIBILITY................................................................................ 2-15 2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS............................................ 2-15 2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.................................... 2-16 2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES .......................................... 2-16 2.4.9.7 WORKING ON LOOSE GROUND ....................................................................... 2-17 2.4.9.8 GAS, DUST, STEAM AND SMOKE ..................................................................... 2-17 2.4.9.9 VENTILATION OF ENCLOSED AREAS.............................................................. 2-18

2 -2

SAFETY

2.5

2.6

2.4.10 STARTING ENGINE ............................................................................................................ 2.4.10.1 WARNING TAG ................................................................................................... 2.4.10.2 CHECKS BEFORE STARTING ENGINE ............................................................ 2.4.10.3 PRECAUTION WHEN STARTING ENGINE........................................................ 2.4.10.4 PRECAUTION IN COLD AREAS ......................................................................... 2.4.11 OPERATION........................................................................................................................ 2.4.11.1 CHECKS BEFORE OPERATION ........................................................................ 2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE ............... 2.4.11.3 PRECAUTIONS WHEN TRAVELLING ................................................................ 2.4.11.4 TRAVELLING ON SLOPES ................................................................................. 2.4.11.5 OPERATIONS ON SLOPES................................................................................ 2.4.11.6 PROHIBITED OPERATIONS............................................................................... 2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES....................... 2.4.11.8 PARKING THE MACHINE ................................................................................... 2.4.11.9 TRANSPORTATION ............................................................................................

2-19 2-19 2-19 2-19 2-20 2-20 2-20 2-21 2-22 2-23 2-24 2-24 2-25 2-25 2-25

PRECAUTION FOR MAINTENANCE.............................................................................................. 2.5.1 GENERAL PRECAUTIONS ................................................................................................. 2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES ............................................................................................ 2.5.1.2 STOP ENGINE FOR MAINTENANCE ................................................................. 2.5.1.3 WARNING TAG ................................................................................................... 2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY ............................................................. 2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS ..................................... 2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING ............................................................................................................ 2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS ............................... 2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT........................................................................................................ 2.5.1.9 NOISE .................................................................................................................. 2.5.1.10 WHEN USING A HAMMER ................................................................................. 2.5.1.11 PROPER TOOLS................................................................................................. 2.5.1.12 ACCUMULATOR ................................................................................................. 2.5.1.13 PERSONNEL ....................................................................................................... 2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 2.5.2.1 PRECAUTION WHEN WELDING ........................................................................ 2.5.2.2 BATTERY HANDLING ......................................................................................... 2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE ................................................ 2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES .......................................... 2.5.3.3 REPLACEMENT OF HOSE LINES...................................................................... 2.5.3.4 INSPECTION OF HOSE LINES........................................................................... 2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ............................ 2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE............................................................... 2.5.3.7 AIR CONDITIONING MAINTENANCE ................................................................ 2.5.3.8 COMPRESSED AIR............................................................................................. 2.5.3.9 WASTE MATERIALS ...........................................................................................

2-26 2-26 2-27 2-28 2-28 2-29 2-30 2-30 2-30 2-31 2-31 2-31 2-32 2-32 2-32 2-32 2-32 2-33 2-34 2-34 2-34 2-34 2-35 2-35 2-36 2-36 2-36 2-37

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 2 -3

SAFETY

2.6.3 2.7

2 -4

ADJUSTMENTS................................................................................................................... 2-38 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 2-38

SPECIAL SAFETY EQUIPMENT..................................................................................................... 2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ................ 2.7.2 OBJECT HANDLING ........................................................................................................... 2.7.3 LIGHTING ............................................................................................................................ 2.7.4 WARNING BEACON............................................................................................................ 2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) .................................................................................. 2.7.5.2 INSTRUCTIONS FOR USE ................................................................................. 2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL ......................... 2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), .................................... 2.7.5.5 INSTRUCTIONS FOR USE .................................................................................

2-40 2-41 2-41 2-41 2-41 2-41 2-41 2-43 2-45 2-45 2-47

SAFETY

2.1

SAFETY INFORMATION

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. 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.

DANGER This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE This signal word is used to alert you to information that must be followed to avoid damage to the machine. This precaution is given where the machine may be damaged or the service life reduced if the precaution is not followed.

2 -5

OVERVIEW

2.2

SAFETY

OVERVIEW

The appropriate safety information for specific working modes on the excavator can be found in the following:-

2.2.1

NORMAL OPERATIONS

–

For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.

–

For operational safety information, refer to section 2.4 on page 3-8.

–

For on site safety information, refer to section 2.4.9 on page 3-16.

2.2.2

REGULAR MAINTENANCE

–

For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section of the Operation and Maintenance Manual.

–

For maintenance safety information, refer to section 2.5 on page 3-28.

2.2.3

TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

–

For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 3-40.

–

For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through Komatsu Mining Germany.

–

For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through Komatsu Mining Germany.

2.2.4 –

ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR

Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional safety precautions given in the ASSEMBLY PROCEDURE MANUAL.

2 -6

SAFETY

2.3

SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.

SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.

Fig. 3-1 The sound pressure level in the operator’s cab is measured according to ISO 6396 (Dynamic test method). The sound pressure value is also shown on the decal attached to the wall inside the operator’s cab, see Fig. 3-1.

2 -7

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

WARNING WHEN MISUSED, THESE MACHINES ARE DANGEROUS. Mistakes in operation, inspection, or maintenance may result in personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.

2.4.1

UNDERSTANDING THE MACHINE

Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not understand, ask the person in charge of safety to give an explanation.

2.4.2

PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR

2.4.2.1 ENSURING SAFE OPERATION –

Only trained and authorized personnel can operate and maintain the machine.

–

During operations, personnel are not allowed outside of the operator’s cabin.

–

Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance on the machine.

–

If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.

–

When working with another operator or with a person on worksite traffic duty, discuss the content of the operation beforehand and use pre-determined signals when carrying out these operations.

2.4.3

PREPARATIONS FOR SAFE OPERATION

2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT –

Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired immediately if they are damaged.

–

Understand the method of use of safety features and use them properly.

–

Never remove any safety features. Always keep them in good operating condition.

2.4.3.2 INSPECTING THE MACHINE Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs of the problem location have been completed.

2 -8

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT –

Do not wear loose clothing and accessories. If these catch on the control levers or moving parts, there is a danger that it may cause the machine to move unexpectedly.

–

Always wear a hard hat and safety shoes when working on the machine outside of the cabin. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs and a safety belt when operating or maintaining the machine (Fig. 3-2).

–

If you have long hair and it hangs out from your hard hat, there is a hazard that it may get caught up in the machine, so tie your hair up and be careful not to let it get caught.

–

Check that all protective equipment functions properly before using it.

Fig. 3-2

2.4.3.4 KEEP MACHINE CLEAN –

If you get on or off the machine or carry out inspection or maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machines clean.

–

If water gets into the electrical system (Fig. 3-3), there is a hazard that it will cause malfunctions or a misoperation. If there is any misoperation, there is a danger that the machine may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical components. Fig. 3-3

2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT –

When entering the operator’s compartment, always remove all mud and oil from your shoes. If you operate the pedal with mud or oil affixed to your shoes, you may slip and this may cause a serious accident.

–

Do not leave tools or machine parts lying around inside the operator’s compartment. If tools or parts get into the control devices, they may obstruct operation and cause the machine to move unexpectedly, resulting in serious personal injury or death.

–

Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.

–

Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which could cause serious personal injury or death.

–

Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.

2 -9

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

SAFETY

2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT Always follow the precautions below to prepare for action if any injury or fire should occur. –

Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies.

–

Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used.

–

Provide a first aid kit. Carry out periodic checks and add to the contents if necessary (Fig. 3-4).

Fig. 3-4

2.4.3.7 IF A PROBLEM IS FOUND If you find any problems in the machine during operation and maintenance (noise, vibration, smell, incorrect gauges, smoke, oil, leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.

2.4.4

FIRE PREVENTION

2.4.4.1 PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, antifreeze, or window washer fluid. Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer fluid. There is a danger they may catch fire. To prevent fire, always observe the following: – Do not smoke or use any flame near fuel or other flammable substances. (Fig. 3-5) – Stop the engines before adding fuel. – Do not leave the machine while adding fuel or oil. – Tighten all fuel and oil caps securely. – Be careful not to spill fuel on overheated surfaces or on parts of the electrical system. – After adding fuel or oil, wipe up any spillage. – Put greasy rags and other flammable materials into a safe container to maintain safety in the workplace. – When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline. There is a danger that they may catch fire.

Fig. 3-5

– Do not weld or use a cutting torch to cut any pipe or tubes that contain flammable liquids. – Determine well ventilated areas for storing oil and fuel. Keep the oil and fuel in the determined place and do not allow unauthorised persons to enter. REMARKS: Before carrying out grinding or welding work on the machine, remove any flammable materials.

2 - 10

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

–

Fire caused by accumulation of flammable material. Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or affixed around the engines, exhaust manifold, muffler or battery, or inside the undercovers.

–

Fire coming from electrical wiring Short circuits in the electrical system can cause fire. To prevent fire, always observe the following: – Keep all electrical connections clean and securely tightened. – Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring.

–

Fire coming from piping Check that all hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or death.

–

Explosion caused by lighting equipment – When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications. – When taking the electrical power for the lighting from the machine itself, follow the instructions of this manual.

2.4.4.2 ACTION IF FIRE OCCURS –

Activate the STOP switch to stop the engine.

–

Use the access ladders and steps to get off the machine.

–

If it is impossible to escape from the rear of the cab, use the rope ladder provided for emergency escape to escape from the side of the cab. (Fig. 3-6.)

Fig. 3-6

–

After escaping with the emergency escape ladder, activate the engine stop chains (1 on Fig. 3-7) to shut down the engine if they are equipped on your shovel.

Fig. 3-7

2 - 11

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

SAFETY

2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB If the cab door does not open, use the sliding window for an emergency escape. On machines without a sliding window, use the emergency escape hammer to break the window glass and use the window as an emergency escape.

2.4.5

PRECAUTIONS WHEN CLEANING CAB GLASS

Always keep the cab glass clean to ensure good visibility when operating. Use an ethyl alcohol based washer liquid. Methyl alcohol based liquid may irritate your eyes, so do not use it. If the cab glass on the work equipment side is broken, there is a hazard that the intruding objects may contact the operator's body directly. Stop operation immediately and replace the glass.

2.4.6

PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE

2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE To prevent personal injury caused by slipping or falling off the machine, always do as follows. –

Always use the handrails and steps when getting on or off the machine.

–

To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot - see Fig. 3-8). with the handrails and steps to ensure that you support yourself.

–

When walking around the machine, where possible, move only in areas that have non-slip padded walkways and nonslip gratings. Extra care is to be taken when moving around outside of these areas.

–

Before getting on or off the machine, check the handrails and steps. If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.

Fig. 3-8

2.4.6.2 NO JUMPING ON OR OFF THE MACHINE –

Never jump on or off the machine. Never get on or off a moving machine.

–

If the machine starts to move when there is no operator on the machine, do not jump onto the machine and try to stop it.

2.4.6.3 NO PEOPLE ON THE ATTACHMENT Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment. There is danger of falling and suffering serious personal injury. For further information refer to section 2.7 on page 3-42.

2.4.6.4 WORKING IN HIGH PLACES When working in high places, use safety harness and fall absorber to ensure that the work can be carried out safely. For further information refer to section 2.7 on page 3-42.

2 - 12

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK –

Before standing up from the operator's seat in order to adjust the seat, always lower the work equipment to the ground, turn off the engine, relieve the pressure in the hydraulic system and set lock lever to LOCK position (L, Fig. 3-9.). If the lock is not applied, there is danger of serious personal injury if the work equipment control levers are touched by mistake and the machine moves suddenly. For information on relieving the pressure in the hydraulic system, refer to chapter ’RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the ’OPERATION’ part of this manual.

Fig. 3-9

2.4.6.6 LEAVING THE MACHINE –

When leaving the machine, always lower the work equipment completely to the ground, turn off the engine, relieve the pressure in the hydraulic system and set lock lever (1) securely to the LOCK position (L), then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place (Fig. 3-10). For information on relieving the pressure in the hydraulic system, refer to chapter ’RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the ’OPERATION’ part of this manual.

Fig. 3-10

2.4.7

BURN PREVENTION

2.4.7.1 HOT COOLANT –

To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap (Fig. 3-11 and Fig. 3-12) by hand before starting the operation. Even when the coolant has cooled down, loosen the cap slowly to relieve the pressure inside the radiator before removing the cap.

Fig. 3-11

2 - 13

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

SAFETY

2.4.7.2 HOT OIL –

To prevent burns from hot oil spurting out when checking or draining the oil, wait for the oil to cool to a temperature where it is possible to touch the cap or plug by hand before starting the operation (Fig. 3-12). Even when the oil has cooled down, loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.

Fig. 3-12

2.4.8

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

On jobsites where there is a hazard that falling objects (Fig. 3-13), flying objects (Fig. 3-14), or intruding objects may hit or enter the operator's cab, consider the operating conditions and install the necessary guards to protect the operator. –

When carrying out operations in mines or quarries where there is danger of falling or flying rocks, order/use the optionally available front guard.

–

When carrying out the above operations, always ensure that bystanders are a safe distance away and are not in hazard from falling or flying objects.

–

The above recommendations assume that the conditions are Fig. 3-13 for standard operations, but it may be necessary to add additional guards according to the operating conditions on the jobsite. Always contact your Komatsu distributor for advice.

Fig. 3-14

2.4.8.1 UNAUTHORIZED MODIFICATION –

Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting in modifications made without authorisation from Komatsu.

–

Any modifications made without authorisation from Komatsu can create hazards. Before making a modification, consult your komatsu distributor.

–

Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.

2 - 14

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

Please continue reading on the next page.

2 - 15

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.9

Fig. 3-15

2 - 16

PRECAUTIONS AT JOBSITE

SAFETY

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT

WARNING THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGEROUS! Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of man and equipment is always ensured.

Fig. 3-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels. The grey shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operator’s seat, and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from outside surface of the shovel. Please be fully aware that there are places that can not seen when operating the machine. REMARKS: The blind areas (A) differ depending on the machine type, attachment and position of attachment. The International Standard ISO 5006 defines criteria for Operator’s visibility. This standard is not met and does not apply to large hydraulic mining shovels.

2.4.9.2 CAMERA SYSTEM WITH MONITORS Komatsu Mining Germany offers optionally camera systems and monitors to improve the overall visibility. See latest version of the OMM for typical arrangement of cameras and monitors. The camera system can be installed ex works and can also be retrofitted in the field. If you need more information, please contact your local Komatsu distributor.

2.4.9.3 ENSURE GOOD VISIBILITY When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the following items strictly. –

If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful attention to the signs and follow the instructions of the flagman.

–

The signals should be given only by one flagman.

–

When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set up additional lighting in the area.

–

Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.

–

Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view to ensure good visibility.

–

In areas where it is impossible to confirm the area around the machine and observation cameras have been set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of the machine.

2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS –

Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.

–

Only one signalman should give signals.

Make sure that all workers understand the meaning of all signals and signs before starting work. 2 - 17

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

SAFETY

2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting operations, always check the following to confirm there are no dangers on the jobsite. –

When carrying out operations near combustible materials, there is a hazard of fire, so be careful when operating.

–

Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do not operate where there is a hazard of landslides or falling rocks.

–

If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or damage any of these lines (Fig. 3-16).

–

Take necessary measures to prevent any unauthorized person from entering the operating area.

–

If there is a fire near the machine, there is danger of sparks being sucked in and causing a fire on the machine.

–

When travelling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations.

–

Maintain the travel path on the jobsite so that there is no obstruction to travel operations.

Fig. 3-16

2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES

DANGER HIGH VOLTAGE! Do not travel or operate the machine near electric cables (Fig. 3-17). There is a hazard of electric shock, which may cause serious injury or property damage. Even going close to high-voltage cables can cause an electric shock, which may cause serious burns or even death.

Fig. 3-17

2 - 18

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

On jobsites where the machine may go close to electric cables, always do as follows. –

Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.

–

Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations.

–

To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body.

–

Use a signalman to give warning if the machine approaches too close to the electric cables.

–

When carrying out operations near high voltage cables, do not let anyone near the machine.

–

If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone near the machine.

Voltage of Cables 100 V - 200 V 6,600 V 22,000 V 66,000 V 154,000 V 187,000 V 275,000 V 500,000 V

Safety Distance Over 2 m (7 ft) Over 2 m (7 ft) Over 3 m (10 ft) Over 4 m (14 ft) Over 5 m (17 ft) Over 6 m (20 ft) Over 7 m (23 ft) Over 11 m (36 ft)

2.4.9.7 WORKING ON LOOSE GROUND –

Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas.

–

When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.

2.4.9.8 GAS, DUST, STEAM AND SMOKE

WARNING RISK OF EXPOLSION AND FIRE! Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which may result in serious injury or death. All relevent safety measures must be followed and only under expressly obtained authorization. Special care must be taken before welding, flame-cutting and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting and grinding operations are carried out on the counterweight. Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases from the counterweight chambers. (See Volume 2 binder)

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GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

SAFETY

WARNING RISK OF EXPLOSION! Substances and objects igniting can lead to fire or explosion resulting in serious injury or death. Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated as there is a risk of explosion.

2.4.9.9 VENTILATION OF ENCLOSED AREAS

WARNING POISONOUS FUMES! Unventilated areas where poisonous fumes can accumulate can kill. Always ensure adequate ventilation.

–

Operate internal combustion engines and fuel operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation (Fig. 3-18). Observe the regulations in force at the respective site.

–

If it is necessary to start the engine within an enclosed area, or when handling fuel, flushing oil, or paint, open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning.

Fig. 3-18

2 - 20

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.10 STARTING ENGINE 2.4.10.1 WARNING TAG –

If there is a "DANGER DO NOT OPERATE!" warning tag displayed, it means that someone is carrying out inspection and maintenance on the machine (Fig. 3-19). If the warning sign is ignored and the machine is operated, there is a danger that the person carrying out the inspection or maintenance may be caught in the rotating parts or moving parts and suffer personal injury or death. Do not start the engine or touch the levers.

Fig. 3-19

2.4.10.2 CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur with the operation of the machine, and there is the danger that this could lead to serious personal injury or death. –

Remove all dirt from the surface of the window glass to ensure a good view.

–

Completely remove all flammable materials accumulated around the engine and battery, and remove any dirt from the windows, mirrors, handrails, access ladder and steps.

–

Check the coolant levels, fuel levels, and oil levels, and check for damage to the electric wiring.

–

Adjust the operator's seat to a position where it is easy to carry out operations, check the camera system functions and check that there is no damage or wear to the seat belt or mounting clamps.

–

Check the operation of the instruments and gauges, check the angle of the mirror, and check that the control levers are all at the Neutral position.

–

Before starting the engine, check that lock lever (Fig. 3-20) is in LOCK position (L).

–

Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat.

–

Check that there are no persons or obstacles above, below, or in the area around the machine.

Fig. 3-20

2.4.10.3 PRECAUTION WHEN STARTING ENGINE –

Start and operate the machine only while seated.

–

Do not short circuit the starting motor circuit to start the engine. Short circuiting can cause fire.

–

When starting the engine, sound the horn as a warning.

2 - 21

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

–

SAFETY

Do not let any person on the machine other than the operator and the operator's assistant (1 person). For demonstration purposes or during training, more than two people can be present in the operator’s cabin at the same time. All personnel within the cabin at such times must secure good hand-holds and be aware of sudden movements. All appropriate relevant safety measures are to be observed.

2.4.10.4 PRECAUTION IN COLD AREAS –

Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers or control pedals are operated, the reaction of the machine will be slow or the machine may move in a way not expected by the operator. Particularly in cold weather, be sure to carry out the warming-up operation thoroughly.

–

If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a hazard that this will ignite the battery and cause the battery to explode.

–

Before charging or starting the engine with a different power source, melt the battery electrolyte and check that there is no leakage of electrolyte before starting.

2.4.11 OPERATION 2.4.11.1 CHECKS BEFORE OPERATION If the checks before starting are not carried out properly, the machine will be unable to display its full performance, and there is also danger that it may lead to serious personal injury or death. When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. –

Always fasten your seat belt.

–

Check that the movement of the machine matches the display on the control pattern label in the cabin. If it does not match, replace it immediately with the correct control pattern label.

–

Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel system and swing system.

–

Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is no leakage of oil or fuel.

–

If any problem is found, carry out repairs immediately.

2 - 22

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE –

Before travelling, set the machine so that sprocket (1) is behind the operator's seat (Fig. 3-21).

–

If sprocket (1) is in front of the operator's cab, the machine moves in the opposite direction from the operation of the pedals (front and rear travel is reversed, left and right steering is reversed). Be extremely careful when operating the machine in this situation.

Fig. 3-21

–

Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles (Fig. 3-22).

–

Before travelling, sound the horn to warn people in the area.

–

Always operate the machine only when seated.

–

Do not allow anyone apart from the operator to ride on the machine.

–

Check that the travel alarm works properly.

–

Secure the cab door when it is both open and closed.

–

Always keep the cab door closed when operating the machine. Fig. 3-22

–

If there is an area to the rear of the machine which cannot be seen, position a signal person. Take special care not to hit other machines, objects or people when turning or swinging the machine (Fig. 3-23)

Fig. 3-23 NOTE!

Always be sure to carry out the above precautions even when the machine is equipped with mirrors or camera systems.

2 - 23

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.11.3 PRECAUTIONS WHEN TRAVELLING –

When travelling on flat ground, keep the work equipment 100 to 150 cm (39 to 59 in) high above the ground (Fig. 3-24).

–

If the view to the right side is poor, raise the boom to ensure better visibility.

–

When travelling on rough ground, travel at low speed and do not operate the steering suddenly. There is danger that the machine may turn over. The work equipment may hit the ground surface and cause the machine to lose its balance, or may damage the machine or structures in the area.

–

Fig. 3-24

–

Avoid travelling over obstacles when possible. If the machine has to travel over an obstacle, keep the work equipment close to the ground and travel at low speed. Never travel over obstacles which make the machine tilt strongly to one side (Fig. 3-25).

–

When travelling or carrying out operations, always keep a safe distance from people, structures or other machines to avoid coming into contact with them.

Fig. 3-25

2 - 24

SAFETY

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.11.4 TRAVELLING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. –

Keep the work equipment 100 - 150 cm (39 - 59 in) above the ground surface so that the work equipment can be lowered to the ground immediately to stop the machine in emergencies (Fig. 3-26).

–

When travel up slopes, set the operator's cab facing uphill, when travel down slopes, set the operator's cab facing downhill. Always be aware and informed about the firmness and bearing capacity of the ground under the machine when travelling. Cavaties and underground mines may cause the ground beneath the excavator to collapse. Fig. 3-26

–

When travelling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 100 to 150 cm (39 to 59 in) above the ground, and travel at low speed (Fig. 3-27).

Fig. 3-27

–

When travelling downhill, keep the travel pedals close to the neutral position, and travel at low speed.

–

Always travel straight up or down a slope. travelling at an angle or across the slope is extremely dangerous.

–

Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine, then travel on to the slope again (Fig. 3-28).

–

Travel on slippery ground with low speed. Even with slight slopes there is a hazard that the machine may slip

Fig. 3-28

2 - 25

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.11.5 OPERATIONS ON SLOPES –

When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully.

–

Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded. This operation is dangerous, and may cause the machine to tip over.

–

If the machine has to be used on a slope, pile the soil to make a platform (A on Fig. 3-29) that will keep the machine as horizontal as possible. Fig. 3-29

2.4.11.6 PROHIBITED OPERATIONS –

Never dig the work face under an overhang. There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine (Fig. 3-30).

Fig. 3-30

–

Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall (Fig. 3-31).

Fig. 3-31

2 - 26

SAFETY

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

–

To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations (Fig. 3-32).

–

Generally speaking, the machine is more liable to overturn when the work equipment is at the side than when it is at the front or rear. – Do not suddenly lower, swing, or stop the work equipment. – Do not suddenly extend or retract the boom cylinder. There is a hazard that impact will cause the machine to tip over.

–

Do not pass the bucket over the head of other workers or over the operator's seat of dump trucks or other hauling equipment. The load may spill or the bucket may hit the dump truck and cause serious injury or property damage.

Fig. 3-32

2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES –

Snow-covered or frozen surfaces are slippery, so be extremely careful when travelling or operating the machine, and do not operate the pedals suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.

–

With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the machine to tip over.

–

If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful not to leave the road shoulder or to get trapped in a snow drift.

–

When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations carefully.

2.4.11.8 PARKING THE MACHINE –

Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low.

–

Lower the work equipment completely to the ground.

–

When leaving the machine, set lock lever (1) to the LOCK position (L), then stop the engine (Fig. 3-33).

–

Always close the operator's cab door, and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine. Always remove the key, take it with you, and leave it in the specified place.

–

If it is necessary to park the machine on a slope, always set the bucket on the downhill side, then dig it into the ground.

Fig. 3-33

2.4.11.9 TRANSPORTATION This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. Use only appropriate means of transport and lifting gear of adequate capacity. The recommissioning procedure must be strictly in accordance with the General Assembly Procedure Manual.

2 - 27

PRECAUTION FOR MAINTENANCE

2.5

PRECAUTION FOR MAINTENANCE

2.5.1

GENERAL PRECAUTIONS

SAFETY

–

Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation,- Lubrication and Maintenance Manual, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

–

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

–

In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the Operation,- Lubrication and Maintenance Manual and the information on maintenance work.

–

Ensure that the maintenance area is adequately secured.

–

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: – locking the principal control elements and removing the ignition key and/or – attaching a warning tag to the main switch or control levers. – setting the maintenance safety switch to the 0 position and securing it with a padlock

–

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movement and buckling.

–

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

–

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

–

For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out maintenance work at greater heights. Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

–

Always tighten any screwed connections that have been loosened during maintenance and repair.

–

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work.

–

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

–

Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 3-1.

–

Park the Excavator at a safe place on level ground. Proceed according to the instructions ”Parking the Shovel”. Lower the attachment flat onto the ground. Move all control levers to neutral position.

–

Stop the engines and move all control levers through their shift positions to relieve the pressure in the hydraulic system. Refer to ”Stopping the Engines” for detailed description of the stopping procedure.

–

Before any maintenance work is started, set the maintenance safety switch to 0 position. Find to the location of the maintenance safety switch refer to section 2.5.1.3 on page 3-30. In the 0 position the engines can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten padlocks can be attached to the holes provided.

–

A warning plate ”Caution Machine Maintenance” must be fixed in the Operator’s cab before any lubrication or maintenance work is started.

–

Block the machine to prevent machine movement

2 - 28

SAFETY

PRECAUTION FOR MAINTENANCE

–

Always use safety devices to block hydraulic cylinders. Never rely on the machine hydraulic system to hold when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidently strike the control levers causing the loader to fall.

–

Relieve all pressure in the hydraulic system before servicing the hydraulic system.For information on relieving the pressure in the hydraulic system, refer to chapter ’Relieving The Pressure In The Hydraulic System’ in the ’Operation’ part of this manual.

–

Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting maintenance work.

–

Switch-off battery main switch and remove key, before working on the electrical system.

–

Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this necessary. Observe the local safety rules.

–

Never allow unauthorized persons access to the machine during lubrication and maintenance work.

–

After servicing, remove oily cloth, inflammable material and all tools from the machine.

–

Clean the Excavator with a steam jet, especially after servicing the hydraulic system and fuel system.

WARNING BEWARE OF STEAM! Hot steam can cause serious personal injury. When using a steam cleaner, wear safety glasses and protective clothing.

–

For cleaning the Excavator and its components use only fresh water with a salt content of less than 0.05%.

–

DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid valves, sensors, cable connections and bearings.

–

Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES –

Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

–

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

–

All personnel must be aware of the appropriate safety measures when working on or around the machine.

–

Make sure that only authorized personnel works on or with the machine.

–

Define the machine operator’s responsibilities - also with regard to observing traffic regulations - giving the operator the authority to refuse instruction by third parties that are contrary to safety.

–

Do not allow persons to be trained or instructed or persons taking part in a general training course on or with the machine without being permanently supervised by an experienced person.

–

Work on the electrical system and equipment of the machine must be carried out only by skilled electricians or by persons instructed under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

–

Work on the chassis, brake and steering systems must be performed only by skilled personnel who have been specifically trained for such work.

Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

2 - 29

PRECAUTION FOR MAINTENANCE

SAFETY

2.5.1.2 STOP ENGINE FOR MAINTENANCE –

Stop the machine (Fig. 3-34) on firm, level ground.

–

Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low.

–

Lower the work equipment completely to the ground and stop the engine.

Fig. 3-34

–

Turn the main key switch to the ON position. Operate the work equipment control lever back and forth, left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit, and then push up lock lever (1) to the LOCK position (Fig. 3-35).

–

Check that the battery main switch is off and main power is not conducted. (Wait for approx. one minute after activating the engine STOP switch and press the horn switch. If the horn does not sound, it is not activated.)

Fig. 3-35

2.5.1.3 WARNING TAG –

Always attach the “DO NOT OPERATE“ warning tag (Fig. 336) to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.

–

Keep this warning tag in the tool box while it is not used. If there is not the tool box, keep the tag in the operation manual pocket.

–

If any other person starts the engine, or touches or operates the control levers or control pedals while you are performing service or maintenance, you may suffer serious injury. Fig. 3-36

2 - 30

SAFETY

–

Before entering the machinery house, switch off maintenance safety switch (Fig. 3-37)

–

The maintenance safety switch is located in the machinery house, next to the entrance door (Pos. 1 on Fig. 3-38).

–

Before beginning maintenance operations, set the safety switch to "0" to prevent a starting of the engines. Secure this position by inserting a padlock into the holes of the safety switch. Up to ten padlocks can be attached.

PRECAUTION FOR MAINTENANCE

Fig. 3-37

Fig. 3-38

2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY

CAUTION HAZARD OF ACCIDENTS! If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure yourself. Observe the following points.

–

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out operations safely.

–

Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying 2 - 31

PRECAUTION FOR MAINTENANCE

SAFETY

2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his instructions during the operation.

2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING –

To prevent injury, do not perform maintenance or adjustments while the engine runs. If work must be carried out with the engine running, carry out the operation with at least two workers and do as follows: – One worker must always sit in the operator's seat and be ready to stop the engine at any time. All workers must maintain contact with each other and be fully aware of all relevant safety measures.

–

For safety information when working with high pressure oil in the hydraulic system, refer to section 2.6 on page 3-40.

–

When carrying out operations near rotating parts, there is a hazard of being caught in the parts, so be careful not to come close (Fig. 3-39).

–

Fig. 3-39

Do not touch any control levers or pedals. If they must be operated, always give a signal to other workers to warn them to move to a safe place.

2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS –

Appoint a leader before starting removal or installation operations for attachments.

–

Place attachments that have been removed from the machine in a stable condition so that they do not fall (Fig. 3-40). And take steps to prevent unauthorized persons from entering the storage area.

Fig. 3-40

2 - 32

SAFETY

PRECAUTION FOR MAINTENANCE

2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT –

If it is necessary to go under the work equipment or the machine to carry out service and maintenance (Fig. 3-41), support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine.

–

It is extremely dangerous to work under the machine if the track shoes are lifted off the ground and the machine is supported only with the work equipment. If any of the control levers are touched by accident, or there is damage to the hydraulic piping, the work equipment or the machine will suddenly drop. This is extremely dangerous. Never work under the work equipment or the machine. Fig. 3-41

2.5.1.9 NOISE When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.

2.5.1.10 WHEN USING A HAMMER When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. –

If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, there is a hazard that pieces might be scattered and cause injury. Always wear safety glasses and gloves (Fig. 3-42).

–

When hitting pins or bucket teeth, there is a hazard that broken pieces might be sent flying and injure people in the surrounding area. Always check that there is no one in the surrounding area.

–

There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.

Fig. 3-42

2 - 33

PRECAUTION FOR MAINTENANCE

SAFETY

2.5.1.11 PROPER TOOLS –

Use only tools suited to the task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury (Fig. 3-43).

Fig. 3-43

2.5.1.12 ACCUMULATOR The accumulator is charged with high-pressure nitrogen gas. When handling the accumulator, careless procedure may cause an explosion which could lead to serious injury or property damage (Fig. 3-44). For this reason, always observe the following precautions. –

Do not disassemble the accumulator.

–

Do not bring it near flame or dispose of it in fire.

–

Do not make holes in it, weld it, or use a cutting torch.

–

Do not hit or roll the accumulator, or subject it to any impact.

–

When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed.

Fig. 3-44

2.5.1.13 PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer.

2.5.2

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2.5.2.1 PRECAUTION WHEN WELDING

WARNING RISK OF EXPOLSION AND FIRE! Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which may result in serious injury or death. All relevent safety measures must be followed and only under expressly obtained authorization.

Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.

2 - 34

SAFETY

PRECAUTION FOR MAINTENANCE

2.5.2.2 BATTERY HANDLING

WARNING RISK OF EXPLOSION AND FIRE! Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Wrong handling can lead to serious injury or fire. For this reason, always observe the following precautions.

–

Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line.

–

When working with batteries, always wear safety glasses and rubber gloves.

–

Never smoke or use any flame near the battery (Fig. 3-45).

Fig. 3-45

–

If you spill acid on your clothes or skin, immediately flush the area with large amount of water.

–

If acid gets into your eyes (Fig. 3-46), flush them immediately with large amount of water and seek medical attention.

–

Before working with batteries, activate the STOP switch and remove battery main switch key.

Fig. 3-46

As there is a hazard that sparks will be generated, always do as follows. –

Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other metal objects lying around near the battery.

–

When disconnecting the battery terminals, wait for approx. one minute after activating the engine STOP switch and be sure to disconnect the grounding terminal (negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then the grounding (-) terminal. Make sure that all the terminals are connected securely.

–

Attach the battery terminal securely.

–

Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take it to a well-ventilated place, and remove the battery caps before charging it.

–

Tighten the battery caps securely.

–

Install the battery securely to the determined place. 2 - 35

PRECAUTION FOR MAINTENANCE

2.5.3

SAFETY

PRECAUTIONS WITH HIGH PRESSURE FLUID

WARNING FLUID UNDER HIGH PRESSURE! The hydraulic system is always under internal pressure and can lead to serious injury when leaking. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released.

2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE –

For details of the method of releasing the pressure, see the latest version of the Operation and Maintenance Manual. If the circuit is still under pressure, do not carry out any inspection or replacement operation.

–

If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses.

–

When carrying out inspections, wear full-face protection and penetration resistant clothing and gloves (leather).

–

There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly (Fig. 3-47). If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.

Fig. 3-47

High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before starting inspection or maintenance.

2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES –

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor.

Replace the hose if any of the following problems are found. –

Damaged or leaking hydraulic fitting.

–

Frayed or cut covering or exposed reinforcement wire layer.

–

Covering swollen in places.

–

Twisted or crushed movable portion.

–

Foreign material embedded in covering.

2.5.3.3 REPLACEMENT OF HOSE LINES Hydraulic hoses are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years.

NOTICE The maximum permissible storage time of hydraulic hoses must be observed.

2 - 36

SAFETY

PRECAUTION FOR MAINTENANCE

–

This storage period is part of the usable lifetime and must be considered when installing a new hose line. If, for example, a hose line with a one year storage time is to be installed, the remaining service life of the hose line must be considered. All hose lines are marked with the date of production.

–

Hose lines considered as Safety Critical Parts have to be replaced earlier. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for further information.

All hydraulic hoses of the Shovel have to be replaced when their service life has expired, even if there is no visible damage. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for further information.

NOTICE Repairs on hydraulic hoses are not allowed. Use ONLY GENUINE Komatsu Mining Germany replacement hose lines.

2.5.3.4 INSPECTION OF HOSE LINES

WARNING FLUID UNDER HIGH PRESSURE! The hydraulic system is always under internal pressure and can lead to serious injury when leaking. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released.

Inspect all hoses, hose lines and fittings carefully during the course of the daily walk-around inspection. Check for leaks and damages. Beware of pinhole leakages. Replace damaged parts without delay. Some examples of faults on hydraulic hoses requiring replacement of the concerned part: –

Damage to the outer layer (e.g. chafed spots, cuts or scratches).

–

Brittle top layers. Flaws on the hose material

–

Distortion of the hose line (strong deviation from the original shape) under pressurized and pressureless conditions or when kinked or crushed, e.g. disintegration of hose layers or blistering.

–

Leaks.

–

Detachment of hose and fitting. Damaged hose fitting.

2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To ensure safety at all times when operating the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts given in the table. These parts are particularly closely connected to safety and fire prevention. With these parts, the material changes as time passes, or they easily wear or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function completely. However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately. If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

2 - 37

PRECAUTION FOR MAINTENANCE

–

SAFETY

Ask your Komatsu distributor to replace safety critical parts.

2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE

DANGER HIGH VOLTAGE! High voltage appliances cause serious injury or death. Authorized staff only.

–

When the engine is running and immediately after it is stopped, high voltage is generated inside the engine controller and the engine injector.

–

The headlights also operates using high voltage. Never perform maintenance on the headlights.

–

If it is necessary to touch the inside of the controller or the engine injector portion, or the headlight electrics please contact your Komatsu distributor.

–

The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff only.

2.5.3.7 AIR CONDITIONING MAINTENANCE

WARNING AIR CONDITIONING REFRIGERANT IS HARMFUL! If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite. Never touch refrigerant.

2.5.3.8 COMPRESSED AIR

WARNING COMPRESSED AIR IS HAZARDOUS! When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. Wear protective clothing.

–

When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment.

–

Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.

2 - 38

SAFETY

PRECAUTION FOR MAINTENANCE

2.5.3.9 WASTE MATERIALS Operation –

Avoid engine idling over long periods. Long periods of idling (more than 10 minutes), will not only waste fuel, but is also harmful to the engine.

–

Avoid operation against the main relief valves of the hydraulic system. Move control lever to neutral position before the loader attachment stalls due to overload.

–

Position trucks in such a way, that loading operation can be carried out in a safe and economic manner. Avoid swing angles over 90°.

Maintenance –

Preserve our environment. To prevent environmental pollution, pay careful attention to the method of disposing waste materials.

–

Always drain fluids from your machine into containers. Never drain fluids onto the ground or dump it into the sewage system, rivers, the sea or lakes. (Fig. 3-48).

–

Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in accordance with local environmental regulations and laws.

Fig. 3-48

2 - 39

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS

2.6

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS

2.6.1

INSPECTION OF THE HYDRAULIC SYSTEM

SAFETY

A hands-on approach to inspecting the hoses and pipes of the hydraulic system can only be made when the excavator is shut down and there is no oil pressure in the hydraulic system. –

Do not use your hands during inspection or move in the vicinity of the hydraulic system’s piping or tubing when the engine is running before checking for leaks, as hydraulic fluid escaping under pressure can cause serious injuries.

–

Additional to the general personal protective clothing as described on page 3-9, full face protection and penetration resistant clothing and gloves must be worn.

–

Troubleshooting and adjustments may only be performed by personnel trained by Komatsu Mining Germany in safe and correct hydraulic handling procedures.

–

Before troubleshooting or adjustments, the inspection of areas of potential dangers for damages, leaks or loose connections on the pressure lines and hydraulic components must be carried out visually only when the engine is shutdown and when there is no hydraulic pressure in the system.

–

When the machine is running, the areas of potential danger can only be entered when no leakages or other irregularities have been noticed when the high pressure oil circulation has been brought up to maximum pressure from a safe distance (operator’s cab, machinery house roof, ladder platform).

2.6.2

TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS

To prevent injury, do not carry out adjustments with the engine running. If work must be carried out with the engine running, perform the task with, at maximum, two maintenance workers and an operator and do as follows. –

An operator that has been trained on the machine he is operating, must always sit in the operator's seat and be ready to stop the engine at any time. All workers must maintain contact with the other workers and be fully aware of all relevant safety measures.

–

When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in the parts, so be careful not to come close (Fig. 3-49).

–

Do not touch any control levers or control pedals. If any control levers or control pedals must be operated, always give a signal to the other workers to warn them to move to a safe place. Fig. 3-49

2.6.3

AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR

General safety rules for working on the excavator –

Only trained personnel who are aware of all dangers are allowed to work on the hydraulic system

–

Visually inspect all potential danger areas for leakages before pressure build up.

–

Do not remain on or around the excavator for longer than is absolutely necessary in order to perform your tasks.

2 - 40

SAFETY

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS

Please continue reading on the next page.

2 - 41

SPECIAL SAFETY EQUIPMENT

2.7

Fig. 3-50 2 - 42

SPECIAL SAFETY EQUIPMENT

SAFETY

SAFETY

2.7.1

SPECIAL SAFETY EQUIPMENT

FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB

The Shovel must be equipped with a front guard protective structure ”OPG Front Guard” if it is used for applications where there is a risk of hitting objects from the front.

2.7.2

OBJECT HANDLING

Object handling operations are not allowed.

2.7.3

LIGHTING

The Shovel must only be operated when the operator has sufficient visibility in relation to the work area. Disturbing shady areas or dazzling effects must be avoided. If necessary, the Shovel must be retrofitted with additional lighting equipment (working lights) in order to ensure sufficient visibility conditions.

2.7.4

WARNING BEACON

The Shovel can be retrofitted with a warning beacon which is fitted on the cab roof by means of a magnetic bracket. REMARKS: The above-mentioned special safety devices can be ordered as accessories together with the Shovel. They are also available as a field package for installation through our service organization.

2.7.5

SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

The safety harness should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. See the following pages for further information.

2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

WARNING RISK OF FALLING! Injuries can occur when working in high areas. Always use a Safety Harness (1) in conjunction with a strap type Fall Absorber (2), illust. (Fig. 3-50) before boarding the loader attachment or other unsecured areas on the Shovel.

–

The Safety Harness is located in the Cabinet in the Operator’s Cab.

–

The illustration (Fig. 3-50) shows the standard use of the safety harness with a strap type fall absorber.

2 - 43

SPECIAL SAFETY EQUIPMENT

2 - 44

SAFETY

SAFETY

SPECIAL SAFETY EQUIPMENT

Legend for Fig. 3-50 (1)

Safety Harness according to EN 361

(2)

Strap-Type Fall Absorber according to DIN EN 355

(3)

Railings (attachment points)

(4)

Walkway on the boom

(A)

Shoulder Strap

(B)

Back Plate

(C)

Catching Hook

(D)

Shoulder-Strap Fixing

(E)

Belly Strap

(F)

Holding Hook

(G)

Hold-Back Hook

(H)

Pelvis Strap

(J)

Leg Strap

2.7.5.2 INSTRUCTIONS FOR USE Open the lock, lift the harness by the catch hook (C), ensuring the leg straps hang below (J). Pull the harness over the shoulders as you would a jacket. Insert the end of the belly strap (E) through the buckle and tighten securely, as shown in the illustration (Fig. 3-50). Prevent the shoulder straps from slipping by fastening the breast strap. Pull the leg straps (J) between the legs and securely buckle them at the front as illustrated. Adjust the harness so that it snugly fits the body ensuring that the catching hook (C) is in the center of the back. The safety harness is a personal accessory and should only belong to its owner. The safety harness should only be used together with connectors acc. to EN 354, and fall arrest acc. to EN 355, or fall protection devices acc. to EN 360. The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attachment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795.

2 - 45

SPECIAL SAFETY EQUIPMENT

2 - 46

SAFETY

SAFETY

SPECIAL SAFETY EQUIPMENT

2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL –

Carry out a visual check of the system or component; correct functioning and perfect working order have to be assured.

–

Make sure that the recommendations for use with other components of the system be observed in conformity with the instructions for use.

The system or component must no longer be used, if there are any doubts in respect of its safe condition. The equipment has to be inspected by the manufacturer or by a qualified person. It is essential for safety reasons that a fall protection system or system component which has already been subjected to fall be removed from service and sent back to the manufacturer or an authorized qualified repair shop for maintenance and renewed testing. Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharpedged objects. Should the harness have become wet during use or cleaning, do not dry near a fire or other sources of heat, but rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up. When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest Systems" have to be observed for protection against danger. At least every 12 months, the safety harness and its components have to be inspected by a competent person authorized by the manufacturer and maintained, if the manufacturer considers it necessary.

2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), During the holding function, the connectors may only be placed around a mast or other construction between the two holding hooks, so that free fall is limited to max. 0.5 m. It should be strictly seen to it that the connector be not slung around constructions with too small diameter or sharp edges. With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs). The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be reached.

2 - 47

SPECIAL SAFETY EQUIPMENT

2 - 48

SAFETY

SAFETY

SPECIAL SAFETY EQUIPMENT

2.7.5.5 INSTRUCTIONS FOR USE Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD) Use Within a fall-arrest system, the strap-type fall absorber (2) has to be used in conjunction with a safety harness (1) acc. to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a rope-shortening device has to be applied in addition. Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the safety harness. The attachment point should be above the wearer and its minimum carrying capacity should be 10 KN, acc. to DIN EN 795. The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor get them burnt by welding sparks. Storing and maintenance The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be ex-posed to acids, caustic chemicals, nor to an aggressive atmosphere, and contact with oils has to be avoided. If the strap-type fall absorber is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or other sources of heat). Protect it from sharp-edged objects. Inspection Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed from service immediately. The strap-type fall absorber must not be changed in any way.

2 - 49

SPECIAL SAFETY EQUIPMENT

2 - 50

SAFETY

HYDRAULIC MINING EXCAVATOR PC5500E-6

Machine model

Serial numbers

PC5500E-6

15016 and up

01 Specification

® Copyright 2010 KOMATSU MINING GERMANY GmbH

PC5500-6E

1

OPERATING WEIGHT 531-549 ton 1,170,000-1,200,000 lb 29

m3

SHOVEL CAPACITY 38 yd3 SAE 2:1 heaped

BACKHOE CAPACITY 29 m3 38 yd3 SAE 1:1 heaped

PC5500 PC

5500

SUPER SHOVEL

PC 5500

S UPER S HOVEL

WALK-AROUND Quality ● Quality management ISO 9001 certified. ● Environmental Management ISO 14001 certified. ● Consistent high quality through continuous investment in personnel, design and manufacturing systems and processes.

Reliability and Durability Designed for lower operating costs ● Robust structural design developed from field experience and finite element analaysis. ● Extended life undercarriage wear parts; Big diameter rollers, idlers and sprockets. Large surface area and extensive precision hardening. Hardened track link pin bores.

Productivity Designed for more tons per hour ● Powerful digging forces. ● Ease of bucket filling. ● Proven attachment design. ● All cylinders mounted under the shovel attachment for additional protection. ● Buckets and Wear Packages to suit all material densities and ground conditions.

2

SUPER SHOVEL

PC 5500 MATCHED FOR 150 to 320 U.S. ton TRUCKS

Large Comfortable Cab Full shift comfort ● Komatsu low noise cab on multiple viscous mounts for reduced noise and vibration. ● Large volume cab with deep wide front window. ● Comprehensive climate control with pressurised filtered air ventilation and air conditioning. ● High specification multi-adjustable air suspension seat. ● Well elevated operator position giving good all round view.

SHOVEL AND BACKHOE BUCKET CAPACITY 29 m3 38 yd3

Advanced Hydraulics Extended reliability and precise control ● Comprehensive monitored filtration. ● Simple open circuit hydraulic system with high efficency swing out oil coolers.

Powerful Diesel Engine Two Komatsu SSA12V159 engines ● Rated (each) 940 kW 1260 HP, at 1800 rpm. ● Electronic engine management. ● Low engine emission levels meet EPA regulations. ● Time saving oil management system fitted as standard; Centinel Engine Oil Management, Reserve Engine Oil Supply and Eliminator Oil Filter systems. Option: ● Two Komatsu SDA12V159E-2 engines Tier 2 certificated Rated (each) 940 kW 1260 HP at 1800 rpm.

Easy Maintenance Simple, common-sense design gives quick safe access to all major components ● Generous access to all major service points from machinery house floor level. ● Enclosed, internally lit machinery house with firewall separating engine from pump area. ● Automatic central lubrication. ● ECS electronic monitoring system providing real time information about the operating status of the machine. ● Ground-level access to hydraulically powered swing down service arm with Wiggins connections.

3

PC 5500

S UPER S HOVEL

SPECIFICATIONS DIESEL DRIVE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x Komatsu SSA12V159 Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rated power. . . . . . . . . . . . . . . . . 2x 940 kW 1260 HP @ 1800 rpm

SWING SYSTEM Hydraulic motors and drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Swing brake, service . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake Swing brake, parking. . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc Swing ring teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Swing speed (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 rpm

(SAE 1995/J1349)

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronic Optional US Tier 2 Version: Model . . . . . . . . . . . 2x Komatsu SDA12V159E-2 Tier 2 certificated Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rated power. . . . . . . . . . . . . . . . . 2x 940 kW 1260 HP @ 1800 rpm (SAE 1995/J1349)

Controller/Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantum The integrated engine oil and filter system combining the oil stabilising systems, Reserve and Centinel, with the Eliminator self cleaning oil filter extends, with oil analysis, the oil change interval to 4000 hours. (not available in Australia)

ELECTRIC DRIVE Type . . . . . . . . . . . . . . . . . . . . . . . 2x Squirrel-cage induction motor Power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x 900 kW Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6600 V* Amperage (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 A Start-up . . . . . . . . . . . . . . . . . . Soft start each motor in succession Frequency (standard) . . . . . . . . . . . . . . . . . . . . . 50 Hz @ 1500 rpm Optional frequency . . . . . . . . . . . . . . . . . . . . . . . 60 Hz @ 1800 rpm *Other voltages available on request

UNDERCARRIAGE ELECTRICS System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V Batteries (series/parallel) (diesel version). . . . . . . . . . . . 2 + 6 x 12 V Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x 100 A Standard working lights. . . . . . . . . . . . . . . . . . . . . . . 8 Xenon lights Standard service lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 lights

HYDRAULICS The power train consists of two main drives. Diesel engines or electric motors can be supplied. Each connected to a gearbox and 3 identical main pumps which draw hydraulic oil from an unpressurized hydraulic tank. Open circuit hydraulics provide maximum cooling and filtering efficiency. Rated flow (total output) . . . . . . . . . . . . 4200 ltr/min 1110 U.S. gal Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . 310 bar 4,495 psi Swing flow rate . . . . . . . . . . . . . . . . . . . . . 700 ltr/min 185 U.S. gal High pressure in line filters . . . . . . . . . . . . . . . . . . . . . . 200 microns

Undercarriage consists of one center carbody and two track frames, each side attached by 80 high torque bolts. Center frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-type Track frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel box-section

CRAWLER ASSEMBLY Track adjustment . . . . . . . . . . . . . . . . . . . Automatic hydraulic type Number of shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 each side Number of top rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 each side Number of bottom rollers. . . . . . . . . . . . . . . . . . . . . . . . 7 each side

COOLING SYSTEM The high capacity engine radiators are cooled by hydraulically driven fans for superior cooling efficiency and require little maintenance. The hydraulic system includes four large swing-out vertical air-to-oil hydraulic coolers with temperature-regulated hydraulically driven fans.

one per pump located at the valve blocks

Full flow return line filters (10 double elements) . . . . . . . 10 microns at head of hydraulic tank

Case drain/by-pass return line filters . . . . . . . . . . . . . . . . 3 microns The four-circuit system features a load-limiting governor with oil delivery summation to the working circuits and incorporates pressure cut-off control. Hydropilot prioritizes hydraulic flow giving smooth hydraulic response, simple hydraulic system layout, and a reduced number of components. Filtration is at the oil intake to pumps, valve blocks, heat exchangers and the oil tank.

AUTOMATIC CENTRALISED LUBRICATION Two hydraulically powered Lincoln single line automatic lubrication systems are provided as standard, complete with time and volume variable controls. Activity and malfunction events are linked to the ECS. The central lube grease system is supplied from a refillable 300 litre 80 gal. container. A second, identical system supplies open gear lubricant to the swing ring teeth through a lube pinion. Replenishment of the containers is through the service arm.

DRIVES AND BRAKES Travel control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 foot pedals Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 50% Travel speed (maximum) . . . . . . . . . . . . . . . . . . . 2.1 km/h 1.4 mph Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc

4

SERVICE CAPACITIES Hydraulic oil tank . . . . . . . . . . . . . . . . . . .3800 ltr 1,000 U.S. gal Hydraulic system . . . . . . . . . . . . . . . . . . .6000 ltr 1,585 U.S. gal Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.800 ltr 2,853 U.S. gal Engine coolant . . . . . . . . . . . . . . . . . . . .2x 360 ltr 2x 95 U.S. gal Engine oil . . . . . . . . . . . . . . . . . . . . . . . .2x 190 ltr 2x 50 U.S. gal Centinel engine oil make up tank . . . . . .2x 580 ltr 2x 153 U.S. gal

SUPER SHOVEL

PC 5500

CAB The large welded steel safety cab is mounted with 18 viscous damping pads and sound insulated. It is equipped with automatic climate control and is pressurised. The operator’s seat is fully adjustable, air suspended, electrically heated and has a lap seat belt. There is a trainer’s seat. Low effort joy stick controls are electric over hydraulic and foot controls are for front shovel clam, crawler and swing brake. Full instrumentation and ECS are provided. Space in the console is provided for an additional monitor. AM/FM radio is fitted. The windshield wash wiper has two speed and intermittent operation. (Water reservoir 7 litres 1.8 gal.) Amenities include a wash basin with running water, water reservoir, (50 litres 13 gal.), refrigerator and storage cabinets. Powered mirrors are adjusted from inside the cab. There are left and right hand sliding windows. All windows are tinted parsol green. External metal louvres are provided on the cab side windows.

Cab engineering standards are; • ISO 3449 Falling Objects Protection Structure • ISO 6396 Noise in operator´s cab is 76 dB(A) • ISO 2631-1/ 5349-1 Vibration and Shock • Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . .10kW 34120 Btu • Heater/Demister (Diesel version) . . . . . . . . . . . . .10kW 34120 Btu • Heater/Demister (Electric version) . . . . . . . . . . . .12kW 40940 Btu

CS

HEALTH MONITORING SYSTEM The ECS digital diagnostic system, mounted in the operator‘s console, provides a text display of real time and stored information about the status of the operating machine. Non serious and critical faults are immediately announced, and for major malfunctions the engines are also shut down. The integrated digital storage provides full event history, which can be down loaded with a laptop computer. The ability to electronically record service events provides precise service information to assist in reducing downtime.

OPERATING WEIGHTS (APPROXIMATE) PC 5500 Backhoe:

PC 5500 Front Shovel:

Operating weight including 11.000 mm 36’1’’ boom, 5100 mm 16’9’’ stick, 29 m3 38 yd3 backhoe bucket, operator, lubricant, coolant, full fuel tank and standard equipment.

Operating weight including 7600 mm 24’11’’ boom, 5600 mm 18’4’’ stick, 29 m3 38 yd3 shovel bucket, operator, lubricant, coolant, full fuel tank and standard equipment.

Shoe Width

Operating Weight

Ground Pressure

Shoe Width

Operating Weight

Ground Pressure

1350 mm 53’’

535 t 1,180,000 lb

23.9 N/cm2 33.4 psi

1350 mm 53’’

531 t 1,170,000 lb

23.1 N/cm2 33.5 psi

1800 mm 71’’

549 t 1,210,000 lb

18.3 N/cm2 26.5 psi

1800 mm 71’’

545 t 1,200,000 lb

18.2 N/cm2 26.4 psi

Diesel Explanation 1 Operator’s Cab 2 Power Trains 3 Hydraulic Cooler 4 Hydraulic Reservoir 5 Valve Blocks

SKZ 5506_50A

6 7 8 9

Swing Motors Fuel Tank Counterweight Autolube Systems (on upper deck) 10 Secondary Egress

Electric Variation for Electric Drive Version 2 Electric Motor 7 High Voltage Electric Cabinet

SKZ 5506_51

Lower-Level Walkways

Upper-Level

5

PC 5500

S UPER S HOVEL

PRODUCTIVITY-FEATURES BACKHOE ATTACHMENT

5506074

Boom length

11000 mm

36’ 1”

Max. digging height

15500 mm

50’ 10”

Stick length

5100 mm

16’ 9”

Max. dumping height

10100 mm

33’ 2”

Break-out force (SAE)

1450 kN

326,250 lb

Max. digging depth

8300 mm

27’ 3”

Tear-out force (SAE)

1290 kN

290,250 lb

Max. digging reach

19800 mm

64’ 12”

Max. digging reach at ground level

18700 mm

61’ 4”

Bucket Capacity (Heaped 1 :1) SAE

Width

Wear Package

Weight

Max. Material Density (Loose)

Recommended Mining

cum

cuyd

mm

foot/inch

qty

*)

t

lb

t/cum

lb/cuyd

Uses

26.0 29.0

34.0 38.0

4380 4380

14’4” 14’4”

5 5

3 2

32.2 33.1

71,000 73,000

2.0 1.8

3400 3000

Heavy Duty Standard Mining

*) WP 1 Non abrasive WP 2 Standard Mining WP 3 Heavy Duty

Alternative buckets on request

6

Teeth

PC 5500

SUPER SHOVEL

FRONT SHOVEL ATTACHMENT

5506068

Boom length

7600 mm

24’ 11”

Max. cutting height

19500 mm

63’ 12”

Stick length

5600 mm

18’ 4”

Max. dumping height

13300 mm

43’ 8”

Break-out force (SAE)

1865 kN

419,200 lb

Max. digging depth

2700 mm

8’ 10”

Crowd force (SAE)

1870 kN

420,300 lb

Max. digging reach

16500 mm

54’ 2”

Bucket Capacity (Heaped 1 : 2) SAE

Width

Teeth

Wear Package

cum

cuyd

mm

foot/inch

qty

*)

21.0 26.0 29.0

27.5 34.0 38.0

4410 4570 4570

14’6” 14’12” 14’12”

5 6 6

4 3 3

*) WP 1 WP 2 WP 3 WP 4

Level crowd at ground level

5600 mm

18’ 5”

Bucket opening width

2700 mm

8’ 10”

Weight t

lb

48.6 107,200 48.9 107,800 49.5 109,100

Max. Material Density (Loose)

Recommended Mining

t/cum

lb/cuyd

Uses

2.6 2.2 1.9

4400 3700 3200

Heavy Duty Standard Mining Standard Mining

Non abrasive Light abrasive Standard Mining Heavy Duty

Alternative buckets on request

7

STANDARD EQUIPMENT Hydraulic Mining Shovel with Diesel Drive will comprise: ● FRONT SHOVEL ATTACHMENT 7.6 m 24'11" boom and 5.6 m 18'4" stick complete with cylinders. 29 m3 38 yd3 (SAE 2:1) shovel bucket with mechanical teeth and lip system. OR ● BACKHOE ATTACHMENT 11.0 m 36'1" boom and 5.1 m 16'9" stick with 29 m3 38 yd3 (SAE 1:1) bucket with mechanical teeth and lip system. ● CRAWLER UNDERCARRIAGE Heavy-duty shovel type undercarriage consisting of a center carbody and 2 heavy box-type track frames, each having 7 bottom rollers, 3 top rollers, and 1350 mm 53" cast steel track shoes. Hydraulic track adjustment and parking brake provided.

● SUPERSTRUCTURE The main frame mounted over an externally toothed swing circle carries the main drive module, including two Komatsu SSA12V159 diesel engines, oil and fuel reservoirs, counterweight, operator’s cab and base.

Windshield wash wipers with two speed and intermittent operation. (reservoir 7 ltr 1.8 gal). AM-FM radio. External metal sun blinds. Left and right hand sliding windows. All windows tinted parsol green.

● LIGHTING 8 Xenon high performance working lights. 14 service lights throughout platform. ● OPERATOR’S CAB Fully enclosed steel cab which incorporates the ISO 3449 standard FOPS structure and CARRIER SÜTRAK air-conditioning unit. Mounted on viscous pads. GRAMMER full suspension operator´s seat with lap-belt. An auxiliary seat. Full selection of controls, switches, and ECS (Electronic Health Monitor). Joy stick and pedal-operated controls are electric over hydraulic.

● LUBRICATION LINCOLN central lubrication for basic machine, attachment, and bucket. 300 ltr 80 gal refillable container. LINCOLN automatic pinion lubrication system for swing circle teeth with 300 ltr 80 gal refillable container. Service point (diesel version only as standard) on hydraulic arm carrying WIGGINS fluid receiving connectors for filling of fuel, engine oil and coolant, hydraulic oil, grease, cabwater and the evacuation of coolant, and hydraulic and engine oils. ● ACCESSORIES Acoustic travel alarm Hydraulically actuated ground access ladder Electric air horn

OPTIONAL EQUIPMENT ● 1800 mm 71’’ track shoes ● Extra or alternative, lighting ● Fire suppression system

● Electric drive ● Cable reel (Electric version) ● Independant LINCOLN central lubrication system for bucket

● Low temperature package (incl. KIM hot start)

DIMENSIONS

BASIC MACHINE WITH COUNTERWEIGHT OR

N

A B CA CB D E F G

1350mm 1800mm 7540mm 7990mm 2715mm 3712mm 7424mm 9720mm

53" 71" 24'9" 26'3" 8'11" 12'2" 24'4" 31'11"

H I J K L M N O OR

3310mm 3100mm 7910mm 8610mm 3970mm 3300mm 7900mm 7260mm 7550mm

M

10'10" 10'2" 25'11" 28'10" 13'0" 10'10" 25'11" 23'10" 24'9"

L

O

K

H

D A B

E F

CA

G

CB

Ground Clearance: 995mm 3'3"

QESS0556 04

I

J

SKZ5506_49

SKZ5506_48

©2008 Komatsu Printed in Germany

KOMATSU MINING GERMANY GMBH BUSCHERHOFSTRASSE 10 D-40599 DÜSSELDORF PHONE +49 (0) 211/ 71 09-0 FAX +49 (0) 211/ 71 58 22

www.komatsu-mining.de

Materials and specifications are subject to change without notice. is a trademark of Komatsu Ltd. Japan.

SHOP MANUAL

HYDRAULIC EXCAVATOR PC5500-6 Diesel

Machine model PC5500E-6

Serial numbers 15016 and up

10 Structure, function

PC5500-6

1

Contents and 00_Foreworda15028.doc

04.01.07

Contents and 00_Foreworda15028.doc

04.01.07

CONTENTS TABLE OF CONTENTS

00 01 02

Safety - Foreword Technical DATA (Leaflet) Assembly PROCEDURE (Brochure)

Section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Main assembly groups Drive. Hydraulic oil tank. Hydraulic oil cooling. Controlling. Components Main hydraulic pumps and pump regulation. Operating hydraulic. Hydraulic track tensioning system. Hydraulic operated access ladder Cable weel Hints for the hydraulic circuit diagram Hints for the electric circuit diagram ECS-T Lubrication Systems

APPENDIX

)

• Each section includes a detailed table of contents.

Contents and 00_Foreworda15028.doc

04.01.07

SAFTEY

SAFTEY NOTICE

SAFETY SAFETY NOTICE • IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. The following Symbols are used in this Manual to designate Instructions of particular Importance.

WARNING -

Serious personal injury or extensive property damage can result if the warning instructions are not followed. To prevent injury to workers, this symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

)

CAUTION -

Minor personal injury can result or a part, an assembly, or the shovel can be damaged if the caution instructions are not followed.

NOTICE -

Refers to special information

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. continued 00-1

SAFTEY

SAFTEY NOTICE

Cont'd: GENERAL PRECAUTIONS 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower bucket, hammer or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out work on the oil or water circuits. continued 00-2

SAFTEY

SAFTEY NOTICE

Cont'd: PRECAUTIONS DURING WORK 13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

00-3

ENVIRONMENT PROTECTION

Environment NOTICE

RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS

OPERATION • • •

Avoid engine idling over long periods. Long periods of idling, more than 10 minutes, will not only waste fuel, but is also harmful to the engine. Avoid operation against the main relief valves of the hydraulic system. Move control lever to neutral position before the loader attachment stalls due to overload. Position trucks in such a way, that loading operation can be carried out in a safe and economic manner. Avoid swing angles over 90°.

MAINTENANCE • • •

00-3

Preserve our environment. To prevent environmental pollution, pay careful attention to the method of disposing waste materials. Always drain fluids from your machine into containers. Never drain fluids onto the ground or dump it into the sewage system, rivers, the sea or lakes. Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in accordance with environmental regulations and laws.

ENVIRONMENT PROTECTION

Environment NOTICE

FOREWORD GENERAL With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major systems of the Hydraulic Excavator PC5500-E. We describe for you all functions and how to carry out the inspections and adjustments. How do you find "your" desired information? In the table of CONTENT all the functions and components are shown in their sequence of the description. If after reading this SERVICE MANUAL you can give us suggestions and comments for improvements - please do not hesitate to contact us. Komatsu Mining Germany GmbH - Service Training Postfach 180361 40570 Düsseldorf Tel.:0211 / 7109 - 206 Fax.:0211 / 74 33 07 The editorial staff will be pleased about your co-operation. - FROM THE PRACTICE - FOR THE PRACTICE -

)

• This service manual corresponds to the state of development of the machine at the time the manual was produced. Variations based on special customers request and special equipment are not included in this manual

00-4

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING • Heavy parts (25 kg or more) must be lifted with a hoist etc.

)

• If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1. Check for removal of all bolts fastening the part to the relative parts. 2. Check for existence of another part causing interface with the part to be removed.

WIRE ROPES 1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter [mm]

10,0

11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0

Allowable load [tons]

1,0

1,4

)

1,6

2,2

2,8

3,6

4,4

5,6

10,0 18,0 28,0 40,0

• The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.

2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

continued Cont'd:

00-5

FOREWORD

HOISTING INSTRUCTIONS

WIRE ROPES 3. Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. • Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.

00-6

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm) STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

Bolt dia.

Tightening torque [Nm] Quality grades

Wrench size [mm]

8.8

10.9

12.9

M 8

13

6

21

31

36

M 10

17

8

43

63

73

M 12

19

10

74

108

127

M 14

22

12

118

173

202

M 16

24

14

179

265

310

M 18

27

14

255

360

425

M 20

30

17

360

510

600

M 22

32

17

485

690

810

M 24

36

19

620

880

1030

M 27

41

19

920

1310

1530

M 30

46

22

1250

1770

2080

M 33

50

24

1690

2400

2800

M 36

55

27

2170

3100

3600

M 39

60

2800

4000

4700

M 42

65

3500

4950

5800

M 45

70

4350

6200

7200

M 48

75

5200

7500

8700

M 52

80

6700

9600

11200

M 56

85

8400

12000

14000

M 60

90

10400

14800

17400

M 64

95

12600

17900

20900

M 68

100

15200

21600

25500

32 35 41 46

Insert all bolts lubricated with MPG, KP2K

00-7

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. (a) Locate the number 5 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (b) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (c) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2. Convert 550 mm into inches. (a) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. (b) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (c) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

00-8

FOREWORD

00-9

CONVERSION TABLE

FOREWORD

CONVERSION TABLE

00-10

FOREWORD

00-11

CONVERSION TABLE

FOREWORD

CONVERSION TABLE

00-12

FOREWORD

CONVERSION TABLE

Basic Values in Ohm according to DIN 43 76 For Measuring Resistor PT100

°C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80,31

79,91

79,51

79,11

78,72

78,32

77,92

77,52

77,13

76,73

-40

84,27

83,88

83,48

83,08

82,69

82,29

81,89

81,50

81,10

80,70

-30

88,22

87,83

87,43

87,04

86,64

86,25

85,85

85,46

85,06

84,67

-20

92,16

91,77

91,37

90,98

90,59

90,19

89,80

89,40

89,01

88,62

-10

96,09

95,69

95,30

94,91

94,52

94,12

93,73

93,34

92,95

92,55

0

100,00

99,61

99,22

98,83

98,44

98,04

97,65

97,26

96,87

96,48

°C

0

1

2

3

4

5

6

7

8

9

0

100,00

100,39

100,78

101,17

101,56

101,95

102,34

102,73

103,12

103,51

10

103,90

104,29

104,68

105,07

105,46

105,85

106,24

106,63

107,02

107,40

20

107,79

108,18

108,57

108,96

109,35

109,73

110,12

110,51

110,90

111,28

30

111,67

112,06

112,45

112,83

113,22

113,61

113,99

114,38

114,77

115,15

40

115,54

115,93

116,31

116,70

117,08

117,47

117,85

118,24

118,62

119,01

50

119,40

119,78

120,16

120,55

120,93

121,32

121,70

122,09

122,47

122,86

60

123,24

123,62 124,01, 124,39

124,77

125,16

125,54

125,92

126,31

126,69

70

127,07

127,45

127,84

128,22

128,60

128,98

129,37

129,75

130,13

130,51

80

130,89

131,27

131,66

132,04

132,42

132,80

133,18

133,56

133,94

134,32

90

134,70

135,08

135,46

135,84

136,22

136,60

136,98

137,36

137,47

138,12

100

138,50

138,88

139,26

139,64

140,02

140,39

140,77

141,15

141,53

141,91

110

142,29

142,66

143,04

143,42

143,80

144,17

144,55

144,93

145,31

145,68

120

146,06

146,44

146,81

147,19

147,57

147,94

148,32

148,70

149,07

149,45

130

149,82

150,20

150,57

150,95

151,33

151,70

152,08

152,45

152,83

153,20

140

153,58

153,95

154,32

154,70

155,07

155,45

155,82

156,19

156,57

156,94

150

157,31

157,69

158,06

158,43

158,81

159,18

159,55

159,93

160,30

16067

00-13

FOREWORD

CONVERSION TABLE

TEMPERATURE Fahrenheit – Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

00-14

Main Assembly Groups

Section 1.0 Page 1

Table of contents section 1.0 Section 1.0

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Page Main assembly groups General lay out

2

1.1

Superstructure

3

1.1.1

Machine house

4

1.1.2

Hydraulic Oil Reservoir

5

1.1.3

Hydraulic Oil Cooler

6

1.1.4

High tension switch cabinet

7

1.1.5

Counter weight

8

1.1.6

Cab support

9

1.1.7

Operators cab

10

1.1.8

Control Blocks

11

1.1.9

Swing gears

12

1.2

Under carriage

1.3

Attachment

13

1.3.1.

Backhoe Attachment (BHA)

14

1.3.2.

Front Shovel Attachment (FSA)

15

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Main Assembly Groups

1.

Section 1.0 Page 2

General lay out Legend for illustration (Z 22387): (1) Superstructure (2) Under carriage (3) Front Shovel Attachment (FSA) (4) Backhoe Attachment (BHA)

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1.0 3

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Main Assembly Groups

1.1

Section 1.0 Page 3

Superstructure Legend for illustration (Z 22386): (1) Operators Cab with integrated FOPS (2) Cable drum (3) (4) Cab support (contains the low tension electric switch board) (5) Swing ring connection (6) Switch cabinet, middle tension (main electric supply ) (7) Hydraulic ladder (8) Counter weight (9) Hydraulic oil cooler with hydraulic driven fans (10) Hydraulic oil reservoir (11) Batteries (12) Swing Gear (13) Grease pump of the Central Lubrication System (CLS) (14) Grease pump of the Swing gear pinion Lubrication System (SLS) (15) Main Control blocks with high pressure filters

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(16) (17) (18) (19) (20)

Main electric motor 1 Flexible coupling PTO gear with hydraulic pumps Main hydraulic pumps 1, 2 and 3 Capacitor motor 1

(21) (22) (23) (24) (25)

Main electric motor 2 Flexible coupling PTO gear with hydraulic pumps Main hydraulic pumps 4, 5 and 6 Capacitor motor 2

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Main Assembly Groups

1.1

Section 1.0 Page 4

Superstructure 1.1.1

Machine house

Legend for illustration (Z 22390a): A B C

View from the back of machinery house without counter weight View from the right side of machinery house Top view

(1) (2) (3) (4) (5) (6) (7)

Motor coolant air outlet Main motor supply cable Capacitor Hydraulic control and filter panel PTO gear box Main hydraulic pumps Auxiliary pumps, installed at the drive through shaft of the main hydraulic pumps (piggyback pumps) Hydraulic pump for radiator fan drive Hydraulic pump for the hydraulic oil cooler fan drive Suction oil reservoir Flexible coupling, oil filled Batteries Engine 1 Engine 2 Hydraulic motor for the radiator fan drive Radiator for the engine cooling system

(8) (9) (10) (11) (12) (13) (14) (15) (16)

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Main Assembly Groups

1.1

Section 1.0 Page 5

Superstructure 1.1.2

Hydraulic Oil Reservoir

Legend for illustration (Z 22391a): (1) Breather filter (2) Temperature controlled back pressure valve (3) Drain coupling of the hydraulic oil reservoir (4) Return oil filter (5) Case drain (leak oil) filter (6) Main shut-off valve (Gate valve) with compensator (7) Return oil collector tube (8) Drain coupling of the Return oil collector tube (9) Back pressure valves for swing motors

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Main Assembly Groups

04.01.07

Section 1.0 Page 6

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Main Assembly Groups

1.1

Section 1.0 Page 6

Superstructure 1.1.3

Hydraulic Oil Cooler

Legend for illustration (Z 22392): (1) Cooler frame with swing out facility (2) Hydraulic motor of upper fan (3) Upper fan (4) Fan guard (5) Outer part of the upper radiator set (6) Inner part of the upper radiator set (7) Hydraulic motor of lower fan (8) Lower fan (9) Fan guard (10) Outer part of the lower radiator set (11) Inner part of the lower radiator (12) Swing out doors (13) Locking bars to secure the swing out doors

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1.0 7

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Main Assembly Groups

1.1

Section 1.0 Page 7

Superstructure 1.1.4

High tension switch cabinet

Legend for illustration (Z 22638):

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A B C X

Left side view Front side view Top view High tension switch cabinet

(1) (2) (3) (4) (5) (6) (7)

Main fuses, high tension Main supply switch, manual controlled Main motor switches, remote controlled Current transformer Main transformer Air condition for switch cabinet Access stair

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Section 1.0 Page 8

Main Assembly Groups

1.1

Superstructure 1.1.5

Counter weight

Legend for illustration (Z 21474): (1) Counter weight Total weight ~40000 kg (2)

Mounting bolts Quantity 16

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Bolt size (mm) M 48 x 380

*

SW = Wrench size

(3)

Lifting points

Grade

SW* (mm)

10.9

75

Tightening torque (Nm) 7500

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1.0 9

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Section 1.0 Page 9

Main Assembly Groups

1.1

Superstructure 1.1.6

Cab support

Legend for illustration (Z 21475): (1) Cab support (Location of electrical switch board “X2”) (2) Mounting bolts Quantity Bolt size Grade SW* Tightening (mm) (mm) torque (Nm) 6

M 36 x 320

10.9

55

Grade

SW* (mm)

10.9

55

3100

* SW = Wrench size (3)

Mounting bolts Quantity Bolt size (mm) 6

M 36 x 160

Tightening torque (Nm) 3100

* SW = Wrench size (4) (5) (6)

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Door Gasket Door handle (adjustable)

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Main Assembly Groups

1.1

Section 1.0 Page 10

Superstructure 1.1.7

Operators cab

Legend for illustration (Z 21476): (1) (2) (3) (E19)

Monitor panel Switch panel Operators seat Control lever – EURO Control

– KMG Control

(E20)

Control lever – EURO Control

– KMG Control

(E21a)

Control pedal

A - forward Left track B - reverse

(E21b)

Control pedal

A - forward Right track B - reverse

(E22) (E23) (E24)

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Control pedal - Swing brake Control pedal (left) Control pedal (right)

Clam closing Clam opening

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Main Assembly Groups

1.1

Section 1.0 Page 11

Superstructure 1.1.8

Control blocks

Legend for illustration (Z 21477a): (1) Control block carrier (2) Remote control valves (3) Main control blocks (4) High pressure filter

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1.0 12

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Main Assembly Groups

1.1

Section 1.0 Page 12

Superstructure 1.1.9

Swing gears

Legend for illustration (Z 22395): (1) Swing gear box (2) Swing parking brake (3) (4) (5) (6) (7) (8) (9) (10) (20.1 + 20.2) (49.1 + 49.2)

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– Spring loaded multi disk brake (Released by oil pressure) Parking brake Control port (X) Oil level gauge - gear box Breather – gear box Oil filling plug – gear box Oil level gauge – motor adapter housing Breather – motor adapter housing Oil drain plug – motor adapter housing Oil drain plug - gear box Swing motor Swing brake valve block

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Main Assembly Groups

1.2

Section 1.0 Page 13

Under carriage Legend for illustration (Z 21481a): (1) Undercarriage center body (2) Crawler carrier R.H.-side (3) Crawler carrier L.H.-side (4) Connecting pins, center body to crawler carriers (5) Crawler tracks (6) Rotary distributor (7) Brake valves (8) Travel motors (9) Parking brakes, spring loaded disk type brakes (10) Travel gear (11) Sprocket (12) Track rollers (13) Carrier rollers (14) Guide wheel (Idler)

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1.0 14

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Main Assembly Groups

1.3

Section 1.0 Page 14

Attachment 1.3.1

Backhoe attachment (BHA)

Legend for illustration (Z 21482): (1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5) Bucket (6) Bucket Cylinders (7) Control arm (8) Linkage

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1.0 15

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Main Assembly Groups

1.3

Section 1.0 Page 15

Attachment 1.3.2

Front Shovel Attachment (FSA)

Legend for illustration (Z 21483): (1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5) Bucket backwall (6) Bucket Cylinders (7) Clam (8) Bucket Clam cylinders

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Drive

Section 2.0 Page 1

Table of contents section 2.0 Section 2.0

Page Prime drive assembly General

2

2.1

Coupling

3

2.2

Pump-spline lubrication

4

2.3

PTO Lubrication and cooling

5-6

2.4

Hydraulic pumps – location, drive speed and flow rates

7

2.0 2

Drive

Section 2.0 Page 2

2.0 Prime drive assembly Legend for illustration (Z 22644): (1) Cooling air intake (2) Cooling air exhaust (3) Electric Motor (4) Alignment shims (5) Alignment supports (6) Motor frame (7) Coupling (8) Pump distributor gear (PTO)

General The two electric motors are solid bolted to the motor frame (6). The alignment shims (4) thickness must be determined due the alignment procedure. The alignment must be done in accordance to the Parts & Service News AH01523, last edition.

)

• The alignment shims thickness must be also determined when replacing the electric motor! Never use the existing shims without determination.

2.0 3

Drive

Section 2.0 Page 3

2.1 Coupling Legend for illustration (Z 22645): (1) Input drive hub (2) Output drive flange (3) Outside rubber support ring (4) Rubber element (5) Motor drive shaft (6) Gearbox input flange (7) Hub looking washer (8) Coupling ring

)

• Repair and replacement have to be done accordingly to Parts & Service News AH01523, last edition.

Design: VULASTIC-L – coupling type are provided with one flexible rubber element (4). The flexible ring connect the input drive hub (1) via the coupling ring (8) with the output drive flange (2) of the coupling.

Function: The high flexible VLULASTIC–L coupling transfers the torque without any rotational gap. They are wear-resisting and maintenance free. Because of symmetrical arrangement of the flexible rings, there are no returning forces either by the torque transfer or the centrifugal forces. VULASTIC-L couplings dampen rotating vibrations, reducing same by partial storing of the shock energy and damp noises. The coupling allows in an acceptable range axial, radial and angular misalignment of the shafts. Replacement and alignment refer to Parts & Service News AH01523, last edition.

2.0 4

Drive

2.2

Section 2.0 Page 4

Pump-spline lubrication Drive shaft housings Legend for illustration (Z 21608): (1) Oil filler plug with breather pipe of main pump drive shaft housing (2) Oil collector reservoir for auxiliary pump drive shaft housing (M) Configuration, main pump drives (A) Configuration, auxiliary pump drives All drive shaft housings are filled with the same gear oil as the pump distributor gear. This is done for two reasons: 1. To lubricate the multi-spline connections, to prevent wear and corrosion. 2. It makes it easier to determine a sealring leak at one of the drive shaft connections. Function: M If the oil level increases the oil drops out of the breather pipe (1). If this oil is gear oil it indicates a possible leak at the gearbox side. If the oil is a mixture of gear oil and hydraulic oil it shows a possible leak at the pump side. If at an oil level check a loss of oil is found it may be due to worn or defective radial seal rings. Function: A The oil is filled in via the oil collector reservoir (2). All auxiliary drive shaft housings are connected by pipes with the reservoir. The reservoir is filled approx. one half with oil. If the oil level in the reservoir increases due to leakage the oil drops out from the breather filter (with oil level gauge) on top of the reservoir. Now a check has to be done to find out which one of the drive shafts seals is damaged. It can be done by disconnecting temporary the pipe to the reservoir. Disconnect the pipe at the drive shaft housing, plug the pipe and leave the union open. If now at operation the oil still comes out of the union, this drive shaft seal is gone. Otherwise check sequential all auxiliary drives.

2.0 5

Drive

2.3

Section 2.0 Page 5

PTO Lubrication and cooling Legend for illustration (Z 22410e): The machine is equipped with two motors and gearboxes. The motor close to the counter weight is called motor 1 and the motor to the front is called motor 2. The extension of the component designation shows the mounted position. Example: Pressure filter (69.1) is the pressure filter for the PTO lubrication of motor 1 and (69.2) of motor 2. (1) Line to the cooler (hot oil) (2) Return line from the cooler (cooled oil) (3) Return line from valve (4) Suction line from PTO oil pan to the pump (P) Pressure port (8.1)(8.4) Gear pump PTO-gearbox lubrication (69.1)(69.2) Pressure filter - PTO gear lubrication (74.1)(74.2) Pressure relief valve, 7,5 bar (78.14)(78.15) Solenoid valve (Y53-x), (reduction of relief valve pressure) (105.3+105.4) Oil cooler, part of hydraulic oil cooler motor 1 (105.1+105.2) Oil cooler, part of hydraulic oil cooler motor 2 (M1-1)(M1-2) Pressure check point (B17-1)(B17-2) Pressure switch, 0,5 bar (B27-1)(B27-2) Maintenance switch, 5 bar (B49-1) Temperature sensor Function: Pump (8.1)/(8.4) forces the gear oil from the gear oil pan through filter (69.1)/(69.2)) to pressure relief valve (74.1/74.2). This pressure relief valve acts as a back pressure valve causing that most of the oil passes through the gear oil coolers (105.3+105.4)/(105.1+105.2). The gear oil coolers are a small part of the hydraulic oil coolers, thus the gear oil gets cooled by the same air stream as the hydraulic oil. From the coolers the oil flows to the port (P) of the gear and internally via a system of pipes to the several spray nozzles. The spray nozzles in the gear case ensure proper and adequate distribution of the lube oil. The circuit is monitored by the pressure switches (B17-1). At too low lube oil pressure (0.5 bar), a fault message will be displayed on the monitor at the dash board. The gear oil temperature is monitored by the sensor unit (B49-1) (B49-2). At too high oil temperature a fault message will be displayed on the monitor at the dash board. If the oil temperature is to low, solenoid valve (Y53-1) (Y53-2) energised and opened port X of the pressure relive valve (74.1) (74.2). This reduced the relieve valve pressure setting. The main gear oil flow direct back to the PTO to quick warm up of the gear oil. continued

2.0 6

Section 2.0 Page 6

Drive

Cont`d. 2.3

PTO Lubrication and cooling Legend for illustration (Z 22414): (1) Pilot operated relief valve (2) Plug screw (3) Valve piston (4) Port for pressure switch B17-1 (6) Port for pressure check stud (7) Jet bore

(8) (9) (B27-x) (74.x) (A) (T)

Valve spring Seal rings Maintenance switch Pressure relief valve Pressure port Return from valve

Adjustments: • The adjustment of the maximum permissible PTO lube pressure, has to be carried out with cold oil to avoid serious damages to the coolers. • The check for a sufficient PTO lube pressure has to be carried out with warm oil to avoid serious damages gearbox. Setting the pressure relief valve (74.x) at cold oil. 1. Connect a pressure gauge to check point (M1.x). 2. Disconnect plug of solenoid valve Y53-1/ Y53-2 3. Start the respective motor 4. Required pressure: 7,5 bar. If adjustment is required: 5. Remove protection cap (1a). 6. Loosen lock nut (1b). 7. Set the pressure with set screw (1c). 8. Tighten lock nut (1b) and re-install protection cap (1a) 9. Reconnect plug of Y53-1/ Y53-2

)

• If the pressure of 7,5 bar cannot be adj. 100 %, adj. to the maximum visible pressure.

Checking the PTO lube pressure at operating temperature (warm oil) 1. Connect a pressure gauge to check point (M1.x). 2. 3.

Start the motor and let it run with max. speed. Required pressure: 2-7,5 bar.

2.0 7

Section 2.0 Page 7

Drive

2.4

Hydraulic pumps – location, drive speed and flow rates Legend for illustration (Z 22415b): (1 - 6) Axial piston pump (swash plate type) pump volume theoretical flow rate, each Drive speed* for all working motions

Vg Qmax n pmax

= 500 cm³/rev = 700 Liter/min = 1409 min-1 = 310 bar

(10.1), (10.2) Axial piston pump pump volume theoretical flow rate Drive speed* for oil cooler fan drive

Vg Qmax n pmax

= 80 cm³ = 142 Liter/min = 1632 min-1 = 180 bar

Gear pump pump volume theoretical flow rate Drive speed* for PTO gear lubrication

Vg Qmax n pmax

= 58.7 cm³/rev = 82,2 Liter/min = 1409 min-1 = 7,5 bar

Gear pump pump volume theoretical flow rate Drive speed* for hydraulic oil circulation

Vg Qmax n pmax

= 58.7 cm³/rev = 82,2 Liter/min = 1409 min-1 = 15 bar

Gear pump pump volume theoretical flow rate

Vg Qmax

= 85.7 cm³/rev

Drive speed* for pilot pressure supply

n pmax

(8.1), (8.4)

(8.2), (8.5)

(7.1), (7.2)

)

= 120 Liter/min = 1409 min-1 = 60 bar

• * at 1500 min-1 (50Hz) or 1800 min-1 (60Hz) input drive speed

Hydraulic Oil Reservoir

Section 3.0 Page 1

Table of contents section 3.0 Section 3.0

Page Hydraulic oil reservoir General lay out

2

3.1

Main oil tank, location of switches, sensors etc.

3

3.2

Suction oil tank with strainers

4

3.3

Return oil collector tube with strainer

5

3.4

Back pressure valve

6

3.6

Return and Leak Oil Filter

8

3.7

Breather Filter

9

3.5

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3.0 2

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Hydraulic Oil Reservoir

3.

Section 3.0 Page 2

General lay out Legend for illustration (Z 22416b): (1) Filter cover retainer (2) Filter cover (3) (A) – Return oil filter – 10 µm (4x) (B) – Case drain filter – 3 µm (1x) (4) Man hole cover (5) Hydraulic oil filler plug (6) Differential pressure switch, screen filter monitoring (7) Test port, back pressure 8 bar (8) Test port, back pressure swing motor 15 bar (24) Pressure switch B24 – monitors item (132.1+132.2) (39) Hydraulic oil level gauge (41) Main oil reservoir (114) Return oil collector tube with pressure check point M10 (115) Back pressure valve (118) Oil drain, quick release coupling (128) Shut off valve (Gate valve) with monitoring switch S31 (129) Compensator (132.1 + 132.2) Breather filter (178) Oil cooler filter (screen filter) The hydraulic oil tank is a welded sheet-metal construction. The filling capacity is about 3800 litres. The tank contains four return oil filters (3-A) and one case drain filter (3-B). The breather filter (132.1 + 132.2) cleans the air that streams into the tank. The back pressure valve (115) and the pressure check point (M10) are located at the collector tube (114) for return oil. The connection to the suction tank can be closed with the shut- off valve (118) to prevent oil flow during repairs on the hydraulic pumps. This unit is controlled by the switch S31, to prevent a motor start with closed shut-off valve. Fault message ”Start blocked because of main Shut-Off (gate) valve” is displayed at the operators dash board. The screen filter (178) protect the oil cooler for internal contamination, the filter is monitored by differential pressure switch (178). The back pressure valves (8) increase the circulation pump pressure to 15 bar for cavitation protection of the swing motors.

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3.0 3

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Hydraulic Oil Reservoir

3.1

Section 3.0 Page 3

Main oil tank, location of switches, sensors etc. Legend for illustration (Z 21495a): (B4) Oil level sensor “Hydraulic oil level too low” (B15) Hydraulic oil temperature probe “Hydraulic oil temperature below: too hot” (B24) Breather filter pressure switch (B25) Pressure switch – Pressure leak oil chamber (B26) Pressure switch – Pressure return oil chamber (B32) Hydraulic oil temperature probe “Temp. gauge cabin” (B42) Oil level sensor “Oil level maximum” (B50) Oil level sensor “Hydraulic oil refill level” (Y101) Solenoid valve “Back pressure reduction”

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3.0 4

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Hydraulic Oil Reservoir

3.2

Section 3.0 Page 4

Suction oil tank with strainers Legend for illustration (Z 22418): (1) Suction oil reservoir (2) Drain coupling (3) Bolt (4) Gaskets (5) Main suction oil strainer (6) Gaskets (7) Intermediate pipe (8) Nut (9) Bolt (10) Compensator (11) Suction strainer – one for each main pump (12) Suction hose connection pipe The suction oil tank (1) is a welded sheet-metal construction. The capacity is 187 liters. The suction lines of all hydraulic pumps are connected to the suction tank.

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3.0 5

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Hydraulic Oil Reservoir

Section 3.0 Page 5

3.3 Return oil collector tube with strainer Legend for illustration (Z 21497a): (1) Return oil collector tube - Part 1 (2) Return oil collector tube - Part 2 (3) Return oil collector tube - Part 3 (4) Strainer (5) Bolt (6) Self locking nut (7) Gasket (8) Differential pressure switch B165

Task: The strainer is installed to prevent the hydraulic oil coolers from getting clogged up in case of contamination in the main return oil circuit. Excessive increase of the hydraulic oil temperature can be an indication for a restricted strainer, i.e. bad cooling performance due to insufficient oil flow through the coolers. In case that main components such as cylinders or motors are internal fragmentary damaged, the strainer should be inspected for metal chips.

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Hydraulic Oil Reservoir

3.4

Section 3.0 Page 6

Back pressure valve Legend for illustration (Z 21498): (1) Back pressure valve assembly (2) Solenoid valve (Y101)

Task: The back pressure valve has to fulfill two functions in the hydraulic system: 1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply oil via the anticavitaton valves to the low pressure side of cylinders, respectively motors. 2. To force the return oil through the coolers depending on the present hydraulic oil temperature, controlled by solenoid valve Y101. - Low temperature ⇒ low volume through the coolers - High temperature ⇒ high volume through the coolers

)

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• Further information about the function principle and adjustments, refer to Section 4.0 this Manual.

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Hydraulic Oil Reservoir

3.6

Section 3.0 Page 7

Return and Leak Oil Filter Legend for illustration (Z 21500): (1) Filter cover retainer (2) Filter cover with o-ring (3) Pre-tensioning spring (4) Retainer (5) Filter assembly (6) Filter pot with machined cover (7) Main filter element, 10 micron absolute (8) Safety filter element (200 micron strainer) (9) By pass-valve, 2.3bar (9.1) Valve cone (9.2) Valve spring (9.3) O-ring (10) Profile gasket (11) Seal ring (12) Self locking nut (13) Self locking nut Function: The returning oil flows into the filter chamber (A) of the hydraulic tank. (The sketch shows one section only). The chamber is split into two sections; one sections with 4 filters for the return oil and one for the leak oil. But the five filters are all the same. The hydraulic oil enters the filter at the top and passes then on its way to the entire tank the filterelement (7). "Inside to outside filtration." The filter element condition is monitored by a pressure switch (B25, 0.5 bar for the leak oil filter) and (B26, 2 bar for the return oil filter). As soon as the pressure inside the filter chamber reaches the set pressure of those switches due to the restriction of the filter-element which is caused by foreign matters, the fault message ”Return oil filter restricted" or ”Leak oil filter restricted” is displayed at the operator's dash board The filter elements must be replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As the filter chamber pressure increases the by-pass valve opens at 2.3 bar and protects the element from bursting. But the oil flows not totally unfiltered into the tank because it must flow through the strainer (8).

)

•

•

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The switch point of the pressure switch for the leak oil has been chosen so low with best intention to protect first of all the radial seal rings of the hydraulic motors. Because the filter is oversized for this purpose, the message ”Leak oil filter restricted” is displayed very seldom under normal circumstances. Maintenance see MAINTENANCE MANUAL

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Hydraulic Oil Reservoir

3.7

Section 3.0 Page 8

Breather filter Legend for illustration (Z 21501a): (1) Nut (2) Cover (3) Filter element (4) Filter pot A breather filter is installed to clean the air that streams into the tank any time the oil level decreases while extending attachment cylinders The filter element condition is monitored by a vacuum type pressure switch (B24, 80mbar). Maintenance see MAINTENANCE MANUAL

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Hydraulic Oil Cooling

Section 4.0 Page 1

Table of contents section 4.0

Section 4.0

Page Hydraulic oil cooling 4.1

General

2

4.2

Function of the hydraulic oil cooling circuit

3

4.3

Adjustment of the Back Pressure Valve

4

4.4

Fan drive (Two stage cooler fan RPM control)

5+6

4.5

Pressure relief valves and solenoid valve

7+8

4.6

Fixed Displacement Pump, with variable setting

4.7

Radiator fan drive speed adjustment

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9 10 – 12

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Hydraulic Oil Cooling

4.1

Section 4.0 Page 2

General The hydraulic oil cooling system maintains the hydraulic oil at a normal operating temperature. Legend for illustration (Z 21594) (1) Noise shield (1) Cooler (Radiator) (2) Cooler frame (3) Fan (4) Fan motor (Axial piston motor) (5) Bolt (6) Bolt (7) Drive shaft (8) Shaft protecting Sleeve (9) Drive shaft seal (10) Ball bearings (11) Seeger clip ring (12) Bearing group carrier (13) Oil level plug (14) Breather filter Design: There are four hydraulic oil coolers in front of the hydraulic tank on the R.H. side of the platform. They are in pairs mounted in one frame, one above the other. The air stream needed for the cooling is produced by hydraulic driven fans. The air flows from inside to outside through the coolers. For a better cleaning, the coolers can be moved to the side. (“Swing out cooler”) The bearing group carrier is filled with oil to lubricate the bearings.

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Hydraulic Oil Cooling

4.2

Section 4.0 Page 3

Function of the hydraulic oil cooling circuit Legend for illustration (Z 22419aa) (107.1-107.4) Restrictor, shock absorbers for the hydraulic oil cooler (106.1-106.4) Hydraulic oil cooler (41) Main oil reservoir (114) Return oil collector tube (115) Back pressure valve (L6 + L7) Return line from control blocks (C1 + C2) Supply line for the anticavitation circuit of the swing motors (M10) Pressure check point (C1 + C2) Supply line for the anticavitation circuit of the swing motors (Y101) Solenoid valve – 4/2-directional control valve (H) Lines to cooler (hot oil) (C) Lines to tank (cold oil) Function: The returning oil from the system flows via the lines (L6 - L7) into the collector tube (114). On the top of it is the Back Pressure Valve (115) installed. The back pressure valve (115) causes a back pressure which forces most of the relative hot oil through the lines (H) to the cooler (106.1-106.4). On its flow through the cooler the hydraulic oil gets cooled and flows than through the restrictors (107.1-107.4) and the lines (C) into the filter chamber of the main oil reservoir (41). The restrictors are acting like shock absorbers to prevent cooler cracking at pressure peaks. Besides the back pressure valve acts as an oil flow control valve as far as the oil temperature has not reached its steady temperature. During the warm up period (1/2 Qmax) the back pressure valve (115) is wide open, because solenoid valve Y101 is energized, which results in less oil flows through the cooler which causes that the oil gets quicker its optimum operating temperature. With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously solenoid valve Y101 will be de-energized, so that the valve piston will be more closed by the force of the spring thus that more oil passes the cooler.

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Hydraulic Oil Cooling

4.3

Section 4.0 Page 4

Adjustment of the Back Pressure Valve Checks and settings only at normal operating temperature of the hydraulic oil, main pumps in maximum flow position and "Idle Time" control eliminated (service switch S151 actuated)! 1. Connect a pressure gauge to check point (M10). 2. Disconnect plug connector (13) of solenoid valve Y101. 3. Actuate service switch S151 (). 4. Start both both the motors.. 5. Required pressure: 8 ±0,5 bar If adjustment is required: a) Take off protective cap (12). b) Loosen lock nut (5). c) Adjust the pressure with the set screw (6). d) Tighten lock nut (5) and refit protective cap (12). 6. Disconnect the pressure gauge, reconnect solenoid valve Y101 and switch back service switch S151. Legend for illustration (Z 21596c): (1) Control oil port (2) "Y"- port (external return to tank) (2a) "X"- port (external return to tank via solenoid valve Y101) (3) Poppet (4) Valve spring (5) Lock nut (6) Set screw (7) Jet bore (large) (8) Valve spring (9) Valve piston (10) Jet bore (small) (11) Plug screw (12) Protective cap (13) Plug connector (A) Return to tank (Filter chamber) (Z) Pressure oil to valve

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Hydraulic Oil Cooling

4.4

Section 4.0 Page 5

Fan drive (Two stage cooler fan RPM control) Legend for illustration (Z 22420aa) (10.2) Axial piston pump Motor 1 (fixed displacement pump, with variable setting) (10.4) Axial piston pump Motor 2 (fixed displacement pump, with variable setting) (22.1) Fan motor (Axial piston motor) (22.2) Fan motor (Axial piston motor) (41) Main oil reservoir (168.1) Pressure relief valve – Motor 1 radiator fan drive (168.2) Pressure relief valve – Motor 2 radiator fan drive (68.1) Pressure filter with pressure differential switch B28-1 (Motor 1) (68.2) Pressure filter with pressure differential switch B28-2 (Motor 2) (103.1) Check valve– (Anti cavitation valve for fan drive motor) (103.2) Check valve– (Anti cavitation valve for fan drive motor) (148.11) 4/3 direction flow valve – Motor 1 radiator fan speed (stop, low and high speed), solenoid Y6A-1 + Y6B-1 (148.12) 4/3 direction flow valve – Motor 2 radiator fan speed (stop, low and high speed), solenoid Y6A-2 + Y6B-2 (169.1) pressure reduction valve (low fan speed adjusting) motor 1 (169.2) pressure reduction valve (low fan speed adjusting) motor 2 (L) Leak oil (case drain) to tank (P) Pressure to motor (R) Return oil to tank Mot1 Mot1 PVG PVG of Motor 1 Mot2 Mot2 PVG PVG of Motor 2

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Hydraulic Oil Cooling

Section 4.0 Page 6

Function: From pump (10.x) flows the oil through the filter (68.x) to the fan motor (22.x) and then back to the tank. The check valve (103.x) act as an anti cavitation valve and is installed, because the fan motor -driven by inertial force- is running for a short period after the oil flow is interrupted by solenoid valve (Y6A-x/Y6B-x) or if the motor has been switched off. The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief valves (168.x) and (169.x). These valves are working together with the solenoid valve (Y6A-x/Y6B-x), controlled by the PLC, depending on the hydraulic oil temperature: • With de-energized solenoids Y6A-x and Y6B-x the relief valve (168.x) is functioning and the fans are running with max. adjusted speed (1300 RPM) • With solenoid Y6A-x energized the relief valve (168.x) is not functioning and the fans are running with a very low speed caused by the flow resistance only. • With solenoid Y6b energized the relief valve (169.x) is controlling the relief valve (168.x) and the fans are running with 1000 RPM RPM only. (See also description on next page)

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Hydraulic Oil Cooling

4.5

Section 4.0 Page 7

Pressure relief valves and solenoid valves Pressure relief valves (168.x) Legend for illustration (Z 21598b) (1) Valve cartridge (2) Spring (3) Spring chamber (4) "X" port (5) Jet bore, Pilot poppet (6) Jet bore, Main piston (7) Main piston (8) Valve housing (9) Pilot poppet (Y) (A) (B)

External leak oil port Pressure port Return oil port

Function: Pressure in line A affects the main piston (7). At the same time there is pressure via the jet bore (6) on the spring-loaded side of the main piston and via jet bore (5) at the pilot poppet (9) of the relief valve cartridge (1). If system pressure in line A exceeds the value set at the spring (2), pilot poppet (9) opens. The signal for this comes from line A via the jet bores (6) and (5). The oil on the spring-loaded side of the main piston (7) now flows via the jet bore (5) and poppet (9) into the spring chamber (3). From here it is fed internally by means of the control line (Y) to tank (port B). Due to the state of equilibrium at the main piston (7), oil flows from line A to line B, while the set operating pressure is maintained. The pressure relief valve can be changed (Remote controlled) by means of the port "X" and the function of the solenoid valve Y6A-x / Y6B-x and pressure reduction valve 169.x. .( Function see next page)

continued

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Hydraulic Oil Cooling

Section 4.0 Page 8

Cont’d. 4.5

Pressure relief valves and solenoid valve, illustration (Z 21599c)

Function: With de-energized solenoids (Y6A-x and Y6B-x), the spool (3) of the 4/3 direction flow valve 148.x keeps the "X" connection of valve (168.x) and port “B“ to port “P“ closed. The pressure relief valve (168.x) operates normal with the max. adjusted pressure. The fan turn with maximum speed. The energized solenoid Y6B, operate the spool (3) of the 4/3 direction flow valve 148.x and a connection is made between port “P“ , port “B“ and port "X" of valve (168.x) The system pressure now opens main piston (7) of valve (168.x), because via solenoid Y6B (P to B) the oil from the rear side of piston (7) flows from the "X"-port to the “P“ port of valve (169.x). This valve (169.x) reduce now the max. adjusted pressure of valve (168.x) to a lower value. The fan turn with reduced speed. The energized solenoid Y6A, operate the spool (3) of the 4/3 direction flow valve (148.x) and a connection is made between port “P“ and port “A” and port "X" of relief valve (168.x). The system pressure now opens the main piston (7) of valve (168.x) because via the "X"-port the oil from the rear side of piston (7) flows to tank. The normal relief valve function is eliminated. The fan turn with minimum speed, nearly stand still.

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Hydraulic Oil Cooling

4.6

Section 4.0 Page 9

Fixed Displacement Pump, with variable setting

Legend for illustration (Z 21852) (1) Drive shaft (2) Bearings (3) Cylinder with pistons (4) Center pin (5) Control lens (6) Q-min adjustment bolt (7) Q-max adjustment bolt (8) Pressure port (9) Tank port Description. Pump type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft. Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of an adjusting screw. • With an increase in the swivel angel, the pump output increase together with necessary drive torque. • With an decrease in the swivel angel, the pump output decreases together with the necessary drive torque. • When increasing to maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motor!

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Hydraulic Oil Cooling

4.7

Section 4.0 Page 10

Oil cooler Radiator fan drive speed adjustment Basic Adjustment Legend for illustration (Z 22400a): (1) Dust cap (2) Lock nut (3) Set screw (P) Axial piston pump (fixed displacement pump, with variable setting) (6) Qmin stop bolt (6.1) Lock nut (7) Qmax stop bolt (7.1) Lock nut (10) Positioning pin (mover) (168.1) Pressure relief valve – bottom oil cooler fan (Motor 1) (168.4) Pressure relief valve – top oil cooler fan (Motor 2) (169.1) pressure reduction valve – bottom oil cooler fan (Motor 1) (169.2) pressure reduction valve – top oil cooler fan (Motor 2) (Y6A-1 /Y6B-1) 4/3 direction flow valve – Motor 1 (Y6A-2 /Y6B-2) 4/3 direction flow valve – Motor 2 (L1) Measurement of Qmin stop bolt (L2) Measurement of Qmax stop bolt (M5-1) Pressure check points - Motor 1 oil cooler fan drive operating pressure (M5-2) Pressure check points - Motor 2 oil cooler fan drive operating pressure

)

• A blocked cooler, restricted air flow, defect cooler seal or bend fan influence the fan RPM and air flow. • Basic adjustment has to be carried out whenever one of the following components has been replaced: - pump - relief valve - hydraulic motor continued

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Hydraulic Oil Cooling

Section 4.0 Page 11

Cont'd 4.7

Oil cooler fan drive speed adjustment Radiator fan drive speed adjustment Basic Adjustment max fan speed 1. Reduce the output flow of the respective pump (P),by adjusting the minimum possible swivel angle, to avoid over speeding the fan: To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)and turn in bolt (7) up to final stop. This is necessary to avoid a loose positioning pin (10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts. 2. Remove protection cap (1) from relief valve (168.x), loosen lock nut (2) and turn set screw (3) fully clockwise and then a half turn counter clockwise. 3. Disconnect the plug connectors (Y6A-x and Y6B-x) of the 4/3 direction flow valve, to ensure that the full flow of pump P will be delivered to the fan motor. The valve is in neutral position and all ports are blocked. 4. Connect a pressure gauge to check point (M5-x). 5. Start the respective motor. and let it run in high idle. 6. Check the fan speed with a non-contact rev counter Required fan speed: 1300250 RPM • Be careful not to get caught in the fan or other rotating parts 7.

)

Increase the output flow of pump P ,by adjusting the swivel angle, until the fan speed is 20 RPM higher than required: To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6) and turn out bolt (7) the same length. This is necessary to avoid a loose positioning pin (10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts (6.1 + 7.1). • Do not exceed the maximum permissible operating pressure of 230 bar • Note down the lengths ”L1” and ”L2” as reference measurements.

continued

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Hydraulic Oil Cooling

Section 4.0 Page 12

Cont'd 8.

Loosen lock nut (2) of the relief valve (168.x), and decrease the pressure with set screw (3) until the correct fan speed is obtained. Tighten lock nut (2) and fix protection cap (3).

9.

Basic Adjustment middle fan speed 10. Activate the 4/3 direction flow valve (Y6B-x), by connecting the solenoid plug (Y6B-x ) to permanent 24 V. Use a the 24V socket (close to the motor house light switch or emergency switch.at the PTO *) or activate the fan via PLC control ( digital output, key switch required). 11. Check the fan speed with a non-contact rev counter Required fan speed: 1000 RPM 12. If adjustment is necessary loosen lock nut (5) of the relief valve (169.x), and decrease the pressure with set screw (4) until the correct fan speed is obtained. 13. Stop motor and reconnect the plugs to the correct positions. 14. Disconnect the pressure gauge from check point (M5-x). Fan speed check If the maximum fan speed is out of adjustment, increase or decrease first the pressure at relief valve (168.x), to change the speed. • Do not exceed the maximum permissible operating pressure of 230 bar

If the speed can not be raised by increasing the pressure then increase the output flow of pump (10.x). *)

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Prepare a test wire with a plug ET-No. 891 039 40, and a plug ET-No. 440 305 99. Connect terminal 1 to positive (+) (center off plug 440 305 99) and terminal 2 to ground (-).

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Controlling

Section 5.0 Page 1

Table of contents section 5.0

Section 5.0

04.01.07

Page Controlling General lay out

2

5.1

Control and filter panel location of components (valves, switches, sensors etc.)

3

5.2

Pilot Pressure Supply and Adjustments

4–7

5.3

Remote control valves arrangement

8

5.4

Function principle of the Electro-Hydraulic- Proportional Control

9 + 10

5.5

Potentiometer Control (Lever, Joy Stick)

11

5.6

Potentiometer Control (Pedal)

12

5.7

Proportional amplifier module, Type A (for swing brake only)

13

5.8

Proportional amplifier module, Type B (for Boom, Stick, Bucket, Swing and Travel)

14

5.9

Ramp Time Module (Analogue command value module for Boom, Stick, Travel and Swing function)

15

5.10

Adjustments of Amplifier Modules (General)

16

5.11

Adjusting the Amplifiers Type B

17 + 18

5.12

Adjusting the Amplifiers Type A

19 + 20

5.13

Adjusting the Ramp Time Module

21 + 23

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X4 - pump support pressure

X2 pilot pressure

X3 – remote control pressure (1/2Qmax; Qmin) pump regulation

X1 - pump regulation pressure

to (45.2); (45.3) and (43)

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Controlling

5.0

Section 5.0 Page 2

General lay out Legend for illustration (Z 21631): (7.1 / (7.2) Pumps for pilot pressure and pump regulation system (84.1 / 84.2) Check valve (for combined operation) (68.1) Filter (70.1) Pressure relief valve (X4 – pressure) (70.2) Pressure relief valve (X2 – pressure) (85) Pressure accumulator (10 Liter, 10 bar pre-charge pressure) (91) Check valve (45.1; 45.2 ;45.3, 43) Remote control valves (14; 15; 16; 13)) Control blocks General The controlling includes the pilot pressure system and the pump regulation system. The pumps (7.1 / 7.2) forcing the oil through the filter (68.1) to all involved valves. The pressure accumulator ensures that under any circumstances enough pilot pressure oil is available. The accumulator (85) is also functioning as a hydraulic battery for a certain time when the motor was shut down or to pressure relive the system for repair works. When the operator is using his controls an electrical signal causes energizing of the selected solenoid valve of the remote control valves(14). By the function of the remote control valves pilot pressure oil is send to the relevant control block spools which in turn allows operating hydraulic oil to the users.

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Section 5.0 Page 3

Controlling

5.1

Control and filter panel location of components Legend for illustration (Z 22497): Solenoid valves

Motor 1

Motor 2 (Y5)

(Y6A-1) (Y6A-2) (Y14A-1) (Y14B-1)

(Y6B-1) (Y6B-2) (Y14A-2) (Y14B-2) (Y16) (Y17) (Y17a) (Y127)

(Y61.1) (Y61.2) (Y102.1) (Y102.2) (Y124A/B) (Y124c) (Y48) (Y120) (Y123A/B) (Y125)

Swing gear house brake (swing parking brake) Oil cooler fan RPM control Oil cooler fan RPM control Radiator fan RPM control, low speed (only diesel drive) Radiator fan RPM control, middle speed (only diesel drive) Travel gear house brake (travel parking brake) Idle time control (Qmin) ½ Q-max (reduced oil flow at cold oil) Swing service brake control „XLR“ pressure, pumps 1 - 3, „XLR“ pressure, pumps 4 - 6 „X4“ pressure, pumps 1 - 3, „X4“ pressure, pumps 4 - 6 Refilling arm – up and down (only with diesel engines) Refilling arm lock (only with diesel engines) Swing motor power/ speed control Emergency swing service brake control ladder up and down ladder speed control

Pressure switches: (B16) (B21.1)

(B21.2) (B22)

(B27.1) (B28.1)

(B27.2) (B28.2) (B48)

(B97.1) (B85.1)

(B97.2) (B85.2) (B86)

Pilot pressure for Swing gear house brake (24 bar) Radiator fan drive filter differential switch (filters 68.3+5) (only diesel) Differential pressure switch, pilot pressure system filter Differential pressure switch, PTO gear oil filter Pressure switch, cooler fan drive filter Pilot pressure for travel gear house brake (24 bar) „X4.1“ pressure, pumps 1 - 3, „X4.2“ pressure, pumps 4 - 6 “X1.1” pressure, pumps 1+2; “X1.2” pressure pumps 4 - 6 X2 pressure sensor

Pressure check points: (M1.1)

(M1.2) (M2) (M3)

(M5.1)

(M5.2) (M6) (M7) (M11) (M18)

(M19.1) (M20.1)

(M19.2) (M20.2) (M30) (M32) (M40)

Pressure PTO gear lubrication X4 - pressure X2 - pressure Cooler fan drive pressure Pressure travel gear house brake Pressure Swing gear house brake Pressure swing brake (safety circuit ) Pressure for hydraulic pump regulation (electronic out) Radiator fan drive pressure (only with diesel engines) X1 pressure pumps 1, 2, 4, 5, 6 X3 pressure for pumps at ½ flow position X3 pressure for pumps at ½ flow position Pilot pressure, X-2

Filter: (68.1) (68.2) (68.3) (69.1)

(68.4) (68.5) (69.2)

Pilot pressure and pump regulation Oil cooler fan drive Engine radiator fan drive (only with diesel engines) PTO gear lubrication

continued

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5.2

Section 5.0 Page 4

Pilot Pressure Supply and Adjustments Pilot Pressure Circuit The pilot pressure oil is used for the following functions. To move the control block spools, to supply the main pump regulation system, to lubricate the main pump bearings, to release the travel- and swing gear house brakes (spring loaded multi disk brakes), to drive the Lincoln Lubrication pumps, to move the hydraulic operated ladder, to move the hydraulic operated refilling arm and to supply the hydraulic track tensioning system. Legend for illustration (Z 22498): (7.1 / 7.2) Pilot pressure pumps (84.1 / 84.2) Check valve (for combined operation) (68.1) Filter (70.1) Pressure relief valve 60 bar (70.2) Pressure relief valve 35 bar (85) Pressure accumulator (43 + 45.x) Remote control valves (M2) 60 bar pressure check point (X4-Pressure) (M3) 35 bar pressure check point (X2-Pressure) (M40) 35 bar pres. check point (X2-Pressure in front of accumulator) Function: Study together with the hydraulic circuit diagram The pumps (7.1 and 7.2) are delivering the oil through the filter (68.1) to port A of the pressure relief valve (70.1) and the pressure relief valve (70.2) port A. The pressure relief valve (70.1) maintains the adjusted pressure of 60 bar it is called X4-pressure. X4 - pressure: Pump support pressure Pump bearing lubrication Actuation of refilling arm and ladder Lubrication system Track tensioning system continued

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Section 5.0 Page 5

Cont’d.: The pressure relief valve (70.2) maintains the adjusted pressure of 35 bar it is the X2-pressure. X2 – pressure: Pilot pressure system Pump regulation system Capacity regulation swing motors Travel- and Swing gear house brakes (spring loaded multi disk brakes) The pressure accumulator (85) holds an amount of oil under pressure to ensure sufficient pilot pressure during normal operations and a limited number of operations without motor power. The check valves (91) prevents return flow of the pilot pressure oil.

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Section 5.0 Page 6

Cont'd: 5.2

Pilot Pressure Supply and Adjustments Pilot Pressure Circuit Legend for illustration (Z 22500): (41) Main oil reservoir (91) Check valve (85) Bladder Accumulator – 10 liter, 10 bar (located behind the filter and valve panel of motor 2 on top of the PTO) (PX2) Pilot pressure line (LX2) Leak / return oil line from the remote control blocks Function: The pilot pressure oil flows via line (PX2) to port (P) of each remote control block and is present via a gallery at all proportional and directional solenoid valves. These solenoid valves are energized by the function of the Electro proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to the respective spools of the main control blocks with a variable pilot pressure proportional to the deflection of the controls.

)

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• For the location and designation of the proportional and directional solenoid valves of the remote control blocks see “5.3 Remote control valves arrangement” in this section.

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5.2

)

Section 5.0 Page 7

Pilot Pressure Supply and Adjustments Checks and Adjustment of Pilot Pressure Legend for illustration (Z 21635a): (85) Bladder Accumulator – 10 liter, 10 bar pre-charge pressure (located underneath the catwalk in front of the PTO) (70.1) Pressure relief valve for pump support pressure X4 (60 bar) (70.2) Pressure relief valve for pilot pressure X2 (35 bar) (M2) Pressure check point X4, pump support pressure (60 bar) (M3) Pressure check point X2 pressure, pilot pressure (35 bar) (M40) Pressure check point for accumulator (If not factory installed, fit a T-union with test connector as shown in illustration Z 21635a) • Since the “X2” and the “X4” pressure are influencing each other it is always necessary to adjust both valves 70.1+70.2 alternately. 60 bar pressure „X4“, valve 70.1: 1. Connect pressure gauge to check point (M2) 2. Start both motors 3. Read pressure, required = 60 -2 bar If readjustment is required *: 35 bar pressure „X2“, valve 70.2: 1. Connect pressure gauge to check point (M3) 2. Start both motors 3. Read pressure, required = 35+3 bar If readjustment is required *: * Valve adjustment: a Remove dust cap (1). b. Loosen lock nut (2). c. Set pressure with set screw (3). d. Tighten lock nut (2) and re-fit dust cap (1). Checking of Accumulator Function 1. Connect pressure gauge to check point (M40). 2. Start one motor. 3. After build-up of pressure stop the motor, but do not turn the key switch to zero position. 4. Watch pressure gauge. Pressure should remain constant for at least 5 minutes.

)

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• If the pressure droops the system must be checked for leakage’s. • To check the accumulator charging pressure refer to SERVICE BULLETIN AH01531a latest edition.

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Controlling

5.3

Remote control valves arrangement Legend for illustration (Z 21636)

No.

45.1

45.2

45.3

43

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Solenoid Proportional valve valve

Function FSA

BHA

Y20a Y20b

Y20

L.H. Crawler forward L.H. Crawler reverse

Y21a Y21b

Y21

Stick extending Stick retracting

Y22a Y22b

Y22

Bucket filling (curl) Bucket emptying (dump)

Y23a Y23b

Y23

Boom raising Boom lowering

Y24a X24b

Y24

Clam closing Clam opening

Bucket filling (curl) Bucket emptying (dump)

Y25a Y25b

Y25

Bucket filling (curl) Bucket emptying (dump)

Boom raising Boom lowering

Y26a Y26b

Y26

Boom raising Boom lowering

Reserved Reserved

Y27a Y27b

Y27

Stick extending Stick retracting

Stick extending Stick retracting

Y28a Y28b

Y28

R.H. Crawler reverse R.H. Crawler forward

Y29a Y29b

Y29

Boom raising Boom lowering

Y30a Y30b

Y30

Bucket filling (curl) Bucket emptying (dump)

Y31a Y31b

Y31

Stick extending Stick retracting

Y32a Y32b

Y32

R.H. Swing L.H. Swing

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5.4

Section 5.0 Page 9

Function principle of the Electro-Hydraulic- Proportional Control Legend for illustration (Z 21637) (1) Pump (2) Filter (3) Pressure relief valve (4) Check valve (5) Pressure Accumulator (6) Directional Solenoid valve, a side (7) Directional Solenoid valve, b side (8) Proportional Solenoid valve (9) Control valve block (10) Battery (11) Electronic units with amplifiers etc. (12) Control lever Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the control valve blocks. Hydraulically: The oil volume of pump (1) flows through filter (2) into the pilot pressure system. The pressure is limited by the pressure relief valve (3). With the pressurized oil stored in accumulator (5), a limited number of spool movements can be carried out with the motors at standstill. When a lever (or pedal) is actuated, proportional solenoid valve (8) and one of the directional solenoid valves (either 6 or 7) are energized, and allows the pilot pressure oil to flow to the spools of the control blocks. Electrical Whenever a lever or a pedal is moved out of its neutral position, an amplifier will created a current between 0 and 1000 mA. (For detailed information refer to page 10 in this section) Depending on the lever direction, simultaneously one of the directional solenoid valves (either 6 or 7) is energized. The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position. continued

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Section 5.0 Page 10

Cont'd: 5.4

Function principle of the Electro-Hydraulic- Proportional Control (Exemplary illustration of the function of two axis with one Amplifier only) Legend for illustration (Z 21638a) (1) Control lever (joystick) (2) Capacitor-Module (3) Ramp time module (4) Proportional-Amplifier-Module (5) Relay (Supply Voltage) (6) Proportional solenoid valve-(Pressure-Reducing Valve) (7) Directional solenoid valve (8) Control block spool General Function Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts and for the internal electronics to create the signal voltage. When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives at relay (5) and energizes the Proportional Amplifier (4) with capacitor supported 24 VDC via terminal 1. Depending on the function of the control lever, 1 to 4 Amplifiers can be involved for the „Y-axis“ (forward/ backwards direction) and 1 to 4 Amplifiers for the „Xaxis“ (left/right direction.) The polarity of the Output Signal from joystick (1), either positive or negative, between 0 and 10 VDC indicates the direction of the lever movement and is proportional to the lever deflection. This is the Input Signal to the ramp time module (3) at terminal 5 which will arrive after the adjusted ramp time delay via terminal 7 to the proportional amplifier (4) at terminal 5. This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal between 0 to 1000 mA and is simultaneously send via terminal 7 (negative) or terminal 8 (positive) to the Proportional Solenoid valve (6) and to the Directional solenoid valve (7) via terminal 3 (negative) or terminal 9 (positive) to the “a” or “b”-side. The proportional Solenoid valve (6) alters the pilot pressure (“X2”) of 35 bar to a value proportional to the Current Signal. This pressure controls the movement of the control block spool (8) between neutral and full stroke position.

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5.5

Section 5.0 Page 11

Potentiometer Control (Lever, Joy Stick) Legend for illustration (Z 21639b) (1) Push button * (2) Toggle switch * (3) Inductive linear transmitter (4) Universal joint (5) Electronics (6) Push pin (7) Shaft seal (8) Reset spring (9) Coil core (10) Coil * Alternative application The non-contacting lever control (inductive linear transmitter) contains both the electronic and mechanical components which converts the lever movement into a proportional electrical voltage. The lever can be operate in two axes: Axis "Y", splitted into the half axis Y- and Y + (backward and forward) Axis "X", splitted into the half axis X- and X + (left and right) Of course the lever can be moved in any other direction (Joy stick function) In order to be able to monitor the direction of the lever movement and the neutral position, the electronics (8) sends a 24V signal as soon as the lever gets moved out of its neutral position. For one axis are used two inductive linear transmitter (3). The motion of the coil core (9) connected to the push pin (6) causes a variation of the induction in the coils (10). The electronics convert this inductive signal into a proportional output signal of –10...0...+10 V for the amplifiers. The electronic part of the lever is equipped with a internal fault detector. In case of a internal electronic fault the electronic send a 24V signal to the test output. The test input is used for a lever system check before motor start. The inductive system is designed as a redundant system with two separate coils.

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Controlling

5.6

Potentiometer Control (Pedal) Legend for illustration (Z 21300) (1) Potentiometer Control Unit (2) Pedal (3) Standard cable (4) Connection cable for combined operation Application for: (A) Swing foot brake (B) Clam Opening/closing, (only face shovel attachment) (C) Travelling The Potentiometer Control (inductive linear transmitter) contains both the electronic and mechanical components which converts the pedal movement into a proportional electrical voltage. In order to be able to electrically monitor the pedal (2) action a neutral position switch is fitted. This switch closes when the pedal is moved out of the rest position. When using the double unit (B) (combined operation) only the signal output from one unit is used for the Clam Operation. Due to the cross lined connection via the connection cable (4) the signal is once positive and once negative (inverted), depending on the Pedal used.

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5.7

Section 5.0 Page 13

Proportional Amplifier Module, Type A Legend for illustration (Z 21516) Type A (for swing brake only) (LED) LED for Solenoid A or B (P) Set Potentiometer R1 for the lowest current value R2 for the highest current value The amplifier module is snapped onto mounting rails inside the X2-box. The amplifier module contains the necessary electronics for the control of two proportional solenoids. Depending on the input polarity, either solenoid A or solenoid B is operated. The solenoid current (solenoid A - solenoid B) is measured and compared with the external input value. Differences between feed-back and input values, for example caused by changes in solenoid temperature or supply voltage, are compensated. The module also generates a direction-dependent voltage signal (solenoid A solenoid B) as soon as the solenoid current reaches the lowest set value. The lowest and highest values are set externally via the potentiometer R1 + R2. The brightness of the LED's changes with the current. This function should not be used for setting.

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5.8

Section 5.0 Page 14

Proportional Amplifier Module, Type B Legend for illustration (Z 21640) Type B (for Boom, Stick, Bucket, Clam, Swing and Travel) (LED) (P) Set Potentiometer: AX: Proportional output AX active - 10% for the lowest current value AS: Switched output AS active - J2 for the highest current value BX: Proportional output BX active (Pt) Set Potentiometer for the „Ramp BS: Switched output BS active Time“ Power: Internal supply voltage Fault: Fault indication The amplifier module is snapped onto mounting rails inside the X2-box. The amplifier module contains the necessary electronics for the control of two proportional solenoids and two directional solenoids. The outputs for proportional solenoids Ax and Bx and the switched outputs As and Bs are activated by connecting a minimum of approx. 10 % signal voltage at the amplifier input. A positive signal voltage controls outputs A, a negative signal voltage controls output B. A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the amplifier, produces a stepped output voltage. The height of this 10% jump may be set separately for proportional outputs Ax and Bx via external potentiometer. As the signal voltage rises the solenoid current for the proportional outputs increases linearly. A further step in output current occurs at approx. 90% signal voltage. The maximum current or the 90% jump may be set separately for outputs Ax and Bx via external potentiometers and hence the gradient of the output curve may be influenced. LED’s indicate the current output to each proportional and switched output, whereby the brightness is approx. proportional to the solenoid current in Ax and Bx. This function should not be used for setting. A Ramp Time function is included in the amplifier which may be externally changed by a set potentiometer. The setting range for the ramp time is approx. from 80 ms to 1s. The time setting applies to both up and down ramps and to both proportional solenoids. A fault is indicated by the LED „Fault“.

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5.9

Section 5.0 Page 15

Ramp Time Module (Analogue command value module for Boom, Stick, Travel and Swing function) Legend for illustration (Z 21518) Potentiometer: "t1" to "t5" ⇒ Ramp times "w1" to "w4" ⇒ Command value call-ups "G" ⇒ Zero point matching "Z" ⇒ Amplitude attenuation for the differential input LED displays: (1) green ⇒ Operational power (2) "4-Q" ⇒ Quadrant recognition (3) "INV" ⇒ Inversion active (4) yellow ⇒ display for potentiometer t1 to t4 (5) yellow ⇒ display for potentiometer w1 to w4 (6) Measurement sockets: "t" ⇒ Actual ramp time "w" ⇒ Internal adjustment variable "⊥" ⇒ Reference potential / GND General The Ramp Time Module is snapped onto mounting rails inside the X2-box. The electrical connection is done via screw terminals. The module is operated with 24 VDC. A power supply provides the internally required positive and negative supply voltages. As soon as the power supply is in operation the green LED (power) lights up. Internal command values The internal command value signal is generated from the external command value signal which is being applied to the differential input, a called-up signal and an offset signal (zero point potentiometer "Z"). The external command value signal can, via potentiometer "G", changed from 0 % to approx. 110 %. Command value call-ups The call-up signals w1 to w4 also have an adjustment range of 0 % to 110 %. No settings required. (factory set to 100 %). Ramp time call up If the quadrant recognition is not activated, then each command value call-up "w1" to "w4" is allocated its own ramp time "t1" to "t4". As long as there is a signal change, the LED allocated to the actual ramp time is alight.

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Controlling

5.10

Adjustments of Amplifier Modules (General) Legend for illustration (Z 21641) (1) Potentiometer control (2) Terminal with a separating possibility (3) Ramp time module (4) Amplifier (5) Solenoid valve (6) Service module Introduction: The illustration shows simplified the route of the signal voltage from Potentiometer Control (1) to Solenoid-Valve (5): A. With ramp time module, i.e. Boom,- Stick,- Travel,- and Swing Function. B. Without ramp time module, i.e. Bucket and Clam Function. The ramp time modules (3) and the amplifiers (4) are adjustable. Adjustments are required: Ramp time modules • When commissioning the machine • When replacing a module

Amplifiers • When replacing a solenoid valve • When replacing an amplifier

For Checking and Setting the Signal Current at the Proportional-Amplifier (4), both separating terminal (2) before and behind the Amplifier (4) must be opened. For the setting procedure the signal voltage from the potentiometer control (1) can be simulated with the potentiometer of Service-Module (6),which is installed on the X2-panel. Accessories required for the adjustments: a) A multimeter, good readable for values between 0 and 1000 mA. b) More convenient is a second meter for reading voltage simultaneously. c) A simple wire, 1m length, or better a prepared test lead same length d) Four test leads, 1m length, with banana type connectors on each end.

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"a"

"b"

mA

VDC

"c" "d"

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5.11

Section 5.0 Page 17

Adjusting the Amplifiers Type B, illustration (Z 21642a) Procedure applicable for all amplifiers except the one for the swing brake: (Do not start the motors leave only the key switch in ON – position.) 1. Open* the respective separating terminal (T1) between the lever unit and the amplifier module to be set. 2. Open* the respective separating terminal (T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from terminal five. 4. Connect the positive output of the service module with terminal five of the amplifier module, using test lead (2). 5. Attach a multimeter for voltage reading to the service module, using test lead (3). 6. Attach a multimeter (in series) for Amp reading to the terminal between amplifier module and solenoid valve, using test leads (3). 7. Move the lever of the Potentiometer Control into its final position; or override manual the relay which allows 24 V operating voltage to the amplifier module; thus the amplifier gets 24 V operating voltage. The power LED and simultaneously LED A(+) or B(-) lights up, depending on the polarity. 8. Turn the potentiometer (P) of the Service-Module until the multimeter shows 1 VDC (it may be either positive or negative); the multimeter for the current reading will show a value which should correspond to the value giving in the electric circuit diagram (see page adjustments of amplifier and time ramp modul) e.g. 330 mA. (The first step (10 %) value) If necessary correct the value with potentiometer (10%). 9. Turn the potentiometer (P) of the Service-Module further until the multimeter shows 9 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 570 mA. (The second step (90 %) value). If necessary correct the value with potentiometer (J2). * How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed. continued

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Section 5.0 Page 18

Cont'd: 5.11

Adjusting the Amplifiers Type B, illustration (Z 21642) 10.

Repeat settings of item 8 and 9 until both mA values are stabilized, because the 10% and J2 adjustment influence each other. 11. If the setting with either positive or negative potential was successful, turn the potentiometer (P) of the service module into the opposite direction and check the settings with the other polarity i.e. if the first setting was done with positive potential then turn the pot into negative direction; otherwise ice versa. Attantion! The adjustment values can be different betwin the directions (poitiv A or negative B) and the single amplifier. Use the respective electric diagram of your machine (page: adjustments of amplifier and time ramp modul) 12. Repeat the setting as described under item 7 to 10. 13. Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module. Adjusting the Ramp Time

1. 2.

In the amplifier module is a ramp time function integrated which is active when there is no additional ramp time module in the respective control circuit. Turn potentiometer (time) 30 revolutions counter clockwise to guarantee the correct start position at the complete left side. Turn potentiometer (time) so many revolutions clockwise as shown in the table below (part of the electrical circuit diagram).

* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed.

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5.12

Section 5.0 Page 19

Adjusting the Amplifiers Type B, illustration (Z 21643) The amplifiers for the crawler foot pedals are adjustable in the same way as the amplifiers for the joy sticks.(refer to page 17 and 18 in this section) The amplifier for the swing foot brake is similar. Procedure for the swing foot brake: 1. Open* the respective separating terminal (T1) between the pedal unit and the amplifier module to be set. 2. Open* the respective separating terminal (T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from terminal five. 4. Connect the positive output of the service module with terminal five of the amplifier module, using test lead (2). 5. Attach a multimeter for voltage reading to the service module, using test lead (3). 6. Attach a multimeter (in series) for Amp reading to the terminal between amplifier module and solenoid valve, using test lead (3). 7. Press the pedal fully down ; or manual override the relay which allows 24 V operating voltage to the amplifier module; thus the amplifier gets 24 V operating voltage. 8. Turn the potentiometer (P) of the Service-Module until the multimeter shows 1 VDC ; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 10 mA. (10 % value) If necessary correct the value with potentiometer (R1). * How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed. continued

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Section 5.0 Page 20

Cont'd: 5.12

Adjusting the Amplifiers Type B, illustration (Z 21643) 9.

) 10. 11.

Turn the potentiometer (P) of the Service-Module further until the multimeter shows 10 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 500 mA. (100 % value). If necessary correct the value with potentiometer (R2). • It is important that the pilot pressure for the pressure increasing valve is 19± 1 bar. For more information refer to section 8.2 „Swing Circuit“ Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other. Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module.

* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed.

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5.13

Section 5.0 Page 21

Adjusting the Ramp Time Module Legend for illustration (Z 21644) (2) Capacitor-Module (3) Ramp time module (6) Service module (P) Potentiometer

)

• The following adjustments have to be done when commissioning the machine and whenever the Ramp Time Module has been replaced. • Do not start the motors turn only the key switch in ON – position.

Basic Adjustment: 1. Connect 0 VDC with a test lead from the red positive terminal of the service module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot Z" a value of 0 VDC measured at terminal 7. Disconnect the test lead after the setting is done. 2. Connect +10 VDC with a test lead from the red positive terminal of the service module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot G" a value of 10 VDC measured at terminal 7. Check the negative voltage as well(- 10 VDC). Disconnect the test lead after the setting is done.

)

• Repeat settings of item 1 and 2 until both values are stabilized, because "Pot Z" and "Pot G" influence each other. • The factory setting of potentiometer "w1" to "w4" for the command value call-ups must not be adjusted.

continued

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Controlling

Cont'd: 5.13

Adjusting the Ramp Time Module Legend for illustration (Z 21645) (1) Control lever (joystick) (2) Capacitor-Module (3) Ramp time module (4) Proportional-Amplifier-Module (5) Relay (Supply Voltage) Ramp time adjustment in relation to the operating movements: 3.

Disconnect the cables at terminal 3 and terminal 5 of the respective module. Connect 24 Volt with a test lead to terminal 9, 10, 11 and 12 one after another and adjust with the respective "Pot t1, t2, t3 and t4" the values giving in the table on the next page. (Measure the voltage only at the Measurement socket "t" of the ramp time module)

4.

To check the adjustments under operating conditions reconnect terminal 3 and terminal 5 and measure the ramp time with a stopwatch.

5.

If the above mentioned values are not suitable for the local working conditions, for example due to, different Attachments or different operation feeling of the operator, the ramp time can be changed according to the NOTE on illustration Z 21645, to ensure smooth and efficient working cycles.

continued

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Controlling

Cont'd: 5.13

Adjusting the Ramp Time Module (values as a example only)

E48 Stick 24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral ⇒ Stick out

0V to +10V

t1

0,10 Volt = 1000 ms

Terminal 10

Stick out ⇒ Neutral

+10V to 0V

t2

0,10 Volt = 1000 ms

Terminal 11

Neutral ⇒ Stick in

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Stick in ⇒ Neutral

-10V to 0V

t4

0,10 Volt = 1000 ms

Pot

Value to be measured at socket "t"

E49 Boom 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Lower

0V to +10V

t1

0,10 Volt = 1000 ms

Terminal 10

Lower ⇒ Neutral

+10V to 0V

t2

5,00 Volt = 20 ms

Terminal 11

Neutral ⇒ Lift

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Lift ⇒ Neutral

-10V to 0V

t4

5,00 Volt = 20 ms

Pot

Value to be measured at socket "t"

E50 Swing 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Swing R

0V to +10V

t1

0,20 Volt = 500 ms

Terminal 10

Swing R ⇒ Neutral

+10V to 0V

t2

0,10 Volt = 1000 ms

Terminal 11

Neutral ⇒ Swing L

0V to -10V

t3

0,20 Volt = 500 ms

Terminal 12

Swing L ⇒ Neutral

-10V to 0V

t4

0,10 Volt = 1000 ms

Pot

Value to be measured at socket "t"

E50B Swing brake 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ counter swing right

0V to +10V

t1

0,10 Volt = 1000 ms

Terminal 10

Counter swing right +10V to 0V ⇒ Neutral

t2

0,500 Volt = 20 ms

Terminal 11

Neutral ⇒ counter swing left

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Counter swing left ⇒ Neutral

-10V to 0V

t4

0,500 Volt = 20 ms

continued

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Section 5.0 Page 24

Controlling

E51 Left crawler 24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral ⇒ Forward

0V to +10V

t1

0,500 Volt = 20 ms

Terminal 10

Forward ⇒ Neutral

+10V to 0V

t2

0,500 Volt = 20 ms

Terminal 11

Neutral ⇒ Backward

0V to -10V

t3

0,500 Volt = 20 ms

Terminal 12

Backward ⇒ Neutral

-10V to 0V

t4

0,500 Volt = 20 ms

Pot

Value to be measured at socket "t"

E52 Right crawler 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Backward

0V to +10V

t1

0,500 Volt = 20 ms

Terminal 10

Backward ⇒ Neutral

+10V to 0V

t2

0,500 Volt = 20 ms

Terminal 11

Neutral ⇒ Forward

0V to -10V

t3

0,500 Volt = 20 ms

Terminal 12

Forward ⇒ Neutral

-10V to 0V

t4

0,500 Volt = 20 ms

Pot

Value to be measured at socket "t"

E59 Bucket (only BHA) 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Fill

0V to +10V

t1

0,05 Volt = 2000 ms

Terminal 10

Fill ⇒ Neutral

+10V to 0V

t2

0,10 Volt = 1000 ms

Terminal 11

Neutral ⇒ Dump

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Dump ⇒ Neutral

-10V to 0V

t4

0,10 Volt = 1000 ms

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Section 6.0 Page 1

Components

Table of contents section 6.0

Section 6.0

Page Components 6.1

17.01.07

Hydraulic 6.1.1 Main Control Blocks and High Pressure Filter FSA

2-3

6.1.2

Main Control Blocks and High Pressure Filter BHA

4-5

6.1.3

Distributor Manifold – Restrictor blocks FSA

6

6.1.4

Distributor Manifold – Restrictor blocks BHA

7

6.1.5

Restrictor Block with Pressure Relief Valve

8

6.1.6

Anti Cavitation Valve Block

9

6.1.7

Remote Control Valves

10

6.1.8

Directional Solenoid Valves (4 way / 3 positions)

11

6.1.9

Proportional Solenoid Valves

12

6.1.10

High Pressure Filter

13

6.1.11

Control Blocks and Valves

6.1.12

Load Holding Valve

18

6.1.13

Travel Brake Valve

19

6.1.14

Pressure Reducing Valve

20

6.1.15

Directional Solenoid Valves (2 positions / 4-ways)

21

6.1.16

Pressure Increasing Valve

22

14-17

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Section 6.0 Page 2

Components

6.1.1

Main Control Blocks and High Pressure Filter Front Shovel Attachment FSA Legend for illustration (Z 22566): Pump circuit No. I (14 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,) (46.1) High pressure filter, Pump 2 and 5 (31.01) SRV Travel motors left backward (32.01) ACV Travel motors left backward (31.02) SRV Travel motors left forward (32.02) ACV Travel motors left forward (33.1) SRV Stick cylinder piston side (32.3) ACV Stick cylinder piston side (32.4) ACV Stick cylinder rod side (32.5) ACV Bucket cylinder rod side (33.2) SRV Bucket cylinder rod side (32.6) ACV Bucket cylinder piston side (32.7) ACV Boom cylinder rod side (32.8) ACV Boom cylinder piston side Pump circuit No. II (15 / II) Control block II (Bucket, Boom, Reserved, Stick) (44.2) High pressure filter, Pump4 (32.9) ACV Bucket cylinder rod side (32.10) ACV Bucket piston side (30) SRV Clam cylinder piston side (33.06) SRV Bucket cylinder rod side (32.11) ACV Bucket cylinder rod side (32.12) ACV Bucket cylinder piston side (32.13) ACV Boom cylinder rod side (33.4) SRV Bucket cylinder rod side (32.14) ACV Boom cylinder piston side (32.15) ACV Stick cylinder piston side (191) SRV (pressure increasing valve) Stick cylinder rod side (32.16) ACV Stick cylinder piston side continue

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Section 6.0 Page 3

Components

Pump circuit No. III (176 / III) Control block (R. H. Travel, Boom, Bucket, Stick) (46.2) High pressure filter, Pump 1 and 6 (31.03) SRV Travel motors right forward (32.17) ACV Travel motors right forward (31.04) SRV Travel motors right backward (32.18) ACV Travel motors right backward (32.19) ACV Boom cylinder rod side (32.20) ACV Boom cylinder piston side (32.21) ACV Bucket cylinder rod side (32.22) ACV Bucket cylinder piston side (32.23) ACV Stick cylinder rod side (32.24) ACV Stick cylinder piston side Pump circuit No. IV (13 / IV) Control block IV (Single spool for swing) (44.1) High pressure filter, Pump 3

)

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• There is one MRV in each control block.

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Section 6.0 Page 4

Components

6.1.2

Main Control Blocks and High Pressure Filter Backhoe Attachment Legend for illustration (Z 22433): Pump circuit No. I (175 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,) (46.1) High pressure filter, Pump 2 and 5 (31.01) SRV Travel motors left backward (32.01) ACV Travel motors left backward (31.02) SRV Travel motors left forward (32.02) ACV Travel motors left forward (33.1) SRV Stick cylinder piston side (32.3) ACV Stick cylinder piston side (32.4) ACV Stick cylinder rod side (32.5) ACV Bucket cylinder rod side (32.11) ACV Bucket cylinder piston side (32.12) ACV Boom cylinder rod side (32.13) ACV Boom cylinder piston side Pump circuit No. II (15 / II) Control block II (Bucket, Boom, Reserved, Stick) (44.2) High pressure filter, Pump4 (32.14) ACV Bucket cylinder rod side (32.15) ACV Bucket piston side (33.06) SRV Boom cylinder rod side (32.11) ACV Boom cylinder rod side (33.05) SRV Stick cylinder piston side (32.15) ACV Stick cylinder piston side (32.16) ACV Stick cylinder rod side continue

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Section 6.0 Page 5

Components

Cont’d Main Control Blocks and High Pressure Filter BHA Pump circuit No. III (176 / III) Control block (R. H. Travel, Boom, Bucket, Stick) (46.2) High pressure filter, Pump 1 and 6 (31.03) SRV Travel motors right backward (32.17) ACV Travel motors right backward (31.04) SRV Travel motors right forward (32.18) ACV Travel motors right forward (32.19) ACV Boom cylinder rod side (32.20) ACV Boom cylinder piston side (32.21) ACV Bucket cylinder rod side (32.22) ACV Bucket cylinder piston side (32.23) ACV Stick cylinder rod side (32.25) ACV Stick cylinder piston side Pump circuit No. IV (13 / IV) Control block IV (Single spool for swing) (44.1) High pressure filter, Pump 3

)

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• There is one MRV in each control block.

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Components

6.1.3

Section 6.0 Page 6

Distributor Manifold - Location of restrictor blocks and anti cavitation valves Front Shovel Attachment (FSA) Legend for illustration (Z 22434): (1) Distributor manifold (2) Synchronization (Equalization) lines (3) Synchronization (Equalization) lines (4) Anti Cavitation Valve Block (ACV) (5) Restrictor Block (Throttle valve) (6) Restrictor Block (Throttle valve) (7) Service-line Relief Valve

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Components

6.1.4

Section 6.0 Page 7

Distributor Manifold - Location of restrictor blocks and anti cavitation valves Backhoe Attachment Legend for illustration (Z 22434): (1) Distributor manifold (2) Synchronization (Equalization) lines (3) Synchronization (Equalization) lines (5) Service-line Relief Valve (4) ACV Block Section A ,Boom cylinder rod side (6) Service-line Relief Valve Pressure check point (7) Restrictor blocks

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Components

6.1.5

Section 6.0 Page 8

Restrictor Block with Pressure Relief Valve

)

• A restrictor block is used for limiting cylinder lowering speeds. • A Service Line Relief Valve is installed to limit the maximum system pressure due to external forces.

Legend for illustration (Z 21834): (1) (2 + 3) (4) (5 + 6) (7) (8) (9) (10) (11 (12) (13) (14) (15) (16) A+B M Y

Adjustment spindle O-ring with back-up ring Retainer O-ring with back-up ring Spring Spring cup Throttle sleeve O-ring Housing Return line port, T Pressure relief valve Allen bolt Clip ring Lock nut Line ports Pressure check point Control oil drain port

Function: Setting of the maximum permissible cylinder speed (flow B to A) is carried out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in the valve poppet (9) will be partially opened to achieve the required throttling of the oil flow. The extra holes (fixed throttle 9.2) prevents the valve from becoming completely closed. For the lifting operation (flow A to B), the valve poppet (9), which is guided by the spindle (1), is pressed against spring (7) so that the valve will be completely open.

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Section 6.0 Page 9

Components

6.1.6

Anti Cavitation Valve Block

)

• ACVs are installed to avoid cavitation damages on users (hydraulic cylinders), by compensating a possible lack of oil, when the SRV at the opposite side of the cylinder opens (see circuit diagram).

Legend for illustration (Z 21835): (Type 64.1 to 64.9 of the hydraulic circuit diagram) (1) Housing (2) Valve cone (3) Spring (4) O-ring (5) Control and leak oil bore (6) Cap screw (torque 900 Nm) S Supply line (Return oil pressurized to approximately 10 bar by back pressure valve) A and B Line connections Function: The circuit pressure in the line A and B hold the valve cone (2) closed. The pressure of the supply line S forces onto the valve cone. The valve cone opens, whenever the pressure at the A and B side is lower than the back pressure at return oil port S, to allow necessary oil supply into the circuit.

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Section 6.0 Page 10

Components

6.1.7

Remote control valves

)

• Remote control valves are part of the electric-hydraulic control system

Legend for illustration (Z 21838a): (1) (2) (3) (4) (5)

Pilot pressure supply port (marked with P) Pilot pressure return port to tank (marked with L) Pilot pressure output lines to the control block (marked with A1/B1, A2/B2, . . . . ) Directional solenoid valve, 3 position / 4 ports Proportional solenoid valve, (0 – 700 mA, 0 – 35 bar).

Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the main control valve blocks. When a lever (or pedal) is actuated, a proportional solenoid valve (5) and one of the directional solenoid valves (3 either Ax or Bx) are energized, and allows the pilot pressure oil to flow to the spools of the main control blocks. The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position.

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Components

6.1.8

Section 6.0 Page 11

Directional Solenoid Valves (4/3 direction flow valve = 4 way / 3 positions)

)

• This solenoid operated directional spool valves are installed to control the start, stop and direction of an oil flow.

Legend for illustration (Z 21839): (1) Housing (2) Solenoids (3) Control spool (4) Reset springs (5) Plunger (6) End cover Function: In un-operated condition the control spool (3) is held in the neutral or starting position by the reset springs (4). Operation of the control spool is by means of oil immersed solenoids (2). The force of the solenoid (2) acts via the plunger (5) on the control spool (3) and pushes its from its resting position into the required end position. This results in the required free flow from P to A and B to T or from P to B and A to T. When the solenoid (2) is de-energised, the control spool (3) is returned to its original position by the reset springs (4).

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Components

6.1.9

Section 6.0 Page 12

Proportional Solenoid Valve

)

• This valves are responsible for the creation of a variable control pressure proportional to the electrical signal output of an amplifier.

Legend for illustration (Z 21697): (1) Proportional solenoid (2) Control piston (3) Valve housing (4) Pressure measuring spool

(5) (6) (7) (8)

Pressure measuring spool Connection plug Return spring Bleed screw

Function: In un-operated condition the control spool (2) is held in the neutral or starting position by reset springs. The control spool (2) is directly operated by the proportional solenoid (1). If the solenoid is energized, it produces a force to operate the control spool (2) via the pressure measuring spool (4) and moves the spool to the left. Oil flows from P to A. As pressure in A increases, it passes via the radial borings in the control spool (2) to the inner end of the pressure measuring spool (2). The force generated by the pressure now works against the solenoid force and pushes the control spool (2) to the right (closing direction) until a balance is achieved between the two forces. In order to achieve this, the pressure measuring spool (2) moves to the left until it is supported by the pin (5). When the force balance is achieved, the connection between P and A is interrupted and the pressure in line A is held constant. Any reduction in the solenoid force leads to the pressure force exceeding the solenoid force on the control spool (2). The control spool is then moved to the right causing a connection from A to T allowing the pressure to fall until a balance is reestablished at a lower level. At rest, when the solenoid is de-energized, ports A and B are open to tank, whilst port P is blocked from both ports A and B.

W

17.01.07

• In order to achieve optimum functioning of the valve, it must be bleed when commissioning: - Supply pressure to the valve - Remove plug 8 - When no more air bubbles appear screw in plug 8.

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Components

6.1.10

Section 6.0 Page 13

High Pressure Filter

)

• There is one filter in each pump line installed.

Legend for illustration (Z 21696): (1) Filter head (2) Drain plug (3) Filter case (4) Hexagon (5) Filter element (6) Seal (7) O-ring (8) Back-up ring (9) O-ring (10) Spring (11) Differential pressure switch P1 Input pressure P2 Output pressure a Electrical connection b REED contact c Permanent magnet piston d Spring e Plug screw Function: High-pressure in-line filters prevent contamination from entering the hydraulic circuits. The high pressure filters are installed between the main hydraulic pumps and main control blocks. All hydraulic components, behind the pumps, are effectively protected from damage and undue wear. Each filter is equipped with a differential pressure switch to monitor the filter flow restriction. If the pressure reaches an unsafe difference of 8.5 bar, a visual/acoustic warning appears on the display in the cab and the engines will be shifted automatically to low idle.

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Components

Section 6.0 Page 14

6.1.12 Control Blocks and Valves

)

• This is a principle drawing, showing valve block I, II and III.

Legend for illustration (Z 22436): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Control block housing Cab ("A side) Cap ("B" side) Solid spool "B" side service line ports Centering springs MRV, main relief valve Port A, to cylinder/motor Port B, to cylinder / motor Fine controlling grooves Port P, from pumps Port T, to tank Load holding valves Spin look spool extension (only block I and II) Spin look balls (only block I and II) Spin look cab extension

Control blocks with "Open Center and Closed Ports". Control blocks I, II and III are 4 spool blocks and IV is a 1 spool block. See hydraulic circuit diagram for spool details. Each spool is provided with "Fine Controlling Grooves" and ring grooves for hydraulically centering of the spool. Between 8 and 19 bar pilot pressure the spools are moved in their fine control range. Spool number 4 of block I, 2 of block II and 4 of block III are special designed, to keep the pressure channel connected to the center channel during the floating function is activated, so that pump flow is available for other functions. This spools are marked in the hydraulic diagram with (#) symbol. The Load Holding Valves are installed inside of the spool, for each port to the cylinder or motor one valve. The hydraulic diagram shows only one. The MRV is a pilot operated pressure relief valve. Control block I, II and III are equipped with a spool spin look system (item 14, 15, 16) to prevent spool spinning because of high oil flow during lowering function.

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Components

6.1.11

Section 6.0 Page 15

Control Blocks and Valves Legend for illustration (Z 22440): (1) Main relief valve (MRV)Control block housing (2) Load holding valve (3) Anti cavitation valve (ACV) (4) Service line relief valve (SRV) Explanation of the schematic drawing of the control block: The hydraulic oil flows through the control block from port P to T, if all spools are in neutral position ("pressure-less circuit" or “Free circulation“).

(A) 4 valve block E.g. the spools moves up when pilot pressure is build up in the control pipe line a1. (Imagine the lower symbol box moves to the center position.) Now pump oil flows through holding valve (2) to the user port A1 because the free flow circulation to the hydraulic reservoir is closed. The main relief valve (1) limits the maximum operation pressure in this circuit. Via port B1 the return oil from the user is flowing back to the hydraulic reservoir. During down hill travelling motion and stopping procedure (e.g. travel motors) the anti cavitation valves (3) prevents cavitation on the hydraulic motors. Because during these short periods of time the hydraulic motor needs a higher oil supply than the pump can deliver. E.g. the spool (4) moves up when pilot pressure is build up in the control pipe A4. Now the user port A4 is connected to the pump pressure line and the free circulation to the tank. There is no high pressure build up only 8 bar from the back pressure valve and line resistance. Via port B4 the return oil from the user is flowing back to the hydraulic reservoir. Service line relief valve (4) is additional installed in this circuit to protect the circuit for extreme pressure. The shortly extreme pressure closes also the holding valve (2) which secures the hydraulic pump from extreme pressure peaks.

(B)

17.01.07

The holding valves (2) have also the function of load holding valves because during the fine controlling period all lines are connected together (negative over-lapping). The load pressure is for a moment higher than the pump pressure. single valve block

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Components

6.1.11

Section 6.0 Page 16

Control Blocks and Valves Legend for illustration (Z 22441): (1) Spool (2) Reset springs (3) Load holding valve Function: Reset springs (2) moves the spool (1) in neutral position. Fine control grooves provide for sensitive controlling, because a motion is started always while the pressure oil and the return oil first passes this fine control grooves before spool (1) is inter connecting the entire groove to the user channel. In neutral position of spool (1) the pump oil is flowing back via port PU to the tank. Lower picture: Example. The spool is moved by pilot pressure on the left spool side to right position: Port PU is closed and the connection through the holding valve (3) to the user (port A) is open. Also the connection from the other user side (port B return)is connected to the port T (return line to tank).

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Components

6.1.11

Section 6.0 Page 17

Control Blocks and Valves Legend for illustration (Z 21705): (01) Service -Line Relief Valve (02) Anti Cavitation Valve (03) Main Relief Valve (04) Closing plate (5) Plug screw (6) Spring (7) Valve cone (8) Dust cap

(9) (10 (11) (12) (13) + 16) (14) (15) (17)

Set screw Lock nut Spring, pilot part Poppet Jet bore Spring, main cone Main valve cone Pilot oil dump line to tank

MRVs and SRVs are pilot operated relief valves. The MRV limits the max. Pump supply line pressure. The SRV limits the max. possible pressure peak in the service-line. The valves have an „opening characteristic“. That means, that in case of contamination after the response procedure no further pressure increasing is possible and damages are avoided. Function: The circuit pressure P forces with the force F1 on the piston surface A of the main valve cone (15). Because there is via the jet bore (16) the same pressure on the back side of the main cone, this results together with the spring (14) force in a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit pressure is in front of the poppet (12). Exceeds the circuit pressure the setting value of the spring (11), the poppet opens against the force of the spring (11). This causes that the force F2 decreases and there is no more balance condition between F1 and F2. Valve cone (15) is moved upwards by the greater force F1. That means there is now a direct connection from port P to T (tank). ACVs serve for compensation possible lack of feed when the SRV at the opposite port is actuated (see circuit diagram) and for avoiding cavitation damages. In addition, to supply a user in case it is continuously moved by acceleration forces at zero position of the control spool. Function: The circuit pressure inside the spring chamber closes the valve cone (7). The back pressure of the return line acts on the surface of the valve cone (7). Whenever the pressure in the service-line is lower than the springs force the valve cone opens by the force of the back pressure and hydraulic oil is additional supplied.

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Components

6.1.12

Section 6.0 Page 18

Load Holding Valve Legend for illustration (Z 22441): (1) Spool (2) Reset springs (3) Load holding valve Control Blocks I to IV (4 spool blocks and single spool block) Two load holding valves are fitted into each spool of the control blocks, one valve for each port (A and B). They have three tasks: 1. When circuit pressure due to attachment weight is higher than pump pressure these valves prevent dropping of the attachment, within their sensitive (fine controlling) range. 2. Due suddenly pressure peaks in the service lines the valves also protect the pump. 3. When two pumps flows are used for one user they ensure that at least the flow of one pump reaches the user in case one MRV is defect or not more correct adjusted. That means: Up to the max. Pressure of the defective valve both load holding valves are open allowing the flow of both pumps to the user, then one valve will be closed by the higher pressure and the flow of one pump only flows to the user. Function: The system pressure forces onto the front area of the valve cone (1). This force moves the valve cone against the spring and allows the oil to flow from the pump through the spool centre to the port. In neutral position of the spool no further flow is possible. (see circuit diagram) If the spool is not more in neutral the flow continues to the user. If due to an external force the pressure directed to the pump overcomes the pump line pressure, this pressure forces the valve onto its seat (closed position)

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Components

6.1.13

Section 6.0 Page 19

Travel Brake Valve Illustration Z 21695 Task: Travel brake valves control the oil flow from the hydraulic motor to the tank depending on operating pressure. This braking action prevents the motors from over speeding. Function: Spring force keeps the spool in the lowest flow position. with increasing operating pressure the opening for the return oil flow becomes larger. On its way to the hydraulic motor the oil flows from A to A1 respectively from B to B1 depending on the selected travel motion. Example: Operating pressure at port A moves spool (1) against the force of the spring (2) and opens the way for the return oil (B1 to B). Holding valve (3) prevents a direct oil flow from B1 to B. If the operating pressure decreases to such an extend that the spring force overcomes the pressure, the flow to the tank becomes restricted, resulting in braking of the machine. For more information and adjustment see section 8.3.

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Components

6.1.14

Section 6.0 Page 20

Pressure Reducing Valve

)

• Pressure reducing valves are installed to reduce the common 35 bar pilot pressure to a lower pressure for other systems, e.g. the pump regulation system.

Legend for illustration (Z 21844): (1) Set screw (2) Spool (3) Compression spring (4) Threaded sleeve (5) Non return valve (6) Boring (7) Spring chamber (8) Control land Function: Pressure reducing valves type DR & DP are direct operated valves of 3 way design, e.g. with a pressure relief function on the reduced pressure side. At rest, the valve is normally open, and fluid can flow unhindered from port P to A. Pressure in port A is also present on the end of the spool (2), via control line (6), opposing the compression spring (3). When the pressure in port A reaches the pressure level set at spring (3), spool (2) moves to the control position and holds the pressure in port A constant. Fluid to control the valve is taken from port A via the boring (6). If the pressure in port A rises still further due to external forces, the spool (2) is moved still further towards the compression spring (3). This causes a flow path to be opened over control land (8) in the control spool (2) to tank. Sufficient fluid then flows to tank to prevent any further rise in pressure. An optional non return valve (5) is available to allow free flow from A to P.

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Components

6.1.15

Section 6.0 Page 21

Directional Solenoid Valves (2 positions / 4-ways)

)

• This solenoid operated directional spool valves are installed to control the start, stop or direction of an oil flow.

Legend for illustration (Z 21845): (1) Housing (2) Solenoid (3) Control spool (4) Return spring (5) Plunger (6) Dust cap with stem for manual operation Function: When there is no flow through the valve, control spool (3) is held in neutral or output position by means of the return springs (4). The control spool (3) is operated by means of oil immersed solenoid (2). The force of the solenoid (2) effects control spool (3) by means of the plunger (5) and pushes it from its resting position to the required end position. This results in free flow from P to B and A to T. When solenoid (2) is de-energized, control spool (3) is moved back to its resting position by means of return springs (4). An optional hand emergency (6) allows movement of the control spool (3) without energizing the solenoid.

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6.1.16

Section 6.0 Page 22

Pressure Increasing Valve

)

• The pressure increasing valve is a remote controlled pressure relief valve, actuated by hydraulic pressure. The individual pressure is in such a way determined by the pilot pressure.

Legend for illustration (Z 21846): (1) Pilot valve with valve seat (2) Valve poppet (3) Compression spring (4) Main valve with sleeve (5) Main piston (6) Closing spring (7+8) Set screws (9) Piston (10) Pin (11+12) Jet bore (13+14) Lock nut Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the pressure port (P). If static pressure increase above the set pressure value, the valve poppet (2) opens and allows oil to flow freely via port (T1) to tank. This out flowing oil generates a pressure drop in the spring chamber of the main spool (5). The closing force of the spring (6) is now lower as the oil pressure from the pressure port (P) and the main piston (5) opens to release pressurized oil to the tank via port (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 35 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly. The maximal possible pressure (P) adjustment is 440 bar with max. control pressure at port X. The lower setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn of setting screw reduce or increase the pressure about ~150 bar.

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 1

Table of contents section 7.0 Section 7.0

Page Main hydraulic pumps and pump regulation system General 7.1 Main Pumps 7.1.1 Location of Pumps 7.1.2 Pump bearing flushing / lubrication 7.1.3 Operating Principles 7.1.4 Checks and Adjustments 7.2 Electronic Pump Regulation System 7.2.1 Electronic load limiting control - General 7.2.2 Electronic Power Module EPM 7.2.3 Electronic Signal Rectifier ESR 7.2.4 Microcontroller MC7 7.2.5 Checks and adjustments - General Method A - With 24V supply to terminals - X1- pressure adjustment - Demanded power adjustment - PID – Factor adjustment Method B - With the electronic service tool BB-3 - Language selection - Adjustment mode SET1 and SET2 - Number of motor selection - X1-pressure (max. current) adjust. - Demanded power adjustment - PID – Factor adjustment - Storage new settings Method C - With a laptop and BODEM software - Starting the program - Language selection - Entering of the password - Number of Motor selection - X1-pressure (max. current) adjust. - Demanded power adjustment - PID – Factor adjustment 7.3 Hydraulic Constant Regulation System 7.3.1 General 7.3.2 X1-pressure adjustment (constant-pressure)

2–5 6 7 8 - 15 16 - 20 21 22 23 - 24 25 26 27 28 - 29 30 31 - 32 33 34 35 36 37 38 39 - 40 41 42 43 44 45 - 47 48 49 50

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Main Hydraulic Pumps and Pump Regulation System 7.0

Section 7.0 Page 2

Main hydraulic pumps and pump regulation system Pump regulation system general

Legend for illustration (Z 22442): (1 - 6) Main hydraulic pumps (7.1) Pilot pressure pumps, motor 1 (7.2) Pilot pressure pumps, motor 2 (68.1) Pilot pressure filter unit (70.1) 60 bar pressure relief valve (70.2) 35 bar pressure relief valve (Y17) Solenoid valve: "Idle time control and low hydraulic oil temperature" Q-min flow for all main pumps (Y17a) Solenoid valve: "Remote control pressure" ½ Q-max flow reduction for all main pumps (low hydraulic oil temperature) (Y102-1) Solenoid valve: "Pump regulation support pressure and pump bearing lubrication" (Y102-2) Solenoid valve: "Pump regulation support pressure and pump bearing lubrication" (81.1) Pressure reducing valve: "Remote control pressure" ½ Q-max flow reduction for the warming-up period (81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic pump regulation" (Hydraulic constant regulation mode) (Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation, motor 1" (Standard operation mode) (Y61-2) Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation, motor 1" (Standard operation mode) (79.1) Change over valve: "Electronic or Hydraulic pump regulation", motor 1 (79.2) Change over valve: "Electronic or Hydraulic pump regulation", motor 2

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Main Hydraulic Pumps and Pump Regulation System 7.0

Section 7.0 Page 3

Main hydraulic pumps and pump regulation system Pump regulation system general

Controlled output flow of the main pumps is necessary: • To utilize the available motor power most efficiently in every operating mode. • To limit the power consumption of the hydraulic pumps depending of the load of the motor. (Electronic pump regulation with micro-controller MC7) • For additional functions, such as rotating dependent or temperature-dependent flow reduction. Function: X1 – pump regulation pressure (0 – 24 bar): The power controller of the main pumps can be remotely controlled by applying an external pilot pressure (X1 ) at port X LR to the spring chamber of the power control valve. The start of destroking can be varied in proportion to the applied X1 - pressure.

X2 – pilot pressure (35 bar): Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix pump # 3 in Q-max position (pump for swinging.)

X3 – remote control pressure (0 / 16 / 35bar): Basic setting Q-min (0 bar), the flow rate increases with the pilot pressure X3 at port Pst, up to Q-max (35 bar). The hyperbolic power control is superimposed on the pilot pressure signal and keeps the specified drive power constant. (p x Vg = constant). The flow rates are: Q-min.: X3 = 0 bar ½ Q-max.: X3 = 16 bar Q-max.: X3 = 35 bar

X4 – pump support pressure (60 bar): Constant pilot pressure to support the regulation function at low operating pressure and to lubricate the main pump bearings.

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Main Hydraulic Pumps and Pump Regulation System 7.0

Section 7.0 Page 4

Main hydraulic pumps and pump regulation system Pump regulation system general Function: Solenoid valve Y17: (33/7)* If de-energized pumps #1-6 are in Q-min position. It gets energized as soon as one of the control levers/pedals has been operated and de-energized when ever all controls are in neutral position for more than 20 seconds. Solenoid valve Y17a: (33/5)* The solenoid is de-energized as long the hydraulic oil temperature is below the values of temperature range „T2“ (depending on the filled in hydraulic oil) shown in the table. ( pumps #1-6 are in ½ Q-max. position)

Note:

* Electric circuit diagram page / column (based on Id # 897 899 40)

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Main Hydraulic Pumps and Pump Regulation System 7.0

Section 7.0 Page 5

Main hydraulic pumps and pump regulation system Pump regulation system general Function: Proportional Solenoid valve Y61-1 and Y61-2: (40/2)* This valves, connected to the MC7 micro-controller E32 (electronic pump regulation), creates a X1-pressure depending on the load of the motor. This X1-pressure is the information to reduce pump delivery, in order to keep the motor at rated power. Pressure reducing valve 81.1: "Remote control pressure" (X3) ½ Q-max flow reduction during the warming-up period for all pumps by the function of solenoid valve Y17a. ½ Q-max flow reduction only for pump #1 while swinging with max. speed by the function of solenoid valve Y126. Pressure reducing valve 81.2: Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic constant regulation mode) by the function of change over valve (79.1 / 79.2). One valve for both motors. This valve create a constant X1 pressure, the pressure can be change for different pump regulation checks and adjustments. Change over valve 79.1 and 79.2: Change over three way cock valve to select "Electronic or constant regulation mode", one for each motor.

Note:

* Electric circuit diagram page / column (based on Id # 897 878 40)

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 6

Main Pumps 7.1.1. Location of Pumps Legend for illustration (Z 22415b): (1 - 6) Axial piston pump (swash plate type) theoretical flow rate, each Drive speed* for all working motions

Qmax n pmax

= 700 Liter/min = 1400 min-1 = 310 bar

(10.2), (10.4) Axial piston pump theoretical flow rate Drive speed* for oil cooler fan drive

Qmax n pmax

= 142 Liter/min = 1770 min-1 = 180 bar

Gear pump theoretical flow rate Drive speed* for PTO gear lubrication

Qmax n pmax

= 82,2 Liter/min = 1400 min-1 = 7,5 bar

Gear pump theoretical flow rate Drive speed* for hydraulic oil circulation

Qmax n pmax

= 82,2 Liter/min = 1400 min-1 = 15 bar

Gear pump theoretical flow rate Drive speed* for pilot pressure supply

Qmax n pmax

= 120 Liter/min = 1409 min-1 = 60 bar

(8.1), (8.4)

(8.2), (8.5)

(7.1), (7.2)

)

• * at 1500 min-1 input drive with electric motor speed

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 7

Main Pumps 7.1.2. Pump bearing flushing / lubrication The installed main pumps are provided with an external cooling and lubrication system for flushing of drive shaft bearing and shaft seal. Oil supply is provided from the X4-pressure circuit. To reach the restricted guidance of the coolant for external bearing flushing, the throttle screw (located behind the union at port U) must screwed in all the way. An information sign is fixed at the pump. Legend for illustration (Z 22443): (1 – 4) Main pumps (147.1-147.6) Orifice (one for each main pump) (33) Filter for pilot pressure (P) Ports for X4-pressure (pump support pressure) (U) Port for the pump bearing flushing / lubrication

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Section 7.0 Page 8

Main Pumps 7.1.3 Operating Principles Main hydraulic pump A4VSO 500 LR3DN / 30L Type code explanation: A4VSO 500 LR 3 D N / 30 L Rotation Series Basic adjustment for minimum displacement With pressure control Hydraulic remote adjustment facility Constant power with hyperbolic curve Max displacement in cm3 at one (1) revolution Axial piston pump series 4, variable displacement ,swash plate design for open circuits

Function and characteristics: • The A4VSO variable displacement axial piston pump in swash plate design is intended for drives in open circuit operation. • The flow volume is proportional to the drive speed and the displacement. By adjusting the swash plate a infinitely variable flow adjustment is possible. • Pumps of the same nominal size can be built onto the trough drive. Combinations with gear pumps are also possible. Legend for illustration (Z 22446): The lower illustration shows only a principle pump construction (1) Drive shaft (2) Cylindrical roller bearing (3) Slipper pad (4) Swivel angle indicator (5) Positioning piston (6) Swivel pin (7) Cylinder with pistons (8) Final connecting plate (9) Cylindrical roller bearing (10) Splints for the through drive coupling (Aux. pump drive) (11) Swivel cradle (12) Q-min stop bolt (13) Power control valve (14) Pressure balance valve (15) Power curve correction (16) Pressure cut off valve (17) Q-max. stop bolt (18) Remote control valve continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 9

Main Pumps 7.1.3 Operating Principles Cont'd: Symbol of main hydraulic pump A4VSO 500 LR3DN / 30L Legend for illustration (Z 22447): (1) Main pump (swash plate pump, variable displacement) (2) Pump bearing group (3) Drive shaft (4) Non return valves (5) Remote control valve (5.1) Mechanical stroke limitation* (5.2) Remote pressure (PST) operated piston for item 6 (5.3) Mechanical stroke limitation* (6) Spool valve (pressure balance valve) (7) Nozzle (8) Power control valve (9) Nozzle (10) Pressure cut-off valve (11) Auxiliary pump (Gear pump, fixed displacement (12) Positioning piston (13) Slipper pad piston (14) Lever (15) Cam (16) Through drive shaft

)

• * Factory side adjusted, no field adjustment required

B/B1 S MB Mst R(L) T, K1, K2 P Pst U XLR

Pressure port Oil intake (suction port) Operating pressure check point Control pressure check point Filler and bleeder port Connection port for chip indicator Pump support pressure (”X4”-pressure) Remote control pressure port (”X3”-pressure) Bearing flushing port Regulating pressure port (”X1”-pressure) continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Main Pumps 7.1.3 Operating Principles Cont'd: Sectional drawing of Power Controller LR3DN / 30L Legend for illustration (Z 21551a): (5) Remote control valve (5.1) Mechanical stroke limitation (5.2) Remote pressure (PST) operated piston for item 6 (5.3) Mechanical stroke limitation (6) Spool valve (pressure balance valve) (8) Power control valve (10) Pressure cut-off valve (12) Positioning piston (13) Slipper pad piston (14) Lever

)

• Refer also to illustration Z 22447 on the previous page.

Section 7.0 Page 10

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Section 7.0 Page 11

Main Pumps 7.1.3 Operating Principles, illustration (Z 21552a) Cont'd: Q-min position: (remember Q means volume) When are the pumps in Q-min position? A: Motor at standstill B: Motor running and the controls are not used for 20 sec. or longer at low operating temperature C: Motor running and service switch S150 activated Example C with the following conditions: • Motor running • Pump pressure lower as X4 = 60 bar (pump support pressure) • X1 = 24 bar (pump regulation pressure), this pressure will not influence the Q-min position under these conditions. • X3 = 0 bar (remote control pressure); Y17 de-energized (S150 activated) for pumps #1, #2 #4, #5, #6 and #3 except during swinging than the pump is out of regulation and keeps in Qmax. • X4 = 60 bar (pump support pressure) Pump support pressure is present at valve #6, the slipper pad of piston #13 and the small area side of the positioning piston #12 Response of pump control mechanism: Valve #6 moves to position "b" because the X4-pressure will overcome the spring force, since the oil behind nozzle (7) flows through valve #5 (which is in position "a", due to the missing remote control pressure X3) back to tank. Pump support pressure X4 passes valve #6 position "b" and flows via power control valve #8 position "a" to the large area side of positioning piston #12. Because the large area side of positioning piston #12 is approximately three times larger as the small area side, the pump support pressure X4 of 60 bar present on both sides, resulting in stronger force at the large area side, keeps the pump in Q-min position. The pump remains in Q-min position continued

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Section 7.0 Page 12

Main Pumps 7.1.3 Operating Principles, illustration (Z 21553a) Cont'd: Q-max position: (remember Q means volume) When does the pumps move into Q-max position? and and and

Motor running hydraulic oil at normal operating temperature (> T2) the controls frequently used within 20 sec. (or Service switch S151 activated) a pump pressure below start of de-stroking.

Example with the following conditions: • Motor running • Pump pressure between 60 bar and 300 bar, present at the slipper pad of piston #13 and the small area side of the positioning piston #12 • X1 = 24 bar (pump regulation pressure) • X3 = 35 bar (remote control pressure); Y17 and Y17a energized for all six pumps. • X4 = 60 bar (pump support pressure), present at valve #6. Response of pump control mechanism: Valve #6 moves to position "a" because the spring force is supported by the X4pressure, since the oil flow back to tank is blocked at valve #5 (which is in position "b", due to the 35 bar remote control pressure X3). The large area side of positioning piston #12 is connected, via power control valve (8) position "a" and pressure balance valve (6) position "a", to the return oil line. The pump moves into Q-max position, because the pump pressure acts only at the small area side of positioning piston #12.

The pump moves into Q-max position continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 13

Main Pumps 7.1.3 Operating Principles, illustration (Z 21554a) Cont'd: ½ Q-max position: (remember Q means volume) When does the pumps move into half Q-max position? and and and

Motor running hydraulic oil below normal operating temperature (< T2) the controls frequently used within 20 sec. (or Service switch S151 activated) a pump pressure below start of de-stroking.

Example with the following conditions: • Motor running • • •

•

Pump pressure between 60 bar and 300 bar, present at the slipper pad of piston #14 and the small area side of the positioning piston #13 X1 = 24 bar (pump regulation pressure) X3 = 16 bar (remote control pressure); Y17 energized and Y17a deenergized for all six pumps. X4 = 60 bar (pump support pressure), present at valve #6.

Response of pump control mechanism: Valve #6 moves to an intermediate position (in-between "a" and "b"), since a certain amount of oil behind nozzle (7) flows through valve #5 (which is also in an intermediate position, due to the 16 bar remote control pressure X3) back to tank. The large area side of positioning piston #12 is connected, via power control valve (8) position "a" and pressure balance valve (6), to the return oil line. The pump moves into ½ Q-max position, because the return oil flow through pressure balance valve (6) is restricted (due to its intermediate position), resulting in a pressure at the large area side of the positioning piston (12).

The pump moves into ½ Q-max position continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 14

Main Pumps 7.1.3 Operating Principles, illustration (Z 21555a) Cont'd: Destroking: (Pump moves from Q-max. into of Q-min. direction) When does the pumps start to destroke Motor running and hydraulic at normal operating temperature (> T2) and Service switch S150 deactivated and The hydraulic load is higher than the rated power of the motor. ⇒ (The electronic pump regulation system will reduce the X1-pressure) or With pump pressure above ≈ 150 bar (Hydraulic constant regulation) (Constant X1-pressure of approximately 8 bar) Example with the following conditions: • Motor running • Pump pressure 260 bar adjustable at main relief valve, present at the slipper pad of piston #13 and the small area side of the positioning piston #12 • X1 = 12 bar (constant regulation pressure adjustable at pressure reducing valve 81.2) Change over valve (79.1 / 73.2) switched to hydraulic mode • X3 = 35 bar (remote control pressure); Y17 energized and Y17a energized • X4 = 60 bar (pump support pressure), present at valve #7. Response of pump control mechanism: Valve #6 moves to position "a" because the spring force is supported by the X4pressure, since the oil flow back to tank is blocked at valve #5 (which is in position "b", due to the 35 bar remote control pressure X3). The operating pressure (with the value for start of de-stroking) at the slipper pad of piston #13 moves the power control valve (8) into position "b" (against the spring force supported by the X1-pressure). This in turn connects the operating pressure to the large area side of positioning piston #12. Because the large area side of positioning piston #12 is approximately three times larger as the small area side, the operating pressure present on both sides, resulting in stronger force at the large area side, moving the pump in Q-min direction. The pump de-strokes until the forces at positioning piston #12 are balanced continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 15

Main Pumps 7.1.3 Operating Principles, illustration (Z 21556a) Cont'd: Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position) When is the pressure cut-off valve active? Motor running and With pump pressure above ≈ 300 bar Example with the following conditions: Motor running Pump pressure 300 bar X1 = 24 bar (pump regulation pressure) X3 = 35 bar (remote control pressure) X4 = 60 bar (pump support pressure) Response of pump control mechanism: Independent of the position of power control valve #8 the pressure cut-off valve #10 causes the pump to de-stroke to the pre-adjusted Q-min position. The operating pressure moves the pressure cut-off valve #10 (at set pressure) into position "b" and flows to the large area side of positioning piston #12. Because the large area side of positioning piston #12 is approximately three times larger as the small area side, the operating pressure present on both sides, resulting in stronger force at the large area side, moving the pump in Q-min position. The pump moves into Q-min position

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 16

Main Pumps 7.1.4

Checks / Adjustments

Location of Adjustments Legend for , illustration (Z21557) (1) Remote control valve (2) Q-min. stop bolt (3) Pressure balance valve (4) Start of destroking (5) Power curve correction (6) Pressure cut-off valve (7) Q-max. stop bolt (8) Angle indicator The average length of the measurement "L" is: set screws (bolts) location 1 2 3 4 5 6 7

)

Length “L” (mm) 13.4 21.9 7,6 8.1 ---6.0 27.6

• The measurement "L" is an orientation only if the adjustment is totally out of requirements. They must not be used for final adjustments. The detail for (5) shows the position of the housing edge and the edge of the eccentric set bolt. The example shows them in parallel position which is mostly not the case. The adjustment should never be altered.

Further information see next pages

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Section 7.0 Page 17

Main Pumps 7.1.4

Checks / Adjustments

Pressure balance valve (Δ P 20bar), illustration (Z21558) Pressure balance valve, illustration (Z 21558b)

• The pressure balance valve is bench adjusted. There is no field setting with a sufficient result possible.

continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 18

Main Pumps 7.1.4 Checks / Adjustments Cont'd: Start of destroking(LR valve), illustration (Z21559) The reason of this check is to make sure, the pump starts destroking at an operating pressure of 150 bar with a pump regulation pressure X1 of 0 bar. 1. 2. 3. 4. 5. 6. 7.

Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked. Connect a 25 bar pressure gauge to respective pressure check point M20-1 or M20-2 at the control and filter panel (X1-pressure). Change over the respective three way cock to electronic regulation. Unplug the respective proportional valve Y61.1 / Y61.2. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of. Start the respective motor. The X1-pressure should be 0 bar. Stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV between 140 and 160 bar. Start of de-stroking should be at an operating pressure of 150 bar, shown at the gauge connected to the high pressure filter.

If readjustment is required proceed as follow: a) Adjust with the MRV an operating pressure of 150 bar. b) Loosen lock nut #6 (Power control valve). c) Turn set bolt #7, so that the pump is still in Q-max. position, but just at the beginning of de-stroking. d) Tighten lock nut #6. 8.

9.

Re-adjust the operating pressure at the MRV to 310+10 bar and plug on the Y61.1 resp. Y61.2 (For exact values refer to the final test report.) Remove Allen key and gauges. continued

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Section 7.0 Page 19

Main Pumps 7.1.4 Checks and Adjustments Cont'd: Pressure cut-off valve (DR control valve), illustration (Z21560) The sense of this check is to make sure that the pump is in Q-min. position at an operating pressure between 300 bar and 310 bar. 1. 2. 3.

Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of de-stroking. Start the respective motor, stall the hydraulic only for the pump to be checked and alter the operating pressure with the respective MRV between 280 and 310 bar. • Stall only one pump per motor to prevent an influence of the regulation system..

Recommendation to stall the respective pump with FSA: Pump 1 and 6: a) Unplug solenoid valve Y16 (park brake travel motor active) b) Activate carefully the left travel motor with full pressed pedal in one direction Pump 3 and 4: a) Activate carefully the clam open function and keep it in final position Pump 2 and 5 a) Unplug solenoid valve Y16 (park brake travel motor active) b) Activate carefully the right travel motor with fully pressed pedal in one direction and keep it in this position. 4. The angle indicator must indicate Q-min. position at a pressure of 300 bar shown at the gauge connected to the high pressure filter. If readjustment is required proceed as follow: a) Loosen lock nut #8. b) Turn set bolt #9, so that the pump is in Q-min. at the required value. c) Tighten lock nut #8. 5. Re-adjust the operating pressure at the MRV to 310+10 bar 6. Remove Allen key, gauges and plug in the unplugged plugs. continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 20

Main Pumps 7.1.4 Checks and Adjustments Cont'd: Q-max. and Q-min. stop bolt, illustration (Z21561) 1. 2. 3. 5.

Unscrew box nut (10 or 14). Loosen the lock nut (11 or 13) Turn the stop (12 or 15) in or out until required length Length "X" or "Y" Tighten the lock nut and screw on box nut (12).

• Turning the Q-min. stop bolt too much out can cause serious damage to the pump. The pump moves over 0 (zero) position into the opposite drive direction: (suction line becomes pressure line and pressure line becomes suction line)

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Section 7.0 Page 21

Electronic Pump Regulation System 7.2.1

Electronic load limiting control - General, illustration (Z 22448)

The drive train of the excavator consists of two electric motors, several hydraulic pumps, which supply cylinders and hydraulic motors. The load limiting control ensures optimum use of the power required for the excavator under varying operating conditions and avoiding overload of the motors. Illustration Z22407a shows the principle of the electronic load limiting control. The MC7 (E32-1) processes the following input signals: • Voltage (Pin 47) from electronic signal rectifier (A32) • Current motor 1 (Pin 45) from electronic signal rectifier (A33-1) • Current motor 2 (Pin 46) from electronic signal rectifier (A33-2) The MC7 (E32-1) processes the following output signals: • Signal value to control the proportional solenoid valve Y61-1 (Pin 28) Motor 1 • Signal value to control the proportional solenoid valve Y61-2 (Pin 30) Motor 2 • Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32-1) Each electric motor drives three variable displacement pumps by means of a PTOgearbox. Each pump is equipped with a hydraulic power controller (HPC). This controller limits the input torque of the pump to an adjusted command value (X1pressure, for start of destroking). The command value (X1-pressure) is present via proportional solenoid valves Y61-1 respectively Y61-2 at the hydraulic power controllers of each pump.

)

• The auxiliary hydraulic pumps and other consumers can be operated without being directly affected by the load limiting control.

Function: The ESR-Module (A32) transforms an AC Voltage, which is proportional to the net voltage, into a proportional DC Voltage and transfers it into the MC7 (E32-1). The ESR-Module (A33-1 + A33-2) transforms an AC Voltage, which is proportional to the respective motor current, into a proportional DC Voltage and transfers it also into the MC7 (E32-1). These input signals are the information about the actual load to the motors and serves the MC7 (E32-1) The control algorithm of the load limiting control (MC7) always compares the actual required power with the rated power. With increasing load the motor torque will rise and in turn the required power. For this reason the electronic load limiting control will be initiated when the required power is higher than the rated power, i.e. the torque of the main pumps will be lowered (by reducing the X1-pressure) until the rated power is attained again.

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Section 7.0 Page 22

Electronic Pump Regulation System 7.2.2

Electronic Power Module EPM, illustration (Z 22624b)

The power – Module A31a transforms the 24 VDC battery voltage into positive/negative 15 VDC and the power Module A31b into positive 5 VDC which is the supply voltage for the ESR Modules.

Function check: Measure the supply voltage. (24 VDC; GND = 0 V). If the supply voltage is not there, check the supply cable and the circuit breaker. If the circuit breaker always trips there may be a short within the cables to the Power Module or a short in the unit itself. If the supply voltage is ok. the Output Voltages have to be checked. Check pos. 15 VDC, neg. 15 VDC, 5 VDC to GND. If the supply voltages are not ok. the short circuit monitoring system of the Power Modules might be activated, therefore disconnect the cables at the terminals (+15 VDC, -15 VDC and +5 VDC) and repeat the voltage check. If now (with disconnected cables) the voltages are as they should be there is either a short within the cables or in the other modules itself. To determine the fault connect the entire modules in sequence. If the voltage is not ok., even when the cables are disconnected from the Power Module, the Module is defect.

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Section 7.0 Page 23

Electronic Pump Regulation System 7.2.3 Electronic Signal Rectifier ESR – Modules, illustration (Z 22625a) Function: The ESR-Module transforms an AC signal-voltage, which is proportional to the network voltage respectively the motor current, into a proportional DC Voltage and transfers it into the MC7. Testing the ESR-Module, A32 + A33.1 + A33.2 Testing the ESR input/output voltage For a transformer function test the AC-Input Voltage and the DC-Output Voltage must be measured and compared. • The potentiometer settings are under no circumstances allowed to be altered, because the setting is possible only with a HFGenerator and an Oscilloscope. • If the potentiometer set-positions have been altered, a new Module, with sealed potentiometers, must be ordered. Procedure: Same procedure for all three Modules 1.

Disconnect the wire from terminal 23 of the ESR Module.

2.

Start the motor and let it run without an extra load on it.

3.

Measure the AC-Voltage between the terminals 21 and 41 and record it.

4.

Measure the DC-Voltage between the terminals 23 and 11 and record it.

5.

The measured DC-Voltage must be 1/4 of the AC-Voltage. Example:

2.5 VDC ________ = 1/4 = 0,25 (1 % plus/minus is ok) 10 VAC

Small variations are based on amplitude variations of the AC-Input voltage while measuring the DC-Output voltage. Greater variations denotes a faulty ESR Module. continued

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Section 7.0 Page 24

Electronic Pump Regulation System 7.2.3 Electronic Signal Rectifier ESR – Modules, illustration (Z 22626a) Cont'd: The DC-Output Voltage (UaDC ) can be compared with a calculated Voltage Value. The calculation can be done with the ratios of the intermediate transformers given in the circuit diagram, and by the Voltmeter and Ammeter readings of the cab gauges.

)

• The picture shows a schematic design only and not the actual circuit diagram, the voltage- and current values may vary, therefore they are exemplary used.

With the below shown formulas the exact Output Voltages UaDC of an ESR can be calculated. Small variations are caused by the transformers. Variations greater than 20 % denotes a faulty transformer.

EXAMPLE FOR ESR 1: U ESR1 ----------------T1 x T2 x T3

6570 V --------------66 x 10 x 4

= 2,488 VDC

Voltage

EXAMPLE FOR ESR 2: I ESR2 ----------------T1 x T2 x T3

80 A ----------------30 x 0.5 x 4

= 1,333 VDC

Current Motor 1

= 1,25 VDC

Current Motor 2

EXAMPLE FOR ESR 3: I ESR3 ----------------T1 x T2 x T3

75 A ----------------30 x 0.5 x 4

The AC Input Voltage for an ESR-Module can be calculated with the same formula but without the value for T3.

EXAMPLE FOR ESR 2: I ESR2 ----------T1 x T2

80 ----------30 x 0.5

= 5,333 VDC

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Electronic Pump Regulation System 7.2.4

Microcontroller MC7, illustration (Z 21716)

The MC7 microcontroller is used for the programmable control of a maximum of four proportional solenoids and two additional switching functions. As input signals, the microprocessor processes analog voltages in the 0V to 5V range and switching information. All inputs are protected against over-voltage and electrical interference. As output signals, the output stages of the MC7 deliver closed loop controlled currents for the connection of proportional solenoids. The analog voltage output is suitable for the simple forwarding of analog information to other electronic circuits. Characteristics • Closed loop control of solenoid currents, i.e. independent of voltage and temperature. • Pulse width modulated (PWM) solenoid currents for minimal hysteresis. • Internal buzzer for programmable monitoring of functions or errors. Setting and Display Facilities All calibration operations and the display of functions, faults and system variables are connected via the serial interface to the BB-3 control panel or to a PC running the BODEM software. MC7 - Unit Dimensions Plug Contacts

8 junior power timer contacts 47 micro timer I contacts MC7 - Block Circuit Diagram

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Electronic Pump Regulation System 7.2.5 Checks and adjustments General Microcontroller MC7, illustration (Z 21714c) The adjustment of the X1-pressure can be done with three different methods: A. With 24V supply to separating terminals at the X2-switch board or B. With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab) or C. With a laptop, running the BODEM software, connected to the serial interface X13-1 (located in the operators cab)

)

• Procedure B and C should only be carried out by authorized personnel. [ Dealer or KMG-factory staff ] Because it is possible to influence the behavior of the pump regulation system. On the following pages are only the necessary setups described. If additional information is required, please contact KMG-Service department.

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22628)

Method A - X1-pressure adjustment with 24V supply to separating terminals at the X2-panel. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. 2. 3.

4.

5.

) 6.

7.

Make sure the change over valves (79.1 – motor 1 respectively 79.2– motor 2) are in position “Electronic Pump Regulation” Connect a pressure gauge to the respective check points (M20.1 or M20.2), using a long pressure gauge hose to be able reading the pressure in front of the X2-panel. Selection of adjusting mode: Turn the main key switch in on position and activate the adjusting mode as follows: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test leads and disconnect the voltage thereafter. Selection of the motor and in turn the required proportional solenoid valve : With the main key switch still in on position, select the applying terminal for proportional solenoid valve Y61-1 or Y61-2 as follows: Motor1 →Y 61-1 → No connection to 24V required. Motor2 →Y 61-2 → Connect permanent 24V to terminal 53, using a test lead. Adjusting the X1-pressure: Start the respective motor. Read the pressure, required = 24± 0,5 bar If necessary increase the X1-pressure as follows: Connect 24V to terminal 54. • As long as voltage is supplied, the X1-pressure drops to zero. After interrupting the voltage supply, the gauge pointer will move slowly to the new present X1-pressure. • Example: Keeping voltage supply for two seconds , will increase the X1-pressure of approximately 1bar. • The adjusted value will be saved immediately and will be available after power off. To decrease the X1-pressure connect 24V to terminal 55 and proceed as described under item 5, keeping voltage supply for two seconds , will decrease the X1-pressure of approximately 1bar. After the adjustment is finished, remove the test leads and pressure gauge and turn the main key switch in OFF position to deactivate the adjusting mode. continued

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Electronic Pump Regulation System 7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22629a) Cont'd: Method A - Demanded power adjustment Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air.

) 1. 2. 3. 4. 5. 6. 7. 8.

)

• The adjustment has to be carried out separately for each motor Connect pressure gauges to check points M12.1, M12.2, M12.3 and M12.4 at the high pressure filters. Connect pressure gauges to the X1 pressure check points M20.1 and M20.2. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hydraulic oil cooler fans are running with maximum speed. Start main motor of the circuit to be adjusted. Set the MRV individually to approx. 120 bar *, to prevent the motors from overloading during the adjustment. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant) Regulation Mode”. Set the X1-pressure at pressure reducing valve (81.2) > 25 bar **, to ensure that the pumps remain in Q-max. flow position during the adjustment. Apply max. load to all pumps (e.g. extend the bucket cylinders to the final stop position and keep it fully under load), and increase the pressure at all 4 MRV’s * equally to 212 bar. Expected motor current at 3 times 212 bar ≅ 88 Ampere (reading of text display) (peak point). Record this current for other tests. • If the motor current is lower respectively the operating pressure is higher than required there is probably not the full volume available. *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. continued

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Electronic Pump Regulation System

7.2.5 Cont'd:

Checks and adjustments Microcontroller MC7, illustration (Z 22629a)

Method A - Demanded power adjustment 1.

) 2. 3. 4. 5.

Store the demanded power (peak point) into the MC7 as follows: a) Activate the adjusting mode: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using test leads and disconnect the voltage thereafter. b) Select the demanded power adjusting mode of Motor 1: Connect 24V, simultaneously to terminal 50 and 52 permanent. c) Select the demanded power adjusting mode of Motor 2: Connect 24V, simultaneously to terminal 50, 52 and 53 permanent. d) Stall the hydraulic with the values of item 8 (Peak point) 3 times ≅ 212 bar => ≅ 88 Ampere (each motor) (all pumps Q-max position and cooler fans with max. speed). e) Save the actual measured power: Connect 24V to terminal 55 for 1 second and disconnect the voltage thereafter. • The actual measured power will be saved immediately as the demanded power Re-set the X1-pressure at pressure reducing valves (81.2) as recorded**. Shift the three way cock valves (79.1 and 79.2) to position “Electronic Regulation Mode” Reset the MRV’s to 310 bar+5bar , and remove the gauges. After the adjustments are finished, remove the test leads and pressure gauges, stop the motors and turn the main key switch in OFF position to deactivate the adjusting mode. *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Loosen the lock nut (e). − Turning the set screw (f) − Turning the set screw

cw the pressure will increase. ccw the pressure will decrease. continued

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Electronic Pump Regulation System

7.2.5 Cont'd:

Checks and adjustments Microcontroller MC7, illustration (Z 22636)

Method A - PID - Factor adjustment to obtain the most efficient pump regulation characteristic. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. • With the PID-Factor adjustment (proportional, integral and differential factors) it is possible to influence the regulation dynamics. • The PID-Factor adjustment range is between 80 % and 120 % • The voltage at the analogue output (terminal 60) represents the actual adjusted value. (80 % = 0VDC / 100 % = 2,5VDC / 120 %= 5VDC) • This factor is multiplied with all PID parameters.

) 1.

Jerky movements while lifting and swinging at the same time: a) Activate the adjusting mode: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test leads and disconnect the voltage thereafter. b) Select the PID-factor adjusting mode: Connect 24V, to terminal 50 permanent, using a test lead. c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the value (represents the actual adjusted value) d) Reduce the voltage in steps of 250mV until the system works smoothly, by connecting 24V to terminal 55. (As close as possible to the boarder line)

2.

No Jerky movements: a) Activate the adjusting mode: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test leads and disconnect the voltage thereafter. b) Select the PID-factor adjusting mode: Connect 24V, to terminal 50 permanent, using a test lead. c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the value (represents the actual adjusted value) e) Increase the voltage in steps of 250 mV until the system jerks, by connecting 24V to terminal 54. (As close as possible to the boarder line) f) Now reduce the voltage in steps of 250mV until the system works smoothly again, as described under item 1d.

3.

After the adjustments are finished, remove the test leads and multi-meter, stop the motors and turn the main key switch in OFF position to deactivate the adjusting mode.

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Electronic Pump Regulation System 7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357a) Method B With the electronic service tool (EST) BB-3 connected to the serial interface X13 (located in the operators cab) Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. 2.

3. 4.

Make sure the respective change over valve is in position “Electronic Pump Regulation” Connect a pressure gauge to check point (respective M20-1, M20-2 ), using a long pressure gauge hose to be able reading the pressure inside the operators cab. Connect the electronic service tool (BB-3) to the data link adapter X13, with key switch (S1) in OFF position. Turn key switch (S1) in ON position: After switching on the power for the Control panel BB-3 the following functions are carried out and shown on the display: 4.1 Self-test and baud rate recognition: The BB-3 automatically recognizes the rate of data transmission from the MC electronics. 4.2 Identification: On recognition of the MC electronics the relevant software in the BB-3 will be started up. 4.3 Main menu: Initialization of remote control unit BB-3 is complete. One of the four main menu items can be selected using the given keys.

First screen (main menu) after connection and Key switch turned ON in German.

F1 F2 PROC TE ACH Language selection To change the language press simultaneously the buttons ALT + Clear

ALT

+

CLEAR

Config/Cal. Diagnostic Status Storage

The language selection menu appears

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage continued

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Cont'd: Method B Language selection Press button 2

2

The language will change to English and the display show the main menu

1. 2. 3. 4.

Deutsch English - - - - -

One of the four main menu items can be selected using the given keys.

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Method B - A: Adjustment mode SET 1 and SET 2 There are two adjustment modes (SET 1 and SET 2) integrated. SET 1 is for the main settings and SET 2 is only for the basic adjustments. SET 2 can only activated with a password. After start up of the MC7 with connected BB3 the adjustment modes SET 1 is active. Main display SET 1 Standard after start up F1 F2 PROC TE ACH

Main display SET 2 Only with password

Config/Cal. Diagnostic Status Storage

F1’ F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

Change from SET 1 to SET 2:

Press

F1

Press

ALT

SET 1 Config/Cal

+

in the same time

1 2 3 4

Demand Power Max current PID - Factor Error Lamp

A password will be requested Enter password (5 7 0 8 7 5)

1 Press

MENU

...

9

SET 2 to go back to the main menue

To switch back to SET 1 repeat this procedure or switch off and on the MC7.

?: _

1 2 3 4

Configuration PID Control Low Voltage –––

F1’ F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

continued

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Method B - Number of motor selection: Activate adjustment mode SET 2 as described on page 65 Press

F1

Press

1

Configuration

Press

2

No of motors

Config/Cal

F1’ F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

1 2 3 4

Configuration PID Control Low Voltage –––

1 2 3 4

No of valves No of motors –– ––

Select desired number of motors

2

No of motors

use

1

motor

2

No of motors

2

motors

1 2 3 4

No valves No motors –– ––

Press

or

ENTER Acceptation

Press. 2 x MENU Return to sub menu.

F1’ F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

Save setting to the EEPROM of the MC7 as described at page 75. continued

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Micro-controller MC7, illustration (Z 22357a)

Method B X1-Pressure (maximum current) Adjustment:

F1

Press

Config/Cal

If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 65.

2

Press

Max current

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

1 2 3 4

Demand Power Max current PID - Factor Error Lamp

1 2 3 4

Valve Valve Valve Valve

Select desired valve Press or Press

1

Valve 1, Motor1

3

Valve 1, Motor2

Example Motor 1, Valve1

Start the respective motor. Do not load the motor. Check the X1-pressure with a pressure gauge and set it to the desired value by: pressing

Press

or

ENTER

Press. 2 x

Accept tion

MENU

Return to main menu

1 2 1 2

Mot. Mot. Mot. Mot.

1 1 2 2

1 Valve 1 Mot. 1 0 – 100±1 71

1 Valve 1 E1 0 – 100±1 78

1 2 3 4

Valve Valve Valve Valve

F1 F2 PROC TE ACH

1 2 1 2

Mot. Mot. Mot. Mot.

1 1 2 2

Config/Cal. Diagnostic Status Storage

Save setting to the EEPROM of the MC7 as described at page 75. continued

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22357)a

Method B Demanded power adjustment: Cont'd: Press

F1

F1 F2 PROC TE ACH

Config/Cal

If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 65.

Press

1

Configuration

Config/Cal. Diagnostic Status Storage

1 2 3 4

Demand Power Max current PID-Factor Error Lamp

1 2 3 4

Set demand m. Set demand m. Demand power Demand power

Select desired demand power adjustment Press or Press

SET 1

1

demand power Motor1

2

demand power Motor2

1 2 1 2

1 Set demand m. 1 0–0±1 0

Example Motor 1

and Load respective Motor with max power Press ENTER

Selection

Start? ––> <ENTER> Cancel? ––> <ENTER>

Press ENTER

Starting

Function ended Saved Press <ENTER>

Press ENTER Confirm

Press. 2 x

MENU

Return to main menu

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

Save setting to the EEPROM of the MC7 as described at page 75. continued

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Method B Cont'd: PID-Factor adjustment: Jerky movements while lifting with full bucket and swinging at the same time: Reduce jerking ⇒ Reduce the PID-Factor in short steps. To obtain the most efficient pump regulation characteristic adjust to the PID-Factor until the system jerks as close as possible to the boarder line.

Press

F1

F1 F2 PROC TE ACH

Config/Cal

If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 65.

SET 1

Press

3

PID-Factor.

Press

1

PID-Factor.

Adjust the PID-Factor by pressing . or

Press

ENTER

Acception

and check the machine movement again if necessary repeat PID-Factor adjustment

Press. 2 x

MENU

Return to main menu.

Config/Cal. Diagnostic Status Storage

1 2 3 4

Demand Power Max current PID-Factor Error Lamp

1 2 3 4

PID-Factor ––– ––– –––

1 PID-Factor 80–120±1% 100

1 2 3 4

PID-Factor ––– ––– –––

F1 F2 PROC TEACH

Config/Cal. Diagnostic Status Storage

Save setting to the EEPROM of the MC7 as described at page 75. continued

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Method B Cont'd: Storage all new settings to the MC7: This menu item permits storage of all edited parameters to the EEPROM of the MC electronics .

Press TEACH

Press

1

Press ENTER

Press. MENU

Activate storage menu

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

Save Params

1 2 3 4

Store parameters

Teach? ––> <ENTER> Cancel? ––> <ENTER>

Return to main menu.

1 2 3 4

Save Params Default Rarams Get EEPROM Send EEPROM

Save Params Default Rarams Get EEPROM Send EEPROM

If all adjustments are correct and stored in the MC7, proceed as follow: • Stop the motors and turn key switch (S1) in OFF position • Disconnect the electronic service tool (BB-3) and the pressure gauge.

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C -

With a laptop computer and BODEM software connected to the serial interface X13 (located in the operators cab) Starting the program Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. Connect the laptop computer to the data link adapter X13, with key switch (S1) in OFF position. 2. Make sure that the dongle is connected to the laptop computer. If not

3. Turn key switch (S1) in ON position. 4. Start the computer. 5. Click on the Bottom - icon to start the program.

continued

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Electronic Pump Regulation System 7.2.5

Method C, Cont'd:

Checks and adjustments Microcontroller MC7, illustration (Z 22358a) Starting the program

6. The program starts (only) the first time with the Demo Version.

7. Open menu FILE → INTERFACE , select the required interface connection (Standard COM1), confirm with OK and leave the program.

8. Start the program again. Now the computer is connected to the Microcontroller. During uploading of the MC7 data to the PC a window opened and shows some hardware and software information.

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C Language selection Open menu FILE → Language , select the required language and confirm with OK .

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C Entering of the password:

)

• The password is only required to adjust the number of valves or engines and for fine tuning of special regulation parameters. All other adjustments are possible without the password.

Open menu Parameters and select Enter password.... Write the correct password and confirm with OK. (Password 570875)

)

• After entering a correct password and confirming with OK the BODEM software start a new upload from the MC7 memory to the PC.

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C Cont'd: Number of Motor selection: Pre condition: The correct password was entered as described on page 83. Open Parameters and select Display / Edit Parameters. Then select in the left window Configuration. Now on the right side there two pull down menus. Example: select for PC 5500 1 valve per motor and 2 Motors. Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C X1-Pressure (maximum current) Adjustment: Make sure the change over valve is in position “Electronic Pump Regulation” Connect a pressure gauge to the respective check point (M20-x), using a long pressure gauge hose to be able reading the pressure inside the operators cab. Open menu Parameters select Display/Edit parameters and Max current, start respective motor without load and wait 30 sec.. The X1-pressure will raise to the max. adjusted value. If necessary adjust the required pressure (according to the final test report or hydraulic diagram) with the respective slide bar. (Valve 1 Mot. 1 is the X1-1 pressure and Valve 1 Mot. 2 the X1-2 pressure). Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.

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Electronic Pump Regulation System 7.2.5

Checks and adjustments Microcontroller MC7, illustration (Z 22360a)

Method C Demand power adjustment:

)

• The adjustment has to be carried out separately for each motor

Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. Open menu Parameters and in the pull down window the menu point Display / Edit Parameters.... Now the window with the demand power adjustment will be on screen.

Screen with password Screen without password. The demand power adjustment is possible both modes. continued

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Electronic Pump Regulation System 7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22360a) Cont'd: Method C Demand power adjustment:

)

• The adjustment has to be carried out separately for each motor

Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. 2. 3. 4. 5. 6. 7.

Connect pressure gauges to the high pressure check points at the high pressure filters. (M12.1, M12.2, M12.3 and M12.4) Connect pressure gauges to the X1 pressure check points (M20.1 and M20.2). Unplug fan control solenoid valves (Y6a-1, Y6b-1 and Y6a-2, Y6b-2) to ensure that the hydraulic oil cooler fans are running with maximum speed. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant) Regulation Mode”. Start one motor. Set the X1-pressure at pressure reducing valve (81.2) > 25 bar **, to ensure that the pumps remain in Q-max. flow position during the adjustment. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally to the demand power pressure written in the final test report (PC5500, S/N 15016 = 212 bar). Check the current drawn of the respective motor at this stage (reading of text display) Expected approx. ~ 88 Ampere. Record this values for other tests. *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) − Turning the set screw **Altering the X1-Setting: − Loosen the lock nut (e). − Turning the set screw (f) − Turning the set screw

cw the pressure will increase. ccw the pressure will decrease.

cw the pressure will increase. ccw the pressure will decrease. continued

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Electronic Pump Regulation System 7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22360a) Cont'd: Method C Demand power adjustment: 8.

9.

Select Execute... of menu point Set demand m. 1 for motor 1 or Set demand m. 2 for motor 2. Select Start to set the actual power as demand power. Confirm with OK. The new actual demand power will be only shown after a new upload of the MC7 settings. Exit the BODEM software and start again. Stop motor and repeat from item 5 for the second motor.

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Electronic Pump Regulation System 7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358a) Cont'd: PID Factor adjustment: Method C to obtain the most efficient pump regulation characteristic. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. • With the PID-Factor adjustment (proportional, integral and differential factors) it is possible to influence the regulation dynamics. • This factor is multiplied with all PID parameters. • Only one factor / adjustment for both motors

)

Open Parameters and select Display / Edit Parameters. Select in the left window PID control. Adjust now the PID-Factor with the slide bar or write direct the requested value to the window with the % value. Write new adjustment permanent to the MC7 EEPROM with Apply and confirm with OK. • Jerky movements while lifting and swinging at the same time: Reduce the PIDFactor in short steps until the system works smoothly. (As close as possible to the boarder line) • No Jerky movements: 1. Increase the PID-Factor in short steps until the system jerks. (As close as possible to the boarder line) 2. Now reduce the PID-Factor in short steps until the system works smoothly again.

7.0 49

Main Hydraulic Pumps and Pump Regulation System 7.3

Section 7.0 Page 49

Hydraulic Constant Regulation System 7.3.1

)

General The pilot pressure pumps ( 7.1 and 7.2) deliver the oil through the pressure filter (68.1) to port A of the pressure relief valve (70.1) for limiting the pump support pressure X4 to 60 bar. By the function of pressure reducing valve (70.2), the X4 pressure of 60 bar is reduced to the pilot pressure X2 of 35 bar. The common X2 pressure will be reduced by the function of pressure reducing valves ( 81.2 ) to the necessary constant X1 pressure, to prevent the motors from overloading. • For testing purposes the pump regulation system can be changed to the hydraulic operation mode. In case of a failure in the electronic regulation system the hydraulic operation mode can also be used for emergency operation. • The standard operation mode of the pump regulation system is the Electronic Operation Mode.

Legend for illustration (Z 22442a): (1 - 3) Main hydraulic pumps (driven by Motor 1) (4 - 6) Main hydraulic pumps (driven by Motor 2) (7.1) Pilot pressure pump (driven by Motor 1) (7.2) Pilot pressure pump (driven by Motor 2) (68.1) Pilot pressure filter unit (70.1) Pressure relief valve 60 bar (X4) (70.2) Pressure reducing valve 35 bar (X2) (81.1) Pressure reducing valve: "½ Qmax , remote control X3 pressure” (81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic constant regulation mode " (Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic operation mode" (Standard mode Motor 1) (Y61-2) Proportional solenoid valve: "Pump regulation pressure X1 at electronic operation mode" (Standard mode Motor 2) (79.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 1 (79.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 2

7.0 50

Main Hydraulic Pumps and Pump Regulation System 7.3

Section 7.0 Page 50

Hydraulic Constant Regulation System 7.3.2

X1-pressure adjustment (constant-pressure), illustration (Z 22639a)

1.

Connect pressure gauges to check points M12.1, M12.2, M12.3 and M12.4 at the high pressure filters. Connect pressure gauges to the X1 pressure check points M20.1 and M20.2. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hydraulic oil cooler fans are running with maximum speed. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant) Regulation Mode”. Start motor 1. Set the X1-pressure at pressure reducing valve (81.2) to approx. 3 bar ** Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally to 260bar. Check the current drawn of motor 1 at this stage (reading of text display) Expected approx. .. ≅ 70±5 Ampere. If necessary adjust the X1-pressure at pressure reducing valve (81.2) . Record this values for other tests. Stop motor 1 and start motor 2 . Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and set the pressure at all 4 MRV’s * equally to 260 bar. Check the current drawn of motor 2 at this stage (reading of text display) The current of motor 1 should be approx. ≅ 70±5 Ampere depend on the setting of motor 1. There is only one valve (81.2) for both motors. Shift the three way cock valves (253.1 and 254.1) to position “Electronic regulation“. Plug on the unplugged solenoid valve. Reset the MRV’s * to 310 bar+5bar , and remove the gauges.

2. 3. 4. 5. 6. 7.

8.

9. 10.

11.

12. 13. 14.

)

04.01.07 rev.2

• The adjustment has to be carried out separately for each motor

*Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) − Turning the set screw

cw the pressure will increase. ccw the pressure will decrease.

**Altering the X1-Setting: − Remove dust cap (d). − Loosen the lock nut (e). − Turning the set screw (f) − Turning the set screw

cw the pressure will increase. ccw the pressure will decrease.

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Section 8.0 Page 1

Operating Hydraulic

Table of contents section 8.0 Section 8.0

01.04.03

Page Operating Hydraulic General 8.0.1 Floating function of boom and stick cylinders

2 3+4

8.1

Hydraulic for the attachment cylinder FSA and BHA

8.2

Hydraulic for the swing circuit

8.3

Hydraulic for the travel circuit

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8.0 &2

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Operating Hydraulic

8.0

Section 8.0 Page 2

General Overall view of the Hydraulic system, illustration (Z 21955): (1 – 6) (7) (8) (9) (10) (11) (12) (13)

Main pumps High pressure filters Main control blocks Distributor manifold Attachment cylinders Swing motors Rotary joint Travel motors

General information The control blocks, the piping to the distributor manifold and the connecting hoses to the attachment are in some points different between the Backhoe Attachment (BHA) and the Front Shovel Attachment (FSA). If a conversion is required, contact the service department for further information. Function:

F

• •

Study together with the circuit diagram. The following numbering refers to the hydraulic circuit diagram.

Each main pump (1 to 6) delivers oil trough the high pressure filter (44.1, 44.2, 46.1 and 46.2) to port P of the main control blocks (FSA – 14, 15, 16 and 13) (BHA - 175, 15,176 and 13). The single valve block IV (13) is in line to valve block II (15) connected. This results in three main circuits. If all spools of the control blocks (1 to 6) are in neutral position, the oil leaves the block at port T and returns via return oil pipes, return oil collector manifold (35), return oil pipes (L6 and L7), return oil collector tube (114), back pressure valve (115) and the return oil filters (117.1-117.4) into the tank (41). The function of back pressure valve (115) ensures: - sufficient oil supply for all anti-cavitation valves - and that sufficient oil is forced through the oil coolers. If a control lever or pedal is actuated, pilot pressure oil moves the spools of the control blocks, directing the oil flow from the main pumps to one side of the user (either cylinders or motors). From the opposite side of the user the oil returns to the control block and from there via the return oil circuit back into the tank. Each circuit is provided with one MRV (also called primary valve, at least one SRV (also called secondary valve) and at least one flow restrictor. continued 01.04.03

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8.0 &3

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8.0 &4 8.0

General Cont'd: 8.0.1

Floating function of boom and stick cylinders FSA: illustration (Z 22568): The Excavator (only front shovel attachment) operates automatically with the float position for boom and stick activated. That means the lowering movement of boom and stick is always done in the float position. For deactivation of the float position, two push buttons are installed: a) S95 in the right joy stick (E19) for the Boom function b) S95a in the left joy stick (E20) for the Stick function Press the respective button and keep it depressed as long as the float position shall be deactivated. When releasing the button the float position is activated again. Function: There are different main valve spools in the three main valve blocks (14, 15 and 16) for boom and stick installed. Only by lowering of the boom or retracting of the stick is the floating function active if the button on the lever is not pushed. The piston and rod side of the respective cylinders are in floating position direct connect to the return line (tank). The pressure free pump circulation is still active there is no pump pressure to the respective cylinders. By external force the cylinder can move up or down with negligible hydraulically resistance. In floating position of the boom only valve spool 4 of main valve block I and 2 of block III active. In floating position of the stick only valve spool 2 of Main valve block I and 4 of block III active. To push down the boom or retract the stick by hydraulically force the respective button on the lever must by activated. S98 for the Stick cylinders S95 for the Boom cylinders In normal operation mode (i.e. float position) the piston side, the rod side and the tank are connected together when lowering the boom or retracting the stick. If a pressurised lowering of the boom or retracting of the stick cylinders is required the connection of piston side, rod side and tank must be disconnected and the rod side must be connected to the pump pressure. This is done by disconnecting the respective special floating valve spool and activating the respective standard valve spool. Now pressurised pump oil can flow to the cylinder rod side.

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8.0 &4

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Operating Hydraulic

Boom: S95 ON

K160 ON

A10 deactivated A10A activated S95 OFF

K160 OFF

A10 activated A10A deactivated Stick: S98 ON

K170 ON

A8B deactivated A8A activated S98 OFF

K170 OFF

A8B activated A8A deactivated

F

01.04.03

•

Section 8.0 Page 4

Float position deactivated Floating spool block I section 4 off Standard spool block II section 3 ON Float position activated Floating spool block I section 4 ON Standard spool block II section can be on or off

Float position deactivated Floating spool block III section 4 off Standard spool block II section 4 ON Float position activated Floating spool block III section 4 ON Standard spool block II section can be on or off

Due to the two different operation modes for lowering, the lowering speed of boom and stick cylinder must be adjusted twice: A. Float position deactivated B. Float position activated

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Section 8.1 Page 1

Hydraulic for the Attachment Cylinders Table of contents section 8.1 Section 8.1

Page Hydraulic for the attachment cylinder FSA and BHA 8.1.1 Electric / Hydraulic Flowchart Boom raising 8.1.2 Electric / Hydraulic Flowchart Boom lowering 8.1.3 Electric / Hydraulic Flowchart Stick extending 8.1.4 Electric / Hydraulic Flowchart Stick retracting 8.1.5 Electric / Hydraulic Flowchart Bucket filling (curl) 8.1.6 Electric / Hydraulic Flowchart Bucket emptying 8.1.8 Electric / Hydraulic Flowchart Clam opening 8.1.9 Electric / Hydraulic Flowchart Clam closing 8.1.10 Checks and adjustments of the Main Relief Valves (Primary valves) 8.1.11 Checks and adjustments of the Service Line Relief Valves (Secondary valves) Boom cylinder piston side FSA + BHA Boom cylinder piston rod side FSA + BHA Stick cylinder piston side FSA Stick cylinder piston side BHA Stick cylinder piston rod side FSA Stick cylinder piston rod side BHA Bucket cylinder piston side FSA Bucket cylinder piston side BHA Bucket cylinder piston rod side FSA Bucket cylinder piston rod side BHA Clam cylinder piston rod side FSA Clam cylinder piston side FSA 8.1.12 Checks and adjustments for the lowering speed. General: Flow Restrictors Boom cylinder FSA (Float position activated / deactivated) Boom cylinder BHA Stick cylinder FSA (Float position activated / deactivated) Stick cylinder BHA Bucket cylinder FSA Bucket cylinder BHA Clam cylinder 8.1.13 Checks for the valve control logic.

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2+3 4+6 7+8 9 + 11 12 + 13 14 + 15 17 18 19 + 20

21 + 22 23 + 24 25 + 26 27 + 28 29 + 31 32 + 33 34 + 35 36 + 37 38 + 39 40 + 41 42 43 44 44 + 46 47 48 + 49 50 51 52 53 54

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 2

8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA Legend for illustration (Z 22493): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (Y-) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10A) Amplifier module – Boom (A10B) Amplifier module – Boom (K79) Relay – pilot control: Contacts 8 / 12 only closed while lifting the boom. (K160) Relay – Floating control: Contacts 2 / 10 closed auto floating active . (K80) Relay – pilot control: Contacts 2 / 10 open while bucket filling (priority function). (K76A) Relay – pilot control: Contacts 2 / 10 open while stick extending (priority function). (45.1 – 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23a, Y26a, Y29a) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via ramp time module (E49) and the relay contacts (K79, K160) at terminal 5 of the three amplifier modules (A10, A10a and A10b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, and 45.3). Hydraulic signal flow. (pilot pressure) When the respective proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to IV) and arrives via the distributor manifold at the hydraulic cylinders.

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8.1 3

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 3

8.1.1 Electric / Hydraulic flowchart “ Boom raising ” BHA Legend for illustration (Z 22471): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YD) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom (45.1 – 45.3) Remote control valves (Y23, 25 + Y29) Proportional solenoid valve (Y23a, Y25a, Y29a) Directional solenoid valve (175, 15, 176) Main control blocks I – IV Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5 of the amplifier modules (A10 to A10b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to III) and arrives via distributor manifold at the hydraulic cylinders piston side. The piston extend and the boom move up.

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8.1 4

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 4

8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA, Auto Float off

Legend for illustration (Z 22530): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10A) Amplifier module – Boom (A10B) Amplifier module – Boom (K76A) Relay – pilot control: Contacts 6 / 10 open while extending the stick. (K79) Relay – pilot control: Contacts 6 / 10 open while filling the bucket. (K80) Relay – pilot control: Contacts 8 / 12 closed while moving the boom up. (K160) Relay – pilot control: Contacts 2 / 10 closed and 5 / 9 open while auto floating on. (K207C) Relay – pilot control: Contacts 5 / 9 closed while warming up hydraulic oil (S205). (45.1 – 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23b, Y26b, Y29b) Directional solenoid valve (I – III) Main control blocks I – IV Electrical signal flow (EURO control). The auto float button in the right lever E19 is still engaged this will energize relay K160. Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at terminal 5 of the amplifier modules (A10a and A10b) and further to the proportional and directional solenoid valve of the remote control blocks (45.2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the respective main control blocks. Hydraulic oil flow Only the oil of main pump 3 and 4 flows through the main control blocks (II) and arrives via the distributor manifold at the boom hydraulic cylinders piston rod side. Through main valve block III for boom lowering is no pressure oil flow depend on a different valve spool with closed pressure port.

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8.1 5

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 5

8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA, Auto Float on

Legend for illustration (Z 22531): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10A) Amplifier module – Boom (A10B) Amplifier module – Boom (K76A) Relay – pilot control: Contacts 6 / 10 open while extending the stick. (K79) Relay – pilot control: Contacts 6 / 10 open while filling the bucket. (K80) Relay – pilot control: Contacts 8 / 12 closed while moving the boom up. (K160) Relay – pilot control: Contacts 2 / 10 closed and 5 / 9 open while auto floating on. (K207C) Relay – pilot control: Contacts 5 / 9 closed while warming up hydraulic oil (S205). (45.1 – 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23b, Y26b, Y29b) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control). The auto float button in the right lever E19 is disengaged and relay K160 is deenergized. Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at terminal 5 of the amplifier modules (A10 and A10b) and further to the proportional and directional solenoid valve of the remote control blocks (45.1 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the respective main control blocks. Hydraulic oil flow Now the pump oil flow still back to the return line. Both pressure lines at valve block I section 3 (A3 and B3) are connected to the same back pressure charged return line. Valve spool 2 of main valve block III connect only port B2 to the return line. The return line, the piston side and the piston rod side of the boom cylinders now connected together. The boom can moved up and down by external force.

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8.1 6

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 6

8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” BHA Legend for illustration (Z 22473): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom (45.1 – 45.3) Remote control valves (Y23, 25 + Y29) Proportional solenoid valve (Y23a, Y25a, Y29a) Directional solenoid valve (175, 15, 176) Main control blocks I – IV

Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5 of the amplifier modules (A10, A10a and A10b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1 – 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to III) and arrives via distributor manifold at the hydraulic cylinders piston rod side. The piston retract extend and the boom move down..

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8.1 7

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Section 8.1 Page 7

8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA Legend for illustration (Z 22532): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YC) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (K76A) Relay – pilot control: Contacts 7 / 11 and 8 / 12 closed while extending the stick. (K80) Relay – pilot control: Contacts 1 / 9 open while bucket filling. (K170) Relay – pilot control: Contacts 5 / 9 closed and 7 / 11 opened while floating system active. (45.1, 45.2, 45.3) Remote control valves (Y21, Y27, Y31) Proportional solenoid valve (Y21a, Y27a, Y31a) Directional solenoid valve (I, II + III) Main control blocks I – III Electrical signal flow (EURO control). Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, III) and arrives via the distributor manifold at the hydraulic cylinders.

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8.1 8

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 8

8.1.3 Electric / Hydraulic flowchart “ Stick extending ” BHA Legend for illustration (Z 22474): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (Y+) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (45.1-45.3) Remote control valves (Y21, Y27, Y31) Proportional solenoid valve (Y21a, Y27a, Y27b) Directional solenoid valve (I, II, III) Main control blocks I, II III Electrical signal flow (EURO control). Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, III) and arrives via distributor manifold at the hydraulic cylinders.

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8.1 9

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 9

8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Auto Float off Legend for illustration (Z 22534): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YD) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (K76A) Relay – pilot control: Contacts 7 /11 and 8 / 12 open while retracting the stick. (K80) Relay – pilot control: Contacts 1 / 9 only open while bucket moving. (K170) Relay – pilot control: Contacts 1 / 9 closed and 3 / 11 open while auto floating off. (K207C) Relay – pilot control: Contacts 5 / 9 closed while warming up hydraulic oil (S205). (45.1, 45.2, 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23b, Y26b, Y29b) Directional solenoid valve (I + III) Main control blocks I + III Electrical signal flow (EURO control). Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a) and further to the proportional and directional solenoid valves of the remote control blocks (45.1 and 45.2). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the control blocks ( I and II ). Hydraulic oil flow Only the oil of main pump 3 and 4 flows through the main control block (II) and arrives via the distributor manifold at the stick hydraulic cylinders piston side. Through main valve block I for stick retracting is no pressure oil flow depend on a different valve spool with closed pressure port.

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8.1 10

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Section 8.1 Page 10

8.1.3 Electric / Hydraulic flowchart “ Stick retracting ” FSA, Auto Float active

Legend for illustration (Z 22535a): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (-Y) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (45.1-45.3) Remote control valves (Y21, Y27, Y31) Proportional solenoid valve (Y21a, Y27a, Y27b) Directional solenoid valve (I, II, III) Main control blocks I, II III Electrical signal flow (EURO control). The auto float button in the left lever E20 is disengaged relay K170 is deenergized. Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to the proportional and directional solenoid valve of the remote control blocks (45.1 and 45.3). Amplifier module A8a disengaged with open K80 if bucket filling is actuated.. Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the respective main control blocks. Hydraulic oil flow Both pressure lines at valve block III section 4 (A4 and B4) are connected to the same back pressure charged return line. Valve spool 4 of main valve block I connect only port B2 to the return line. The return line, the piston side and the piston rod side of the stick cylinders now connected together. The stick can move forward and backward by external force. If only the stick retracting function is active section 4 of main valve block II opened additional port A4 and B4 to extend the max. oil flow for max. stick speed.

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Section 8.1 Page 11

8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” BHA Legend for illustration (Z 22475): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (Y-) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (45.1-45.3) Remote control valves (Y21, Y27, Y31) Proportional solenoid valve (Y21b, Y27b, Y31a) Directional solenoid valve (I, II, III) Main control blocks I, II, III

Electrical signal flow (EURO control). Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, III) and arrives via distributor manifold at the hydraulic cylinders.

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8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA Legend for illustration (Z 22536): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (-X) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws / gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is in normal operating temperature. (K78) Relay – pilot control: Contacts 1 / 9 only open while bucket dump. (K79) Relay – pilot control: Contacts 1 / 9 only open while lifting the boom. (45., 45.2, 45.3) Remote control valves (Y22, Y24, Y30) Proportional solenoid valve (Y22A, Y24A, Y30A) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to III) and arrives via the distributor manifold at the hydraulic cylinders.

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Section 8.1 Page 13

8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” BHA Legend for illustration (Z 22476): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (XB) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws / gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated. (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (45.1-45.3) Remote control valves (Y22, Y24, Y30) Proportional solenoid valve (Y22a, Y24a, Y30a) Directional solenoid valve (I, II, III) Main control blocks I, II, III Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.,45.2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, III) and arrives via distributor the manifold at the hydraulic cylinders.

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8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” FSA Legend for illustration (Z 22537): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+X) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws / gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is in normal operating temperature. (K78) Relay – pilot control: Contacts 1 / 9 only open while bucket dump. (K79) Relay – pilot control: Contacts 1 / 9 only open while lifting the boom. (K205) Relay – pilot control: Contacts 1 / 3 only open while S205 activated (hydraulic oil warming up) (45., 45.2, 45.3) Remote control valves (Y22, Y24, Y30) Proportional solenoid valve (Y22A, Y24A, Y30A) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 19 of the ELB modules. From ELB modules the signal voltage arrives at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Only while bucket dump together with boom up K78 and K79 opened the contacts 1 / 9 and deactivate amplifier module A9 (priority to the boom). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to III) and arrives via the distributor manifold at the hydraulic cylinders. There is no oil flow through main control block I to the bucket cylinder if bucket dump and boom up is activated.

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Section 8.1 Page 15

8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” BHA Legend for illustration (Z 22477): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+X) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws / gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated. (14.1 + 14.3) Remote control valves (15) Remote control valves (Y64) Proportional solenoid valve (Y71 + Y75) Proportional solenoid valve (Y23 + Y45) Directional solenoid valve (Y37) Directional solenoid valve (II, III + IV) Main control blocks II, III + IV (42) Distributor manifold Electrical signal flow (EURO control) Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45,2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and arrives via distributor manifold (42) at the hydraulic cylinders.

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8.1.8 Electric / Hydraulic flowchart “ Clam opening ” FSA Legend for illustration (Z 21970): (E24) Control pedal (D32) Time relay – Pilot control: Neutral position monitoring (-10V) Signal voltage (Maximum) (rs) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A11) Amplifier module – Clam (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler. (15) Remote control valves (Y72) Proportional solenoid valve (Y39) Directional solenoid valve (II) Main control block II (42) Distributor manifold Electrical signal flow (EURO control). Signal voltage of control pedal (E24) arrives via relay contact at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (15). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure port of the main control block . Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and arrives via distributor manifold (42) at the hydraulic cylinders.

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Section 8.1 Page 18

8.1.9 Electric / Hydraulic flowchart “ Clam closing ” FSA Legend for illustration (Z 21971): (E23) Control pedal (D32) Time relay – Pilot control: Neutral position monitoring (+10V) Signal voltage (Maximum) (rs) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A11) Amplifier module – Clam (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler. (15) Remote control valves (Y72) Proportional solenoid valve (Y38) Directional solenoid valve (II) Main control block II (42) Distributor manifold Electrical signal flow (EURO control). Signal voltage of control pedal (E23) arrives via relay contact at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (15). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure port of the main control block . Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and arrives via distributor manifold (42) at the hydraulic cylinders.

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Hydraulic for the Attachment Cylinders 8.1.10

Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 22481): There are four main relief valves (primary valves) installed, one in each main control block, to limit the maximum pump supply line pressure (operating pressure).

Pump circuit I Pump circuit II Pump circuit III Pump circuit IV

MRV block

Check point

I

M12.1

travel

stick

bucket

boom

II

M12.3

clam

bucket

Boom

stick

III

M12.4

travel

boom

bucket

stick

IV

M12.2

Functions FSA

Swing, (if no swing active circuit II)

Each Pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit. Checking: 1. Connect the gauge to the required check point M12.1 - M12.4. 2. Start both motors. 3.

Extend or retract the cylinder to the stop position for the valve being tested until the hydraulic system stalls. 4. Read the pressure. Required: 310 + 5 bar If the pressure is not correct, carry out a comparative measurement with an other function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system.

)

•

When using the single function “bucket fill”, (gray shadow), all MRV can be adjusted, because all four pump circuits are engaged.

Adjusting: 1. Remove protective cap (a). 2. Loosen lock nut (b). 3. Turn set screw (c) -clockwise to increase pressure, Counter-clock wise to decrease pressure. 4. Tighten lock nut (b) and install cap (a).

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• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened with 300 Nm. Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Hydraulic for the Attachment Cylinders 8.1.10

Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 22481): There are four main relief valves (primary valves) installed, one in each main control block, to limit the maximum pump supply line pressure (operating pressure).

Pump circuit I Pump circuit II Pump circuit III Pump circuit IV

MRV in control block I II III IV

Check point M12.1 M12.3 M12.4 M12.2

Functions BHA Travel Stick Bucket Boom Bucket Boom Stick Travel Boom Bucket Stick Swing, (if no swing active circuit II)

Each Pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit. Checking: 1. Connect the gauge to the required check point M12.1 – M12.4. 2. Start both motors.. 3. Extend or retract the cylinder to the stop position for the valve being tested until the hydraulic system stalls. 4. Read the pressure. Required: 310 + 5 bar If the pressure is not correct, carry out a comparative measurement with an other function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system.

)

•

When using the single function “bucket fill”, (gray shadow), all MRV can be adjusted, because all four pump circuits are engaged.

Adjusting: 1. Remove protective cap (a). 2. Loosen lock nut (b). 3. Turn set screw (c) -clockwise to increase pressure, Counterclock wise to decrease pressure. 5. Tighten lock nut (b) and install cap (a).

)

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• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 21

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22482): Boom cylinder “piston side” FSA + BHA There are three service line relief valves (secondary valves) installed, all three at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. SRV FSA SRV BHA 141.1 138.1 141.2 138.2. 141.3 138.3 MRV I MRV II MRV III MRV IV 1. 2. 3. 4.

)

5. 6. 7. 8.

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Press. check point M23 M29.1 M29.2 M12.1 (at HP filter) M12.3 (at HP filter) M12.4 (at HP filter) M12.2 (at HP filter)

Location Manifold section B Manifold section N Manifold section N Double HP filter R.H. Single HP filter, block II Double HP L.H.. Single HP filter, block IV

Connect gauges to all above listed check points (min. 400 bar). Start both motors.. Extend the boom cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s in control block I, II, III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the boom cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22482a): Boom cylinder “piston side” FSA +BHA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 141.1 þ 141.2 þ 141.3 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 141.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-143.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 141.2 þ 141.3

• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all six service line relief valves.

12.

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Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments. PC5500-6-D_Sec_8-1_rev3.doc

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Section 8.1 Page 23

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22483b): Boom cylinder “piston rod side” FSA +BHA There is one service line relief valve (secondary valve) installed in the main control block II, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point SRV 33.4 FSA M12.3 (High pressure filter) SRV 33.6 BHA MRV circuit II M12.3 (High pressure filter) MRV circuit IV M12.2 (High pressure filter)

1. 2. 3.

4.

5. 6.

)

Location Control block II, section A3 FSA section A2 BHA Single high pressure filter, control block II Single high pressure filter, control block IV

Connect gauges to all above listed check points. Start both motors.. Press floating system button S95 at the lever with the boom function and retract the boom cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV in control blocks II, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. If there is a setting required follow Turn set screw (3) of the MRV ¼ turn further in, the gauge pointers will remain at the value shown at item #4 . Tighten lock nut (2).

• To ensure that only the SRV open during checks and adjustments it is necessary to further increase the setting of MRV control block II..

continued

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Section 8.1 Page 24

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22483b): Cont'd: 7. Adjust the SRV until the gauges show a pressure of 350 bar. 8. Tighten lock nut (2). 9. Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished 10. Tighten lock nut (2). 11. Stop engine. 12. Install all protective cups (1).

)

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• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 25

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22542): Stick cylinder “piston side” FSA There are three service line relief valves (secondary valves) installed, all three at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 142.5 SRV 142.6 SRV 142.7 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV 1. 2. 3. 4.

)

5. 6. 7. 8.

Press. check point M27.1 M12.1 (High pressure filter) M12.3 (High pressure filter) M12.4 (High pressure filter) M12.2 (High pressure filter)

Location Manifold section F Manifold section F Manifold section J Double high pressure filter R.H. Single HP filter, control block II Double high pressure filter L.H.. Single HP filter, control block IV

Connect gauges to all above listed check points. Start both motors.. Extend the stick cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV in control block IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22542): Stick cylinder “piston side” FSA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.5 þ 142.6 þ 142.7 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase, Counter-clock wise to decrease the setting. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure at SRV 142.5 to a value below the required value, and increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-65.2 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.6 þ 142.7

• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all three service line relief valves. 12.

) 06.10.05

Reset the MRV to 310 bar + 5 bar (320 bar block IV) after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 27

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22484): Stick cylinder “piston side” BHA There are two service line relief valves (secondary valves) installed, in main control blocks I and II, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 33.1 SRV 33.5 MRV circuit I MRV circuit II MRV circuit IV 1. 2. 3. 4.

)

5. 6. 7. 8.

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Press. check point M12.1 (High pressure filter) M12.3 (High pressure filter) M12.1 (High pressure filter) M12.3 (High pressure filter) M12.2 (High pressure filter)

Location Control block I, section A2 Control block II, section A42 Control block I Control block II Control block IV

Connect gauges to all above listed check points. Start both motors.. Extend the stick cylinder (stick retracting) to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22484): Stick cylinder “piston side” BHA 9. Adjust all two SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 33.1 þ 33.5 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 33.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-33.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 33.1 þ 33.5

• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all three service line relief valves. 12.

) 06.10.05

Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Hydraulic for the Attachment Cylinders 8.1.11

Section 8.1 Page 29

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22543a): Stick cylinder “piston rod side” FSA There are two service line relief valves (secondary valves) installed, in main control blocks I and II, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 33.1 SRV 33.5 MRV circuit I MRV circuit II MRV circuit IV 1. 4. 5. 6.

Location Double high pressure filter R.H. Single HP filter, control block II Double high pressure filter R.H. Single HP filter, control block II Single HP filter, control block IV

Connect gauges to all above listed check points. Start both motors.. Retract the stick cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in all above listed control blocks I, II, IV, while observing the respective pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. a) b) c) d)

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Press. check point M12.1 (High pressure filter) M12.3 (High pressure filter) M12.1 (High pressure filter) M12.3 (High pressure filter) M12.2 (High pressure filter)

Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counterclock wise to decrease pressure. Tighten lock nut (2). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22543a): Stick cylinder “piston rod side” FSA

)

• Since the piston rod side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one valves have a higher setting • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s.

7.

Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #6 (350 bar + 5 bar). Adjust the SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (1) (SRV’s) in the following sequence : 33.1 þ 33.5 Turn set screw (3)-clockwise to increase pressure, Counter-clockwise to decrease pressure. Adjust pressure at SRV 33.1 to ~360 bar if the pressure don’t increase turn set screw from the last setting max. ¼ turn in (c.w.). Adjust pressure at the SRV 33.5 to ~350 bar.

8.

9.

10.

) 11.

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•

Now all gauges will show the same value of 350 bar, but only SRV-33.1 has the correct setting. Reduce the pressure, at SRV 33.1 to a value below the required value and then increase up to the required pressure (350 bar), while observing all gauges.

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Section 8.1 Page 31

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22543a): Stick cylinder “piston rod side” FSA • Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. 14. 15. 16.

)

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Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished Stop engine. Install all protective cups (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 32

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22485): Stick cylinder “Piston rod side” BHA There are three service line relief valves (secondary valves) installed at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 142.5 SRV 142.6 SRV 142.7 MRV circuit I MRV circuit II

Press. check point M27.1 M27.2 M28 M12.1 (High pressure filter) M12.3 (High pressure filter)

MRV circuit III M12.4 (High pressure filter) MRV circuit IV M12.2 (High pressure filter)

1. 2. 3. 4.

)

5. 6. 7. 8.

Location Manifold (42) section G Manifold (42) section J Manifold (42) section J Double high pressure filter R.H. Single high pressure filter, control block II Double high pressure filter L.H.. Single high pressure filter, control block IV

Connect gauges to all above listed check points. Start both motors.. Retract the stick cylinder (extend the stick) to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston rod side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22485): Stick cylinder “Piston rod side” BHA 9. Adjust all SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.5 þ 142.6þ 142.7 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 142.5 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-142.5 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.6þ 142.7

• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. 12.

) 06.10.05

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 34

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22544): Bucket cylinder “Piston side” FSA There are three service line relief valves (secondary valves) installed, all three at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 142.1 SRV 142.2 SRV 142.3 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV 1. 2. 3. 4.

)

5. 6. 7. 8.

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Press. check point M24.1 M24.2 M25 M12.1 (High pressure filter) M12.3 (High pressure filter) M12.4 (High pressure filter) M12.2 (High pressure filter)

Location Manifold (42) section C Manifold (42) section C Manifold (42) section D Double high pressure (HP) filter R.H.

Single HP filter, control block II Double HP filter L.H.. Single HP filter, control block IV

Connect gauges to check points M12.1.to M12.4 and M24.1. Start both motors.. Extend the Bucket cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of all four MRV’s in control block I to IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22544): Bucket cylinder “Piston rod side” FSA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.1 þ 142.2 þ 142.3 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 142.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-142.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.2 þ 142.3

• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all six service line relief valves. 12.

) 06.10.05

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 36

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22486): Bucket cylinder “Piston side” BHA There are three service line relief valves (secondary valves) installed at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 142.1 SRV 142.2 SRV 142.3 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV 1. 2. 3. 4.

)

5. 6. 7. 8.

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Press. check point M24.1 M24.2 M25 M12.1 (High pressure filter) M12.3 (High pressure filter) M12.4 (High pressure filter) M12.2 (High pressure filter)

Location Manifold section C Manifold section C Manifold section D Double high pressure filter R.H. Single high pressure filter, block II Double high pressure filter L.H.. Singe high pressure filter, block IV

Connect gauges to all above listed check points. Start both engines and let them run with max. speed. Extend the bucket cylinder (Bucket filling) to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block I, II, III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 37

Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22486): Bucket cylinder “Piston side” BHA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.1 þ 142.2 þ 142.3 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 142.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-142.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.2 þ 142.3 þ 142.

• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all three service line relief valves. 12.

) 06.10.05

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 38

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22545): Bucket cylinder “Rod side” FSA There are two service line relief valves (secondary valves) installed, one in main control block I section 3 and one in block II section 2, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 33.2 SRV 33.6 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV 1. 2. 3. 4.

)

5. 6. 7. 8.

Press. check point M12.1 (High pressure filter) M12.3 (High pressure filter) M12.1 (High pressure filter) M12.3 (High pressure filter) M12.4 (High pressure filter) M12.2 (High pressure filter)

Location Control block I, section A3 Control block I, section A2 Double high pressure filter R.H. Single high pressure filter, block II Double high pressure filter L.H.. Single high pressure filter, block IV

Connect gauges to all above listed check points. Start both motors.. Stall the system with full retracted bucket cylinder in final stop position. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston rod side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 39

Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21999): Bucket cylinder “Rod side” FSA 9. Adjust both SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 33,2 þ 33.6 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 33.2 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-33.2 has the correct setting. Proceed with the other valve in the same manner.

• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. 12.

)

06.10.05

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 40

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22487): Bucket cylinder “Piston rod side” BHA There are three service line relief valves (secondary valves) installed at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point Location SRV 142.8 M34.1 Manifold section L SRV 142.9 M34.2 Manifold section L SRV 142.10 M34.3 Manifold section M MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H. MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H.. MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV 1. Connect gauges to all above listed check points. 2. Start both engines and let it run with max. speed. 3. Retract the Bucket cylinder (Bucket dump) to the stop position until the hydraulic system stalls. 4. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in control block I, I, III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar.

)

5. 6. 7. 8.

06.10.05

• Since the piston rod side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 41

Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22487): Bucket cylinder “Piston rod side” BHA 9. Adjust all SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.8 þ 142.9 þ 142.10 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 142.8 to a value below the required value and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-142.8 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.9 þ 142.10

• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all three service line relief valves. 12.

) 06.10.05

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 42

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22546): Clam cylinder “Rod side” (clam opening) FSA There is one service line relief valve (secondary valve) installed at the distributor manifold section E, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 142.4 MRV circuit II MRV circuit IV 1. 2. 3. 4.

5. 6. 7. 8. 9. 10.

)

06.10.05

Press. check point M26 M12.3 (High pressure filter) M12.2 (High pressure filter)

Location Manifold (42) section E Control block II Control block IV

Connect gauges to the above listed check points. Start engine 2 and let it run in high idle. Retract the clam cylinder (open the bucket) to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block II and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. If necessary correct the adjustment as follows: Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). Reduce the pressure, at SRV 142.4 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all auges. Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 43

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22561): Clam cylinder “Piston side” (clam closing) FSA There are three service line relief valves (secondary valves) installed, two at distributor manifold section K and one at main control block II section 1, to limit the maximum possible pressure in the service line when closing the bucket. To avoid damages at the clam shell, due to wrong operation, the SRV’s should be adjusted in a way that the pressure is just sufficient to close the clam with horizontal back wall. Valve SRV 144 (1) SRV 144 (2) SRV 32.10 1. 2. 3.

•

•

06.10.05

Location Manifold section K Manifold section K Control block II

Connect gauges to all above listed check points. Start engine 2 and let them run in high idle. Raise the attachment and bring the back wall of the bucket in a horizontal position (bucket dump). Press carefully pedal “bucket closing”. The clam should close complete and must stay closed after pedal in neutral position. Adjust the SRV’s as follows: Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure while depressed pedal “clam closing”. Tighten lock nut (2) and install cap (1). Adjust all three SRV’s equally, until the gauges show a pressure of 220 bar. Now reduce the pressure at one SRV in steps of 5 bar until the bucket opens by gravity (check with released pedal). Now read the pressure and adjust 10% plus the reading to compensate the weight of material stuck at the clam shell.

4.

)

Press. check point M22 M22 MM12.3 (High pressure filter)

Since the piston side of the clam cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Because of different wear packages the pressure can be between 150 bar and more as 200 bar.

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Section 8.1 Page 44

8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22489): General On excavators equipped with Face Shovel Attachment (FSA) there are two different operation modes for lowering the boom and stick: I.

Float position activated the lowering speed has to be adjusted by altering the flow restrictors (throttle valves) at the distributor manifold section B, throttle valve 141.1 and section N, throttle valve 141.3.

II.

Float position deactivated the lowering speed has to be adjusted by altering the flow restrictor (throttle valve) at the distributor manifold section N, throttle valve 141.2.

On excavators equipped with Backhoe Attachment (BHA) the lowering speed has to be adjusted at all flow restrictors on distributor manifold section B and N, throttle valves 141.1, 141.2 and 141.3. Purpose of the Flow Restrictors: • To avoid an interruption of the pump delivery. • To provide an uniform and smooth cylinder travel. • To limit the return oil flow through the control block to the maximum permissible volume.

)

Checks and Adjustments: • Activate service switch S151 (located in the cab base) during the checks and adjustments, to ensure that the main pumps are in Qmax position. • Standard test method is measuring the total cylinder running time by using a stop watch. If it is impossible to move the cylinder over the whole way, mark a distance of one meter with permanent pen P/N 621 566 40 on the piston rod and measure the time for only one meter movement. • Adjust the restrictor as follows: • For easy turning of set screw (2) lower the attachment to ground, stop engines and allow pressure equalizing by moving the lever several times. • Loosen the lock nut (1) and turn the bolt (2) cw for more restriction and ccw for less restriction. If more than one restrictor is used for one movement make sure all set screws are equally adjusted. During commissioning, a throttle adjustment has to be carried out on all machines. For safety reasons, the throttle valves are completely screwed in before each machine is leaving the factory. For more information refer to the respective newest Service Bulletin

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Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22489): Boom cylinder FSA Due to the two different operation modes for lowering the boom, the lowering speed must be adjusted twice: I. Float position activated II. Float position deactivated Maximum permissible lowering speed for both operation modes: Boom FSA

Cylinder retracting time/meter (s /m) 1,4

Total time(s) 4,3

Adjustments / Checks: I. 1. 2. 3. 4.

Float position activated: Use a stop watch to measure the cylinder running time. Raise the fully extended attachment with empty bucket to the maximum height position (A). Shift both engines to high idle speed. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). • Lower the boom so, that the bucket stops just above the ground.

5.

If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 141.1 (section B) and 141.3 (section N, pointing to the attachment). Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6. 7.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1). continued

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Section 8.1 Page 46

Cont'd: 8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22489): Boom cylinder FSA Adjustments / Checks: II. 1. 2. 3. 4. 5.

Float position deactivated (with push button S95): Adjust the throttle adjustment bold of throttle valve 141.2 to the same amount of revolutions as the valve 141.1 and 141.3. Use a stop watch to measure the cylinder running time. Raise the fully extended attachment with empty bucket to the maximum height position (A). Shift the engines to high idle speed. Press push button S95 and keep it depressed while lowering the attachment. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). • Lower the boom so, that the bucket stops just above the ground.

6.

The lowering speed will be the same as with floating position. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valve 141.1, 141.2 and synchronous 141.3 at the distributor manifold section B and N. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

7. 8.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 47

Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22488): Boom cylinder BHA Maximum permissible lowering speed:

Boom BHA

Cylinder retracting time/meter (s /m) 1,4

Total time (s) 5,0

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engines to high idle speed. 4. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). • Lower the boom so, that the bucket stops just above the ground.

5.

If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 141.1, 141.2 and 141.3 at the distributor manifold. Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the boom cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 48

Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed,

illustration (Z 22490):

Stick cylinder FSA Due to the two different operation modes for lowering the stick, the lowering speed must be adjusted twice: I. Float position activated II. Float position deactivated Maximum permissible lowering speed for both operation modes:

Stick FSA

Cylinder retracting time/meter (s /m) 0,9

Total time (s) 2,4

Adjustments / Checks: I.

Float position activated: 1. 2. 3.

4.

Use a stop watch to measure the cylinder running time. Raise the fully extended attachment with empty bucket to the maximum height position (A). Rapidly move the control lever (E20) to the rear end position (start the stop watch until the stick start moving) and hold it until close to the final position (B) is reached.(stop the stop watch). If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 142.5 and 142.7 at the distributor manifold. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.

Since there are several valves throttling the return oil flow of the stick cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

5.

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1). continued

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Section 8.1 Page 49

Cont'd: 8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22490): Stick cylinder FSA Adjustments / Checks: II. 1. 2. 3. 4. 5.

6.

Float position deactivated (with push button S95a): Adjust the throttle adjustment bold of throttle valve 142.6 to the same amount of revolutions as the valve 142.5 and 142.7. Use a stop watch to measure the cylinder running time. Start both engines and let it run in high idle. Raise the fully extended attachment with empty bucket to the maximum height position (A). Press push button S95a and keep it depressed while lowering the stick. Rapidly move the control lever (E20) to the rear end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). The lowering speed will be the same as with floating position. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valve 142.5, 142.6 and synchronous 142.7 at the distributor manifold section F and J. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the stick cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

7. 8.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 50

Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22491): Stick cylinder BHA Maximum permissible lowering speed:

Stick BHA

Cylinder extending time/meter (s /m) 0,6

Total time (s) 1,5

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Start both engines and let it run in high idle. 3. Raise the fully extended attachment with empty bucket to the maximum height position (A). 4. Rapidly move the control lever (E20) to the rear end position (start the stop watch) and hold it until close to the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 142.5, 142.6 and 142.7 at the distributor manifold. Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the stick cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6. 7.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22562): Bucket cylinder FSA Maximum permissible lowering speed:

Bucket FSA

Cylinder retracting time/meter (s /m) 1,1

Total time (s) 3,0

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Start both engines and let it run in high idle. 4. Rapidly move the control lever (E19) to the r.h. end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 142.1, 142.2 and 142,3 at the distributor manifold section C and D. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the bucket cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6. 7.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 52

Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22492): Bucket cylinder BHA Maximum permissible lowering speed:

Bucket BHA

Cylinder retracting time/meter (s /m) 0,5

Total time (s) 1,1

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Start both engines and let it run in high idle. 4. Rapidly move the control lever (E19) to the r.h. end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 142.1, 142.2, 142.3, 142.8, 142.9 and 142.10 at the distributor manifold. Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the bucket cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6. 7.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 53

Checks and adjustments of the lowering speed, illustration (Z 22563): Clam cylinder FSA Maximum permissible lowering speed: Adjustments / Checks: 1. 2. 3. 4.

5.

6. 7.

06.10.05

Use a stop watch to measure the cylinder running time. Start both engines and let it run in high idle. Open the clam of the empty bucket to the maximum position (A). Rapidly push the control pedal (E23) to the end position (start the stop watch) and hold it until the final position (B) is nearly reached.(stop the stop watch). If the lowering speed is too high, i.e. the speed is uncomfortable, the speed must be reduced by altering the throttle valve 142.4 at the distributor manifold section E. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1) and write down the adjusted running time for later checks.

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Hydraulic for the Attachment Cylinders 8.1.13

Section 8.1 Page 54

Checks for the valve control logic

Legend for illustration (Z 22582a): (1) Main pump condition Ö P = pressurized outlet (2) Main pump condition Ö (-) = free flow to reservoir (3) Pilot ports a = outlet ports a (4) Pilot ports b = outlet ports b (5) Port condition Ö (-) = closed port (6) Port condition Ö O = open port (7) Respective function (8) Single control valve block for swing (9) control valve block number (10) Swing parking brake switch S29 General: For harmonic attachment motion and well working floating function the valve spools must be activated with different priorities. The whole valve control logic is a arrangement of electric relay controlling and the main hydraulic control valve sequence. The correct function of the valve control logic can be checked by pressure gauges (0 -50bar) connected to the pressure test ports at the control valve cabs. Checks: a) Connect the pressure gauges (0-50 bar) to all test ports at the pilot control cabs (26 gauges necessary *) and (0-400 bar) to the high pressure filter test ports M44.1, 44.2, 46.1, 46.2 b) Mark the control cab with the respective function and port designation. c) Use the Check list for the Valve Logic in the appendix in this binder. d) Unplug solenoid valve Y16 (travel parking brake closed) and activate the swing brake with the switch at the dash board. The ladder and the refilling arm are in high position (working position) the operator sits on the operators seat. Make sure that the machine can move hazardless all functions e) Start one motor. f) The operator activate carefully step for step the respective lever or pedal as shown in the check list. Compare each step with the pressure condition of the control cabs and main pressure to the check list. If there is a wrong result, check the respective electric circuit and hydraulic pilot circuit.

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Hydraulic for the Swing Circuit

Section 8.2 Page 1

Table of contents section 8.2 Section 8.2

Page Hydraulic for the swing circuit 8.2.1 Swing Circuit (Brief description)

2+3

8.2.2 Swing Motor

4-7

8.2.3 Swing Gear Box

8

8.2.4 Swing Parking Brake (Gear house Brake)

9

8.2.5 Swing Brake Valve

10+12

8.2.6 Electric / Hydraulic flowchart “Swing Left”

13

8.2.7 Electric / Hydraulic flowchart “Swing Right”

14

8.2.8 Swing Monitoring System

15 + 16

8.2.9 Adjustments for the swing circuit

17 - 19

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Hydraulic for the Swing Circuit

Section 8.2 Page 2

8.2.1 Swing Circuit (Brief description) Legend for illustration (Z 22501b): (I - VI) (13) (48) (20.1+ 20.2) (71.1+ 71.2) (25.2) (49.1 + 49.2) (Y48) (Y120) (43) (Y32) (Y32a/b) (20) (50) (A7)

Main pumps Single control block IV Manifold Swing motors Manifold at the control and filter panel Double check valve Pressure increasing valve (swing brake valve) Swing motors power control valve Solenoid valve Remote control valve block Proportional valve of the remote control block Directional solenoid valve of the remote control block Control lever left hand Ramp module Amplifier module

Brief description (Control circuits) (Study together with the for the machine valid hydraulic and electric circuit diagram). When the lever (E20) is moved out of its neutral position, proportional solenoid valves Y32 are energized. Simultaneously the directional solenoid valves Y32a (R.H.-swing) or Y32b (L.H.-swing) are energized. By the function of the remote control valve (43) pilot pressure oil is sent to one side of the control block (13/IV) when operating the control lever for "Swinging". At the same time by the function of the proportional valve (Y127) pilot pressure (proportional to the lever deflection) is present at port „X“ pressure increasing valve (PIV)of each brake valve block (49.1+ 49.2) thus a internal pressure built up (higher as 150 bar) in the service lines is possible. continued

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Section 8.2 Page 3

Cont'd.: 8.2.1 Functional description: Illustration (Z 22501b): Brief description (Service circuits) (Study together with the for the machine valid hydraulic and electric circuit diagram). The swing motors (20.1 + 20.2) are feed by the main pump (III). This pump is at port XLR permanent with 35 bar X2- pressure fix adjusted to Qmax. The oil flows from the pumps through check valve (47.3) and filter (153.3) to the single control block (13 / IV). In neutral position of the spool oil flows via port C into control block II for additional oil volume from pump 3 to valve circuit II. If no function of control block II is activated the oil flow via port T in to the collector tube (35) and further via the return oil lines (L6 + L7) into the tank. On its way to tank the oil must flow through the back pressure valve (115) and the return oil filter (117.2 - 117.5). (Back pressure valve function see chapt. 4.) When operating the control lever for "Swinging" the pump line is connected in the control block (33/IV) with the corresponding service line (A1 or B1) to the swing motors (20.1 + 20.2). The oil flows from the control block through each one of the swing brake valves (49.1 + 49.2; description see page 6 and 7) and the swing motors (20.1 + 20.2). Each swing gear includes one spring loaded multi disk brake (House brake) for locking the superstructure. The leak oil (case drain) flows through the line (L11 + L12) and the leak oil filter (108) back to tank.

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Swing motor A6VM

8.2.2 Swing Motor

Section 8.2 Page 4

Axial Piston Motor A6VM355 HD1D

Legend for illustration (Z 22430): (1) Check valve (2) Check valve (3) Governor valve (4) Positioning piston (5) Boost pressure valve (6) Flushing valve (16l/min) (7) Flow control valve (8) Constant pressure control valve (adjusted: 280 bar) General: A6VM355 HD1D is a variable displacement motor with an axial piston rotary group of bent axis design for hydrostatic drives. Its control range allows the variable displacement motor to meet both, high speed and torque requirements. The output speed is proportional to its displacement. The output speed increases with decreased displacement trough lower operating pressure. The output torque increases with increased displacement trough higher operating pressure.

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Section 8.2 Page 5

Swing motor A6VM

8.2.1 Swing Motor

Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22430 By switching pilot pressure to port X at the motor (0 bar or 35 bar) the displacement is fixed in Vg max or variable. Without pilot pressure at port X (0 bar) the displacement is fixed to Vg max . With pilot pressure at port X (35 bar) the displacement is variable from Vg min (175 cm3/rpm) to Vg max (355 cm3/rpm). With a swing speed of 0 up to 120 impulses per minute (measured by a proximity switch located at the swing gear) the motors are in maximum displacement position, i.e. min. speed and max. torque available. With a swing speed of more as 120 imp./min. pilot pressure is directed via a solenoid valve to port X at the motors, to actuate governor valve (3). Now the output speed is variable depending on the operating pressure, controlled by the function of control valve (8). As a result of decreasing operating pressure the motors are reducing their displacement so that the swing speed will increase. If the operating pressure rises as a result of load torque, to the setting of the constant pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher displacement) and the swing speed will decrease. Function

Operating pressure bar

Torque

Motor displacement

0

310 à ~280

Max.

Vg max

Swing movement 120-max. Low speed to Max. speed

35

280 à ~75

Swing movement Max. speed

Max.

35

~75

Reduced

Vg min

Swing down path

120-0

0

~170 à 0

Max.

Vg max

120-0

0

330 à 0

Max.

Vg max

Start swing Standstill to low speed

Speed Xindicator pressure imp/min bar 0-120

Reduced Vg max à Vg min variable

Control lever in neutral

Counter Swing (braking) Control lever moved to the opposite side of swing direction

Continued

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Swing motor A6VM

8.2.2 Hydraulic Motor

Section 8.2 Page 6

Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22431b Cont'd:

A

Flow from A to B without „X-pressure“ (slow swing speed) : The operating pressure opens check valve (1) and closes the opposite valve (2). The same pressure is present at the control port of pressure control valve (8) and inside the small area side of the positioning piston (4). The large area side is connected via the governor valve (3) to tank (port T2). The motor remains in Vgmax position. = max. torque by low speed.

B

Flow from A to B, with „X-pressure“ (higher swing speed), operating pressure 0 –280 bar: Operating pressure opens check valve (1) and closes the opposite valve (2). The same pressure is present at the control port of pressure control valve (8) and inside the small area side of the positioning piston (4). Because of the „X“ pressure at the control port of governor valve (3) a connection is made from the operating pressure to the large area side of positioning piston (4). Same pressure on both sides but different areas causes a greater force at the piston side moving the motor into the Vgmin position. The motor is in regulation mode due to 35 bar “X-pressure” Motor displacement to Vgmin position (<280bar).

C

Flow from A to B, with „X-pressure“ (higher swing speed), operating pressure 280-310 bar: Depending on the system pressure (more as 280 bar), valve (8) connect the large area side of the positioning piston (4) with the pressure less return line (T2). Low pressure at the large side cause a greater force at the pressurized small area side of the positioning piston (4) moving the motor into the Vgmax position. The motor is in regulation mode due to high operating pressure (>280bar) : Motor displacement to Vgmax position (>280bar). As a result of decreasing operating pressure the motors are reducing their displacement so that the swing speed will increase. If the operating pressure rises as a result of load torque, to the setting of the constant pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher displacement) and the swing speed will decrease.

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Swing motor A6VM

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Swing motor A6VM

8.2.2

Section 8.2 Page 7

Checks and Adjustments, illustration Z22432 Preconditions before starting checks and adjustments: 1. Main pump 3 must be in full flow position (X1-pressure = 35 bar), no action required because stabilized X1 pressure is automatic activated during swinging 2. MRV’s and SRV’s (pressure increasing valves) correctly adjusted.

Checking the Q-max. and Q-min. stop bolt setting. Q-max : The average outer length of 25.1 mm must not be altered because the max. possible swivel angle is used. Q-min : The Qmin. adjustment depends on the max. permissible swing speed (with reduced swivel angle). The average outer length is 36.1 mm

)

• It is important that the adjustment is equal on both motors!

How to check the Q-min. adjustment. 1. Lift the extended attachment to horizontal position. 2. Measure the time for 5 revolutions after swinging one turn as an approach swing. The time should be t5rev = 90+5 sec . 3. If a adjustment is required: Turn off box nut (1) and loosen lock nut (3) Turn bolt (2) further in for less speed or further out for higher speed. One turn of the Qmin bolt (2) cause a change of approx. ∆t5rev = 4.6 sec. 4. Re-check speed and tighten lock nut and re-fit box nut (1) after setting is finished. How to check / adjust the start of regulation. 1. Activate manually relay K153 to energize Y48 to pressurized swing motor port X with X2-pressur. 2. Connect a pressure gauge (0-400 bar) to check point M12.2 at high pressure filter of single control block IV. 3. Measure and note outer length (L) of Qmax stop bolt (2) (for resetting later on) Loosen lock nut (3) approx. ½ turn without turning the stop bolt.. 4. Start engine 1 and let it run in high idle. 5. Apply the swing parking brake. 6. Operate carefully the control lever for swing in one direction and keep it in end position. The resulting operating pressure should be 320 bar. 7. Loosen look nut of MRV at single control block IV. 8. Decrease / increase alternately the operating pressure between 300 bar and 260 bar at MRV set screw. Check by turning the Qmax stop bolt (2) by hand, if the motor control lens touches the Qmax stop bolt: The lens must touch the stop bolt with a pressure higher than 280 bar. The lens must not touch the stop bolt with a pressure lower than 280 bar 9. Correct the start of regulation with valve (8) if necessary. 10. Reset MRV. Stop engine and deactivate K153

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Hydraulic for the Swing Circuit

Section 8.2 Page 8

8.2.3 Swing Gear Box Legend for illustration (Z 25305), manufacturer: Siebenhaar (1) Drive housing (11) Bearing ring (2) Drive shaft (12) Cartridge (3) Sun gear shaft (13) Spherical roller bearing (4) Multi disc brake, spring (14) Oil drain plug, gear box loaded pilot pressure released (15) Cylindrical roller bearing (5) Breather filter motor adapter (16) Oil level gauge (dipstick) housing for gear box (6) Oil level gauge (dipstick) (17) First planetary stage for drive shaft housing (18) Drive shaft to second stage (7) Disk brake housing (19) Second planetary stage (8) Cylindrical roller bearing (20) Radial seal ring (9) Internal ring gear (21) Drive pinion (10) Cylindrical roller bearing (22) Grease line port (23) Centering circle

The swing gear is of compact design with a two stage planetary gear including a multi disk house brake. The gear is bolted to the superstructure and fits firmly due to the machined diameter (A) and the bolt torque. The torque loaded on the hydraulic motor is transmitted by drive shafts (2) and sun gear shaft (3) to the first planetary stage (17). The sun shaft (17) of the first planetary stage transmits the torque into the second planetary stage (19). By the planetary gears the output drive shaft is rotated and transmits the torque to the pinion (21). The drive housing, and the gearbox are filled with gear oil. Aeration is done by breather filters. A grease nipple is via a hose connected to the bearing lubrication port (22).

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Hydraulic for the Swing Circuit

Section 8.2 Page 9

8.2.4 Swing Parking Brake (Gear house Brake) The Spring Loaded Multi-disk Brake is a safety brake; applied by spring force and released by oil pressure. Legend for illustration (Z 22439): (1) Clip ring (circlip) (2) Thrust washer (3) Outer discs (4) Inner discs (5) Piston (6) Quad ring with back up ring (7) Quad ring with back up ring (8) Springs (9) Piston back up ring and seal retainer (10) O ring (11) Clip ring (circlip) (12) Oil pressure port Function: Brake applied: The outer disks (3) engaged to the housing by serration and the inner disks (4) in serrated connection with drive shaft are pressed together by the springs (8). This results in a fixed connection between housing and drive shaft. Brake released: Oil pressure via port (12) reaches the bottom of the piston (5) and forces the piston upwards against the thrust washer (2). This function eliminates the spring force to the disc (3) and (4) thus the brake is released. The releasing pressure is 12 - 20 bar, the maximum permissible pressure 60 bar. This is a so named "Wet Brake" because the brake housing is filled with oil.

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Hydraulic for the Swing Circuit

Section 8.2 Page 10

8.2.5 Swing Brake Valve Legend for illustration (Z 21934): (1) Pressure increasing valve (items 6 - 13) (2) Check valve circuit A (3) Check valve circuit B (4) Anti-cavitation valve circuit B (5) Anti-cavitation valve circuit A (6) Jet bore, of main piston plug Ports: (Y) (T) (A) (A1) (B) (B1)

(7) (8) (9) (10) (11) (12) (13)

Spring of main piston Jet bore Valve poppet Spring Intermediate piston Pilot pressure piston Main piston

Leak oil Return oil Service line from control block Service line to the motor Service line from control block Service line to the motor

Pressure check points: (MA) Circuit A (MB) Circuit B Explanation of the function by the symbol: When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (1) at port "X". The pilot pressure pre-loads these valves. The oil for the hydraulic motor from the control block arrives the service line port A or B, depending if a R.H. or a L.H. swing motion is carried out. The ports A and B are internally connected to the ports A1 and B1 and these ports in turn with the hydraulic motor. The operating pressure, at either port A or B closes the anti-cavitation valves (4 or 5) and opens the check valves (2 or 3). That means by the check valves (2 or 3) the service lines are connected to the pressure increasing valve. When ever the pressure is higher than the setting of the pressure increasing valve, this valves opens and dumps the oil into the return line (T) to tank. The pressure can be checked at the check points MA or MB. continued

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Section 8.2 Page 11

Cont'd.: 8.2.5 Swing Brake Valve If after a swing motion the joy stick is released into neutral position without using the foot brake, the superstructure is turned by inertial force and the hydraulic motor acts as a pump because it is driven by the swing gear. Both service line’s (pump line and tank line) are blocked at the control valve block. In this period the service line (previously pump line) acts now as suction line and the return line (previously return line) acts now as output line. Because of the closed service ports at the control block all oil from the swing motor must pass the brake valve block. The pressure increasing valve in the brake valve block acts now as a back pressure valve. This variable back pressure is the brake force. Function of the pressure increasing valve. When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (1) at port "X". The pilot pressure pre-loads these valves. By applying pilot pressure via the external port X to piston (12), the pretensioning of the pressure spring (10) is increased by the amount of the piston stroke "S", which results in the actual valve setting. The system pressure is in front of the main piston (13) and via the jet bore (6) also in the chamber of the spring (7) and via the jet bore (8) at the pressure relief valve poppet (9). Due to the force balance the piston (13) is kept in its position supported by the spring (7). Overcomes the system pressure the setting of the valve (9), this valve opens a channel to the dump line port (Y). Due to the drop of force the piston (13) is moved to the right. The pressure line gets connected with the return line (T). Damped opening and closing are obtained by the throttled volumetric change that is caused by the jet bores.

continued

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Hydraulic for the Swing Circuit

Section 8.2 Page 12

Cont'd.: 8.2.5

Swing Brake Valves Anti cavitation prevention. Illustration Z 22672a (1) Return oil collector tube (2) Main back pressure valve (3) Gear pump (8.2 + 8.5).. (4) Swing motor back pressure valve blocks (195.1 + 195.2) (5) Swing brake valve blocks (49.1 + 49.2). (6) Swing motor (20.1 + 20.2) (7) Pressure relieve valve (swing motor back pressure) (8) Check valve (9) Pressure check point M35.1 and M35.2 (10) Valve drain connection A Input from gear pump B Output to swing brake block T Tank connection to return oil collector tube During the swing down phases the swing motors (6) are working as “pumps”. It means that the pressure side change to a suction side and the suction side change to a pressure side. To prevent cavitation in the swing motors during this change there are two back pressure valves (4) fitted. The valves (4) together with the gear pumps (3) increase the main back pressure up to 15 bar. Port B is direct connected to the tank port (return line) of the swing brake valve block (5). Adjustments - Measurements -Settings Setting of the swing circuit back pressure valves (3) 1. Connect pressure gauge (0 – 25 bar) to check points M35.1 and M35.2 at the valve blocks (195.1 +195.2). The valve blocks fitted at the return oil collector tube in front of the hydraulic tank. 2. Start both engines and let them run in high idle. 3. The pressure at the gauges should be 15 bar if the gauges shows a different value the pressure relieve valves in the back pressure valve must be adjusted. a) b) c)

Loosen look nut Turn in or out set screw to increase or decrease the pressure. Tighten look nut

4. Stop engines 5. Disconnect the gauges.

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Hydraulic for the Swing Circuit

Section 8.2 Page 13

8.2.6 Electric / Hydraulic flowchart “Swing Left” Legend for illustration (Z 22503a): (-10V) Signal voltage (Maximum) (13) Main control block IV (20.1 + 20.2) Swing motors (43) Remote control valve block (48) Distribution block (49.1 + 49.2) Swing brake valve blocks (A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV) (A16) Amplifier module – Swing brake (D32) Time relay – Pilot control: Neutral position monitoring (E20) Control lever (Joy stick) (E50) Ramp time module (E50B) Ramp time module – Swing brake (K165) Relay counter lock (option) (K253) Relay controlled by swing brake (foot brake) (ws/gn) Colour code of signal voltage cable ( Joy stick) (-X) Direction (axis) of joy stick (minus x = left) (X2F...) Terminal rail with number (Y32) Proportional solenoid valve (Y32a + Y32b) Directional solenoid valve (Y127) Proportional valve, controlling pressure increasing valve The electrical signal. Signal voltage of joy stick (E20) arrives via ramp time module (E50) at terminal 5 of the amplifier module (A7) and further via relay K165 (if equipped) to the proportional and directional solenoid valves of the remote control blocks (43). In the same time signal voltage of joy stick arrives via K253 and ramp time module E50B to terminal 5 of the amplifier module A16. Relay contact 2 / 10 of relay K165 (if equipped) opened if the excavator superstructure swing in a different direction as the lever direction (counter look). Relay K253 energized if the swing brake pedal is activated this eliminate the ramp time function of E50B. The hydraulic signal. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pressure ports of the main control blocks. Proportional valve Y127 increase proportional to the lever deflection the pilot pressure to the pressure increasing valves. The hydraulic oil flow Now the oil of the main pump 3 flows through the main control block (IV) and arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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Hydraulic for the Swing Circuit

Section 8.2 Page 14

8.2.7 Electric / Hydraulic flowchart “Swing Right” Legend for illustration (Z 22504a): (+10V) Signal voltage (Maximum) (13) Main control block IV (20.1 + 20.2) Swing motors (43) Remote control valve block (48) Distribution block (49.1 + 49.2) Swing brake valve blocks (A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV) (A16) Amplifier module – Swing brake (D32) Time relay – Pilot control: Neutral position monitoring (E20) Control lever (Joy stick) (E50) Ramp time module (E50B) Ramp time module – Swing brake (K165) Relay counter lock (option) (K253) Relay controlled by swing brake (foot brake) (ws/gn) Colour code of signal voltage cable ( Joy stick) (+X) Direction (axis) of joy stick (plus x = right) (X2F...) Terminal rail with number (Y32) Proportional solenoid valve (Y32a + Y32b) Directional solenoid valve (Y127) Proportional valve, controlling pressure increasing valve The electrical signal. Signal voltage of joy stick (E20) arrives via ramp time module (E50) at terminal 5 of the amplifier module (A7) and further via relay K165 K165 (if equipped) to the proportional and directional solenoid valves of the remote control blocks (43). In the same time signal voltage of joy stick arrives via K253 and ramp time module E50B to terminal 5 of the amplifier module A16. Relay contact 2 / 10 of relay K165 (option) opened if the excavator superstructure swing in a different direction as the lever direction (counter look). Relay K253 energized if the swing brake pedal is activated this eliminate the ramp time function of E50B. The hydraulic signal. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pressure ports of the main control blocks. Proportional valve Y127 increase proportional to the lever deflection the pilot pressure to the pressure increasing valves. The hydraulic oil flow Now the oil of the main pump 3 flows through the main control block (IV) and arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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Hydraulic for the Swing Circuit

Section 8.2 Page 15

8.2.8 Swing Monitoring System, illustration (Z 21947a) There are two reasons why the swing monitoring system is installed: a) ⇒ To prevent adverse effects of a counter action. b) ⇒ To increase the swing speed, by reducing the swivel angel of the swing motor (lowering the required oil volume per motor rotation) Function of the swing monitoring system: The two sensors B98 and B99, (Proximity switches mounted into a housing near the ring-gear) sensing the direction of rotation. How? Because the distance from sensor to sensor (B) is less than the distance of two teeth (A), one of the sensors recognizes first a swing action. The signals of both sensors are used as input signals for the module (E42) which monitors the swing direction. The same signals from sensor B99 are send to the module E43 for sensing the swing speed. Proximity switch B99 together with module E43 monitors the swing speed to control via relay K154 and K153 solenoid valve (Y48). • Activated solenoid valve Y48 allows full X2 pressure to swing motors (20.1 + 20.2) port X = if the working pressure is less then 280 bar increasing of swing speed is possible. • De activated solenoid valve Y48 causes no X2 pressure to swing motor (20.1 + 20.2) port X = the motors are fixed in maximum swivel angel (max. volume = max. torque and min. speed) ⇒ Acceleration During the first acceleration phase the maximum torque by minimum speed is required, the motors must be in maximum swivel angel (x-port 0 bar). E43 detect the swing speed, if the speed is below 120 Imp./min. relays K154 and K153 are still de energized and further solenoid valve Y48 de-energized (xport = 0 bar = max. motor swivel angel = max torque). After this first acceleration the required torque and hydraulic pressure droops and the swing speed increase. E43 detect more as 120 Imp./min and energize relay K154. If the lever direction and the swing direction is the same K153 energized and further D153 energized solenoid valve Y48 (x-port = 35 bar = variable motor swivel angel is possible). ⇒ “ Braking ” with counter position of the lever If the operator release the lever or move the lever to counter position relay K153 opened contact 5 / 9 it de energize time relay D153. After the time is elapsed (one second) solenoid valve Y48 de energize and change over in neutral position so that pilot line L18 release the pressure to the tank (port X = 0 bar). The swing motors move to maximum swivel angel. Now a maximum breaking torque is available.

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Hydraulic for the Swing Circuit

Section 8.2 Page 16

8.2.8 Swing Monitoring System, illustration (Z 21947a) (Study together with the valid hydraulic and electric circuit diagram for the machine) Adjustments - Measurements -Settings a) Distance between Swing ring teeth and the switches B98 and B99 The sensors B98 and B99 are inductive switches with own electronic. Sensor B98 switches 24V via cable “Sig” to terminal 4 of E42 and Sensor B99 switches 24V via cable “Sig” to terminal 11 of E42 if a tooth comes close to the sensor head. Simultaneously these signal arrives at E43 terminal 4. Adjust the distance “C” of the sensors B98 and B99 to 5±1 mm. b)

E42 for monitoring the slew direction E42 is an programmable module which is factory programmed with the parameters are shown in the electric diagram. Therefore no adjustments or settings are required. The indication light (In1 from B98 / In2 from B99) lights/pulses if a input signal comes up. The indication light (Out1 for swing left / Out2 for swing right) lights if the module indicates a swing direction.

c)

E43 for monitoring the slew direction E43 is an programmable module which is factory programmed with the parameters are shown in the electric diagram below. Settings: E43 (speed monitor) “counter prevention” No

Function

nominal setting

1

Setting the start up delay

Not used set to “0”

2

Fine setting of the preset value (pulses / min.)

12 imp/min (i.e.120)

3

Setting the hysteresis

Not used set to “0”

4

LED: lights when the output relay is energised

---

5

Setting the switching function

Set to “III”

6

Coarse setting of the preset value (pulses / min)

X x 10 imp/min

If necessary increase or decrease the imp/min with set screw no. 2 until a smooth slew operation is possible.

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Hydraulic for the Swing Circuit

Section 8.2 Page 17

8.2.9 Checks and adjustments for the swing circuit

)

• It is important that the complete MRV-valve and the Pressure Increasing Valve is firmly (with 300 Nm) tightened. Otherwise, the internal sealing sealed not properly which results in: difficulty setting, loud flow noises and abnormal temperatures. • Whenever pressure checks are carried out, they must be carried out for both, r.h. and l.h. swing, to make sure the check valves in the brake valve are in good shape. • Because the Swing motors are working hydraulically in combined operation, the pressure gauge shows the pressure of the pressure increasing valve with the lowest setting. Even when the gauge shows the required pressure it is possible that one valve has a higher setting. Therefore lower the pressure on one valve below the required pressure and then increase up to required pressure. Proceed with next valve in the same manner.

High pressure check / adjustment 1. Connect the gauge (0-400 bar) to check point M12.2 at the high pressure filter units (153.3) of single control block IV. 2. Release the pilot pressure by several movements of the lever with motor / engine stand still. The key switch S1 must be on the ladder and service arm must be in up position. Disconnect carefully the pilot pressure lines from the pressure increasing valves and close the lines with a suitable plug. 3. Loosen lock nut (3) of both pressure increasing valves (PIV) and screw in set screw (4) until piston (5) comes to stop. 4. Start engine and let it run with max. speed. 5. Lower attachment to ground and apply house brake (swing parking brake). 6. Actuate either l.h. or r.h. rotation until the hydraulic system stalls and increase slowly the MRV-pressure while observing the pressure gauge. Gauge value must remain at 330 -5 bar. Increase MRV setting additional 1/8 turn cw.. 7. If the gauge shows a lower or higher value the pressure increasing valves must be adjusted.

continue

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Hydraulic for the Swing Circuit

8.2.9

Section 8.2 Page 18

Checks and adjustments for the swing circuit Cont'd: High pressure check / adjustment Pressure Increasing Valve (PIV) high pressure adjustment Procedure: a) Loosen lock nut (1) of the first pressure increasing valve PIV. b) Adjust pressure with set screw (2) to ~340 bar if the pressure don’t increase turn set crew from the last setting max. ¼ turn in (c.w.). c) Secure by tightening lock nut (1). d) Loosen lock nut (1) of the second PIV. e) Adjust pressure with set screw (2) to 330 –5 bar. f) Secure adjusted set screw (2) by tightening lock nut (1) g) Loosen lock nut (1) of the first PIV. h) Adjust pressure with set screw (2) of the first PIV to 330 –5 bar (lower pressure c.c.w. just as the pressure gauge show a reaction) i) Secure adjusted set screw (2) by tightening lock nut (1) j) Re-check pressure setting. k) Re-set MRV to 310 + 5 bar after the check / adjustment is finished.

Low pressure check / adjustment (Swinging down path (drifting) (with still disconnected pilot pressure line ) 8.

Actuate either l.h. or r.h. rotation until the hydraulic system stalls. a) loosen lock nut (3) at the first PIV and turn out set screw (4) until 150 +5 bar is reached. b) Tighten lock nut (3). c) Loosen lock nut (3) at the second PIV and turn out set screw (4) until the gauge start lowering the pressure. d) Re-check pressure setting. Re-connect the pilot pressure line. Proceed like item 2.

9.

)

• For later one pressure checks the steps 2 + 3 must not be done. • The Swinging down path may be extended, means the low pressure may be decreased a little; e.g. for greater operating radius such as at strip Mining. But a little only otherwise disturbance due Swinging will occur. • The Swinging down path may be shortened, means the low pressure may be increased approx. 20 bar; but not more because that means greater shocks in the systems which will shorten the life time of the components.

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Hydraulic for the Swing Circuit

8.2.10

Section 8.2 Page 19

Checks and adjustments for the swing circuit Cont'd:

Brake pilot pressure - check / adjustment 1. Connect the gauge to the check point M4. 2. Start engine and let it run with max. speed. 3. Depress fully the foot brake pedal and read the pressure. The pressure must be 19 +3 bar. If adjustment is required: Alter the position of the potentiometer R2 of the amplifier A16 as long as the pressure is 19 +3 bar. Basic adjustment for A16 see section 5

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Hydraulic for the travel circuit

Section 8.3 Page 1

Table of contents section 8.3 Section 8.3

Page Travel System 8.3.1 Travel Circuit (Brief description)

2+3

8.3.2 Rotary Distributor

4+5

8.3.3 Side Frame Components

6

8.3.4 Travel Gear and Parking Brake

7

8.3.5 Parking Brake

8

8.3.6 Electric / Hydraulic Flow Chart

9

8.3.7 Adjustment / Checks

10 + 12

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Travel System

Section 8.3 Page 2

Travel Circuit

Legend for illustration (Z 22521): (1; 2; 5; 6) (14 / I) (16 / III) (21.1- 21.4) (28.1+28.2) (34) (40) (46.1+46.2) (52.1 + 52.4)

Main pumps L.H. Control block R.H. Control block Travel motors (A2FM 355) Travel motors valve blocks Rotary distributor Suction tank Double filter Travel gear house brakes

(M12.1 + M12.4) (M33.1, M33.2) (M33.3, M33.4)

High pressure check points High pressure check points left travel motors High pressure check points right travel motors

Brief description (Study together with the machine valid hydraulic and electric circuit diagram). Control circuits, not shown By the function of the remote control valve (45.1 + 45.3) pilot pressure oil is sent to one side of each control block (14/I + 16/III) when operating the foot pedal for travelling "Forward or Reverse“.

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Travel System

Section 8.3 Page 3

8.3.1 Service circuits ( Z22521) (Study together with the valid hydraulic and electric circuit diagram for the machine). The travel motors (21.1 - 21.4) are driven by the pumps (1; 2; 5; 6). The oil flows from the pumps through check valves and the filters (46.1 + 46.2) to the control blocks (14 / I + 16 / III). In neutral position of the spools the oil flows via the return oil lines into the collector tube (35, not shown). From the collector tube (35) flows the oil via the return oil lines (L6 + L7, not shown) into the collector tube (114) and further to the tank. On its way to tank the oil must flow through the back pressure valve (115) or the oil coolers (106.1 – 106.4) and the return oil filter (117.1 - 117.4). (Back pressure valve function see section 4.) When operating the foot pedal for "Travelling" the pump line of each control block is connected with the corresponding service line (A1 or B1) via the rotary distributor (34) and the valve blocks (175 + 176) to the travel motors (21.1 21.4). The oil flows from the travel motors via the rotary distributor back to the control blocks and further to tank. Each travel gear includes two spring loaded multi disk brakes (House brakes) (52.1 - 52.4). They are used as parking brakes, automatically applied (by the function of Y16) whenever both motors stoped. The brake release pressure is monitored by the pressure switch (B48). The leak oil (case drain) flows through the line (L) and the leak oil filter (108) back to tank.

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Travel System

Section 8.3 Page 4

8.3.2 Rotary Distributor Task: The rotary distributor (joint) permits a hydraulic connection between the superstructure and the under- carriage, that means between the rotating and the stationary part. Legend for illustration (Z 22522): (1) (2) (3) (4) (6) (8+9) (10) (11) (12) (13)

Rotor Rotary distributor housing Cover Thrust washer Sealing plunger Seal ring and O-ring PTFE Sealing V – Sealing Rotor guide rings O-ring

Translations: Schnitt = Cross section Versetzt gezeichnet = Offset drawn Verschlußschraube mit Loctite gesichert = Plug screw sealed with Loctite mit Körnerschlag gesichert = sealed with punch mark Kammer mit Fett gefüllt = Chamber grease filled Ports: A-D L ST X K1 K2

Service lines Leak oil Control oil „Travel break“ Control oil (travel motor flushing) Track tensioning Track tensioning continued

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Travel System

Section 8.3 Page 5

Cont’d.

Function (Z 22522): During operation superstructure and under carriage rotate towards each other. The travel oil motors must be supplied with hydraulic oil in every position in which the superstructure is turned in regard to the undercarriage. Oil is directed by the control blocks to the ports (A-D) of the housing (2). The oil flows to the outlet ports (A-D), of the rotor (1), via ring grooves as well as longitudinal and cross holes. The rotor is bolted to the under carriage and the housing (stator) is fixed by the upper structure. The sealing of the ring grooves among one another is done by seal rings (8) and o-rings (9). The hydraulic connection for the travel motor case drain and the travel motor house brake is done via the ports (L) and (St). The rotor (1) is at the top and bottom section guided in the housing by the guide rings (12).

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Travel System

Section 8.3 Page 6

8.3.3 Side Frame Components, Cross Sections Illustration Z 22523

A B C D

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Under carriage view from the back side Final drive with Side frame with top and bottom roller Track tensioning cylinder

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Travel System

Section 8.3 Page 7

8.3.4 Travel Gear and Parking Brake Function principle ( illustration Z22524a): The spur gear stage (B) is driven by two hydraulic motors via two drive shafts (A). This in turn causes that by the shaft (C) the first planetary stage (D) is driven; opposite the input drive direction. The planetary gears of the second planetary stage are connected to the hollow shaft (G). The drive sprocket is mounted to the hollow shaft (G).

For maintenance see MAINTENANCE MANUAL For more details see PARTS BOOK.

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Travel System

Section 8.3 Page 8

8.3.5 Parking Brake Illustration Z 22525 The Spring Loaded Multi-disk Brake is used as a safety brake (parking brake); applied by spring force and released by oil pressure. Legend: (1) (2) (3) (4) (5) (6)

Disk housing Piston Back-up ring with radial seal rings (15) Bach-up ring Coupler Inner disks (lamellas)

(7) (8 + 9) (10 - 12) (13) (14) (16) (17) (19) (21 + 22)

Outer disks Springs O-ring Clip ring Clip ring Release pressure port Quad-Ring with back-up rings (18) Quad-Ring with back-up rings (20) Plug screw with seal ring

Function: Brake applied: The outer disks (7) engaged to the housing by serration and the inner disks (6) in serration connection with the coupler, are pressed together by the springs (8 + 9). This results in a fixed connection between housing and coupler. Brake released: Oil pressure via port (16) reaches the left side of the piston (2) and forces the piston towards the back-up ring (4), as shown. This function eliminates the spring force onto the disks thus the brake is released. The releasing pressure is 18 bar, the maximum permissible pressure 60 bar. This brake named "Wet Brake" because the brake housing is filled with gear oil. For maintenance see MAINTENANCE MANUAL For more details see PARTS BOOK

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Section 8.3 Page 9

Electric / Hydraulic Flow Charts Illustration Z 22526 On the following pages are shown the electric / hydraulic flow charts for the travel circuit. The electrical signal created by the foot pedals (E21a and E21b) reach first of all the ramp modules (E51 and E52) and further the amplifier modules (A12 and A13). It is a voltage signal from –10 up to +10 Volt dependent to the pedal deflection and direction. The amplifier modules changes this signal in a current signal from 0 to 1000 mA and a directional signal (0 or 24 V). The current signal activate the proportional valve and the directional signal the directional solenoid valve of the remote control block (45.1 and 45.3). The valves in case activate the pilot pressure to the main control valve blocks. This hydraulic signal (pilot pressure) from the remote control valves flow to the main control blocks (175 and 176) to the pilot pressure ports a1 or b1 which in case push the main control valve spool to control the main hydraulic oil flow from the main pump. The main hydraulic oil flows now from the main control blocks via the rotary distributor (34) to the hydraulic motors (21.1 - 21.4).

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Travel System

Section 8.3 Page 10

Adjustments / Checks

)

• It is important that the complete MRV-valve is firmly (with 300 Nm) tightened. Otherwise, the internal sealing sealed not properly which results in: difficulty setting, loud flow noises and abnormal temperatures.

High pressure check / adjustment (illustration Z 22528) 1. Connect the gauge (0-400 bar) to the check points M12.1. and M12.4 at the double high pressure filters. 2. Unplug solenoid valve Y16 (Z 22529, filter and valve panel motor 2) to 3. 4. 5.

keep the parking brake applied. Start both engines and let it run in high idle. Engage carefully desired travel motion and hold foot pedal in final position to built up max. pressure. Increase * slowly the MRV-pressure while observing the pressure gauge. Gauge value must remain at 310 +5 bar.

Motor 2

continued

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Travel System

Section 8.3 Page 11

Cont’d. If the gauge shows a lower or higher value and to be sure both SRVs are correct adjusted the SRVs (main valve block and brake valve block) must be adjusted.

)

• A faulty anti cavitation valve (32.1; 32.2; 32.13; 32.14) can influence the SRV pressure reading / setting. In a doubt inspect the valve. Repair or replace faulty valve if necessary. • A faulty rotary distributor or motor gives the same problems. Repair or replace faulty part.

Procedure: 6. 7. 8. 9.

10. 11.

12.

13.

Set MRV of main valve block I and III to a higher setting (~ 340 bar, for adjustment use the function “stick extending” Engage carefully desired travel motion and hold foot pedal in final position to built up max. pressure Adjust* the respective SRV to a higher setting (~330 bar) Connect pressure gauge to check points M33.1, M33.2, M33.3 and M33.4 at the travel valve block in the car body. The respective high pressure check point is on the other side diagonal to the SRV. Adjust* the SRV at the desired travel function to 310 bar. Reset the respective SRV at the main valve block to 310 bar, increase the setting from a lower pressure just to the point when the gauge stop increasing it should be 310 bar (provided setting from the SRV at the brake valve is correct). Create max. pump pressure with “stick extending” to the max. position and re-set MRV to 310 + 5 bar after the check / adjustment is finished and re-plug solenoid valve Y16 Stop enignes.

* a) b) c) d) e)

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Remove dust cap of the SRV (1) Loosen lock nut (2). Adjust pressure with set screw (3). Secure adjustment by tightening lock nut (2). Re-fit dust cap (1).

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Section 8.3 Page 13

Function Check of the Travel Gear House Brake Illustration Z 22529 Connect pressure gauge to check point (M6) at the filter and valve panel motor 2. Start both engines and let it run in high idle. Read the pressure. Gauge must show common pilot pressure (norm. 35 + 1 bar). If not check the pilot pressure. If the pressure is below 24 bar, the text display must show „Travel gear house brake ON“. Operate the travel foot pedals, the machine must travel. In case the machine doesn’t travel the text display must show „Travel gear house brake ON“ Unplug solenoid (Y16) and operate the travel foot pedals, the machine must not travel. The text display must show „Travel gear house brake ON“

1. 2. 3.

4.

5.

)

• In a case of malfunctioning check the electrical controlling and the solenoid valve Y16.

Function check of the pressure switch (B48) 1. Connect pressure gauge to check point (M6). 2. Start one motor. The gauge must show common pilot pressure (norm. 35 + 1 bar). 3. Set pilot pressure relief valve (70.2) to 22 bar X2 pressure. 4. Unplug solenoid valve Y16 to allow pressure release from the pressure line of the house brake. 5. Reconnect solenoid valve Y16. The text display must show „Travel gear house brake ON“ 6. Increase the pilot pressure up to 26 bar „Travel gear house brake ON“ must disappear If not check the pressure switch B48 and exchange it if it is out of the range. 7. Reset pilot pressure to 35 bar

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Hydraulic Track Tensioning System Section 9.0 Page 1

Table of contents section 9.0 Section 9.0

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Page Hydraulic Track Tensioning System General

2

9.1

Functional description

3+4

9.2

Pressure Increasing Valve

5

9.3

Tensioning Cylinder

6

9.4

Adjustments / Checks

7–9

9.5

Functional test

9

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Hydraulic Track Tensioning System Section 9.0 Page 2

9.0

General: Legend for illustration (Z 22453): (62.1 – 62.4) Track tensioning cylinders (M15.3 + M15.4) Bleeder and hydraulic pressure check points at the R.H.- tensioning cylinders. (M15.1 + M15.2) Bleeder and hydraulic pressure check points at the L.H.- tensioning cylinders. (M15.5) Bleeder and hydraulic pressure check point at the bladder accumulator (59.1) for the L.H.-side. (M15.6) Bleeder and hydraulic pressure check point at the bladder accumulator (59.2) for the R.H.-side. (60.1 + 60.2) Membrane accumulator, 1,3 liter (pre-charge pressure 31bar) (54.2) Service shut-off cock for the L.H.-side (54.3) Service shut-off cock for the R.H.-side * "O" = open - "C" = closed (59.1 + 59.2) Bladder accumulator, 5 liter (pre-charge pressure 150bar) (34) Rotary joint L3 (St) Supply line from solenoid valve Y16 over rotary joint port St

The hydraulic track tensioning system ensures automatically the correct track tension. The pilot pressure pumps (7.1+7.2, see hydraulic diagram page 02) will supply oil to all four tensioning cylinders (62.1-62.4). The maximum pressure is limited by the pressure increasing valve (182), one for both sides. The pressure in the tensioning cylinders transmits the required force to move the guide wheels to the front, until the correct track tension is obtained. External forces acting at the guide wheels will be absorbed through the pressure accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage).

)

For information about the preventative track inspection, refer to the Operation and Maintenance Manual.

Functional description on next page

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Hydraulic Track Tensioning System Section 9.0 Page 3

9.1

Functional description: Illustration Z 22454:

)

Under normal operating condition the shut-off cock (54.1) located on the valve block (181) in the car body are closed. The shut-off cock (184) located on the valve block (181) in the car body and (54.2 and 54.3) located inside the side frames are open.

The oil flow of the pilot pressure pumps (7.1 + 7.2), filtered by pressure filter (68.1) enters port "P" of the solenoid valves Y16 via hydraulic line L3 and the rotary joint to the track tensioning valve block (181) in the car body. If solenoid valves Y16 is actuated (i.e. pressure at sensor B48), the oil flows (X2-pressure with 35 bar) via the pressure relive valve (83), rotary joint (34), the shut-off cock (184) and check valves (180.1+180.2) into the tensioning cylinders (62.1 - 62.4). The resulting force moves the guide wheels toward the front, until the correct track tension is obtained. Simultaneously the system is connected to the pressure increasing valve (182). External forces acting at the guide wheels will be absorbed through the pressure accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage). Purpose of the pressure increasing valve The two system pressures • 35 bar with motors stopped • 315 bar with motors running are controlled by the pressure increasing valve as follows. With stopped motors and switched off ignition there is no pilot pressure (X2) at the pressure increasing valve (182) and only the lowest adjusted pressure of 35 bar remains in the system. As soon as one motor has been started, the pilot pressure (X2) of 35 bar act on the pressure increasing valve. As a result the system pressure can rise to the adjusted pressure of 315 bar.

continued

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Hydraulic Track Tensioning System Section 9.0 Page 4

Cont'd.: 9.1

Functional description: Illustration (Z 22454): Cushioning Function When the tensioning cylinders (62.1 - 62.4) are moved in by external forces, the none return valves (179.1 + 179.2) will be closed. A certain amount from the displaced oil of the tensioning cylinders is taken up by the pressure accumulators. First stage:

at a pressure higher than 31 bar, is taken up by the side frame accumulators (60.1.1 + 60.2).

Second stage: at a pressure higher than 150 bar, is taken up by the center section accumulators (59.1 + 59.2). The system pressure can rise up to 315 bar pressure increasing valve (182) setting. With reduction of external forces, the oil is pushed back by the accumulator pressure into the tensioning cylinders. If the displaced oil volume was higher than the accumulators could take up, oil is added from the pilot pressure circuit (X2), as soon as the pressure in the lines to the tensioning cylinder is lower than 35 bar.

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Hydraulic Track Tensioning System Section 9.0 Page 5

9.2

Pressure Increasing Valve

)

The pressure increasing valve is a remote controlled pressure relief valve.

Legend for illustration (Z 21846): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11+12) (13+14)

Pilot valve with valve seat Valve poppet Compression spring Main valve with sleeve Main piston Closing spring Set screw - low pressure 35 bar Set screw - high pressure 310bar Piston Pin Jet bore Lock nut

Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the P port. If static pressure increases above the set pressure value, the valve poppet (2) opens and allows oil to flow freely to tank (T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (6) is cancelled, and the main piston (5) opens to allow the pump flow to flow to tank (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 60 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly. The setting is fixed by means of the setting screw (7) and lock nut (13); one turn of the screw ~ 150 bar. The possible max. pressure setting with the set screw (8) on block is about 440 bar.

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Hydraulic Track Tensioning System Section 9.0 Page 6

9.3

Tensioning cylinder: Legend for illustration (Z 21929): (1)

Cylinder tube

(2)

Piston

(3)

Piston guide ring

(4)

Piston guide strap

(5)

Seal ring

(6)

O-ring

(7)

Scraper

(8)

Retracting device

(M) Bleeder port (P)

Oil supply

• Maximum permissible piston stroke 350mm! During bench test an external stroke limitation must be used!

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Hydraulic Track Tensioning System Section 9.0 Page 7

9.4

Adjustments / Checks Legend for illustration (Z 22455): (182) (54.3) (54.2) (59.2) (60.2) (MRV)

Pressure increasing valve Service shut-off cock for the R.H.-side Service shut-off cock for the L.H.-side (not illustrated) Bladder accumulator 150 bar Accumulator 31 bar Main relief valve – Operating pressure of main control block I

(M12.4)

Pressure check point – Operating pressure of main control block I

(M15.6)

Bleeder and hydraulic pressure check point at the bladder accumulator (59.2) for the R.H.-side.

(M15.5)

Bleeder and hydraulic pressure check point at the bladder accumulator (59.1) for the L.H.-side (not illustrated).

(M15.3)

Pressure check point - track tensioning system operating pressure – R.H.

(62.3+62.4)

Track tensioning cylinder R.H.

Checking / Setting the pressure increasing valve Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system must be free of air. The description is only for the R.H. track. The same procedure applies also for the L.H. side. Basic Adjustment: 1. Connect a pressure gauge (min.400 bar) to check point M12.4. 2. Start one motor. 3. Increase the MRV-setting (Block I), ~ 330 to 340 bar. 4. Switch OFF the motor, open cock valve (54.1) to allow pressure relieve of the R.H. track, and close it again. continued

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Hydraulic Track Tensioning System Section 9.0 Page 8

Cont'd.: 9.4

Adjustments / Checks 5. 6. 7. 8. 9. 10.

Move the pressure gauge from M12.4 to M15.3 Connect pressure check point M12.4 with pressure check point M16.1, using a long pressure gauge hose. (required for the oil supply) Disconnect the pilot pressure line at port X of the pressure increasing valve (182) and close the hose (P) ith a plug. Loosen lock nut (4) of the pressure increasing valve and screw in set sleeve (5) until piston (1) comes to stop. (substitution of X2 pressure) Start one motor. Stall the hydraulic with the bucket filling function (bucket cylinders completely extended) and observe pressure at check point M15.3. A pressure of 315 + 5 bar must reached within a time period of 10 – 15 minutes and must remain at this value. The maximum pressure will be shown only after the accumulators are completely filled with oil. When the pressure reaches the pre-charge gas pressure ( 31 bar and 150 bar) the gauge pointer moves slower depending on the gas compression.

If the gauge shows a lower or higher value the pressure increasing valve must be adjusted. Setting procedure, high pressure stage (Valve 58.2) a) Loosen lock nut (2). b) Adjust pressure with set screw (3). c) Secure adjustment by tightening lock nut (2). d) Re-check pressure setting. 11.

The low pressure setting of the pressure increasing valve must now be reset (with the pilot pressure line at port X still disconnected): Setting procedure, low pressure stage (Valve 58.2) a) Stall the hydraulic with the bucket filling function (bucket cylinders completely extended) and observe pressure at check point M15.3. b) loosen lock nut (4) and turn set screw (5) ccw until gauge at check-point M15.8 shows 35 bar. c) Tighten lock nut (4). d) Re-check pressure setting. continued 17.01.07

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Hydraulic Track Tensioning System Section 9.0 Page 9

Cont'd.: 9.4

Adjustments / Checks 12. 13.

Switch OFF the motor and open cock (54.1) to allow pressure relieve. Re-connect the pilot pressure line to port X of the pressure increasing valve (182). Remove the pressure gauge hose between pressure check point M12.4 and pressure check point M16.1. Close the cock (54.1). Re-set MRV to 310 + 5 bar after the check / adjustment is finished.

13. 15. 16.

9.5

Functional Test After all adjustments are finished, do the following: a) Bleed all air from the system b) Place shutoff and pressure relief cocks into correct operating position. c) Connect pressure gauge to check point (M15.3). d) Start both motors. e) Travel approx. 10 m with the shovel. The pressure should be rise to a higher value. f) Stop the motors. g) The pressure must drop to 35 bar. If the pressure remains at a higher or lower pressure*, re-adjust the low pressure setting at the pressure increasing valve (182) is necessary.

)

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*

The pressure may drop below 35 bar after a longer time, this is o.k. because of internal leakage.

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Access ladder hydraulically operated

Section 10.0 Page 1

Table of contents section 10.0 Section 10.0

17.01.07

Page Access ladder hydraulic operated 10.0 General

2

10.1

3+4

Function of hydraulic operated access ladder

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Access ladder hydraulically operated 10.

Section 10.0 Page 2

Access ladder hydraulic operated General

legend for Illustration Z22494 (A) Access ladder in lowered position (B) Access ladder way to upper position (C) Stop bar (Z) Hydraulic cylinder (S84) Ladder control switch “up” (S84B) Ladder control switch “down” (S84A) safety switch operated from ground level for lowering (pull switch) (S22) Control sensor : Cut off the pilot control system and actuation of the slew brake with ladder in lowered position. (S91) Monitor and control sensor: It monitors the ladder position and controls the moving speed of the ladder. In case the sensor (S22) fails, the sensor (S91) prevents unintended movement of the ladder .

The access ladder is hydraulic driven by the hydraulic cylinder (Z) via the 60 bar X4 pressure. S84 is the control switch to move the ladder up and down. The additional pull switch S84A move the ladder only down from the ground. To lower the ladder the motor can run or stand still. Only to move the ladder up the motor must running.

)

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If the ladder is out of the upper position the pilot control system switches off (all machine movements stoped) and the solenoid valve Y120 activates the service swing brake. The text display in the cab shows a message.

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Access ladder hydraulically operated 10.1

Section 10 Page 3

Function of hydraulic operated access ladder illustration (Z 22495):

Legend: (7.1+7.2) (84.1+84.2) (68.1) (70.1) (70.2) (162.3 – 5) (171) (174) (172) Y125 Y123A Y123B

Pumps Check valves Filter with filter monitoring switch B22 Pressure relieve valve (60 bar) Pressure relieve valve (35 bar) Check valves Pressure relieve valve (70 bar) Ladder cylinder Orifice Solenoid valve: lower speed limit Solenoid valve: ladder up Solenoid valve: ladder down

The motor is running Additional to the hydraulic diagram Z22495 use the electric diagram on next page The pumps (7.1) and (7.2) are delivering oil through filter (68.1) to port P of the solenoid valve Y123A/B and the pressure relief valve (70.1) port A. The pressure relief valve (70.1) maintains the adjusted pressure of maximum 60 bar. Solenoid valve Y123A/B lead pump oil to the cylinder if one of the solenoids is energised. Depend on the activated solenoid valve the ladder move up or down. The pressure relief valve (171) limits the pressure of the ladder cylinder to max. 70 bar. Return oil from the cylinder flows back via solenoid valve Y123A/B to the solenoid valve Y125. With energised solenoid this valve lead back oil unhindered to the oil tank It is energised when both approximately switch S22 and S91 are not activated (ladder between upper and lower end position). A short way before the ladder reached one of the end positions one sensor (S 22 – in up position; S 91 – in down position) switch on and de energise Y125. Now back oil must pass the orifice (172). By the flow resistance of the orifice the ladder motion will be slowed down. If the ladder is in the “Up – position” the activated sensor S22 de-energised Y125 and energised Y123A, now the still connected pump pressure to the cylinder piston side keep the ladder in the final up position. If switch S84 is in neutral position and the ladder in “down – position” sensor S91 de-energise all solenoids (Y125; Y123 A+B) and the ladder is “blocked”. continued 17.01.07

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Access ladder hydraulically operated

9

Section 10.0 Page 4

Cont'd: The motor is out and the ladder is in the “Up – position” With activated switch S84 to position 2 (ladder down) solenoid valve Y123B and relay K132 are active. Y123B opened the piston side of the cylinder to the tank and K132 activate Y125 that the oil can flow without resistance to the tank. Now the ladder can move down only by its own mass (gravity). The operator have to push the ladder slightly until it starts moving down by its own weight. The rod site of the cylinder receives oil via anti-cavitation valve (162.3). It is no key contact necessary this function is direct supplied to the battery via fuse F17. There is an additional pull switch S84A below the ladder support. With this switch the ladder can moved down from the ground. • Make sure that there are no obstacles in the moving range of the ladder. Stop raising the ladder by releasing the control switch (S84) if there are any obstacles in the moving range. • Mount the ladder only in completely lowered position. • Do not lift persons or objects (tools) with the hydraulic access ladder. Serious injury or death can be the result.

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Cable drum

Section 11.0 Page 1

Table of contents section 11.0 Section 11.0 Cable drum 11.0 General 11.1

Components

11.2

Function

Page 2 3

11.2.1 Controlling of the drive motor

4

11.2.2 Travel motion control

5

11.3

Checks and Adjustments

6

11.4

Description and operating instruction for cam switch 5S4 and 5S6

7

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Cable drum

Section 11.0 Page 2

11.0 Cable drum General Legend for Illustration Z 22831a (5M6) Brake motor (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling and for monitoring of the two last cable windings. (5S6) Pendulum control cam switch, to detect slack or tight cable (5S8, 5S9) Proximity switch to detect cable deflection to right or left (5S10, 5S11) Proximity switch for ground contact protection.

)

Task: The cable drum, driven by a brake motor with slip ring rotor, is installed to wind up or unwind the power supply cable automatically. 1. To considerably improve the mobility of the excavator. 2. To make the operation safer (Material and personnel) i.e. less risk to damage the cable when travelling backwards and less danger of injury because the cable must not manual moved. 3. To increase the lifetime of the cable, because the cable is not dragging on the ground. For the optimal use of the cable drum it is necessary that the operator understands the system very well. Regular maintenance is essential

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Cable drum

Section 11.0 Page 3

11.1 Components Legend for Illustration Z 22832a (5M6) Brake motor (5S1) Service switch for manual actuation of cable drum. (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling and for monitoring of the two last cable. (5S6) Pendulum control cam switch, to detect slack or tight cable. (5S8, 5S9) Proximity switch to detect cable deflection to right or left (5S10, 5S11) Proximity switch to detect ground contact (5K7, 5K8, 5K12, 5K13) Relay for brake motor direction controlling (5K10, 5K11) Relay for brake motor torque controlling (5F13) Circuit breakers (5B79) Brake motor temperature probe (F79) Motor temperature control unit (X8) Terminal box The resistor 5R1 serves as a series resistor for a three- phase motor with a slip ring rotor (stand still, sliding rotor-brake motor) It is a resistor with one or more taps (as a function of drum design), to make a selection of different star bridges possible. The taps serve to regulate the motor and brake torque during winding up and unwinding. With service switch 5S1 is it possible to control the cable drum manually in both directions (windup, unwind, stop and automatic) The terminal box X8 contains the terminal rails , the relays 5K7, 5K8, 5K10, 5K11, circuit breakers 5F13 + 5F14 and motor temperature control unit F79. Direction of rotation monitoring switch 5S3 opens its contact and de-energizes 5K10 and 5K11 while unwinding (traveling forward) and eliminates the resistor which controls the star bridge. (Lowest tensioning force) Gear type cam switch 5S4* reduces the tensioning as soon as half of the cable is unwinded (contact 21/22 opens and de-energizes 5K11) or stops reverse travelling as soon as the max. length of the cable is winded up (contact 31/32 opens and de-energizes K178). The proximity switch 5S8 stops L.H. crawler reverse travelling at too much deflection of the power supply cable to the left (contact br/sw opens and de-energizes K179). The proximity switch 5S9 stops R.H. crawler reverse travelling at too much deflection of the power supply cable to the right (contact br/sw opens and de-energizes K180). Pendulum control cam switch 5S6* stops forward travelling at too tight power supply cable (contact 11/12 opens and de-energizes K177) or reverse travelling at too much slack of power supply cable (contact 21/22 opens and de-energizes K178). The limit switch 5S7* stops forward travelling by de-energizing K177 as soon as the safety cable length on the drum gets unwinded. The motor temperature control unit F79 interrupts all travel motions as soon as drive motor 5M6 reaches a critical temperature (monitored by sensor 5B79).

*Refer to page 7 for adjustment procedure

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Cable drum

Section 11.0 Page 4

11.2 Function Legend for Illustration Z 22834a (5M6) Brake motor (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling (5K7, 5K8) Relay for brake motor direction controlling (5K10, 5K11) Relay for brake motor torque controlling (5F13) Circuit breakers (F79) Motor temperature control unit (X2 + X8) Terminal board D53 Time relay at the X2 board 11.2.1 Controlling of the drive motor General: In the automatic mode of control switch 5S1, the power supply to drive motor 5M6 is controlled by the function of the travel control system, which controls relay 5K7, i.e. while traveling the contacts of 5K7 are closed and kept closed for further 10 seconds after stopping the travelling motion (controlled by time relay D53), before the power supply will be interrupted and the motor brake is active. The torque of drive motor 5M6 is controlled by the function of the relay 5K10 and 5K11; which changes the resistance at the star bridge (5R1). Both relay are simultaneously controlled by switch 5S3 (Direction of rotation monitoring switch), to ensure the lowest tensioning force while unwinding (i.e. traveling forward) Winding up (automatic mode of control switch 5S1): While winding up the NC-contact of switch 5S3 remains closed which allows voltage to the relay 5K10 and (if the contact 21/22 of switch 5S4 is closed) also to 5K11. Example travelling reverse: Cable length on drum: ½Max. – Max. => 5K10 ON + 5K11 ON => max. torque Cable length on drum: Min. – ½Max. => 5K10 ON + 5K11 OFF => reduced torque Unwinding (automatic mode of control switch 5S1): The NC-contact of switch 5S3 opens while traveling forward and de-energizes simultaneously 5K10 and 5K11, with the result that there is just enough torque to hold the cable tight.

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Section 11.0 Page 5

Cable drum

11.2 Function 11.2.2 Travel motion control, illustration Z 22835 General: The cable drum is equipped with safety switches for the protection of the power supply cable during travelling and turning operations. Movements which could damage the power cable are automatically switched off.

Cable condition

Monitored by

Travel shut off relay

Directional Solenoid valves

Travel response

K177

Y20b + Y28b

crawler left + crawler right

Switch / contacts 1. Too tight

5S6 / 11–12

forward motion stopped 2. Too slack

5S6 / 21–22

K178

Y20a + Y28a

crawler left + crawler right reverse motion stopped

3. Too strong deflection to the left

5S8 / br–sw

K179

Y20a

crawler left reverse motion stopped

4. Too strong deflection to the right

5S9 / br–sw

K180

Y28a

crawler right reverse motion stopped

5. Maximum permissible cable length on the drum

5S4 / 31–32

6. Safety cable winding unwinded

5S4 / 11–12

K178

Y20a + Y28a

crawler left + crawler right reverse motion stopped

K177

Y20b + Y28b

crawler left + crawler right forward motion stopped

7. Ground contact

5S10 and/or 5S11

K178

Y20a + Y28a

crawler left + crawler right reverse motion stopped

) )

If the reverse motion stopped because of a activated ground contact switch 5S10 or 5S11 it is possible to activate the reverse motion manually via activation of horn switch at the left control lever in the cab.

Refer to section 8.3 in this Manual for further information.

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Cable drum

Section 11.0 Page 6

11.3 Checks and Adjustments Legend for Illustration Z 22836a (5S3) Rotation direction indicator (switch) No adjustment required. Check the function of contact 2/P. The built-in switch must open while unwinding. (5S4)

Gear type cam switch for resistor controlling and safety switch to detect full cable drum and the last two safety cable windings. The contact 31/32 must open as soon as the maximum permissible cable length is on the drum, travel reverse will stop by deactivated relay K178. As soon as the last second winding comes up contact 11/12 opens and travel forward will stop by deactivated relay K177. Adjusting procedure see section 11.4 on next page and check the function under operating conditions.

(5S6)

Pendulum control cam switch, to detect slack or tight cable. Adjust the switch in such a way that contact 11/12 opens at too tight cable and contact 21/22 opens at too slack cable. Check the function under operating conditions. Make sure that the shock absorber at the pendulum will work in its permissible range. Adjusting procedure see section 11.4 on next page. (5S7)

(5S8, 5S9)

Proximity switch to detect cable deflection to right or left. Adjust the distance between switch and metal bar to 7mm. Check the function under operating conditions.

(F79)

Motor temperature control unit with monitoring LED’s. (R) – red LED on => motor temperature to high. (G) – green LED on => permissible temperature range. Hysteresis: Rcold ≤ 1kΩ, Rswitch point ≥ 3kΩ (Sensor between P1 and P2) Check the function with potentiometer.

(D53)

Time relay for power cut off after 10 seconds without travelling. Check adjustment, refer to service Bulletin 21-584 for more information.

(X2 + X8)

Terminal board

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Section 11.0 Page 7

11.4 Description and operating instruction for cam switch 5S4 Legend for Illustration Z 22837 (1) Micro switch housing (2) Actuator (Roller lever) (3) Cam disc (4) Adjusting spanner (5) Cup spring (6) Tension nut The cam discs (3), arranged in pairs on the centering discs, can be adjusted individually and continuously by means of a adjusting spanner (4) The centering discs can be reversed and are fixed to the square shaft without clearance. Adjustment can be performed in any position without having to turn the control shaft. The cam discs, separated from each other by the guard plate, slide past each other without touching during adjustment. The cam ring next to the cam ring to be adjusted will not shift and remains in the set position. Hollow-type rivets prevent accidental shifting of the cam discs. By selecting the appropriate contact - either make or brake - any angle between 0° and 350° can be set without changing the cam rings. When the cam hits the actuator (2), the latter will operate the micro switch (1). Adjustment of the switch mechanism. 1. Loosen the tensioning nut (6) with the handle of the adjusting spanner (4). 2. Bring the adjusting spanner (4) in the position shown on illustration Z22837. 3. Set the cam discs (3) to the required position. 4. Adjust all other cam discs, following this procedure. 5. When all cam discs have been adjusted, tighten the tensioning nut.

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Section 12.0 Page 1

Table of contents section 12.0 Section 12.0

Page Hints for reading the hydraulic circuit diagram General 12.1

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Symbols 12.1.1 Lines, unions 12.1.2 Components, valves 12.1.3 Sensors 12.1.4 Valves, valve components 12.1.5 Pumps, motors, cylinders 12.1.6 Assemblies and main components

2 5 5-6 7 8 9-12 13-14 15-16

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Section 12.0 Page 3

12.0 General: Legend for Illustration Z22987

) Item

• • • • • • • •

• • 04.01.07

• • •

The illustrations are used for exemplary explanations only. Use original circuit diagram for detailed reading There are more symbols on the following pages shown as in the diagrams drawn. Some symbols of the diagrams not shown in the following pages. Description

Number / Code

Explanation

A

Diagram No. and Type of the 897 895 40 a respective machine PC8000-E

Diagram No. only for the respective machine

B

Respective Serial No.

C

Sheet-No. / Quantity of sheets 01 / 04

1st of four sheets

D

Co-ordinates to describe the location of a component

Page 1 on co-ordinate C vertical and 10 horizontal Remote control valve 102.1

E

Component-No. 127

F

Line-No. with cross hint,

12041 1 C 10

127 L37/3B9

Main control block I Case drain line (Line No.37) comes from / goes to sheet 2 coordinate E7

All the components drawn in neutral and pressure less position. Full wide continues black line shows a main component or assembly. (Ex.: Valve and Filter panel, Main pump, Hydraulic tank, ...) Continues black line shows a main hydraulic line. This lines are temporary or continues load with high or pilot pressure. Broken line shows a return, drain or control oil line. Black dot shows a connection point. The position of this connection is not definitely fixed. White dot shows a connection or port of a component with a fix definitely position or port number. Page 1 shows the high pressure main hydraulic circuits with all pilot control valves, control blocks, distributor manifold and cylinders or motors. Page 2 shows all main pumps and pilot pressure pumps with the main pump control system and the other auxiliary pilot pressure circuits as lubrication system and ladder. Page 3 shows the main pump control arrangement, the auxiliary circuits with oil cooling system and the hydraulic tank. Page 4 shows the car body hydraulic with travel brakes, travel motors and track PC5500-6_Sec_12-0_rev3.doc

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Hints for reading the Hydraulic Circuit Diagram 12.1

Section 12.0 Page 5

Symbols Illustration Z 22988 12.1.1 Lines, unions Symbol

Description

Used as / at / on

1

Oil supply line, can be a hose or a pipe.

2

Return oil line, can be a hose or a pipe.

3

Case drain (leak) oil line, can be a hose or a pipe.

4

Control oil line, can be a hose or a pipe.

5

Crossed lines

Pipes or hoses not connected

6

Connection point, is a connection of hydraulic lines without definite position Component connection point, is a connection with a definite position at a component Plugged connection point, can be plugged with any kind of plugs.

Connection between several lines

7

8

9

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Plugged line inside of a manifold, can be plugged with different kind of plugs.

Suction line or pressurized line of main hydraulic circuit or pilot pressure circuit or auxiliary circuits (e.g. fan drive). Return lines, connected to the return oil filter chamber of the main oil reservoir.

Return lines, connected to the case drain (leak) oil filter chamber of the main oil reservoir. Pilot control line, pump regulation line and parking brake control lines.

Connection to components like, valve blocks, tanks, pumps, ... Not used connection points. Not used connection points.

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12.0 6 12.1

Symbols 12.1.1 Line, union Symbol

10

Description

Used as / at / on

Compensator, Compensate line length differences depend on vibration and temperature. Quick coupling, is a special union with integrated check valve

Oil tank outlet to the pumps

12

Blind, Orifice, not adjustable with orifice diameter in mm

e.g. Oil cooler inlet,

13

Pressure check point With a special quick coupling.

HP Filter, Fan valve block....at all important circuits

14

Distributor block

Connection of lines with the same destination e.g. return lines to tank

11

04.01.07

Tank drain couplings, often removed lines (e.g. at grease systems with removable barrels).

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Section 12.0 Page 7

Symbols 12.1.2 Components, valves Symbol

Description

Used as / at / on

Accumulator, is filled with nitrogen gas with for the respective accumulator specified pressure Screen filter, the screen size is 1.0 mm

Input line to the remote control valves, return oil collecting tube, track tensioning system

17

Oil cooler,

Hydraulic oil cooler, PTO oil cooler

18

Breather filter,

On top of PTO or hydraulic tank

19

Spray nozzles, inside of a case for cooling and lubricating

Gearbox (PTO) cooling and lubricating system

15

16

Installed in suction lines to the pumps, oil tank outlet, return oil collecting tube

continued

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12.0 8 12.1

Symbols 12.1.3 Sensors Symbol

Description

Used as / at / on

20

Pressure switch / sensor Input = pressure Output = electrical signal analogue or digital

e.g. return / leak oil chamber (digital), high pressure filter (analogue)

21

Pressure switch Input = pressure Output = digital electrical The switch point is 24 bar

e.g. swing or travel detection PC3000,

22

Temperature sensor, Input = temperature Output = electric signal proportional to the temperature

e.g. hydraulic tank

23

Level sensor, Input = fluid level Output = electrical signal analogue or digital

Hydraulic tank, fuel tank

24

Chip sensor, Input = contaminate oil Output = electrical digital signal

Main pumps

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Hints for reading the Hydraulic Circuit Diagram 12.1

Symbols 12.1.4 Valves, valve components Symbol

Description

Used as / at / on

25

Manuel operated unit Lever

Valve in track tensioning system,

26

Electric / magnetic operated unit Solenoid

Solenoid valve

27

Pilot pressure controlled unit

Pressure relief valve, disc brake, ...

28

Spring, with fixed force

Solenoid valves,

29

Spring adjustable spring force is adjustable

Pressure relieve valves,....

30

Check valve In drawn pos.: from right to left free flow, from left to right blocked flow.

31

Check valve spring loaded Opened in flow direction only against spring force = pressure Double check valve, in drawn pos.: opened only from the left to the bottom or from the right to bottom

e.g. main pump outlet, swing brake valve block, anti cavitation valves at main control blocks or distribution manifold By pass of the return oil filter, by pass of secondary filter

32

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Swing brake control,

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12.0 10 12.1

Symbols

Symbol

33

12.1.4 Valves, valve components Description Used as / at / on Shut-off Valve with Gate valve between main oil monitoring switch, reservoir and suction tank the adjustable switch monitors the valve position

34

2/2 control valve manual operated, 2/2 cock valve

Track tensioning system

35

3/2 control valve manual operated, 3/2 cock valve

Change over valve from electronically pump regulation to emergency mode (hydraulically pump regulation)

36

4/2 directional control valve as solenoid valve 4/2 way solenoid valve, electrically controlled. Neutral position: P-A and B-T connected. Variable throttle valve hydraulically controlled pilot control port pressure less = maximum restriction 3/2 directional control solenoid valve, seat design = leak oil free 3/2 way solenoid valve, neutral = port P-A open 4/3 directional control solenoid valve 4/2 way solenoid valve, in neutral all ports closed External pilot controlled proportional floating valve

e.g. swing parking brake, travel parking brake, ladder controlling,,

37

38

39

40

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Travel brake valve, located in the car body

Service arm controlling

Ladder controlling, service arm controlling

PC 3000 and PC4000 with floating system

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Section 12.0 Page 11

Symbols 12.1.4 Valves and valve components Symbol

Description

Used as / at / on

41

Main control valve Standard control valve for “standard function” two directions of cylinder or In neutral position: motor. open pump flow (P-PU) and control port flushing (T – a, T – b), in position a or b closed circulation port (P- PU)

42

Main control valve “pressure less lowering” Neutral position: open pump flow (P-PU), control port flushing (T– a, T– b) Position b: closed circulation port (P-PU), normal function P – B and B - T, Position a: open circulation port P – PU, only port B – T connected Main control valve “floating function” Neutral position: open pump flow (P-PU), control port flushing (T– a, T– b), Position b: closed circulation port (P-PU), normal function P – B and B - T, Position a: open circulation port (P – PU) = A, B, T, P connected together via tank Pressure reducing valve, assembly Variable inlet pressure at port B and constant lower output pressure at port A, output pressure is adjustable.

43

44

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Control valve for pressure less lowering. Used to assist the floating function of boom and stick,

Control valve with floating function in position a, e.g. floating valve for boom or stick, .

Emergency mode pressure (X3-pressure), pilot oil pressure

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12.0 12 12.1

Symbols 12.1.4 Valves and valve components Symbol

Description

Used as / at / on

45

Pressure relief valve, direct controlled and adjustable

e.g. ladder controlling, service arm controlling ..

46

Pressure relief valve with anti cavitation valve (check valve) Assembly, external drain at port Y

Secondary relieve valve at main control blocks

47

Pressure increasing valve pressure relieve valve with variable setting, pilot pressure controlled via port X. Low pilot pressure = low relieve pressure

Swing brake block, track tensioning system.

48

Proportional pressure valve, reduce the pressure in port A proportional to the solenoid current. 4 port proportional pressure relief valve, direct operated by a proportional solenoids.

Remote control valves to control the main control blocks,

50

Pressure relief valve, mechanical and hydraulically via pilot port X adjustable, oil drain port Y

Radiator and oil cooler fan drive

51

Throttle check valve with secondary relieve valve, throttle and secondary valve mechanical adjustable, external drain at port Y.

Distribution manifold normally in the line to the cylinder piston side.

49

04.01.07

Pump regulation, only output port A is used for our systems

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Hints for reading the Hydraulic Circuit Diagram 12.1

Symbols 12.1.5 Pump, motor, cylinder Symbol

Description

Used as / at / on

52

Single acting Cylinder, pressurised moving only in one direction, return by external force

Track tensioning system

53

Double acting Cylinder, Cylinder in which the fluid pressure operates alternately in both directions (forward and backward strokes) A = Piston side B = Rod side

Attachment i.e. boom, stick, bucket or clam cylinder

54

Drive shaft of a motor or pump with one direction

Main pumps, swing motor, fan drive, travel drive

55

Hydraulic pump with fix volume per revolution suction port S and pressure outlet P

Fan pump, circulation pump, pilot pump, PTO lubrication pump

56

Hydraulic pump with variable output volume per revolution with external case drain

Main pumps

57

Hydraulic pump assembly with pump bearing lubrication, one direction and external case drain

Main pumps

A

04.01.07

B

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12.0 14 12.1

Symbols 12.1.5 Pump, motor, cylinder Symbol

Description

Used as / at / on

58

Variable hydraulic pump with charge pump and external drive shaft bearing lubrication

Main pump

59

Hydraulic motor can be used in both direction, with external case drain L

Fan motor

60

Motor with disc brake disc brake is spring loaded it means: pressure less pilot line = maximal brake torque

Travel motor

61

Variable swing motor with integrated control valves and flushing valves

Swing motor PC5500

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Section 12.0 Page 15

Symbols 12.1.6 Assembly and main components Symbol

Description

Used as / at / on

62

Lubricant pump drive differential cylinder with integrated control valves to propel the grease pump

Lubricant pump station for central lubrication system and swing ring lubrication system

63

Swing brake valve assembly, act as a hydraulical back pressure system parallel to a motor with variable pressure setting and independent pressure side. Input port A or B and outlet on the opposite connection to the motor..

Swing brake system.

64

Rotary joint Upper part with connections drawn to the top, lower part with connections drawn to the bottom

Hydraulical connection between superstructure and car body

65

Travel brake valve block with secondary pressure relieve valve is connected in the line to the travel motors. The return oil flow is restricted according to the pressure inlet.

mounted in the supply line to the travel motors, is located in the car body

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12.0 16 12.1

Symbols 12.1.6 Assembly and main components Symbol

Description

Used as / at / on

66

Remote control lever to control the main control blocks

Control lever in the operators cabin

67

Remote control pedal to control the main control blocks

Control lever in the operators cabin

68

Hydraulic oil tank with leak and return oil filter, back pressure valve and sensors

Main hydraulic tank

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Section 12.0 Page 17

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 1

Table of contents section 13.0 Section 13.0

Page Hints for reading the electric circuit diagram 13.1

Designation of electrical devices

2

13.2

Symbols

3+4

13.3

General information

5+6

13.4

Reading a circuit diagram

7+8

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 2

13.1 Designation of electrical devices

Indicating letter A B

C D E F G H K L M N P Q R S T U V W X Y Z

Kind of component System, subassembly, parts group, trigger boxes, control units Transducer for conversion of non-electrical variables to electrical variables, and vice versa. Speed sensors, pressure sensors, pressure switches, oil-pressure switches, temperature sensors Condenser, capacitor, Condensers and capacitors, general Elements with time lag, memory elements, binary elements Various devices and equipment Protection device Fuses, current protection circuits Power supply, generator Batteries, generators, alternators Monitor, alarm, signaling device Indicator lights, signal lights, headlights, warning buzzers, horn Relay, contactors Inductor Coils, windings Motor Regulators, amplifiers Measuring instrument High voltage switching units Resistors, heating devices Switches, selectors Transformer Modulator, converter from one electrical in an other electrical value Semiconductor, electron tubes, diodes, rectifiers, zener diodes Transmission path, conductor, antenna Terminal, Plug, Plug and socket connection Electrically actuated mechanical device Solenoid-operated valves Compensating units, filters, limiters cable connection

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Section 13.0 Page 3

13.2 Symbols Legend for illustration (Z 21816): Our common used symbols in accordance to VDE/IEC (Association of German Electrical Engineers DIN 40710 - 40716 and the International Electrical Commission) differ for the most part from the symbols in accordance to JIC/ASA (Joint Industrial Concil and American Standard Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3). For this reason the following comparative chart. 1) Normally open contact

2) Maintained contact

4) Normally closed contact

5)

7) Manual operated switch isolator, disconnect switch 10) NO contact with time lag

8) Foot-operated push-button switch 11) Multi-position switch selector

13) Contacts with time lag

14) Resistor general

16) Battery

17) Tapped resistor

18) Voltmeter

19) Inductive resistance

20) Continuously adjustable, general

21) Recording instrument

22) With iron core

23) Adjustable in steps

24) Signal lamps pilot lights

25) Continuously adjustable

26) Potentiometer rhesostat

27) Operating coil solenoid

28) Transformer

29) Capacitor general, continuously adjustable

30) Rectifier, semi conductor

Push-button switch

3) Single pole two way contact break before make 6) Limit switch NO contact NC contact 9) Pressure operated switch 12) Indicating instrument (general) symbol 15) Ammeter

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Section 13.0 Page 4

13.2 Symbols Legend for illustration (Z 21817): 31) Rectifier bridge

32) Thermal over load limit

33) Phase, 4-wire system

34) Current transformer

35) Undervoltage relay

36) Junction of conductors

37) Voltage transformer

38) Temperature relay

39) Junction

40) Circuit interrupter

41) Contactor

42) Terminal

43) Circuit breaker, three phase

44) Generator (G)Motor (M)

45) Terminal

46) Thermal over- ground, load protection

47) 3-phase-motor

48) Earthing, general

49) Magnetic over- socket current protection

50) 3-phase squirrel cage

51) Plug and

52) Slipring motor

53) Fuse with bolted contacts 54) 3-phase squirrel cage induction motor in Star-delta starting 55) Thermal over- load relay 55) Two speed motor (tapped windings) (for ex. 8 to 4 poles)

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Section 13.0 Page 5

13.3 General information Legend for illustration (Z 21823): Komatsu circuit diagrams Each sheet has the following information in the bottom right hand corner: Diagram Number example: 897 844 40 Machine Type example: PC4000-6 Sheet Number and Total Number of sheets 01/63 - 02/ . etc. Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the top and bottom lines, and lettered down from F (at the top) to A (at the bottom) along the left and right side lines. This coordinate system enables you to find components easily. On the table of contents, page one, the individual circuits are listed up with the respective page number. Example: The circuit for the superstructure lighting is shown on page 39. Pages number two, three and four are cross reference lists of component codes related to page numbers. Example: The relay with the component code “K1-1” is shown on page 8. On page five is a list of answers to frequently asked questions (FAQ) concerning abbreviations, function of components (e.g. time relays) mathematical symbols etc. used in the diagram. All electrical components are connected via cable harnesses to the main switch board “X2”. There is only one Plug connector in between, which is always located close to the respective component like sensors, solenoids etc. All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the wire. (see illustration) The first part of the code shows the required connection and the second part gives the information what is connected at the other side of the wire. Example: going to coming from coming from going to

X2S 45

= X2-Board, terminal group “S” = Terminal No 45

Y136 = Plug connector to solenoid .1 = Terminal 1 of connector

All circuits are shown currentless and all relays and switches are in neutral position.

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Section 13.0 Page 6

13.3 General information Legend for illustration (Z 21824): Explanation of the Drawing Concept (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Drawing number Sheet number / quantity of sheets Designation of drawing Designation of component or assembly Column (vertical sections) Lines (horizontal sections) Component symbol Neutral wire / machine ground Designation of phase Phase strip Terminal strip and terminal Cable plug and pin number Relay coil Relay contacts, partially with detailed information Cross reference for the continuation, Page / Column Indication where the relay contact opens or closes

Location of the Main Terminal Boxes (X1) Dashboard inside the cabin (X2) Main switch board inside the cab base (3E14-1) Electronic control module (ECM- Quantum) left bank of the engine (3E54-1) Electronic control module (ECM- Cense) flywheel end of the engine

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Section 13.0 Page 7

13.4 Reading a Circuit Diagram. Legend for illustration (Z 21825): • Examples are shown by sectional drawings out of the electric circuit diagram 897 844 40 page 08.

) (1)

Section F8 / sheet 08 The hint F11/06.1 indicates that the wire from F11 is continued on sheet 06 column 1.

(2)

Section C4 / sheet 08 Shown is the relay coil K51-1 only and not its contacts. The contacts are shown somewhere else in the diagram. Switching and contact positions are shown below at the foot of that particular circuit in row C-C as shown below.

Example for K51-1: 08.5 : : :

1 5 2 6 3 7 4 8

9 10 11 12

opens on sheet 8 section 5 when relay is energized Not used Not used Not used

When diodes are fitted to a relay, they are fitted to allow a current flow in one direction only. An LED* (Light Emitting Diode) indicates a current flow if it lights up. When diodes ** are fitted anti-parallel to a relay coil, they absorb the high induced voltage caused by making and breaking the current flow through the coil. This occurs each time we operate a switch supplying current to the coil. The diode effect allows the induced current to circulate within the coil windings and decay when the energy to the coil is cut. * **

LED between A1 and coil Diode between A1 and A2.

(3)

Section F7 / sheet 08 Connectors and Terminals are identified by a letter and number code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked with a metal bridge. continued

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Section 13.0 Page 8

Cont.: 13.4 Reading a Circuit Diagram. Legend for illustration (Z 21826): (4)

Section E 1 sheet 08 The components have a letter and a number prefix, and these are explained below in rows A and B. Components are depicted in a system unique to VDE/IEC (Association of German Electrical Engineers DIN 40710-40716 and the International Electrical Commission) or to KMG standard. S27 = Toggle switch (with non-automatic return)

a.

F11

b.

F11 / 10.5 =

Power line F11, comes from circuit breaker F11, sheet 08 section 8 and continues on sheet 10 section 5.

c.

S27 / 20.7 =

Line S27, comes from switch S27, sheet 08 section 1 and continues on sheet 20 section 7.

=

Circuit breaker (24V power supply)

Function: If switch S27 is actuated, terminal A and B are connected and 24VDC will energize the coils of K121 and K121a on page 08 and simultaneously via line S27 a digital input to the PLC on sheet 20 section 7. Now the machine can be operated in emergency mode and a warning text appears on the display.

Electronic Control System ECS

Section 14.0 Page 1

Table of contents section 14.0 Section 14.0

Page Electronic Control System ECS 14.1

14.2

14.3

14.4

14.5

14.6

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General Design of the ECS-T System

2

14.1.1

Input and outputs of the PLC

3

14.1.2 14.1.3 14.1.4

Task PLC DIGSY plus ® Definitions; Symbols and Abbreviations

3 4 5 + 6 +7

How to Proceed due Maintenance and Installation

8+9

14.2.1 14.2.2 14.2.3

10 + 11 12 13

Meaning of the Status LED’s Short Circuit Marker -LED “MK” Diagnostic for Temperature-Module “ANM”

Front Connector Arrangement

14

14.3.1 14.3.2 14.3.3 14.3.4

14 + 15 16 + 17 18 19

Front Connector Arrangement BIM-Module Front Connector Arrangement, ANM-Module Ground connection of the Control Unit Interface-Connection COM SP /SK

Power supply

20

14.4.1 14.4.2 14.4.3 14.4.4 14.4.5

20 21 22 22 22

Operation Voltages +24 V Safety Precautions for Faultfinding CPU Voltage Range Electric Classification Fuse

Function explanations with electrical diagram

23

14.5.1 14.5.2 14.5.3 14.5.4

23 24 25 + 26 27

General Pressure Measuring Temperature Measuring Temperature – Resistance Chart PT100

Hints for reading the functional flow charts

28

14.6.1 14.6.2

28 29

General Example

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Section 14.0 Page 2

14.1 General Design of the ECS System ECS

Electronic Control System

Legend:

Illust. Z 21407a

(1)

PLC Programmable Logic Control (DIGSY plus ®)

(2) (3) (4) (5) (6) (7) (8) I/ O

Text display Keys for function control and pre-adjustments Outlet “X27” for data transfer Field computer system (like MODULAR MINING) Printer Memory card unit Laptop Input / Output data transfer

)

•

Items 5 to 8 are optional equipment

Meaning of the PLC front cover codes • BIM Binary Module • ANM Analogous Module • MK Short Circuit Memory • A Digital Output • E Digital Input • DIAG Diagnostic More in detail see page 4

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Section 14.0 Page 3

Input and Output of the PLC, Illust. Z 21408 PLC = Programmable Logic Control (Programmable Logic Control = Control system with a write-readingmemory, whose content can be altered (via an serial interface) by a PC and the resp. Software. No mechanical action necessary.)

14.1.2

Task The PLC receives from the monitored excavator components the actual values and does an evaluation. The evaluation results in a control and display function. See I / O connection table (chapter 10) and electric circuit diagram for I / O levels and ports.

)

•

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The picture shows as an example the application for a two motor version.

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Section 14.0 Page 4

PLC DIGSY plus ® (circuit diagram code E6) Legend for illustration Z 21409b 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Central Processing Unit (CPU) board. Binary Module (BIM) board. Analogues Module (ANM) board. MK Output short circuit marker LED red Input state-LED green, Inputs E1.1 - E1.8 up to E14.1-E14.8 Input or Output State-LED red (A2/ E9, Af/E10, A6/E11, A8/E12, A14/E21) Can be used as Inputs or Outputs Output state-LED red, Output A1.1 - A1.8 up to A13.1-E13.8 Diagnostic-LED (DIAG), (green flashing = OK.) 5Volt Voltage-LED (+5V), (green = OK.) Diagnostic LED for ANM COM SP Interface (COM SP) (Text display connection) COM SK Interface (COM SK) (PC-Connection) Binary Module BIM-plug-in location (slots) (X1-X5) Analogous Module ANM-plug-in location (slots) (X6-X8) Ground Connection (GND)

)

• The quantity and configuration of the BIM and ANM Module can be vary, depend on the excavator typ and additional options.

MK-LED, The short circuit marker are used to indicate an external short to GND • MK1, MK3, MK5, MK7 & MK9- LED for outputs A1.1 - A1.8 A3.1 - A3.8, A5.1 - A5.8, A7.1 - A7.8 & A13.1 – A13.8 • MK2, MK4 , MK6, MK8 and MK10 if there groups as outputs used • A MK-marker is placed, if an output (e.g. A1.1) gets from the program an output signal and at the same output happens an external short. The red MK 1-LED lights ON

)

• If there is a short all outputs of the resp. Output group i.e.. A1.1 - A1.8) are switched Off • The short circuit marker remains until the control system gets switched Off/ON (after eliminating the short).

State-LED Input lights up with a present 24 Volt signal. State-LED Output lights up with a switched On output. 5V-LED, indicate specified operation states by different colors and duration of lightning (Continuos On or flashing). For detail information see Section 4. DIAG-LED, indicate specified operation states by different colors and duration of lightning (Continuos On or flashing). For detail information see Section 4.

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Section 14.0 Page 5

Definitions; Symbols and Abbreviations

≡ ≠ Bit

Sign used for “corresponds to” Sign used for “not equal to” A bit is the smallest unit for information. It can assume only two conditions: logical 0 or logical 1 ( also referred to as logical L-Level and logical H-Level).

Boolean algebra Mathematical rules for binary variables and conditions. For Boolean equations the following signs are used: Logical AND operation (AND or &) ∧ Logical OR operation (OR or >=1) ∨ Logical Negation (NOT or 0) ¬ Byte

Unit for Information unit comprised of 8 bits. A byte can assume a value between 0 and 255.

Word

Memory unit comprised of 2 byte or 16 bit. A word covers the numeric range from –32767 to +32767.

Clock

Signal pulse

VWP

VerWaltungProgramm: (management program) A control program created by the user.

AWP

AnWender Program: (Application program, user program) A control program created by the user.

AWL

AnWeisungsListe: (instruction sequence) Representation of a program using alphanumeric signs and symbols as defined in DIN 19239. Programming in AWL (selection logic) is the at present widely applied method of programming.

CMOS

Complementary Metal-Oxide Semiconductor: Complementary metaloxide semiconductor technology with very low-level closed circuit current. These semiconductors are used above all for accumulator and battery buffering.

RAM

Random Access Memory: Read-write memory in which each memory cell can be addressed in order to read, write or delete at any time. RAM losses all of its information when the computer is turned off which is why it is often buffered by accumulators or batteries.

EPROM

Erasable Programmable Read Only Memory: Read-only memory erasable by ultraviolet light and electrically programmable. With this memory type, the contents remain intact in the event of a power failure. In the case of DIGSY plus ® this memory contains the management program (firmware). continued

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Section 14.0 Page 6

Definitions; Symbols and Abbreviations

Cont'd: EEPROM

Electrically Erasable Programmable Read-Only Memory (also called E2PROM):Electrically erasable and programmable memory. In the event of a power failure, the contents of this type of memory remain intact. The DIGSY plus ® application program (AWP) is loaded into this type of memory.

COMPILER A program that translates the instructions of a programming language (e.g. instruction sequence [AWL]) into machine code (processor instructions). EDITOR

Utility program for the creation and changing of programs.

Loop

Program loop.

Off-Line

Operational method of a programming device without attached automation device.

On-Line

Operational method of a programming device (PC) is connected to the automation device thereby enabling data and programs to be read or changed.

PC

Personal Computer: Programmable unit for the DIGSY plus ®.

Watch-Dog: Internal supervisory unit in computers and automation devices used to recognize system and memory errors. CPU

Central Processing Unit: Control and central unit in an automation device usually based on a microprocessor. It can read the application program code and run the instructions contained therein.

Cycle Time

Time required for the application program to run through once. continued

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Section 14.0 Page 7

Definitions; Symbols and Abbreviations

Cont'd: Coding Types and Number Systems ASCII

American Standard Code for Information Interchange: A standardized information processing code developed in the USA based on 7 bits = 0 – 127 (7-bit code), (extended ASCII-code of 8-bit = 0 - 255)

Digital

(Eng. Digit) is the representation of a continuos value or a physical quantity (e.g. voltage) in several levels as a numeric value. With regard to automation devices one also refers to “word processing” in which case a “word” is a number (e.g. 573).

Analogue

is the representation of a continuos physical quantity (e.g. current or voltage) which corresponds to the value of a proportional condition (e.g. rotational speed, routing, temperature, etc.) For an automation device this physical value converted into 1024 levels, for example (10-bit analogues-digital conversion). The digitalized value thus acts within a defined range (e.g. 0 ≡ 0 volts to 1024 ≡ 10 volts) in proportion to a certain input quantity (e.g. voltage). Conversely, by using a digital-analog conversion, a digitalized value can be converted into a continuous output signal (current, voltage).

Numeral

A value expressed in one digit: from 0 to 9 in the decimal system and 0-F in the hexadecimal system.

Number

Value consisting of one or more numeric characters.

Baud

Unit used in serial transmission of data: bits per second (bit/s).

Baud Rate

Modulation rate or transmission speed of serial transmission of binary numbers. The DIGSY plus uses a baud rate of 2400 baud for communication and down-loading.

Binary

Numbers, data and information which are exclusively expressed using the two values 0 and 1 are bivalent = binary dates and information, exclusive with the use of digits 0 and 1 (e.g. 1 = current 0 = no current).

Dual(Binary) Number (Dual = 2) is the simplest binary numeric expression. Each position is arranged according to increasing powers of 2. Example: 13463dec. = 0011 0100 1001 0111dual

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Electronic Control System ECS 14.2

Section 14.0 Page 8

How to Proceed due Maintenance and Installation

Keep in mind • - BE CAREFUL • - BE ALERT • - THINK ABOUT WHAT YOU ARE DOING Any PERSON doing any work in or around the machine must be familiar with the local SAFETY INSTRUCTIONS and with the specific SAFETY INSTRUCTIONS REGARDING TO HIS OCCUPATION. • Serious damage may happen at unqualified actions at the System or Unit or when not paying attention to the hints given in this manual or on labels at the units Qualified persons in sense of the safety relevant hints in this manual or on the product, are persons which are • either as project engaged person familiar with the safety concept for automatic control systems; • or as operating personal for the use of an automatic control system being instructed; • or having the authorization and occupation to put such systems into operation or doing repair work as well as having the authorization and occupation to put such systems/units into operation regarding the power circuits and there safety standards and, to earth and to mark it. continued

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Section 14.0 Page 9

How to Proceed due Maintenance and Installation

Cont’d.: • Serious damage may happen at irrelevant opening and improper repair. Open always the resp. circuit breaker before opening a unit. I/O – cables may only be connect or disconnect in a powerless state. A BIM module will be damaged while supplying an external power of 24VDC to the inputs and/ or outputs. If it is necessary for faultfinding or external unit checks the connection to the PLC has to be interrupted. • Without power interruption the interface cable are only allowed to be disconnect or connect when following preconditions are given: 1. The cable must be shielded and the shield must be connected to the cover of the plug-in connector. 2. A potential balance must be made by connecting the GND potential parts of the plug connector parts before connecting the cables. • Replace the fuses only by fuses which matches the values given in the technical dates

m

• Do not through batteries into open flame and do not solder at their cell body, explosion can occur (max. Temperature 100° C). Do not open and do not recharge batteries that contain lithium or mercury. Replace them by same type only! • Dispose batteries and accumulators as special waste.

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Section 14.0 Page 10

Meaning of the Status LED’s, Illust. Z 21431b The DIGSY plus performs by the function of the Status LED’s (5V and DIAG) and the so named Diagnostic Words* (DW1 up to DW256) many data and statuses. With a PC and the Program- and Diagnostic Software the. Diagnostic Words are visible on a monitor. The following sections explain the diagnostic possibilities more in detail. * Can be called-up by PC assistance only. Table: Statuses of the +5 V-LED and their meaning LED Effect Cause 5 V-LED Voltage green o.k. 5 V-LED CPU not working Supply red (RESET) < 4,65V DIAG-LED red 5 V-LED CPU not working Supply OFF (except the is missing LED is defect) Fuse S1 defect

Remedy Check the +24 V Supply if not o.k. *) Check the +24 Volt Replace the ** Fuse F1

LED defect (if DIAG LED is ON)

*)

others

*)

Watchdog in operation

*)

5 V-LED flashing red/green

cyclically new starts

red/ orange Continuos Reset Component fault *) ** Replacement only after co-ordination with Komatsu Mining Germany, Dept. 8124.1 *) = Return PLC to manufacturer continued

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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b Cont’d.: Table: State of the DIAG-LED and their meaning LED Effect Cause DIAG-LED Program Communication via green in operation Interface COM-SP not active (interrupted) COM-SP<╪> Text display DIAG-LED ProgramTemperature orange state inside housing unchanged too high +24 VCPU < 14 V

Increase the voltage

Accumulator voltage too low

Replace the accumulator module

Fixed operands deleted

Check the accumulator connections

SPS in start loop after voltage ON

wait

programming in operation EEPROM not Initialized

Stop the programming *1) Initialize EEPROM *1)

EEPROM- or RAM- fault

Initialize EEPROM *1) if the fault is still present *2) Start program *1)

DIAG-LED RED

DIAG-LED OFF

Program not running (stopped)

Program not running (except LED defect)

Program stopped

No Program otherwise LED defect DIAG ProgramCommunication via flashing state Interface COM-SP or COM-SK active unchanged Color State COM-SP⇔ Text depending Display COM-SK⇔ (PC) *1) Function of the Programming Software PROSYD *2) = Return PLC to manufacturer

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Remedy Check the cable connection and the Interface port

External cooling

Load program *1) *2)

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Section 14.0 Page 12

Short Circuit Marker -LED “MK” The short circuit markers are used to indicate a short of the outputs at an external short to GND. A “MK” marker will be initialized if by the user-program an output signal is given and at the same output is an external short present. The “MK” marker remains until (after short elimination) the control system is switched OFF and ON. See also Section 14.1.3 page 4

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Section 14.0 Page 13

Diagnostic for Temperature-Module “ANM” For the function control a two-color LED is used, visible at the front cover. The diagnostic - LED indicates following states: - LED red: System in reset mode or range overflow of one or more analogous outputs. - LED green:

Ordinary operation, no range overflow.

- LED red/green flashing (2Hz) Watch-dog timer response or cyclically overflow of one ore more analogous outputs.

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Section 14.0 Page 14

14.3 Front Connector Arrangement 14.3.1

Front Connector Arrangement, BIM Module (Digital Input / Output)

)

• .This is an example for the first Slot. Additional BIM Modules can be vary depend on configuration of the variable input/output port A2/E9/ A4E10, A6/E11, A8/E12 or A14/E21. • The configuration for the respective excavator is written in the EA-Configuration chart (EA-Belegungsliste) see Apendix.

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Symbol Input 1.1 Input 1.2 Input 1.3 Input 1.4 Input 1.5 Input 1.6 Input 1.7 Input 1.8 Input 9.1 Input 9.2 Input 9.3 Input 9.4 Input 9.5 Input 9.6 Input 9.7 Input 9.8 0 V (GND) Input 2.2 Input 2.4 Input 2.6 Input 2.8

Operand E 1.1 E 1.2 E 1.3 E 1.4 E 1.5 E 1.6 E 1.7 E 1.8 E 9.1 E 9.2 E 9.3 E 9.4 E 9.5 E 9.6 E 9.7 E 9.8 E2.2 E2.4 E2.6 E2.8

Definition Input 1 of the input group. 1 Input 2 of the input group. 1 Input 3 of the input group 1 Input 4 of the input group 1 Input 5 of the input group 1 Input 6 of the input group 1 Input 7 of the input group 1 Input 8 of the input group 1 Input 1 of the output group 2 Input 2 of the output group 2 Input 3 of the output group 2 Input 4 of the output group 2 Input 5 of the output group 2 Input 6 of the output group 2 Input 7 of the output group 2 Input 8 of the output group 2 Ground Input 2 of the input group 2 Input 4 of the input group 2 Input 6 of the input group 2 Input 8 of the input group 2

continued

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14.3 Front Connector Arrangement 14.3.1

Front Connector Arrangement, BIM Module (Digital Input / Output)

Cont’d.: Pin 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Symbol Output 1.1 Output 1.2 Output 1.3 Output 1.4 Output 1.5 Output 1.6 Output 1.7 Output 1.8 UE/A UE/A UE/A UCPU Input 2.1 Input 2.3 Input 2.5 Input 2.7 Output 1.1 Output 1.2 Output 1.3 Output1.4 Output1.5 Output 1.6 Output 1.7 Output 1.8 UE/A UE/A UE/A UCPU 0 V (GND)

Operand A 1.1 A 1.2 A 1.3 A 1.4 A 1.5 A 1.6 A 1.7 A1.8

E 2.1 E 2.3 E 2.5 E 2.7 A 1.1 A 1.2 A 1.3 A 1.4 A 1.5 A 1.6 A 1.7 A1.8

Definition Output 1 of the output group 1 Output 2 of the output group 1 Output 3 of the output group 1 Output 4 of the output group 1 Output 5 of the output group 1 Output 6 of the output group 1 Output 7 of the output group 1 Output 8 of the output group 1 Under Load Voltage Under Load Voltage Under Load Voltage DIGSY (plus)- Operation Voltage Input 1 of the input group 2 Input 3 of the input group 2 Input 5 of the input group 2 Input 7 of the input group 2 Output 1 of the output group 1 Output 2 of the output group 1 Output 3 of the output group 1 Output 4 of the output group 1 Output 5 of the output group 1 Output 6 of the output group 1 Output 7 of the output group 1 Output 8 of the output group 1 Under Load Voltage Under Load Voltage Under Load Voltage DIGSY (plus)- Operation Voltage. Ground / GND

UE/A = Voltage. Input / Output

There are two pins (two channels) parallel connected only for output A1.1 – A1.8 (the same for additional boards A3, A5, A7, A13). • • •

E1, E2,...E7, E13 and E14 input port fix configured. A2/E9, A4/E10, A6/E11, A8/E12 and A14/E21 variable input or output ports depend on software programming. A1/A9, A3/A10, A5/A11, A7/A12 and A13/A21 output ports fix configured.

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14.3 Front Connector Arrangement 14.3.2

)

Front Connector Arrangement, ANM-Module (Analogues Input) • .This is an example for the first ANM slot. Additional ANM modules configuration can be vary depend on configuration (temperature or pressure). • The configuration for the respective excavator is written in the EAConfiguration chart (EA-Belegungsliste) see Appendix and the respective electric diagram.

PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 •

PIN-NAME KR KG KA GND/ANA GND/ANA GND/ANA GND/ANA A1I A1U A2I A2U A3I A3U A4I A4U A4G A3G A2G GND/ANA GND/ANA GND/ANA E8G E7G E6G E5G

OPERAND

AW Z.1 AW Z.1 AW Z.2 AW Z.2 AW Z.3 AW Z.3 AW Z.4 AW Z.4

COMMENTARY Relay contact Relay contact Relay contact Analogous GND Analogous GND Analogous GND Analogous GND Current output 1 Tension output 1 Current output 2 Tension output 2 Current output 3 Tension output 3 Current output 4 Tension output 4 GND – Output 4 GND – Output 3 GND – Output 2 Analogues - GND Analogues - GND Analogues - GND GND – input 8 GND – input 7 GND – input 6 GND – input 5

All pins are internal connected continued

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Section 14.0 Page 17

14.3 Front Connector Arrangement 14.3.2

Front Connector Arrangement, ANM-Module (Analogues Input)

Cont’d.: PIN 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

PIN-NAME A1G 4U+E4G A2G E3G A3G E2G A4G E1G GND/ANA E8 GND/ANA E7 GND/ANA E6 GND/ANA E5 A1G E4 E4 E3 E3 E2 E2 E1 E1

OPERAND

EW Z+1.4 EW Z +1.3 EW Z +1.3 EW Z +1.3 EW Z.4 EW Z.4 EW Z.3 EW Z.3 EW Z.2 EW Z.2 EW Z.1 EW Z.1

COMMENTARY GND - Output 1 GND - Input 4 GND - Output 2 GND - Input 3 GND - Output 3 GND - Input 2 GND - Output 4 GND - Input 1 Analogues – GND Input (U/I) 8 Analogues – GND Input (U/I) 7 Analogues – GND Input (U/I) 6 Analogues – GND Input (U/I) 5 GND – Output 1 Input (U/I) 4 Input (U/I) 4 Input (U/I) 3 Input (U/I) 3 Input (U/I) 2 Input (U/I) 2 Input (U/I) 1 Input (U/I) 1

• All pins are internal connected

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Section 14.0 Page 18

14.3 Front Connector Arrangement 14.3.3

Ground connection of the Control Unit Attention: The complete shield of the analogous cable must be connected to the ground (GND) bolt of the PLC housing. This bolt must be connected to the X2 frame / machine ground by a cable (as short as possible) with 2,5 mm2 cross section. When using plug connectors with metal boxes and connected shield the additional complete shielding of the analogous cable with the ground bolt is not necessary. But attention must be played that the metal box is connected by screws with the PLC housing. The twisted signal lines are pair wise shielded and already via the 50-pol female part of the connector connected to ground. The single shielding at the free end of the cable must not be connected with earth.

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Section 14.0 Page 19

14.3 Front Connector Arrangement 14.3.4

Interface-connection COM SK / SP

Legend for illustration Z 21425a (Exemplary picture about what possible) (1) Text display (2) PLC (3) Plug socket “X27” (4) Laptop computer (5) Memory card system (6) Portable printer (7) Field dispatch system Cables: VL3 VL4 VL5 VL6 VL7 VL8

X27 to Laptop X27 to Memory Card System 24V Power supply to Memory Card System X27 to Portable Printer 24V Power supply to Portable Printer X27 to Field Computer System

Communication interface: COM-SK => Programming interface (Baud rate 19200) COM-SP => Communication with text display (Baud rate 9600)

)

• Data cables and/or communication systems are optional equipment. • For more detailed information see OPERATION MANUAL of the shovel and the Software Program for the individual Communication System

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14.4 Power supply 14.4.1 Operation Voltages +24 V, Illust. Z 21426 Study together with the relevant circuit diagram 50-pin SUB Connector: + 24 V CPU-Supply: GND: + 24 V I/O-Supply:

Pin 33 and 49 Pin 17 and 50 Pin 30 - 32, 46 – 48

This supply voltage is the operating voltage for the module outputs. It must be strong enough to carry the load current of all outputs. It is provided with a LOAD-DUMP protection to protect (for short times) wrong polarity and over voltage peaks. • Wrong polarity causes destroying of the module! • External 24 V supply to the outputs causes destroying of the module!

See next page for more information

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14.4 Power supply 14.4.2

Safety Precautions for Faultfinding, Illust. Z21427

• As already mentioned no external 24 V supply is allowed to the outputs of the BIM modules of the PLC. • If it is necessary while tracing faults, the cable to the PLC must be disconnected subsequent to a component check, thus as relays, solenoids or others by the PLC controlled components. Procedure: Study together with the relevant circuit diagram 1. Find the terminal between the component and the PLC. 2. Example terminal 8X2-280 for the solenoid valve 8Y6.1. 3. Disconnect the wire on one side of the terminal. 4. Now supply 24 V to the solenoid and check function of it. 5. Finally re-connect the wire to the terminal Binary Outputs A 2A-Short circuit proof Each single Output of the Output group can withstand a load of 2A, but the total load must not exceed 10 A. The Output group will be switched OFF if one of the Output becomes overloaded (> 2 A), the short circuit marker will be set and the “MK”- LED comes ON. (A1¿ MK1, A3¿ MK3, A5¿ MK5)

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Electronic Control System ECS

Section 14.0 Page 22

14.4 Power supply 14.4.3 CPU Voltage Range • Electrical requirements +24 supply volt • 14 V up to 36 V without any restrictions regarding the max. current consumption of 4 amps out of the +5 V logic voltage. • At voltage drops below 18 V the 2amps-outputs switched OFF due to safety reasons. The short circuit markers initiated. • The +24 V CPU is monitored on the CPU plus DB16.1 After the diagnostic bit “Under-voltage UCPU “ DB16.1 has been set, all access to the EEPROM memory of the CPU plus is blocked • A drop below 9V results in a reset. • During and after voltage drops according to DIN 40839 part 2 operates the CPU plus normally.

14.4.4 Electric classification The voltage supply meets the requirements according to: • ISO 7637-2 Automotive Technique 24V • DIN 0871-B • IEC 801-4 step 4, VDE 0843-4. • DIN/VDE 0470 part1 (old DIN 40050)

14.4.5 Fuse TR5 / 2.5AT IEC 127-3 Manufacturer Wickmann,

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Electronic Control System ECS

Section 14.0 Page 23

14.5 Function explanations with electrical diagram 14.5.1

General

Signal Status Voltage level: „1“ = 24 V* between E (Input) and GND „0“ =

0 V** between E (Input) and GND

* 13 V up to actual supply voltage ** 0V up to 5 V

The left half of the picture shows so named PULL-DOWN resistors and the right half PULL-UP resistors. The resistors are installed to get a low ohmical input. A system with contacts only leads to a (high ohmical) input if dust or moisture bridges the contacts. PULL-DOWN resistors are installed with a normal NC contact (means with a de-energized relay or normal closed switch contact) thus the ECS recognize a fault after switching ON the system. PULL-UP resistors are installed with a normal NO contact (means with a deenergized relay or normal open switch contact) thus the ECS recognize a fault after switching ON the system.

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Electronic Control System ECS

Section 14.0 Page 24

14.5 Function explanations with electrical diagram 14.5.2

Pressure Measuring (Hydraulic System), Illustration Z 22805 (study with the respective circuit diagram) (Program run see Flowchart)

Analogous Inputs: „EW 14.1“ for pressure sensor B87A (0 up to 500 bar) Measuring channel: 0......10 V Function: - Voltage supply for the pressure sensor: 24 V - Output voltages Ua (OUT+, pin 2) of the pressure sensors: Sensor 0 – 0,4 bar ¿ K= 25 V / bar Sensor 0 – 60 bar ¿ K= 0,1667 V / bar Sensor 0 – 500 bar ¿ K= 0,02 V / bar (Pressure sensors with +1 V Offset) Possible voltage checks: 24 V Supply between supply line 15 (start at circuit breaker) and GND. Output voltage OUT (pin 2) of the sensor between GND. Use respective circuit diagram for terminal numbers. * How to calculate the Output voltage Ua: Ua = output voltage proportional to the pressure input. P = input pressure K = calculation factor for the respective pressure sensor. Ua = (P x K) + 1 V Example for 200 bar and a 0 – 500 bar sensor: Ua = (200 x 0,02) + 1 V = 5 V

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Electronic Control System ECS

Section 14.0 Page 25

14.5.3 Temperature Measuring and trouble shooting Illustration Z22803a General: (study with the respective circuit diagram) The signal of the PT100 temperature probe can’t connect direct to the ANM – Module (Analog input of the PLC). A temperature transducer module change the PT100 signal (Ohm) into a suitable current (mA) signal for the ANM – Module. The temperature probe is connected with a four wire technique to compensate the line resistance of the long wire between the X2 switch board and the temperature probe. Analogous Inputs (eg.: Hydraulic oil temperature sensor B15) The temperature probe B15 is with 4-wire technology (distorting compensation) connected to the transducer U15 terminal 1, 4, 2, and 3 (measuring range: -50° C......+150° C). The output terminal 5 and 6 of the transducer is connected to the ECS analogues input „EW 2.1“ (input range 4 – 20 mA). The transducer need 24 V power supply via terminal 7 and 8 (+24V, ground). Function: The temperature transducer convert the measured values from the PT100 temperature probe into electrically standardized analog signals. With the four wire technique the length and the cross section of the wires are not important; because the electrical resistance of the two current lines gets compensated. The sensor is supplied with a low electrical current from the temperature transducer (I+ and I-). Additional to the temperature probe (PT100) resistance the line resistance influence the current “flow” what falsified the PT100 measurement. To compensate the line resistance there are two additional lines (U+ and U-) close to the PT100 connected. Via this lines the transducer measure exact a tension drop between in- and output of the PT100 probe witch is only created by the PT100 resistance. Because there is no current “flow” through this lines witch are influenced by the line resistance (compared to hydraulic system- it’s like a test hose with a pressure gauge). The module convert this tension drop into a current signal (4-20mA) which is proportional to the temperature. In the interest of proper function must the line resistance not exceed 50 Ω. Additional the lines must be shielded according to the standards. The picture shows the wiring of a PT100 probe to a temperature transducer in four wire technique. continued PC5500-6-D_Sec_14-0_rev2.doc

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Electronic Control System ECS 14.5.3

Section 14.0 Page 26

Temperature Measuring and trouble shooting, illustration Z22803a Cont’d.: Possible measurements PT100: Disconnect the wires at the resistor and measure the resistance across the resistor. Compare the measured resistance with the values given in the table on next page. If the value correspond to the temperature measured with an other temperature gauge the PT100 resistor is OK.; otherwise replace resistor. Wiring: Disconnect the wires at the resistor and inside X2-box at the temperature transducer terminal 1, 2, 3, and 4. Measure the line resistance to the ground. All single wire resistance must be the same. Transducer: Connect a Ampere-meter in line between terminal 5 of the transducer and the disconnected wire to the ECS. Select mA range and check the current. The value must compare to the PT100 resistance with the following calculation: I = [( 50 + t ) x 0,08 ] + 4 t = temperature [°C] (Check temperature via PT100 resistance and temperature chart next page) I = current [mA] to the ECS

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Electronic Control System

Section 14.0 Page 27

ECS 14.5 Function explanations with electrical diagram 14.5.4

Temperature – Resistance Chart PT100 Basic Values in Ohm according to DIN 43 76 For Measuring Resistor PT100

°C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80,31

79,91

79,51

79,11

78,72

78,32

77,92

77,52

77,13

76,73

-40

84,27

83,88

83,48

83,08

82,69

82,29

81,89

81,50

81,10

80,70

-30

88,22

87,83

87,43

87,04

86,64

86,25

85,85

85,46

85,06

84,67

-20

92,16

91,77

91,37

90,98

90,59

90,19

89,80

89,40

89,01

88,62

-10

96,09

95,69

95,30

94,91

94,52

94,12

93,73

93,34

92,95

92,55

0

100,00

99,61

99,22

98,83

98,44

98,04

97,65

97,26

96,87

96,48

°C

0

1

2

3

4

5

6

7

8

9

0

100,00

100,39

100,78

101,17

101,56

101,95

102,34

102,73

103,12

103,51

10

103,90

104,29

104,68

105,07

105,46

105,85

106,24

106,63

107,02

107,40

20

107,79

108,18

108,57

108,96

109,35

109,73

110,12

110,51

110,90

111,28

30

111,67

112,06

112,45

112,83

113,22

113,61

113,99

114,38

114,77

115,15

40

115,54

115,93

116,31

116,70

117,08

117,47

117,85

118,24

118,62

119,01

50

119,40

119,78

120,16

120,55

120,93

121,32

121,70

122,09

122,47

122,86

60

123,24

123,62 124,01, 124,39

124,77

125,16

125,54

125,92

126,31

126,69

70

127,07

127,45

127,84

128,22

128,60

128,98

129,37

129,75

130,13

130,51

80

130,89

131,27

131,66

132,04

132,42

132,80

133,18

133,56

133,94

134,32

90

134,70

135,08

135,46

135,84

136,22

136,60

136,98

137,36

137,47

138,12

100

138,50

138,88

139,26

139,64

140,02

140,39

140,77

141,15

141,53

141,91

110

142,29

142,66

143,04

143,42

143,80

144,17

144,55

144,93

145,31

145,68

120

146,06

146,44

146,81

147,19

147,57

147,94

148,32

148,70

149,07

149,45

130

149,82

150,20

150,57

150,95

151,33

151,70

152,08

152,45

152,83

153,20

140

153,58

153,95

154,32

154,70

155,07

155,45

155,82

156,19

156,57

156,94

150

157,31

157,69

158,06

158,43

158,81

159,18

159,55

159,93

160,30

16067

Example:

84 ° C

Ì 80° + 4° = 132,42 Ω

124,4 Ω

Ì 124,4 ≈ 124,39 = 60° + 3° = 63 °C

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Electronic Control System ECS

Section 14.0 Page 28

14.6 Hints for reading the functional flow charts 14.6.1

)

General

• Probably the best aid for trouble shooting is the confidence of knowing the system and how to use the ECS. Every component has a purpose in the system. The construction and operating characteristics of each one should be understood. • Use always the electric/hydraulic circuit diagram the flowchart and the operation manual for the specific machine.

1. Select on page 1 of the flow chart, (which contains the table of contents and the main program) the respective subprogram, for example the Power-Master lube system. 2. Components in the flow chart, have the same identification code as in the electric/hydraulic circuit diagram, as shown in cross reference list (page 2-4). For example: Relay K50 = ? On page 2 (cross reference list) you find out that relay K50 is shown on page 43 of the flowchart. 3. On each page of the respective subprogram you will find the functional description in plain text. In case of problems concerning reading the program loops, you may find answers in the frequently asked questions list on page 6 and 7 of the flow chart.

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Electronic Control System ECS

Section 14.0 Page 29

14.6 Hints for reading the functional flow charts 14.6.2

Example: Monitoring the X1-pressure for pump control, illustration Z25072 Grey shaded fields in the table below shows the normal way , used from the program, if the excavator is in “standard condition”. Item 1)

query Sensor or cable defect?

Yes No B85-X : 5 sec. < --6bar B85-X : 5 sec. : Voltage i.e. <1V at EW13.3 between 1V and 11V at or EW13.3 B85-X : 5 sec. > +55,3bar i.e. > 11V at EW13.3

⇓

2) 3)

_running_motor-x > 15 sec ? X1-pressure to high?

Fault message No 1190 Motor X is running for more than 15 seconds B85-X : 2 sec. > 40bar i.e. > 6,5V at EW13.3

⇓

Motor X is not running B85-X : 5 sec. : Voltage below 6,5V at EW13.3

Fault message No 962

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Section 15.0 Page 1

Lubrication System

Table of contents Page General Function Oscillation Cylinder and Control Block Adjustments One line system Electrical function Capacitive analog sensor for lubricant level monitoring Adjustments End Line pressure switch Injectors Function Pinion type (dummy wheel) system Electrical Function (dummy wheel) system Capacitive analog sensor for lubricant level monitoring Adjustments End-Of-Line Switch setting Injectors Components Hydraulically driven lube pump Injectors End-Line Switch In line Filter Vent valve (Solenoid valve)

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3 9 11 13 17 21 23 25 27 31 35 37 39 41 45 51 53 55

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Lubrication System

Section 15.0 Page 3

Lubrication System

General Function

Legend: illustration Z 24042a (1) Lubricant pump drive (Hydraulic cylinder) (2) Solenoid valve (Oil pressure supply) (3) Flow control valve (4) Pressure reducing valve (5) Hydraulic oil supply line (Pilot pressure) (6) Hydraulic oil return line (7) Vent valve (Solenoid valve, de-energized open to barrel) (8) Grease supply line to injectors (9) Lubricant level indication (capacitively analog sensor) (10) Lubricant barrel (11) Pump mechanism (12) Lubricant filter (13) Hydraulic pressure test plug (Operating pressure) (14) Lubricant pressure gauge (Operating pressure) (15) Vent line to barrel (16) Breather (17) Electrical terminal box

)

• Cylinder pressure must not exceed 650 psi (45 bar)

continued

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15.0 4

Lubrication System

Cont'd.

X-axis Y-axis

Time Lubricant supply line pressure

PI S+ PH SPR PT

Pressure Increasing Switch point ON of the end of line pressure switch Pressure Holding Switch point OFF of the end of line pressure switch Pressure Relieve Pause Time

Lubrication System

Function of a lubrication cycle

Section 15.0 Page 5

illustration Z24042c and Z22023a

PT-phase With the pump and controller system in a rest state a pre-set pause time interval occurs as determined by the PLC. Diagram position (a): A 24 VDC signal from the PLC activate solenoid valve (2) that opens and activate the lubrication pump. (*). As solenoid valve (2) opens hydraulic oil flows through the pressure reducing valve (4), it lowers the hydraulically pilot oil pressure to the operating range of the hydraulic driven lube pump. The reduced pilot oil pressure operates now the grease pump. The oil cylinder shuttle’s the grease cylinder at 18 – 20 double strokes per minute and delivering 612 – 680 cm³ (37.3 – 41.5 in³) of lubricant per minute (approx. 550 – 612 g / 19.64 – 21.45 oz.) At the same time a 24 V signal energize release valve (7), it close now the release line to the lubrication container. PI-phase With energized release valve (7) (*) and solenoid valve (2) the pump continues to cycle until maximum pressure is achieved and the injectors have metered lubricant to the bearings. S+ point, diagram position (b) When the maximum system pressure is reached the end-of-line switch (*) open its contact. In the normal application is the end-of-line switch adjusted to 185 bar (2630 psi. ).The pressure increasing phase is now finished. The open pressure switch (*) signals the controller to stop the pumping cycle and the controller terminates the signal to the solenoid valves (2) The pilot oil flow to the pump stops.

Solenoid valve 2 Y7, CLS

Vent valve 7 Y7a, CLS (1)

end-of-line switch B43, CLS

Y8a, CLS (2) Y9, SLS

Y9a, SLS

B46, SLS

SLS = Slew Ring Teeth Lubrication System CLS = Central Lubrication System (*) check respective circuit diagram continued 04.01.07 rev.6

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15.0 6

Lubrication System

Cont'd.

X-axis Y-axis

Time Lubricant supply line pressure

PI S+ PH SPR PT

Pressure Increasing Switch point ON of the end of line pressure switch Pressure Holding Switch point OFF of the end of line pressure switch Pressure Relieve Pause Time

Lubrication System

Section 15.0 Page 7

Cont'd.

PH-phase Release valve (7) is still energized to keep the pressure in the lubricant line for a fix adjusted time (pressure holding time normally 5 min). Diagram position (c): With expired pressure holding time vent valve (7) de-energize. It opens the release line to the lubricant container. The lubricant line pressure drop to zero so the injectors can recharge for the next lubricant injection. (PR-phase). PR-phase In the pressure relieve phase the end of line switch (*) move back to neutral contact position it signals the PLC that the lube pressure relieve phase is now active. PT-phase The system is now at rest (pause time), ready for another lube cycle and the sequence repeats itself.

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Lubrication System

Section 15.0 Page 9

Lubrication System

Oscillation Cylinder and Control Block, illustration Z 21174

Description: Oscillation cylinder (6) is auto directional controlled, non pressure related. This differential cylinder is connected to the pilot pressure suppliy line (P) and a tank line (T). The speed is contolled by a flow contol valve (3) and the maximum working pressure is controlled by a pressure reducing valve (2).

Function: The Oscillatin cylinder (6) starts as soon pilot pressure is send via the connection (P) to the control block (1). Design related the cylinder (6) retract always first after start or from any position the piston has stopped before. When the cylinder reaches the fully retracted position the flow will be redirected automatically and the cylinders moves in the extending position. If the cylinder comes to an stop in between the end positions weather the oil supply get stopped or the cylinder is hold back by a higher work resistance than the supply pressure, the cylinder changes direction and retracts.

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Lubrication System

Lubrication System

Adjustments

Section 15.0 Page 11

(illustration Z21175b):

Stroke speed For a sufficient lube pump operation 18 – 20 double strokes / min for the pump drive cylinder are required. Therefore the flow reducing valve (3) has to be adjusted accordingly. Procedure: 1. Remove electrical plug connection form the discharge valve (7), so no pressure built up will take place during the following test. 2. Start engine and run at high idle. 3. Switch “ON” the lube system annually and count strokes per minute, visible on the moving up and down of pipe (1). If adjustment is required: a. Loosen lock nut (3.1) b. Turn adjustment (3) until the right number of strokes is achieved. turn set screw ccw for more speed and cw to reduce the speed c. Tighten lock nut (3.1). Working pressure The pressure reducing valve (2) mounted in the oscillation control block reduce the supply pressure internally to maximal allowed 45 bar. The pressure ration is 6,55 to 1, that means 45 bar supply pressure result in 295 bar maximum lubricant pressure. At the end of line pressure switch the pressure should be 180 ±0,5 bar. With the lubricant line resistance and different lubricant viscosity the pressure at the lubricant pump output must be higher as 180 bar. For standard condition adjust the maximum pump pressure to 220 bar –250 bar, depend on lubricant line resistance and different lubricant viscosity. Procedure: 1. Disconnect quick coupling (8), so the pump will be blocked when started. 2. Start engine and run at high idle. 3. Switch “ON” the lube system manually, the gauge should show 220-250 bar. If adjustment is required: a. Loosen lock nut (2.1) d. Turn adjustment (2) until the right pressure is shown at the gauge. turn set screw ccw for lower pressure and cw to increase the pressure b. Tighten lock nut (2.1). c. Reconnect quick coupling (8).

) 04.01.07 rev.6

• If the required pressure can’t be adjusted, check adjustment of the 60 bar pilot pressure valve (X-4 pressure) at the filter and control panel in the machinery house. PC5500-6-D_Sec_15-0_rev1.doc

15.0 12

Lubrication System

Section 15.0 Page 13

Lubrication System

One line system Legend: illustr. Z 21176 (1) Lubricant pump drive (Hydraulic cylinder) (2) Solenoid valve (Oil pressure supply) (3) Flow control valve (4) Pressure reducing valve (5) Hydraulic oil supply line (Pilot pressure) (6) Hydraulic oil return line (7) Vent valve (Solenoid valve, de-energized open to barrel) (8) Grease supply line to injectors (9) Lubricant level indication (capacitively analog sensor) (10) Lubricant barrel (11) Pump mechanism (12) Lubricant filter (13) Hydraulic pressure test plug (Operating pressure) (14) Lubricant pressure gauge (Operating pressure) (15) Vent line to barrel (16) End-of-line switch (17) (Pressure check point) (18) Injector block (19) Lubricant feed line to bearing

Function: As soon as the adj. "Pause-Time" is finished the solenoid valves (2) and (7) are energized. The lubricant pump (1) start to pump lubricant in the lubricant supply line. By the function of the solenoid valve (7) the port to the vent line (15) (return line to the lubricant container) is closed, thus a pressure built up is possible. The high-pressure barrel pump (1) supplies lubricant into the supply line (8). It continuos through the lubricant filter (12) to the injectors (metering valves) (18).

)

• The picture shows an example only. The hole system includes much more injectors which are connected via pipes or hoses to the supply line (8).

In the Injectors the lubricant forced with full pump pressure via the feed lines (19) to the lube points. The actual operating pressure can be monitored at the pressure gauge (14) and checked at the pressure check point (17). continued

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Lubrication System

Lubrication System

Section 15.0 Page 15

Cont'd. Illustr. Z 21176 When all injectors pistons have reached there final position no more lubricant is accepted from the supply line which causes a pressure increase in the supply line (8). As soon as the pressure reaches the adjusted value of the end-of-line switch (16) the solenoid valves (2) de-energized and the lubricant pump switched Off. Depend on different factory settings vent valve (7) de energize together with solenoid valve (2) or after a fix adjusted time of max. 5 minutes. With de-energized solenoid valve (7) the port to vent line (15) ( return line to the lubricant container ) opened and release the lubricant and lubricant pressure in to the container. With the diminishing pressure in the main line the pistons of the injector (18) are forced by spring force in their initial position and the discharge chambers are filled with grease for the following lubrication cycle. The system is now prepared for a new lubrication cycle. The operation is reinitiated after the next "Pause Time" is elapsed. The proper build-up of the pressure in the supply line (8) is monitored by the end-of-line switch (16). If the pressure adjusted at the end-of-line switch will not reached within the adjusted "Monitoring Time" the fault message ”Central lubrication system fault” comes up on the text display and the system switch off

W )

04.01.07 rev.6

• Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area 1. The content of molybdenum must not exceed 5 %. 2. Only synthetic graphite allowed in graphite contained lubricants

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Lubrication System

Lubrication System

Section 15.0 Page 17

Electrical function. illustr. Z 21177a

)

• It follows an exemplary explanation for a central lubrication system for machines equipped with PLC System. For details see the circuit diagram of the respective machine. The Lubrication Systems are PLC controlled. No relay adjustment necessary. Central lubrication system controlling : The PLC from the ECS System controls the whole lubrication systems. The solenoid valves (Y7, Y7A or Y9, Y9A) on top of the lubrication stations are direct connected to digital output ports of the PLC. On a few machines there are additional relays between PLC outputs and the solenoid valves. Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a PLC internal time counter the grease system start a lubrication cycle. The lubrication cycle starts. If the pause time elapsed the PLC energize both solenoid valves (Y7, Y7A or Y9, Y9A) of the respective lubrication system. The engine must run in high idle. The pilot pump pressure activate now the lubrication pump and the lubrication pressure to the injectors increase. If the lubricant pressure reach the adjusted pressure of the end-of-line pressure switch (B43 or B46) its contact change and the PLC input signal change. The PLC de energize the respective lubrication pump supply valve (Y7 or Y9) to stop the pump. For the next 5 min the respective pressure releasing valve (Y7A or Y9A) are continued energized to keep the lubricant pressure still on a high level to be able all injectors inject the hole adjusted amount of lubricant. After the 5 min. pressure holding time the PLC de energize the respective pressure releasing valve (Y7A or5 Y9A) The lubricant pressure drops and the injectors move by spring load back in its initial position. A PLC internal counter is still counting a additional decreasing time to monitor the end-of-line pressure switch (B43 or B46) position. The PLC internal time counter is still counting up to the next lubrication cycle. The lubrication cycle is finished. continued

04.01.07 rev.6

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Lubrication System

Lubrication System

Section 15.0 Page 19

Cont'd: Illustr. Z 21177a The next lubrication cycle starts after the decreasing time and pause time has expired. With the switch S24 an additional lubrication can be carried out any time provided the end of line pressure switch (B43) contact is closed.

Monitoring: The orderly built-up of the pressure in the lubricant supply line is monitored by the end-of-line switch (B43 or B46). If the pressure adjusted at the end-of-line switch is not reached within the adjusted maximal increasing time the PLC switch off both solenoid (Y7 and Y7A or Y9 and Y9A) valves and send the fault message ”Central lubrication system fault” or “Swing ring lubrication system fault” to the text display at the dash board. If the excavator is still working additional four hours with faulty lubrication system the PLC stop the bucket function. This function is to prevent trouble depend on a lack of lubricant.

Continued

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Lubrication System

Section 15.0 Page 21

Lubrication System

Capacitive analog sensor for lubricant level monitoring, Illustration Z 21179f Task: A lubricant (L) maximum filling level monitoring is necessary to prevent an overfilling of the grease barrel (C) via the refilling system (only systems with refilling arm). The PLC use the analog level signal from the sensor to activate a lamp at the refilling arm just in the moment when the lubricant container is full. The sensor (S) is mounted on top of the lubricant container and reaches into the lubricant. The refilling level activate only a message at the text display to inform that the lubricant level must be filled up. The message comes up if the lubricant level reach 5% (910 mm from the cover plate). The minimum level stop the respective lubrication pump and release the lubricant pressure until the lubricant level reach the 0% mark (950 mm from the cover plate). It is necessary to stop the lubrication system with empty lubricant container to prevent the lubrication pump from running dry. With empty lubricant container the bucket motion will be switched off after four hours. Function: The capacitively level sensor (S) check continuous the lubricant level (L) and convert the capacitive signal into a current signal between 4 and 20mA. The current signal increase with increasing lubricant level. Use the specific electric circuit diagram and program flow charts.

)

04.01.07 rev.6

• The capacitively proximity switch used in our machines are programmed by the supplier and therefor no adjustment or settings required.

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Lubrication System

Lubrication System

Section 15.0 Page 23

Adjustments End line switch setting. Illustration Z 21180 1.

)

)

Connect pressure gauge to check point.

• Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test

2. 3. 4.

Start engine. Start a lube cycle with the dashboard switch S24. + Watch pressure gauge. At a pressure of 180 10 bar the end-line switch must react and the lubricants pump must stop.*

*

If at the same time the pressure shown at the built-in gauge is noted down, this pressure can be taken for later on checks as a reference pressure.

• 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly If re-setting is required: 5. Screw out screw 1 and take off cover 2. 6. Alter the spring tension with adjustment screw 3 that the switch operates at 180 bar. 7. Install cover 2 and screw 1.

continued

04.01.07 rev.6

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Section 15.0 Page 25

Lubrication System

Cont'd: Injectors, illustr. 21181: Series SL-1 injector: Lubricant output adjustable from 0.13 up to 1.3 cm³ per cycle. Hydraulic type fitting with screw type cover cap is provided for initial filling of feeder line, and may also be used for visual check of injector operation. Series SL-1 injectors incorporate a stainless steel visual indicator. Series SL-11 injector: Lubricant output adjustable from 0.82 up to 8.2 cm³ per cycle. Designed for systems where a high amount of lubricant is required. Principle of operation similar to series SL-1. Adjusting the lubricant output: 1. Loosen lock nut (C). 2. Turn adjusting screw (A) counterclockwise (OUT) for more lubricant output or clockwise (IN) for less lubricant output. 3. Tighten lock nut (C).

)

04.01.07 rev.6

• The max. lubricant output is adjusted if the indicator stem (B) moves not more further outwards

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Lubrication System

Function Pinion type (dummy wheel) system. Legend: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

Z 21183a Lubricant pump drive (Hydraulic cylinder) Solenoid valve Y9 (Oil pressure supply) Flow control valve Pressure reducing valve Hydraulic oil supply line (Pilot pressure) Hydraulic oil return line Vent valve Y9A (Solenoid valve, de-energized open) Grease supply line to injectors Lubricant level indication Lubricant barrel Pump mechanism Lubricant filter Hydraulic pressure test plug (Operating pressure) Lubricant pressure gauge (Operating pressure) Vent line to barrel Breather Electrical terminal box

Principle of operation: By the lubricant pump, the lubricant is supplied to the centered bore hole (B) of the lubrication type pinion (R). Bore hole (B) must be perfectly aligned to the center of the lubrication type pinion (A) to be greased, so that lubricant leaves the tooth flank always when the gear tooth is in contact. The grease outlet (D) of the lubricating type pinion is arranged at a different angle for each tooth, so that the lubricant is distributed in a uniform and perfect manners on the tooth flank of the drive pinion to be lubricated. Function: As soon as the adjusted "Pause-Time" elapse the solenoid valves (2 + 7). energized and the lubricant pump (1) start to pump lubricant. By the function of the solenoid valve (8) the port to the vent line (15) (return line to the lubricant container) closed, thus a pressure built up is possible. The high-pressure lubricant pump (1) supplies lubricant into the supply line (8). It continuos through the lubricant filter (12) to the injectors (metering valves) (18). •

The picture shows an example with one pinion only. There are also machines which have more lubrication type pinion (dummy wheel). By the injectors the lubricant is forced with full pump pressure via the feed line (19) to the centered bore hole (B) of the lubricating type pinion (R). continued

04.01.07 rev.6

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Lubrication System

Section 15.0 Page 29

Cont'd. Illustr. Z 21183a The actual operating pressure can be monitored at the pressure gauge (14) and checked at the pressure check point (17). When all injector pistons have reached there final position no more lubricant will accepted from the supply line (8) which causes a pressure increase in the supply line. Depend on different factory settings vent valve (7) de energize together with solenoid valve (2) or after a fix adjusted time of max. 5 minutes. With de-energized solenoid valve (7) the port to vent line (15) ( return line to the lubricant container ) opened and release the lubricant and lubricant pressure in to the container. With the diminishing pressure in the main line the pistons of the injector (18) are forced by spring force in their initial position and the discharge chambers fill up with grease for the following lubrication cycle. The system is prepared for the next lubrication cycle. The operation is reinitiated after the next "Pause Time". The proper build-up of the pressure in the supply line (8) is monitored by the end-of-line switch (16). If the pressure adjusted at the end-of-line switch is not reached within the adjusted "Monitoring Time" the fault message ”Slew ring gear lubrication system fault” is shown on the text display and the pump switch off.

• Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area

)

04.01.07 rev.6

1. The content of molybdenum must not exceed 5 %. 2. Only synthetic graphite must be contained in graphic lubricants

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Lubrication System

Lubrication System

Electrical function.

)

Section 15.0 Page 31

Illustration Z 21177b

• It follows an exemplary explanation for a Slew Ring Lubrication System for machines equipped with ECS System. For details see the circuit diagram of the respective machine. The Lubrication Systems are controlled through the ECS. No relay adjustment required. Slew Ring Gear Lubrication (Teeth lubrication) controlling : The PLC from the ECS System control the whole lubrication systems. Solenoid valves (Y9, Y9A) on top of the lubrication container are direct connected to digital output ports of the PLC. On few machines there are additional relays between PLC and the solenoid valves. Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a PLC internal time counter the grease system start a lubrication cycle. The lubrication cycle starts. If the pause time elapsed and the swing function was activated for a short time the PLC energize both solenoid valves ( Y9 , Y9A ). To start one swing ring gear lubrication cycle the swing function must be activated one time. If the lubricant pressure reach the adjusted pressure of the end of line pressure switch its contact change the position now the input port of the PLC change. The PLC de energize the respective lubrication pump supply valve (Y9) to stop the pump. For the next 5 min the respective pressure releasing valve (Y9A) are continued energized to keep the lubricant pressure still on a high level to be able all injectors inject the hole amount of lubricant. After 5 min. pressure holding time the PLC de energize the respective pressure releasing valve (Y9A) The lubricant pressure drops and the injectors move by spring load back in its initial position. A internal counter is still counting a additional decreasing time to prevent a to early new lubrication cycle with the risk of not complete reset injectors. The lubrication cycle is finished. continued

04.01.07 rev.6

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Section 15.0 Page 33

Cont'd: Illustr. Z 21177b The next lubrication cycle starts after the decreasing time and pause time has expired. With the switch S26 an additional lubrication can be carried out any time provided the end of line pressure switch (B46) contact is closed.

Monitoring: The orderly built-up of the pressure in the lubricant supply line is monitored by the end-of-line switch (B46). If the pressure adjusted at the end-of-line switch is not reached within the adjusted maximal increasing time the PLC switch off both solenoid valves (Y9 and Y9A) and send the fault message ”Central lubrication system fault” to the text display at the dash board. If the excavator was working additional four hours with faulty lubrication system the PLC stop the bucket function. This function is to prevent trouble depend on a lack of lubricant.

Continued

04.01.07 rev.6

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Section 15.0 Page 35

Lubrication System

Capacitive analog sensor for lubricant level monitoring, Illustration Z 21179f Task: A lubricant (L) maximum filling level monitoring is necessary to prevent an overfilling of the grease barrel (C) via the refilling system (only systems with refilling arm). The PLC use the analog level signal from the sensor to activate a lamp at the refilling arm just in the moment when the lubricant container is full. The sensor (S) is mounted on top of the lubricant container and reaches into the lubricant. The refilling level activate only a message at the text display to inform that the lubricant level must be filled up. The message comes up if the lubricant level reach 5% (910 mm from the cover plate). The minimum level stop the respective lubrication pump and release the lubricant pressure until the lubricant level reach the 0% mark (950 mm from the cover plate). It is necessary to stop the lubrication system with empty lubricant container to prevent the lubrication pump from running dry. With empty lubricant container the bucket motion will be switched off after four hours. Function: The capacitively level sensor (S) check continuous the lubricant level (L) and convert the capacitive signal into a current signal between 4 and 20mA. The current signal increase with increasing lubricant level. Use the specific electric circuit diagram and program flow charts.

)

04.01.07 rev.6

• The capacitively proximity switch used in our machines are programmed by the supplier and therefor no adjustment or settings required. If there is a new calibration required refer to Service News AH 04503

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Section 15.0 Page 37

Adjustments End of line switch setting, illustration Z 21185 1.

)

Connect pressure gauge to check point close to the end of line pressure switch.

• Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test

2. 3. 4. 5.

Block the swing function with the swing ring parking, use the switch at the dash board. Start engine. Start a lube cycle with the dashboard switch S26 and activate for a short time the swing function to the left or right. + Watch pressure gauge. At a pressure of 180 10 bar the end of line switch must react and the lubricants pump must be stopped.*

*

)

If at the same time the pressure shown at the built-in gauge is noted down, this pressure can be taken for later on checks as a reference pressure. But be careful this pressure is higher than the pressure shown at the test gauge because of the long distance between pump and end of the supply line.

• 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly If re-setting is required: 6. 7. 8.

Screw out screw (1) and take off cover (2). Alter the spring tension with adjustment screw (3) that the switch operates at 180 bar. Install cover (2) and screw (1). continued

04.01.07 rev.6

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Section 15.0 Page 39

Lubrication System

Cont'd: Injectors, illustr. 21181: Series SL-1 injector: Lubricant output adjustable from 0.13 up to 1.3 cm³ per cycle. Hydraulic type fitting with screw type cover cap is provided for initial filling of feeder line, and may also be used for visual check of injector operation. Series SL-1 injectors incorporate a stainless steel visual indicator. Series SL-11 injector: Lubricant output adjustable from 0.82 up to 8.2 cm³ per cycle. Designed for systems where a high amount of lubricant is required. Principle of operation similar to series SL-1. Adjusting the lubricant output: 1. Loosen lock nut (C). 2. Turn adjusting screw (A) counterclockwise (OUT) for more lubricant output or clockwise (IN) for less lubricant output. 3. Tighten lock nut (C).

)

04.01.07 rev.6

• The max. lubricant output is adjusted if the indicator stem (B) moves not more further outwards

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Section 15.0 Page 41

Lubrication System

Hydraulically driven “Power Master III” lube pump, illustr. Z 21186 Legend: (more detailed see parts list 90-0781) Fig.: 12 (P) Hydraulic oil supply (T) Hydraulic oil return (Pr) Pressure reducing valve (Q) Flow regulator valve (1) Hydr. actuator piston (2) Oscillator control block (3) Pump tube (4) Breather port (5) Grease outlet port (6) Piston rod (7) Breather plug (8) Ball, outlet check valve (9) Ball and seat, check valve (10) Main piston and plunger (11) Piston rod set (12) Inlet valve (13) Scoop piston (14) Grease inlet HINT: Loss of pressure or to short pump strokes indicates: A

Foreign material lodged under Piston Ball Checks or between Upper and Lower Inlet Checks (8 + 9). To correct this problem the upper lower inlet checks (8 + 9) and inlet valve (13) should be removed and cleaned thoroughly. If sealing surfaces between upper and lower inlet checks (8 + 9) are rough or pitted, replace or resurface if damages are slight.

B

Shovel rod packing worn or damaged. Before installing new packing, inspect surface of shovel rod and replace if rough or pitted. Do not grip shovel rod when disassembling lower pump tube assembly. continued

04.01.07 rev.6

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Lubrication System

Section 15.0 Page 43

Trouble shooting, illustr. Z 21186 If the following procedures do not correct the problem, contact a factory authorized service center. PROBLEMS: CYLINDER PRESSURE GAUGE DOES NOT REGISTER PRESSURE. A. Check system pressure to pump. B. Check for 24 VDC signal at solenoids. C. Pressure reducing valve set too low. Check pressure. PUMP PRESSURE BUILT UP VERY SLOWLY OR NOT AT ALL. A. No oscillation of pump, check oscillation control block (2). B. Pressure reducing valve (Pr) may be setting too low. C. Grease viscosity may be too high for the actual ambient temperature. D. If pressure is not building up at all, solenoid valve (pilot pressure supply solenoid) may be inoperative. E. Pump piston (11) and inlet checks may have foreign matter trapped causing leakage. Remove, inspect and clean if necessary. F. Inspect sealing surface on upper and lower checks (8 + 9). Replace if rough or pitted. G. Replace scoop piston if rough or pitted. Replace rod packing (15) if it is leaking. H. Inspect lubricant supply line for leaks or breaks.

04.01.07 rev.6

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Section 15.0 Page 45

Lubricant Injector (metering valve), illustr. Z 21187

TASK: A readjusted (at the injector) volume of grease is pushed with the injectors to the bearings or to the progressive distributors. Design: (model SL1) (01+02) Metering valve, assy. (03+04) Injector bar (05) Adjusting screw (06) Nut (07) Plug screw (08) Seal ring (09) Disk (10) Seal ring (11) Bolt with nut (12) Disk (13) Seal ring (14) Piston (15) Compression spring (16) Spring retainer (17) Seal ring (18) Disk (19) Seal ring (20) Disk (21) Piston (22) Seal (23) Adapter bolt (24) Valve housing (25) Union

Design: (model SL11) (01) Metering valve, assy. (02) Adjusting screw (03) Nut (04) Plug screw (05) O-ring (06) Disk (07) Seal ring (08) Disk (09) Guide (10) Indicator pin (11) Seal ring (12) Piston (13) Seal ring (14) Pin (15) Compression spring (16) Spring retainer (17) Bolt with piston (18) Seal ring (19) Valve housing (20) Union

continued

04.01.07 rev.6

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Section 15.0 Page 47

Cont'd: Function: illustr. Z 21188 Pos. 1

The injector piston (2) is in its normal or rest position. The discharge chamber (9) is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant the slide valve (4) is about to open the passage (5) leading to the piston.

Pos. 2

When the slide valve (4) uncovers the passage lubricant is admitted to the top of piston (2) forcing the piston down. The piston force lubricant from the discharge chamber (9) through the outlet port (10) to the bearing or progressive distributor. The lubricant pressure at the bearing or the progressive distributor is always the same as the pump pressure.

Pos. 3

As the piston completes its stroke, it pushes the slide valve (4) past the passage, cutting off further admission of lubricant to the passage. Piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved) at the pump. This is indicated by the injector stem (8). (fully in)

Pos. 4

After pressure is relieved the compressed spring (3) moves the slide valve (4) to closed position. This opens the port from the measuring chamber and permits the lubricant to be transferred from the top of the piston to the discharge chamber. This is also indicated by the injector stem (8) (fully out) continued

04.01.07 rev.6

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Section 15.0 Page 49

Cont'd: Connection of one or more injectors, illustr. Z 21189 The injectors are designed so that the lubricant out- put of two or more injectors can be combined without the use of tees. The injector body (1) has two outlets ports (a + b), one above the other. The connector tube (2) is used to couple the injectors together. Lubricant from injector No. 1 is directed through the connector tube into the discharge chamber of injector No. 2 but simply combines with the lubricant delivery of injector No. 2 to yield double output from the out- let of injector No. 2. This does not interfere with the operation of injector No. 2.

04.01.07 rev.6

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Section 15.0 Page 51

End-line switch

TASK: The pressure control unit is monitoring and controlling the centralized lube system.

Design: (1) (2) (3) (4)

illustr. Z 21190 Piston Disk Switch contact Spring

(5) (6) (7) (8)

Pressure switch Adjustment sleeve Connection to pressure circuit Electrical connection

Function: One pressure control unit is installed in each greasing circuit. The grease pressure, produced by the pneumatic barrel pump, is with his force also at the piston (1) If the grease pressure reaches the tension of the spring (4), the piston (1) is forced against the disk (2), thus that the contacts of the switch (5) are operated and a electric impulse is given to the electronic control unit of the greasing equipment. Adjusting has to be done with the sleeve (6). Clockwise - higher switch point, counterclockwise - lower switch point.

04.01.07 rev.6

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In-line filter

Legend: illustr. Z 21191 (1) Plug screw (2) Plug screw gasket (3) Filter element (4) Filter housing (5) Spring guide (6) Spring • Before servicing stop the motor and remove ignition key in order to prevent operation of the system.

)

• A clogged filter element will be moved against the spring force by the lubricant pressure and unfiltered lubricant reaches the system!

For maintenance proceed as follows: 1. Remove plug screw (1) using 36 mm width wrench. 2. Remove plug screw gasket (2). 3. Take out spring (6), spring guide (5) and filter element (3). 4. Clean all parts and inspect for damage. Replace as necessary. 5. Insert filter element, spring guide (5) and spring. 6. Install plug screw (1) with gasket (2) and tighten with a wrench.

)

04.01.07 rev.6

• For service intervals see SERVICE LITERATURE chapter 6.6

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Section 15.0 Page 55

Vent valve, illustr. Z 21192 TASK: By the function of the vent valve the lubricant supply line gets pressurerelieved, after the lubrication cycle is finished. The injector pistons can move into their initial position. Legend: (Valve VP1 S-G). Fig. 19 (1) Solenoid (2) Valve assy. (3) Solenoid stem (4) Lever (5) Main valve cone (6) Auxiliary valve cone (7) Reset spring Function: The solenoid gets energized. When the lubrication starts. The connection from A to B gets closed, thus a pressure build-up is possible. The solenoid gets de-energized, as soon as the lubrication cycle is finished. This causes opening of the connection A to B, thus the supply line to the lubricant barrel is open. The lubricant flows from A to B or vice versa along the main valve cone (5).

04.01.07 rev.6

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Section 15.0 Page 45

Lubricant Injector (metering valve), illustr. Z 21187

TASK: A readjusted (at the injector) volume of grease is pushed with the injectors to the bearings or to the progressive distributors. Design: (model SL1) (01+02) Metering valve, assy. (03+04) Injector bar (05) Adjusting screw (06) Nut (07) Plug screw (08) Seal ring (09) Disk (10) Seal ring (11) Bolt with nut (12) Disk (13) Seal ring (14) Piston (15) Compression spring (16) Spring retainer (17) Seal ring (18) Disk (19) Seal ring (20) Disk (21) Piston (22) Seal (23) Adapter bolt (24) Valve housing (25) Union

Design: (model SL11) (01) Metering valve, assy. (02) Adjusting screw (03) Nut (04) Plug screw (05) O-ring (06) Disk (07) Seal ring (08) Disk (09) Guide (10) Indicator pin (11) Seal ring (12) Piston (13) Seal ring (14) Pin (15) Compression spring (16) Spring retainer (17) Bolt with piston (18) Seal ring (19) Valve housing (20) Union

continued

07.04.09 rev.2

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Section 15.0 Page 47

Cont'd: Function: illustr. Z 21188 Pos. 1

The injector piston (2) is in its normal or rest position. The discharge chamber (9) is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant the slide valve (4) is about to open the passage (5) leading to the piston.

Pos. 2

When the slide valve (4) uncovers the passage lubricant is admitted to the top of piston (2) forcing the piston down. The piston force lubricant from the discharge chamber (9) through the outlet port (10) to the bearing or progressive distributor. The lubricant pressure at the bearing or the progressive distributor is always the same as the pump pressure.

Pos. 3

As the piston completes its stroke, it pushes the slide valve (4) past the passage, cutting off further admission of lubricant to the passage. Piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved) at the pump. This is indicated by the injector stem (8). (fully in)

Pos. 4

After pressure is relieved the compressed spring (3) moves the slide valve (4) to closed position. This opens the port from the measuring chamber and permits the lubricant to be transferred from the top of the piston to the discharge chamber. This is also indicated by the injector stem (8) (fully out) continued

07.04.09 rev.2

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Section 15.0 Page 49

Cont'd: Connection of one or more injectors, illustr. Z 21189 The injectors are designed so that the lubricant out- put of two or more injectors can be combined without the use of tees. The injector body (1) has two outlets ports (a + b), one above the other. The connector tube (2) is used to couple the injectors together. Lubricant from injector No. 1 is directed through the connector tube into the discharge chamber of injector No. 2 but simply combines with the lubricant delivery of injector No. 2 to yield double output from the out- let of injector No. 2. This does not interfere with the operation of injector No. 2.

07.04.09 rev.2

PC5500-6-D_Sec_15-0_rev2.doc

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Section 15.0 Page 51

End-line switch

TASK: The pressure control unit is monitoring and controlling the centralized lube system.

Design: (1) (2) (3) (4)

illustr. Z 21190 Piston Disk Switch contact Spring

(5) (6) (7) (8)

Pressure switch Adjustment sleeve Connection to pressure circuit Electrical connection

Function: One pressure control unit is installed in each greasing circuit. The grease pressure, produced by the pneumatic barrel pump, is with his force also at the piston (1) If the grease pressure reaches the tension of the spring (4), the piston (1) is forced against the disk (2), thus that the contacts of the switch (5) are operated and a electric impulse is given to the electronic control unit of the greasing equipment. Adjusting has to be done with the sleeve (6). Clockwise - higher switch point, counterclockwise - lower switch point.

07.04.09 rev.2

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Section 15.0 Page 53

In-line filter

Legend: illustr. Z 21191 (1) Plug screw (2) Plug screw gasket (3) Filter element (4) Filter housing (5) Spring guide (6) Spring • Before servicing stop the motor and remove ignition key in order to prevent operation of the system.

)

• A clogged filter element will be moved against the spring force by the lubricant pressure and unfiltered lubricant reaches the system!

For maintenance proceed as follows: 1. Remove plug screw (1) using 36 mm width wrench. 2. Remove plug screw gasket (2). 3. Take out spring (6), spring guide (5) and filter element (3). 4. Clean all parts and inspect for damage. Replace as necessary. 5. Insert filter element, spring guide (5) and spring. 6. Install plug screw (1) with gasket (2) and tighten with a wrench.

)

07.04.09 rev.2

• For service intervals see SERVICE LITERATURE chapter 6.6

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Section 15.0 Page 55

Vent valve, illustr. Z 21192 TASK: By the function of the vent valve the lubricant supply line gets pressure-relieved, after the lubrication cycle is finished. The injector pistons can move into their initial position. Legend: (Valve VP1 S-G). Fig. 19 (1) Solenoid (2) Valve assy. (3) Solenoid stem (4) Lever (5) Main valve cone (6) Auxiliary valve cone (7) Reset spring Function: The solenoid gets energized. When the lubrication starts. The connection from A to B gets closed, thus a pressure build-up is possible. The solenoid gets de-energized, as soon as the lubrication cycle is finished. This causes opening of the connection A to B, thus the supply line to the lubricant barrel is open. The lubricant flows from A to B or vice versa along the main valve cone (5).

07.04.09 rev.2

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HYDRAULIC MINING EXCAVATOR PC5500E-6

Machine model PC5500E-6

Serial numbers 15016 and up

40 Troubleshooting Troubleshooting procedures

® Copyright 2010 KOMATSU MINING GERMANY GmbH

PC5500-6E

1

2

PC3000-6D

SHOP MANUAL

HYDRAULIC EXCAVATOR PC5500E-6

Machine model PC5500E-6

Serial numbers 15016 and up

50 Disassembly and assembly

PC5500-6

1

Overview

Overview 1 INTRODUCTION 2 SAFETY 3 SUPERSTRUCTURE 4 UNDERCARRIAGE 5 ATTACHMENT 6 SERVICE INFORMATION 7 TOOLS CATALOGUE 8 PARTS & SERVICE NEWS 9 SUPPLIER’S DOCUMENTATION

Version 2010/1

PC5500-6E

Overview - 1

Overview

Overview - 2

PC5500-6E

Version 2010/1

Table of contents

Table of contents 1 INTRODUCTION........................................................................................ 1-1 1.1

CONTENTS OF THE BINDER ........................................................................................................... 1-2

1.2

FOREWORD ...................................................................................................................................... 1-3 1.2.1 SERVICE ............................................................................................................................... 1-4

2 SAFETY ..................................................................................................... 2-1 2.1

GENERAL INFORMATION ................................................................................................................ 2-2 2.1.1 METHOD OF USING THIS MANUAL .................................................................................... 2-2

2.2

SAFETY INSTRUCTIONS.................................................................................................................. 2-4 2.2.1 GENERAL PRECAUTIONS ................................................................................................... 2-4 2.2.2 PREPARATIONS BEFORE WORK ....................................................................................... 2-6 2.2.3 PRECAUTIONS DURING WORK.......................................................................................... 2-7 2.2.3.1 PRECAUTIONS WITH HIGH PRESSURE OIL ..................................................... 2-9 2.2.4 WARNING OF SPECIAL DANGERS................................................................................... 2-10 2.2.4.1 ELECTRICAL ENERGY ....................................................................................... 2-10 2.2.4.2 GAS, DUST, STEAM AND SMOKE..................................................................... 2-11 2.2.4.3 NOISE .................................................................................................................. 2-11 2.2.4.4 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES ................................... 2-11 2.2.4.5 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT................ 2-12 2.2.4.6 HEAT.................................................................................................................... 2-12 2.2.4.7 HEIGHT................................................................................................................ 2-12 2.2.5 SPECIAL SAFETY EQUIPMENT ........................................................................................ 2-15 2.2.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ..................................................................... 2-15 2.2.5.2 INSTRUCTIONS FOR USE ................................................................................. 2-17 2.2.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS........................................... 2-19 2.2.5.4 INSTARUCTIONS FOR USING THE FALL ABSORBER .................................... 2-21 2.2.6 SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION ............................................... 2-22 2.2.7 SAFETY HINTS FOR LIFTING HEAVY PARTS.................................................................. 2-25 2.2.8 SAFETY HINTS FOR WIRE ROPES................................................................................... 2-25 2.2.9 SAFETY HINTS FOR SLING ACCESSORY ....................................................................... 2-27

2.3

GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM ................................................. 2-28

2.4

EXPLANATION OF ABBREVIATIONS ........................................................................................... 2-31

3 SUPERSTRUCTURE................................................................................. 3-1 3.1

SUPERSTRUCTURE OVERVIEW ..................................................................................................... 3-2

3.2

SERVICE CRANE (OPTIONAL) ........................................................................................................ 3-5 3.2.1 REMOVAL OF THE SERVICE CRANE ................................................................................. 3-5 3.2.2 REPLACEMENT OF THE SERVICE CRANE ....................................................................... 3-7

3.3

ELECTRIC MOTORS ......................................................................................................................... 3-9 3.3.1 PREPARATORY WORK FOR ELECTRIC MOTOR REMOVAL ........................................... 3-9 3.3.2 REMOVAL OF THE REAR ELECTRIC MOTOR (MOTOR 1) ............................................. 3-13 3.3.3 REPLACEMENT OF THE REAR ELECTRIC MOTOR (MOTOR 1) .................................... 3-17 3.3.4 REMOVAL OF THE FRONT ELECTRIC MOTOR (MOTOR 2) ........................................... 3-22 3.3.5 REPLACEMENT OF THE FRONT ELECTRIC MOTOR (MOTOR 2).................................. 3-22

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3.3.6 3.3.7

FINAL ALIGNMENT OF THE ELECTRIC MOTORS ........................................................... CAPACITOR ASSEMBLIES ................................................................................................ 3.3.7.1 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 1) ............................... 3.3.7.2 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 1) ...................... 3.3.7.3 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 2) ............................... 3.3.7.4 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 2) ......................

3-23 3-26 3-27 3-29 3-29 3-29

3.4

BATTERIES...................................................................................................................................... 3-30 3.4.1 REMOVAL OF THE BATTERIES ........................................................................................ 3-30 3.4.2 REPLACEMENT OF THE BATTERIES ............................................................................... 3-32

3.5

FLEXIBLE COUPLING..................................................................................................................... 3.5.1 VULKAN COUPLING ........................................................................................................... 3.5.1.1 REMOVAL OF THE VULKAN COUPLING .......................................................... 3.5.1.2 REPLACEMENT OF THE VULKAN COUPLING .................................................

3-34 3-34 3-35 3-37

3.6

PTO................................................................................................................................................... 3.6.1 MAIN PUMPS ...................................................................................................................... 3.6.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL ................................... 3.6.1.2 REMOVAL OF MAIN PUMPS .............................................................................. 3.6.1.3 REPLACEMENT OF MAIN PUMPS..................................................................... 3.6.2 PTO OIL PUMP (AUXILIARY PUMP) .................................................................................. 3.6.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP).......................................... 3.6.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP) ........................ 3.6.3 OIL CIRCULATION PUMP (AUXILIARY PUMP) ................................................................. 3.6.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP)......................... 3.6.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) ....... 3.6.4 PUMP DISTRIBUTOR GEARBOX (PTO)............................................................................ 3.6.4.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ........................... 3.6.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ..................

3-38 3-38 3-39 3-42 3-44 3-46 3-46 3-48 3-49 3-49 3-51 3-52 3-54 3-58

3.7

HYDRAULICS .................................................................................................................................. 3.7.1 HYDRAULIC COOLER FAN DRIVE PUMP......................................................................... 3.7.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP ........................ 3.7.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP............... 3.7.2 HYDRAULIC COOLER FAN ASSEMBLY............................................................................ 3.7.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY ................................... 3.7.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY .......................... 3.7.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR................................. 3.7.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR ....................... 3.7.3 HYDRAULIC OIL COOLERS ............................................................................................... 3.7.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS .............................................. 3.7.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS ..................................... 3.7.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME ................................... 3.7.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME .......................... 3.7.4 MAIN RELIEF VALVES (MRV) ............................................................................................ 3.7.4.1 REMOVAL OF THE MRV..................................................................................... 3.7.4.2 REPLACEMENT OF THE MRV .......................................................................... 3.7.5 PILOT OIL PUMP (GEAR PUMP)........................................................................................ 3.7.5.1 REMOVAL OF THE PILOT OIL PUMP ................................................................ 3.7.5.2 REPLACEMENT OF THE PILOT OIL PUMP....................................................... 3.7.6 MAIN GATE VALVE............................................................................................................. 3.7.6.1 REMOVAL OF THE MAIN GATE VALVE ............................................................ 3.7.6.2 REPLACEMENT OF THE MAIN GATE VALVE ...................................................

3-59 3-59 3-60 3-63 3-64 3-65 3-68 3-70 3-72 3-74 3-76 3-80 3-82 3-86 3-87 3-87 3-88 3-89 3-89 3-91 3-92 3-92 3-93

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3.7.7

HYDRAULIC OIL RESERVOIR ........................................................................................... 3-94 3.7.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR........................................... 3-96 3.7.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR ............................... 3-102 3.7.8 MAIN CONTROL VALVE BLOCKS ................................................................................... 3-105 3.7.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS................................... 3-114 3.7.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS ......................... 3-120 3.7.9 SERVICE LINE RELIEF VALVES (SRV) ........................................................................... 3-121 3.7.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK .............................. 3-121 3.7.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS................... 3-124 3.7.10 ANTI-CAVITATION VALVES (ACV) ................................................................................. 3-126 3.7.10.1 REMOVAL OF ACV ON MANIFOLD ................................................................. 3-127 3.7.10.2 REPLACEMENT OF THE ACV ON MANIFOLD................................................ 3-132 3.7.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS ............................ 3-133 3.7.10.4 REPLACEMENT OF THE ACV ON MAIN CONTROL VALVE BLOCKS .......... 3-136 3.7.11 THROTTLE CHECK VALVES .......................................................................................... 3-138 3.7.11.1 REMOVAL OF THROTTLE CHECK VALVES ................................................... 3-140 3.7.11.2 REPLACEMENT OF THROTTLE CHECK VALVES.......................................... 3-143 3.7.12 MANIFOLD ........................................................................................................................ 3-144 3.7.12.1 REMOVAL OF THE MANIFOLD ........................................................................ 3-144 3.7.12.2 REPLACEMENT OF THE MANIFOLD .............................................................. 3-146 3.8

SLEW SYSTEM.............................................................................................................................. 3.8.1 SLEW GEAR...................................................................................................................... 3.8.1.1 REMOVAL OF THE SLEW GEAR ..................................................................... 3.8.1.2 REPLACEMENT OF THE SLEW GEAR............................................................ 3.8.2 SWING MOTOR ................................................................................................................ 3.8.2.1 REMOVAL OF THE SWING MOTOR ................................................................ 3.8.2.2 REPLACEMENT OF THE SWING MOTOR ...................................................... 3.8.3 SLEW PARKING BRAKE .................................................................................................. 3.8.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) ............. 3.8.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) .......... 3.8.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) ....................... 3.8.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) .............. 3.8.4 DYNAMIC SLEW BRAKE .................................................................................................. 3.8.4.1 REMOVAL OF THE SLEW BRAKE VALVE ...................................................... 3.8.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE ............................................. 3.8.5 SWING CIRCLE................................................................................................................. 3.8.5.1 REMOVAL OF THE SWING CIRCLE ................................................................ 3.8.5.2 REPLACEMENT OF THE SWING CIRCLE.......................................................

3-147 3-148 3-149 3-153 3-158 3-159 3-162 3-165 3-167 3-170 3-173 3-176 3-180 3-183 3-185 3-186 3-189 3-192

3.9

LUBRICATION SYSTEM ............................................................................................................... 3.9.1 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL) ........................................... 3.9.1.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY ................................ 3.9.1.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY ....................... 3.9.2 LUBRICATION PUMP STATION....................................................................................... 3.9.2.1 REMOVAL OF THE LUBRICATION PUMP STATION ...................................... 3.9.2.2 REPLACEMENT OF THE LUBRICATION PUMP STATION ............................. 3.9.3 REMOVAL OF THE LUBRICATION PUMP....................................................................... 3.9.4 REPLACEMENT OF THE LUBRICATION PUMP .............................................................

3-198 3-198 3-200 3-202 3-204 3-208 3-210 3-211 3-213

3.10 OPERATOR’S CAB ....................................................................................................................... 3-214 3.10.1 REMOVAL OF THE OPERATOR’S CAB .......................................................................... 3-217 3.10.2 REPLACEMENT OF THE OPERATOR’S CAB ................................................................. 3-222 Version 2010/1

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3.10.3 VISCOUS CAB-MOUNTS.................................................................................................. 3.10.3.1 REMOVAL OF THE VISCOUS CAB-MOUNTS ................................................. 3.10.3.2 REPLACEMENT OF THE CAB-MOUNTS ......................................................... 3.10.4 FRONT WINDOW (WINDSCREEN) .................................................................................. 3.10.4.1 REMOVAL OF THE FRONT WINDOW ............................................................. 3.10.4.2 REPLACEMENT OF THE FRONT WINDOW .................................................... 3.10.5 OPERATOR’S SEAT ......................................................................................................... 3.10.5.1 REMOVAL OF THE OPERATOR’S SEAT ......................................................... 3.10.5.2 REPLACEMENT OF THE OPERATOR’S SEAT ............................................... 3.10.6 ECS.................................................................................................................................... 3.10.6.1 REMOVAL OF THE ECS TEXT DISPLAY ......................................................... 3.10.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY ...............................................

3-224 3-224 3-226 3-228 3-228 3-229 3-230 3-230 3-231 3-232 3-232 3-232

3.11 CAB BASE (MEDIUM VOLTAGE SWITCH CABINET)................................................................. 3.11.1 REMOVAL OF THE CAB BASE ........................................................................................ 3.11.2 REPLACEMENT OF THE CAB BASE ............................................................................... 3.11.3 PUMP CONTROLLER ....................................................................................................... 3.11.3.1 REMOVAL OF THE PUMP CONTROLLER....................................................... 3.11.3.2 REPLACEMENT OF THE PUMP CONTROLLER .............................................

3-233 3-233 3-236 3-238 3-238 3-239

3.12 ACCESS LADDER ......................................................................................................................... 3.12.1 REMOVAL OF THE ACCESS LADDER ............................................................................ 3.12.2 REPLACEMENT OF THE ACCESS LADDER................................................................... 3.12.3 REMOVAL OF THE ACCESS LADDER CYLINDER......................................................... 3.12.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER ...............................................

3-240 3-243 3-245 3-247 3-249

3.13 COUNTERWEIGHT........................................................................................................................ 3-250 3.13.1 REMOVAL OF THE COUNTERWEIGHT .......................................................................... 3-250 3.13.2 REPLACEMENT OF THE COUNTERWEIGHT ................................................................. 3-254 3.14 SUPERSTRUCTURE LIFTING ...................................................................................................... 3-256 3.14.1 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE ........................... 3-256 3.14.2 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE............................. 3-261 3.15 HIGH VOLTAGE SWITCH CABINET ............................................................................................ 3-266 3.15.1 REMOVAL OF THE HIGH VOLTAGE SWITCH CABINET................................................ 3-268 3.15.2 REPLACEMENT OF THE HIGH VOLTAGE CABINET ..................................................... 3-272 3.16 SLIP RING UNIT............................................................................................................................. 3-274 3.16.1 REMOVAL OF THE SLIP RING UNIT ............................................................................... 3-275 3.16.2 REPLACEMENT OF THE SLIP RING UNIT...................................................................... 3-277

4 UNDERCARRIAGE.................................................................................... 4-1 4.1

UNDERCARRIAGE OVERVIEW........................................................................................................ 4-2

4.2

TRAVEL SYSTEM.............................................................................................................................. 4-4 4.2.1 TRACK GROUP..................................................................................................................... 4-4 4.2.1.1 CHANGING OF THE TRACK GROUP .................................................................. 4-4 4.2.2 SPROCKET ........................................................................................................................... 4-9 4.2.2.1 REMOVAL OF THE SPROCKET ........................................................................... 4-9 4.2.2.2 REPLACEMENT OF THE SPROCKET ............................................................... 4-14 4.2.2.3 REMOVAL OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) ..................................................... 4-16 4.2.2.4 REPLACEMENT OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) ........................................... 4-20

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4.2.3

4.2.4

4.2.5

4.2.6 4.2.7

4.2.8

4.2.9

4.2.10

4.2.11

4.2.12

4.2.13

4.3

GUIDE WHEELS ................................................................................................................. 4.2.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY ............................................... 4.2.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY ..................................... TRACK TENSIONING ACCUMULATORS .......................................................................... 4.2.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS ................................ 4.2.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS ....................... 4.2.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS ............................... 4.2.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS ...................... TRACK TENSION VALVE BLOCK ...................................................................................... 4.2.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK ............................... 4.2.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK...................... HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM ........................................ 4.2.6.1 SUBSTITUTE THE HYDRAULIC HOSES ........................................................... TRACK TENSIONING CYLINDERS .................................................................................... 4.2.7.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS ................................... 4.2.7.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS .......................... TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE).................................................. 4.2.8.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK ....................................... 4.2.8.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK .............................. TRAVEL MOTORS .............................................................................................................. 4.2.9.1 REMOVAL OF THE TRAVEL MOTORS.............................................................. 4.2.9.2 REPLACEMENT OF THE TRAVEL MOTORS .................................................... TRAVEL PARKING BRAKE................................................................................................. 4.2.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE ................................................ 4.2.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE....................................... TRAVEL GEARBOX ............................................................................................................ 4.2.11.1 REMOVAL OF THE TRAVEL GEARBOX............................................................ 4.2.11.2 REPLACEMENT OF THE TRAVEL GEARBOX .................................................. 4.2.11.3 REMOVAL OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ 4.2.11.4 REPLACEMENT OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ CARRIER ROLLER ............................................................................................................. 4.2.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY ........................................ 4.2.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY ............................... TRACK ROLLER ................................................................................................................. 4.2.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY ............................................ 4.2.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY ...................................

4-22 4-22 4-24 4-25 4-25 4-27 4-28 4-29 4-30 4-30 4-32 4-33 4-33 4-37 4-37 4-39 4-40 4-41 4-43 4-44 4-44 4-46 4-48 4-50 4-52 4-54 4-55 4-57 4-59 4-65 4-70 4-70 4-72 4-73 4-73 4-75

CAR BODY....................................................................................................................................... 4-76 4.3.1 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE) ........................................................................ 4-76 4.3.2 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE) ........................................................................ 4-80 4.3.3 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE) ....................................................................... 4-84 4.3.4 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE) ....................................................................... 4-89 4.3.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS 4-92 4.3.5 ROTARY JOINT................................................................................................................... 4-96 4.3.5.1 REMOVAL OF THE ROTARY JOINT .................................................................. 4-98 4.3.5.2 REPLACEMENT OF THE ROTARY JOINT....................................................... 4-101

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4.3.6

4.3.7

CABLE DRUM.................................................................................................................... 4.3.6.1 PREPARATORY WORK FOR THE REMOVAL AND REPLACEMENT OF THE CABLE DRUM ASSEMBLY ................................................................ 4.3.6.2 REMOVAL OF THE CABLE DRUM ASSEMBLY............................................... 4.3.6.3 REPLACEMENT OF THE CABLE DRUM ASSEMBLY ..................................... CABLE SUPPLY (OPTIONAL)........................................................................................... 4.3.7.1 PREPARATORY WORK FOR THE REMOVAL AND REPLACEMENT OF THE CABLE SUPPLY .................................................................................. 4.3.7.2 REMOVAL OF THE CABLE SUPPLY................................................................ 4.3.7.3 REPLACEMENT OF THE CABLE SUPPLY ASSEMBLY..................................

4-102 4-103 4-104 4-105 4-108 4-109 4-110 4-112

5 ATTACHMENT........................................................................................... 5-1 5.1

BACKHOE.......................................................................................................................................... 5-2 5.1.1 BOOM .................................................................................................................................... 5-4 5.1.1.1 REMOVAL OF THE BOOM.................................................................................... 5-4 5.1.1.2 REPLACEMENT OF THE BOOM .......................................................................... 5-8 5.1.1.3 REMOVAL OF BOOM CYLINDERS .................................................................... 5-10 5.1.1.4 REPLACEMENT OF BOOM CYLINDERS ........................................................... 5-16 5.1.2 STICK................................................................................................................................... 5-20 5.1.2.1 REMOVAL OF THE STICK .................................................................................. 5-20 5.1.2.2 REPLACEMENT OF THE STICK......................................................................... 5-24 5.1.2.3 REMOVAL OF STICK CYLINDERS..................................................................... 5-26 5.1.2.4 REPLACEMENT OF STICK CYLINDERS ........................................................... 5-32 5.1.3 BUCKET............................................................................................................................... 5-36 5.1.3.1 REMOVAL OF THE BUCKET .............................................................................. 5-36 5.1.3.2 REPLACEMENT OF THE BUCKET..................................................................... 5-39 5.1.3.3 REMOVAL OF BUCKET CYLINDERS................................................................. 5-40 5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS ....................................................... 5-46 5.1.4 BUCKET LINK ROD AND STEERING RODS ..................................................................... 5-49 5.1.4.1 REMOVAL OF THE BUCKET LINK ROD ............................................................ 5-49 5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD................................................... 5-51 5.1.4.3 REMOVAL OF THE STEERING RODS............................................................... 5-52 5.1.4.4 REPLACEMENT OF THE STEERING RODS ..................................................... 5-55 5.1.5 GROUND ENGAGING TOOLS (GET)................................................................................. 5-56 5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET................................................. 5-57 5.1.6 HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT................................................. 5-58 5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES............................................................. 5-58 5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES .................................................. 5-62 5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES .................................................. 5-66 5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES .............................................. 5-70

5.2

FACE SHOVEL (FSA)...................................................................................................................... 5-74 5.2.1 USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS.............................. 5-75 5.2.2 BOOM .................................................................................................................................. 5-76 5.2.2.1 REMOVAL OF THE BOOM.................................................................................. 5-76 5.2.2.2 REPLACEMENT OF THE BOOM ........................................................................ 5-82 5.2.2.3 REMOVAL OF THE BOOM CYLINDERS ............................................................ 5-88 5.2.2.4 REPLACEMENT OF THE BOOM CYLINDERS................................................... 5-93 5.2.3 STICK................................................................................................................................... 5-96 5.2.3.1 REMOVAL OF THE STICK .................................................................................. 5-96 5.2.3.2 REPLACEMENT OF THE STICK....................................................................... 5-100

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5.2.3.3 REMOVAL OF THE STICK CYLINDERS .......................................................... 5.2.3.4 REPLACEMENT OF THE STICK CYLINDERS ................................................. BULL CLAM BUCKET ....................................................................................................... 5.2.4.1 REMOVAL OF THE BULL CLAM BUCKET ....................................................... 5.2.4.2 REPLACEMENT OF THE BULL CLAM BUCKET ............................................. 5.2.4.3 REMOVAL OF THE BUCKET CYLINDERS ...................................................... 5.2.4.4 REPLACEMENT OF THE BUCKET CYLINDERS ............................................. 5.2.4.5 REMOVAL OF THE CLAM CYLINDERS ........................................................... 5.2.4.6 REPLACEMENT OF THE CLAM CYLINDERS ................................................. GROUND ENGAGING TOOLS (GET)............................................................................... 5.2.5.1 REMOVAL AND REPLACEMENT OF THE GET .............................................. HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT ....................................... 5.2.6.1 SUBSTITUTE THE BOOM ARC HOSES .......................................................... 5.2.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES ................................................ 5.2.6.3 SUBSTITUTE THE STICK ARC HOSES ........................................................... 5.2.6.4 SUBSTITUTE THE STICK CYLINDER HOSES ................................................ 5.2.6.5 SUBSTITUTE THE BUCKET CYLINDER HOSES ............................................ 5.2.6.6 SUBSTITUTE THE CLAM CYLINDER HOSES .................................................

5-104 5-109 5-112 5-114 5-118 5-120 5-125 5-130 5-135 5-138 5-140 5-142 5-142 5-146 5-150 5-154 5-158 5-162

5.3

METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT ..................................... 5.3.1 OPERATION TEST OF THE METERING VALVES (GREASE INJECTORS)................... 5.3.2 REMOVAL OF THE METERING VALVES (GREASE INJECTORS)................................. 5.3.3 REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS) .......................

5-170 5-171 5-172 5-174

5.4

CYLINDER BYPASS TEST ........................................................................................................... 5-175

5.2.4

5.2.5 5.2.6

6 SERVICE INFORMATION ......................................................................... 6-1 6.1

FLUIDS AND LUBRICANTS.............................................................................................................. 6-2

6.2

FILLING CAPACITIES ....................................................................................................................... 6-2

6.3

WORK INSTRUCTIONS .................................................................................................................... 6-4 6.3.1 SURFACE COATING WITH INTERZINC 697 ....................................................................... 6-4 6.3.2 REMOVE / INSTALL THE CRAWLER CARRIER ................................................................. 6-6

6.4

WEIGHT TABLES .............................................................................................................................. 6-7 6.4.1 SUPERSTRUCTURE ............................................................................................................ 6-7 6.4.2 UNDERCARRIAGE ............................................................................................................. 6-10 6.4.3 BACKHOE ATTACHMENT (BHA) ....................................................................................... 6-12 6.4.4 FACE SHOVEL ATTACHMENT (FSA) ................................................................................ 6-13

6.5

TORQUE CHARTS ACCORDING TO KOMATSU COMPANY STANDARD ................................. 6.5.1 METRIC STANDARD THREAD........................................................................................... 6.5.2 METRIC FINE THREAD ...................................................................................................... 6.5.3 SAE FLANGE CONNECTIONS ...........................................................................................

6-14 6-14 6-15 6-16

6.6

BLIND PLUGS ................................................................................................................................. 6.6.1 DUMMY PLATES FOR SAE FLANGES .............................................................................. 6.6.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ........................................... 6.6.3 PLUGS AND FITTINGS ACCORDING TO DIN 2353 / ISO 8434-1 ....................................

6-18 6-18 6-20 6-21

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6.7

CONVERSION TABLE..................................................................................................................... 6.7.1 METHOD OF USING THE CONVERSION TABLE ............................................................. 6.7.2 MILLIMETER - INCH & KILOGRAM - POUND .................................................................... 6.7.3 LITER - U.S. GALLON & LITER - U.K. GALLON................................................................. 6.7.4 NM - FT.LB........................................................................................................................... 6.7.5 BAR - PSI - KPA - MPA ....................................................................................................... 6.7.6 BASIC VALUES IN OHM ACCORDING TO DIN 4376 / IEC 751 ........................................ 6.7.7 TEMPERATURE ..................................................................................................................

6-22 6-22 6-23 6-24 6-25 6-26 6-27 6-28

6.8

TOOLS.............................................................................................................................................. 6-29 6.8.1 STANDARD TOOL CASE.................................................................................................... 6-29 6.8.2 USED SPECIAL TOOLS (OVERVIEW) ............................................................................... 6-31

7 TOOLS CATALOGUE ................................................................................ 7-1 8 PARTS & SERVICE NEWS ....................................................................... 8-1 AH00511 Installation procedure for the swing circle (SC) AH00514 Track group – Hints for sprocket exchange AH00515 Final drive: Wear and tear measurements / Mounting procedures AH00519 Adhesive lubricants for the slew ring gear AH01513 Bleeding of hydraulic pumps AH01523 Replacement of the elastic coupling (electro drive shovels) AH01531 Hydraulic accumulators - testing and refilling AH02513 Testing wear and tear of swing circle bearing AH02521 Track group – wear measurement AH03506 Hydraulic oil cooler and water cooler fan bearings AH03509 Slew gear GFB 174 E 9017 (Part No. 917 915 40) AH03510 ESCO bucket tooth system AH03511 Pilot Pressure Pump (Part No. 907 209 40) AH03512 Gear Pumps (Part Nos. 907 209 40; 906 442 40; 896 730 40 and 654 930 40 AH03528 Pilot control safety line AH04518 Welding procedure for welded counterweight AH05501 Abnormal vibration on hydraulic pipes AH05510 Bearing flushing of the A4VS variable displacement axial piston pump TOC - 8

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AH05511 Dual cone seal ring mounting AH05518 Swing circle pinion AH05520 Installation hints for a new type of pilot pump AH05525 Suction elbows of the main pumps AH05535 Hints for replacing by the slewing gear of an other manufacturer AH05546 Automatic lubrication system - vent valve (PN 769 879 73) AH06524 Hydraulic cylinder AH06529 Track group - hints for sprocket exchange AH06530 Relieving of the track chain tension AH06542 Swash plate pump H-A4VSO500 AH06543 Gear pumps PN 907 622 40 and PN 940 048 40 (supplied from the company “Kracht”) (Pilot pressure pump; gear oil pump; circulation pump) AH06545 Hydraulic cylinder bushings AH07509 Swing brake manufactured by "Siebenhaar" (Swing gear PN 902 550 40 and PN 925 864 40) AH07526 Bolted undercarriage: Protective coating on the flange plates AH08503 Track drive AH08504 Windscreen AH08507 Steel structure AH08508 Bushings of the attachment and at the undercarriage AH09505 Hoses between boom and stick AH09522 Wishbone and rod

9 SUPPLIER’S DOCUMENTATION ............................................................. 9-1 AVANTI HYTORQUE

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Introduction

1 INTRODUCTION

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Contents of the binder

1.1

Introduction

CONTENTS OF THE BINDER

Assembled in this file are the R&R Procedures with explanations of removing, installing, and adjustments of the major components and circuits for your KOMATSU Hydraulic Mining Shovel.

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Foreword

FOREWORD

Observe the instructions in this manual for: z

Your Personal SAFETY

z

Operating SAFETY, and

z

READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

With this R&R Procedures Manual, KOMATSU provides you with the description of proper removal and replacement procedures of main components.

How do you find "your" desired information? In the TABLE OF CONTENTS all R&R PROCEDURES are shown in their sequence of description. CAUTION Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities and immediate replacement of worn out or broken parts will prevent failures and avoid expenses.

Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If, after reading this R&R Procedures Manual, you can give us suggestions and comments for improvements - please do not hesitate to contact us.

Komatsu Mining Germany GmbH Service Training and Manuals Department 8151.30 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY

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Introduction

WARNING Personnel entrusted with work on the machine must have read the section 2 SAFETY AND STANDARDS before beginning work. Reading the instructions after work has begun is too late.

Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturer’s guarantee. In order to keep your shovel in first-class operating condition only use genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee.

1.2.1

SERVICE

In all your written or phoned inquiries, please indicate the model and serial number of your shovel.

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2 SAFETY

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General information

Safety

2.1

GENERAL INFORMATION

2.1.1

METHOD OF USING THIS MANUAL

When removing or installing a unit assembly, the order of work and techniques used are given for the removal procedure. The order of work for the installation is only given if the installation procedure differs from installation in reverse order of removal, for example any special technique needs to be applied. Tightening torques according to the KOMATSU company standard are not explicitly given in the installation procedures. For tightening torques according to the KOMATSU company standard, refer to section 6.5 on page 6-14. Figure references that appear in the operation procedures use the format (Fig. 4-12, Pos. 4), which means position number 4 in figure 12 of section 4. Special requirements such as listing of special tools or size or numbers of blind plugs etc. are listed in a table at the beginning of each operation procedure. Special tools that appear in the lists are given with part name, part number, and quantity (2 x thread protector, PN 409 329 40). For the special tools list, refer to section 6.8.2 on page 6-31. The following text designations are used in the manual with the following intend: –

Refers to listings of none particular order.

z

Refers to working steps within the procedures.

The following symbols are used in the manual to designate additional information as shown in the following examples: Kind and amount of drained fluids (e.g. drain oil, 1500 liters).

Lifting weight of an assembly (e.g. 140 kg). Kind and amount of fluids to fill (e.g. fill oil, 1500 liters). Special tightening torques for bolts etc., if not according to the company standard (e.g. 129 Nm). General information concerning a section, e.g. tightening torques according to the company standard, refer to section 6.5 on page 6-14.

Special authorized personnel is required.

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General information

All PARTS & SERVICE NEWS which are mentioned in the procedures are listed in chapter 8. The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest edition is always filed to the binder of this manual. The following symbols and designations are used in the manual to designate instructions of particular importance: DANGER Refers to orders and prohibitions designed to prevent serious injury or death.

WARNING Refers to orders and prohibitions designed to prevent injury or extensive damage.

CAUTION Refers to special information and/or orders and prohibitions directed towards preventing damage.

NOTE: Refers to special information on removing or installing assemblies, for example if any special technique needs to be applied.

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Safety instructions

Safety

2.2

SAFETY INSTRUCTIONS

2.2.1

GENERAL PRECAUTIONS CAUTION

Proper service and repair is important for safe machine operation. The service and repair techniques recommended by Komatsu Mining Germany and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu Mining Germany for the specific purpose.

NOTE: Always attend to local regulations regarding the Personal Protective Equipment. WARNING z

Mistakes in operation and service are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

z

Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

z

When carrying out any operation, always wear safety shoes and a helmet. Do not wear loose work clothes or clothes with buttons missing.

z

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

z

Assure fire prevention according to the Operation & Maintenance Manual.

z

If welding repairs are needed, refer to the welding precautions given in the Operation & Maintenance Manual.

z

When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's cab.

z

Keep all tools in good condition and learn the correct way to use them.

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WARNING Decide on a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. An pilot control safety line monitores all safety relevant components at the high voltage system. This pilot control safety line must be connected properly at the excavator and at the power plant / external transformer station. For further information about the monitored components, refer to the PARTS & SERVICE NEWS No. "AH03528" and the wiring diagram of the excavator.

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Safety instructions

2.2.2

Safety

PREPARATIONS BEFORE WORK WARNING

Before beginning any work operations set the maintenance safety switch (Fig. 2-1, Pos. 3) to -0- position to prevent starting of the engines during the work. Fold up the flap (Fig. 2-1, Pos. 2) and secure this position by inserting a padlock into the holes (Fig. 2-1, Pos. 4) of the flap (Fig. 2-1, Pos. 2) and the safety switch (Fig. 2-1, Pos. 1).

Fig. 2-1 WARNING z

Before adding oil or making repairs, park the machine on hard, level ground large enough to accommodate the machine, boom, and additional working equipment (crane mobile working platforms, forklift etc.).

z

If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane mobile working platforms, forklift etc.), make sure that the machine is moved to a place with appropriate ground conditions. Block the tracks to prevent the machine from moving.

z

Before starting work, lower bucket, hammer, or any other work equipment to the ground. If this procedure is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. Additionally, be sure to lock all the control levers and hang warning signs on them.

z

When disassembling or assembling, support the machine with blocks, jacks, or supports before starting work.

z

Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders, or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders, or steps, use a stand to provide safe footing.

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Safety instructions

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only. Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

2.2.3

PRECAUTIONS DURING WORK WARNING

z

When removing the oil filler cap, drain plug, or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. The oil can be very hot, so be careful not to get burnt. Wait for the oil to cool down before carrying out work.

z

Before starting work, isolate the machine according to local regulations. Remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

z

When raising heavy components (25 kg or more), use a hoist or crane.

z

Check that the wire rope, chains, and hooks are free from damage.

z

Always use lifting equipment which has ample capacity.

z

Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

z

When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

z

When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

z

When removing any piping, stop the fluids from spilling out. If any oil drips on to the floor, wipe it up immediately. Oil on the floor can cause you to slip, or can even start fires.

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Safety instructions

Safety

WARNING z

As a general rule, do not use gasoline to wash parts.

z

Be sure to assemble all parts in their original places again. Replace any damaged parts with new parts.

WARNING z

When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.

z

When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

z

When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.

z

When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

DANGER Danger of explosion! Serious injury, permanent disfigurement, and scarring may result! Special care must be taken before welding, flame-cutting, and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting, and grinding operations are carried out on the counterweight. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.

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Safety instructions

2.2.3.1 PRECAUTIONS WITH HIGH PRESSURE OIL DANGER The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious injury. do not carry out any inspection or replacement operation.

If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses. WARNING When carrying out inspections, wear full-face protection and penetration resistant clothing and gloves.

DANGER There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.

Fig. 2-2

WARNING Leaks in high-pressure hoses may cause fire or defective operation, which may lead to serious injury. z

Replace the hose if a damaged or leaking hydraulic fitting is found.

z

Replace the hose if a frayed or cut covering or an exposed reinforcement wire layer is found.

z

Replace the hose if a covering is swollen in places.

z

Replace the hose if movable portions are wisted or crushed.

z

Replace the hose if foreign material (splinters etc.) is embedded in the covering of the hose.

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Safety instructions

2.2.4

Safety

WARNING OF SPECIAL DANGERS

2.2.4.1 ELECTRICAL ENERGY WARNING z

Use only original fuses and circuit breakers with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

z

Work on the electrical system or equipment may only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such electrician and in accordance with the applicable electrical engineering rules.

z

If provided for in the regulations, the power supply to parts of the machine, on which inspection, maintenance, and repair work is to be carried out must be cut off. Before starting any work, check the de-energized parts for the presence of power and ground or short-circuit them in addition to insulating adjacent live parts and elements.

z

If your machine comes into contact with a live wire: z

do not leave the machine.

z

drive the machine out of the hazard zone.

z

warn others against approaching and touching the machine.

z

have the live wire de-energized.

z

do not leave the machine until the damaged line has been safely de-energized.

z

The electrical equipment of the machine is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

z

Necessary work on live parts and elements must be carried out only in the presence of a second person who can cut off the power supply in case of danger by actuating the emergency shut-off or main power switch. Secure the working area with a red-and-white safety chain and a warning sign. Use insulated tools only.

z

Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

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Safety instructions

2.2.4.2 GAS, DUST, STEAM AND SMOKE WARNING z

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly approved, as there may be a risk of explosion and fire.

z

Special care must be taken before welding, flame-cutting and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting and grinding operations are carried out on the counterweight. Danger of explosion. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.

z

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surrounding from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

2.2.4.3 NOISE WARNING z

During operation, all sound baffles must be closed.

z

Always wear the prescribed ear protectors.

2.2.4.4 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES WARNING When handling oil, grease, and other chemical substances, observe the product-related safety regulations given in the material safety data sheet (MSDS).

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Safety instructions

Safety

2.2.4.5 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT WARNING z

Work on hydraulic equipment and the air conditioning system may only be carried out by persons having special knowledge and experience in this systems.

z

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair any damage immediately. Splashed oil may cause injury and fire.

z

Depressurize all system sections and pressure pipes (hydraulic system, compressed-air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

z

Refrigerant in the air conditioning system must be sucked off by authorized service specialists only before opening the refrigerant loop (e.g. removing pipes).

z

Hydraulic, air conditioning and compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths, and quality of the hoses must comply with the technical requirements.

2.2.4.6 HEAT WARNING z

Do not start working on hot machine parts until the temperature is below 50 °C.

z

Be careful when handling hot materials (risk of burning or scalding) such as:

z

z

Hot cables

z

Hydraulic oil

z

Grease

Use gloves when handling hot machine parts.

2.2.4.7 HEIGHT WARNING When working in heights above 1.00 m, a special safety harness is required, refer to section 2.2.5 on page 2-15.

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Safety instructions

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Safety

Safety harness in conformity with EN 361 PC5500-6E

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2.2.5

Safety instructions

SPECIAL SAFETY EQUIPMENT

2.2.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) The safety harness (Fig. 2-3) should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. Legend for Fig. 2-3: (1)

Safety harness according to EN 361

(2)

Strap-type fall absorber according to DIN EN 355

(3)

Ladder to cab roof and railings (attachment points)

(4)

Protection hoods for roof mounted air conditioning, if so equipped

(A)

Shoulder strap

(B)

Back plate

(C)

Catching hook

(D)

Shoulder-strap fixing

(E)

Belly strap

(F)

Holding hook

(G)

Hold-back hook

(H)

Pelvis strap

(J)

Leg strap

WARNING Always use the safety harness (Fig. 2-3, Pos. 1) in conjunction with strap-type fall absorber (Fig. 2-3, Pos. 2), before mounting onto the loader attachment or other unsecured places of the shovel.

NOTE: The illustration (Fig. 2-3) shows a typical use of the safety harness. Shovels with the new type operator’s cab are not equipped with ladder (Fig. 2-3, Pos. 3), because the air conditioner unit of the new type cab is located on the back wall of the cab.

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Safety instructions

Fig. 2-4 2 - 16

Safety

Safety harness in conformity with EN 361 PC5500-6E

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Safety

Safety instructions

2.2.5.2 INSTRUCTIONS FOR USE Open the lock and lift the harness by the catch hook (Fig. 2-4, Pos. C). The blue straps (leg straps Fig. 2-4, Pos. J) must be at the bottom. The harness is being put on just like a jacket. Pull the belly strap (Fig. 2-4, Pos. E) through the lock, as shown in the illustration, and secure it. By closing the breast strap, you avoid the shoulder straps to sideslip. Bring the leg straps (Fig. 2-4, Pos. J) around the legs to the front, pull them in, as shown in the illustration, and tighten them. Adapt the harness to body form, seeing to perfect fit, in particular that the catching hook (Fig. 2-4, Pos. C) is aligned in the center of the back. The safety harness should belong to its wearer personally. The safety harness should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attachment point should be sufficient to correspond with the minimum carrying capacity according to EN 795. z

Before using the harness: z

Carry out a visual check of the system or components. The correct functioning and perfect working order have to be assured.

z

Make sure that the recommendations for use with other components of the system are observed in conformity with the instructions for use. WARNING

The system or component must no longer be used, if there are any doubts in respect of its safe condition. The equipment has to be inspected by the manufacturer or by a qualified person. It is essential for safety reasons that a fall protection system or system component which has already been subjected to fall is removed from the service and sent back to the manufacturer or to an authorized qualified repair shop for maintenance and renewed testing.

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Safety instructions

Fig. 2-5 2 - 18

Safety

Safety harness in conformity with EN 361 PC5500-6E

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Safety

Safety instructions

Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharp-edged objects. If the harness has become wet during use or cleaning, do not dry near a fire or other sources of heat, but rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up. When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest Systems" have to be observed for protection against danger. WARNING At least every 12 months, the safety harness and its components have to be inspected by a competent person authorized by the manufacturer and they have to be maintained, if the manufacturer considers it to be necessary.

2.2.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS During the holding function, the connectors may only be placed around a mast or any other construction between the two holding hooks, so that the free fall is limited to max. 0.5 m. It should be strictly seen to it that the connector is not slung around constructions with too small diameters or sharp edges. With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs). The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be reached.

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Safety instructions

Fig. 2-6 2 - 20

Safety

Safety harness in conformity with EN 361 PC5500-6E

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Safety

Safety instructions

2.2.5.4 INSTARUCTIONS FOR USING THE FALL ABSORBER Strap-type fall absorber according to EN 355 (type E.K.N.-BFD) Use Within a fall-arrest system, the strap-type fall absorber (Fig. 2-6, Pos. 2) has to be used in conjunction with a safety harness (Fig. 2-6, Pos. 1) according to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a rope-shortening device has to be applied in addition. Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the safety harness. The attachment point should be above the wearer and its minimum carrying capacity should be 10 kN, according to EN 795. The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor get them burnt by welding sparks. Storing and maintenance The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be exposed to acids, caustic chemicals, nor to an aggressive atmosphere, and contact with any oil has to be avoided. If the strap-type fall absorber is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or other sources of heat). Protect it from sharp-edged objects. Inspection Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed from the service immediately. The strap-type fall absorber must not be changed in any way. Repair work has to be done by the manufacturer or by an authorized qualified repair shop.

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Safety instructions

2.2.6

Safety

SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION WARNING

The hydraulic hoses undergo natural aging. Hence, as they are safety critical parts, their usable lifetime is limited to a maximum of 6 years (including storage time). For further information refer to the Operation and Maintenance Manual, chapter 4, section "REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE".

To avoid damage to the hydraulic hose lines, follow the installation procedures listed below: CAUTION Pay attention to the Natural curvature of the hose!

Fig. 2-7

CAUTION Do not twist the hoses during installation!

Fig. 2-8

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CAUTION Mount angled flanges at first!

Fig. 2-9

CAUTION Pay attention to the changing in hose length, depending on the pressure inside the hose!

Fig. 2-10

CAUTION Pay attention to the bending radius!

Fig. 2-11

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Safety

CAUTION Pay attention to the bending radius!

Fig. 2-12

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Safety instructions

SAFETY HINTS FOR LIFTING HEAVY PARTS

NOTE: In order to avoid damage to the lifting devices or parts that have to be lifted, use edge protection at all sharp edges. CAUTION Heavy parts (25 kg or more) must be lifted with a hoist etc.

CAUTION If any part cannot be removed from the machine smoothly by hoisting, the following checks should be made: Check for the removal of all bolts fastening the component to other parts. Check for existence of another part causing interference with the component to be removed.

2.2.8 z

SAFETY HINTS FOR WIRE ROPES

Use adequate ropes depending on the weight of the parts to be hoisted, referring to the below table: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter [mm]

10.0

11.2

12.5

14.0

16.0

18.0

20.0

22.4

30.0

40.0

50.0

60.0

Allowable load [Metric tons]

1.0

1.4

1.6

2.2

2.8

3.6

4.4

5.6

10.0

18.0

28.0

40.0

CAUTION The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.

WARNING The table above may differ from local standards. Always attend to local standards when using wire ropes.

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Safety instructions

Safety

z

Sling wire ropes around the middle portion of the hook. Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting, which may cause a serious accident. Hooks have the maximum strength at the middle portion, see Fig. 2-13.

z

Do not sling a heavy load with one rope alone, but sling it with two or more ropes wound symmetrically around the load.

Fig. 2-13

WARNING Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which may cause a serious accident.

z

Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. Figure 2-14 shows the variation of allowable load (kg) where hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be lifted. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.

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Fig. 2-14

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Safety

2.2.9

Safety instructions

SAFETY HINTS FOR SLING ACCESSORY WARNING

Always attend to local standards when using sling accessory.

z

Do not use rigid eye bolts from steel C15 for lifting (e.g. DIN 580). These eye bolts may only be loaded vertically or with a maximum permissible angle of 45° to the ring.

z

Always use suitable swivel hoist rings according to local standards or Vario-Starpoint hoist rings recommended by Komatsu, see following table: Thread

Komatsu Part Number

Tightening Torque

M8

941 650 40

10 Nm

M10

941 651 40

10 Nm

M12

906 519 40

25 Nm

M16

906 780 40

60 Nm

M20

906 782 40

115 Nm

M24

906 783 40

190 Nm

M30

906 421 40

330 Nm

M36

906 233 40

590 Nm

DANGER Vario-Starpoint hoist rings are not suited for turning under load. After installing Starpoint hoist ring disengage the star key. Adjust ring plane in direction of pull before attaching sling accessory.

DANGER Eye bolts or sling accessory which is not suitable can result in serious accidents.

z

Check that the wire rope, chains, and hooks are free from damage.

z

Always use lifting equipment which has ample capacity.

z

Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

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Grounding procedure of the high voltage system

2.3

Safety

GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM

Special tools:

Measuring rod, PN 232 390 40 (for voltage range 3…6 kV) Measuring rod, PN 232 389 40 (for voltage range 5…10 kV) Universal grounding short-circuting device, PN 232 386 40

Additional equipment:

n/a

Electrician with permission to work on high voltage systems

The below procedure must be carried out for safety reasons, before any work is carried out on the high voltage system of the excavator. DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. z

The following safety measures have to be carried out before any work on the high voltage system by authorized electricians having the permission to work on high voltage system systems only.

z

Carry out the work according to the local safety regulations.

z

All safety devices requested by the local safety regulations must be available and used for any work on the high voltage systems.

Safety Measures z

Switch off the power supply from the power station and ground the power supply line securely.

z

Remove the padlock or the bolt (Fig. 2-1, Pos. 3) and open the flap (Fig. 2-1, Pos. 2) at the high voltage switch cabinet (Fig. 2-1, Pos. 1) to gain access to the load cut-off.

z

Turn the load cut-off (Fig. 2-2, Pos. 5) to OFF position using the key (Fig. 2-2, Pos. 4). DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Do not open the high voltage switch cabinet door (Fig. 2-1, Pos. 6) until the load cut-off is in OFF position. Fig. 2-1

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Grounding procedure of the high voltage system

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Do not open the switch cabinet door (Fig. 2-2, Pos. 4) until the load cut-off is in OFF position.

z

Remove the padlock and open high voltage switch cabinet door (Fig. 2-2, Pos. 1).

z

Make sure that the power supply from the power station is switched off by placing a measuring rod (Fig. 2-2, Pos. 3) to the ball headed stud (Fig. 2-2, Pos. 2) of the load cut-off switch copper bar. The indication on the measuring rod must show zero potential. Fig. 2-2

z

Make sure the grounding harness (Fig. 2-3, Pos. 8) is ready for use.

NOTE: The grounding harness is part of the universal grounding short-circuting device, PN 232 386 40. z

Connect the grounding harness (Fig. 2-3, Pos. 8) as follows: z

Connect the long single cable (Fig. 2-3, Pos. 6) of the harness to a threaded stud (Fig. 2-3, Pos. 4) and secure it with the wing nut (Fig. 2-3, Pos. 5).

z

Connect the three remaining cables of the grounding harness to the ball headed studs (Fig. 2-3, Pos. 3) of the load cut-off switch copper bars by means of the clamps (Fig. 2-3, Pos. 2), using the insulated extension rod (Fig. 2-3, Pos. 7).

z

Secure the clamps (Fig. 2-3, Pos. 2) by tightening the screws (Fig. 2-3, Pos. 1) using the insulated extension Fig. 2-3 rod.

NOTE: The insulated extension rod is part of the universal grounding short-circuting device, PN 232 386 40.

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Grounding procedure of the high voltage system

Safety

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Carry out the next steps after relieving the residual voltage from load cut-off switch bars only.

z

Remove one cable (Fig. 2-4, Pos. 3) of the grounding harness from its ball headed stud at the load cut-off switch copper bars using the insulated extension rod (Fig. 2-4, Pos. 4).

z

Touch all mounting bolts (Fig. 2-4, Pos. 2) of the phase lines (L1, L2 and L3) at each current transformer (Fig. 2-4, Pos. 1), located on the opposed wall of the high voltage switch cabinet with the cable (Fig. 2-4, Pos. 3) alternately.

NOTE: These connections will also relief the residual voltage from the capacitors. z

Reconnect the cable to the ball headed stud at the load cut-off switch copper bar.

z

Make sure the grounding harness remains connected as long as any work at the excavator is carried out.

Fig. 2-4

After work: z

Remove the grounding harness from the load cut-off switch and store it in a safe place. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. For safety reasons, the access to the high voltage switch cabinet must be blocked for unauthorized personnel. Lock the switch cabinet door with an appropriate padlock.

z

Close the door (Fig. 2-5, Pos. 6) of the high voltage switch cabinet and lock the door with the provided padlock.

z

Close the flap (Fig. 2-5, Pos. 2) of the load cut-off switch and secure the flap with the provided padlock or a bolt (Fig. 2-5, Pos. 3).

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Fig. 2-5

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2.4

Explanation of abbreviations

EXPLANATION OF ABBREVIATIONS

Abbrev.

Definition

A

Ampere

AC

Alternating Current

ACV

Anti-Cavitation Valve

API

American Petroleum Institute

BHA

Backhoe Attachment

°C

Degree Celsius

CLS

Central Lubrication System

CO

Cut Off function (main pump)

DC

Direct Current

DFT

Dry paint Film Thickness [1/1000 inch]

FSA

Front Shovel Attachment

GET

Ground Engaging Tools

HP

High Pressure

HT

High Tension

kV

Kilo Volt (1000 Volt)

LED

Light Emitting Diode

MRV

Main Relief Valve

PIV

Pressure Increasing Valve

PTO

Power Take-Off (Pump Distributor Gear)

Qmax

Maximum pump delivery = maximum swash plate angle

Qmin

Minimum pump delivery = minimum swash plate angle

1/2 Qmax

1/2 pump delivery

SLS

Swing circle pinion Lubrication System

SRV

Secondary Relief Valve

V

Volt

WFT

Wet paint Film Thickness [1/1000 inch]

1/min

Revolutions Per Minute (RPM)

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Explanation of abbreviations

Safety

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Superstructure

3 SUPERSTRUCTURE

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3 -1

Superstructure overview

Superstructure

3.1

SUPERSTRUCTURE OVERVIEW

Fig. 3-1

PC5500-6E, superstructure - top view

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PC5500-6E

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Superstructure

Superstructure overview

Legend for Fig. 3-1: (1)

Operator’s cab

(2)

Slip ring unit

(3)

Hydraulic oil coolers

(4)

Return oil reservoir with return oil filters

(5)

Slew gear

(6)

Main control valve blocks

(7)

Main hydraulic pumps

(8)

Flexible coupling cover

(9)

Front PTO (pump distributor gear)

(10)

Rear PTO (pump distributor gear)

(11)

Front electric motor (motor 2)

(12)

Rear electric motor (motor 1)

(13)

Motor cooling air intake

(14)

Capacitor assembly motor 2

(15)

Capacitor assembly motor 1

(16)

Counterweight

(17)

Hydraulically operated access ladder

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3 -3

Superstructure overview

Fig. 3-2

Superstructure

PC5500-6E, superstructure - side view

(1)

Operator’s cab

(2)

Motor cooling air outlet

(3)

Automatic lubrication system

(4)

Counterweight

(5)

Hydraulically operated access ladder

(6)

High voltage switch cabinet

(7)

Swing circle

(8)

Emergency exit ladder

(9)

Cab base (medium voltage switch cabinet)

(10)

Cab support frame

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Service crane (optional)

3.2

SERVICE CRANE (OPTIONAL)

3.2.1

REMOVAL OF THE SERVICE CRANE

Special tools:

n/a

Additional equipment:

Crane Service crane with beam: 1900 kg

Dogman/rigger Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

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3 -5

Service crane (optional)

z

Superstructure

Make sure that the safety hook of the service crane is safely connected to the crane base (Fig. 3-1, arrow). DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the switch box has to carried out by authorized electricians only.

z

Disconnect the wire harness from the switch box (Fig. 3-1, Pos. 4) at the hydraulic power unit.

z

Sling the service crane at the crane base (Fig. 3-1, Pos. 1). and the upper part of the crane. Fig. 3-1

WARNING Observe the center of gravity. Make sure that the crane can not knock over while lifting off.

z

Remove the bolts (Fig. 3-1, Pos. 2) and lift the service crane off the mounting blocks (Fig. 3-1, Pos. 3) using a crane.

z

Place the service crane on the ground. DANGER

Risk of falling weights! May result in death or serious injury. When removing the MKG service crane, make sure that nobody steps below the weight.

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3.2.2

Service crane (optional)

REPLACEMENT OF THE SERVICE CRANE

Special tools:

n/a

Additional equipment:

Crane Compound "KP2K", PN 324 969 40 Service crane with beam: 1900 kg

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out installation in reverse order to removal. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the switch box has to carried out by authorized electricians only.

NOTE: Always use new mounting bolts (Fig. 3-1, Pos. 2) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on the bolts.

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Service crane (optional)

Superstructure

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3.3

Electric Motors

ELECTRIC MOTORS

The excavator is powered by two ABB electric motors: Model:

ABB Induction motor

Type:

AMA 450L4A BAXYH

Rated power:

900 kW

3.3.1

PREPARATORY WORK FOR ELECTRIC MOTOR REMOVAL

Special tools:

n/a

Additional equipment:

Crane 4 x swivel hoist rings: M12 Roof plate, PTO side: 355 kg Roof plate, cooling air outlet: 483 kg Roof plate, capacitor side: 186 kg Beam (transfer carrier): 285 kg Dogman/rigger Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. WARNING

Always wear a safety harness when working at the roof.

z

Remove the service crane, if equipped; refer to section 3.2.1 on page 3-5. WARNING

Do not carry out the following work on a hot motor. Wait until the temperature of the motor is below 50 °C. Disobedience may result in personal injury from heated parts.

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3 -9

Electric Motors

Superstructure

Fig. 3-2

z

(1 to 3)

Roof plate

(4)

Sealing

(5, 6)

Bolt with washer

(7)

Bolt

(8)

Resilient sleeve

Clear all wire harnesses from the roof plates (Fig. 3-2, Pos. 2 and 3). WARNING

Pay attention to the Fire Detection and Suppression System. Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression System". The wires of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional.

z

Dismount all attached parts from the roof plates above the electric motors (Fig. 3-2, Pos. 2 and 3).

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z

Electric Motors

Remove the air outlets (Fig. 3-3, Pos. 1) of the electric motors from the roof plate.

NOTE: Check the moldings (Fig. 3-3, Pos. 2) and replace them if required.

Fig. 3-3 z

Remove all bolts (Fig. 3-2, Pos. 5) with washers (Fig. 3-2, Pos. 6) and all bolts (Fig. 3-2, Pos. 7) with resilient sleeves (Fig. 3-2, Pos. 8) of the roof plates.

z

Remove the roof plates (Fig. 3-2, Pos. 2 and 3) with a crane using swivel hoist rings. DANGER

Risk of falling weights! May result in death or serious injury. When removing the roof plates, make sure that nobody steps below the weight.

NOTE: Remove the sealings (Fig. 3-2, Pos. 4). Replace if required.

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3 - 11

Electric Motors

z

Superstructure

Clear all wire harnesses and cable ducts from the beam (transfer carrier) (Fig. 3-4, Pos. 1) and dismount all attached parts from the beam. WARNING

Pay attention to the Fire Detection and Suppression System. Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression System" The wires of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional. Fig. 3-4 z

Remove the mounting bolts (Fig. 3-4, Pos. 3) and resilient sleeves (Fig. 3-4, Pos. 2).

z

Remove the beam (transfer carrier) (Fig. 3-4, Pos. 1) with a crane. DANGER

Risk of falling weights! May result in death or serious injury. When removing the beam, make sure that nobody steps below the weight.

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3.3.2

Electric Motors

REMOVAL OF THE REAR ELECTRIC MOTOR (MOTOR 1)

Special tools:

n/a

Additional equipment:

Crane 2 x Lifting bar for electric motor lifting Electric motor: see rating plate on electric motor

Dogman/rigger Electrician with permission to work on high voltage systems

z

Carry out preparatory work for electric motor removal, refer to section 3.3.1 on page 3-9.

z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28. WARNING

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Remove the cover of the electric motor connection box (Fig. 3-5, Pos. 1).

z

Disconnect the power supply cables (Fig. 3-5, Pos. 2) from the electric motor at the connection box.

z

Remove the cable grommet (Fig. 3-5, Pos. 3).

Fig. 3-5

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3 - 13

Electric Motors

Superstructure

z

Remove the cover of the auxiliary terminal box (Fig. 3-6, Pos. 1) at the electric motor housing.

z

Disconnect and remove the wire harnesses (e.g. temperature monitoring) from the auxiliary terminal box. Clear the wire harnesses from the electric motor.

z

Disconnect the protective earth from the electric motor.

Fig. 3-6

Fig. 3-7 z

Removal of the electric motor

Remove the flexible coupling (Fig. 3-7, Pos. 4), refer to section 3.5.1.1 on page 3-35.

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Version 2010/1

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Electric Motors

z

Loosen the adjusting bolts (Fig. 3-7, see arrows) and the jacking bolts (Fig. 3-7, Pos. 1) on both sides of the motor.

z

Attach the motor (Fig. 3-8, Pos. 1) to a crane using two lifting bars (Fig. 3-8, Pos. 3). CAUTION

Make sure not to damage the motor cooler assembly (Fig. 3-8, Pos. 2). z

Use the Lifting eyes at the motor (Fig. 3-8, Pos. 1) only.

z

Use suitable lifting bars (Fig. 3-8, Pos. 3) which are long enough that the lifting accessory does not come in contact with the motor cooler assembly. Fig. 3-8

z

Lift the motor out of the machinery house. DANGER

Risk of falling weights! Death or serious injury may result. When removing the motor, make sure that nobody steps below the weight.

z

Remove the compensation plates (Fig. 3-7, Pos. 5).

NOTE: The compensation plates should be used as samples for the shape of new plates to be manufactured according to the thickness needed for the proper alignment of the motor.

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Electric Motors

Superstructure

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3.3.3

Electric Motors

REPLACEMENT OF THE REAR ELECTRIC MOTOR (MOTOR 1)

Special tools:

n/a

Additional equipment:

Crane 2 x Lifting bar for electric motor lifting Electric motor: see rating plate on electric motor

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Prepare the contact area of the motor stands before mounting.

NOTE: The contact area must be plane and free of dirt and rust. z

Attach the new electric motor (Fig. 3-9, Pos. 1) to a crane using two lifting bars (Fig. 3-9, Pos. 3). CAUTION

Make sure not to damage the motor cooler assembly (Fig. 3-9, Pos. 2). z

Use the Lifting eyes at the motor (Fig. 3-9, Pos. 1) only.

z

Use suitable lifting bars (Fig. 3-9, Pos. 3) which are long enough that the lifting accessory does not come in contact with the motor cooler assembly. Fig. 3-9

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3 - 17

Electric Motors

Superstructure

Fig. 3-10 Replacement of the electric motor z

Lift the new electric motor into mounting position in the machinery house using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the motor, make sure that nobody steps below the weight.

z

Screw in the jacking bolts (Fig. 3-10, Pos. 1) completely.

z

Insert new motor fixing bolts (Fig. 3-10, Pos.3) of the grade 10.9, and secure the bolts with the nuts (Fig. 3-10, Pos.2). Tighten the nuts hand-tight.

z

If required, install the coupling’s input drive hub onto the motor power take-off shaft (H7 drive fit), refer to section 3.5.1.2 on page 3-37.

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Electric Motors

z

Carry out the alignment procedure, refer to section 3.3.6 on page 3-23.

z

After completion of the alignment procedure, tighten the motor fixing bolts / nuts to the specified tightening torque. Tightening torque for the motor fixing bolts / nuts: 3100 Nm

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Remove the cover of the motor connection box (Fig. 3-11, Pos. 1) and the cable grommet (Fig. 3-11, Pos. 3).

z

Connect the power supply cables (Fig. 3-11, Pos. 2) to the electric motor.

z

Install the cable grommet (Fig. 3-11, Pos. 3).

z

Reinstall the cover of the motor connection box (Fig. 3-11, Pos. 1).

Fig. 3-11 z

Remove the cover of the auxiliary terminal box (Fig. 3-12, Pos. 1) at the electric motor housing.

z

Install the wire harnesses to the electric motor, and connect the wire harnesses (e.g. temperature monitoring) to the auxiliary terminal box.

z

Connect the protective earth to the electric motor.

Fig. 3-12 z

De-isolate the machine according to local regulations and according to the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

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3 - 19

Electric Motors

Superstructure

z

Check the direction of the electric motor’s rotation. Change the connection of the phase lines if required.

z

Isolate the machine according to local regulations.

z

Install a new flexible coupling (Fig. 3-10, Pos. 4) to the motor shaft and the PTO flange, refer to section 3.5.1.2 on page 337.

z

Reinstall the protection grid over the coupling.

z

Reinstall the beam (Fig. 3-13, Pos. 1) (transfer carrier).

NOTE: Use new beam mounting bolts (Fig. 3-13, Pos. 3) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on the mounting bolts. Install the beam mounting bolts with resilient sleeves and tighten the mounting bolts to the specified tightening torque. Tightening torque for the beam (transfer carrier) mounting bolts: 880 Nm Fig. 3-13 WARNING Pay attention to the Fire Detection and Suppression System. Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression System". The wires of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional.

z

Reinstall all previously removed wire harnesses and other parts to the beam (transfer carrier).

z

Install the air outlets (Fig. 3-14, Pos. 1) of the electric motors to the roof plate.

NOTE: Check the moldings (Fig. 3-14, Pos. 2) and replace them if required.

Fig. 3-14

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Electric Motors

Fig. 3-15 z

Reinstall the roof plates using swivel hoist rings and a crane.

z

Install all mounting bolts with washers and resilient sleeves respectively at the roof plates.

NOTE: Use new bolts (Fig. 3-15, Pos. 7) of the grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified torque. Tightening torque for the roof plate mounting bolts (Fig. 3-15, Pos. 7): 108 Nm z

Mount all previously dismounted parts to the roof plates.

z

Reinstall all wire harnesses to the roof plates.

z

Reinstall the service crane, if equipped; refer to section 3.2.2 on page 3-7.

z

De-isolate the machine according to local regulations.

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3 - 21

Electric Motors

Superstructure

WARNING Before each starting make sure that all controls are in neutral position. Be sure to sound the signal horn before starting to make your intention clear.

NOTE: Before starting the engines pay attention to the hydraulic oil temperature. Refer to the Operation & Maintenance Manual, chapter 3, section "STARTING PROCEDURE".

3.3.4

REMOVAL OF THE FRONT ELECTRIC MOTOR (MOTOR 2)

The removal of the front electric motor (motor 2) is analogously the same as the removal of the rear electric motor (motor 1), refer to section 3.3.2 on page 3-13.

3.3.5

REPLACEMENT OF THE FRONT ELECTRIC MOTOR (MOTOR 2)

The replacement of the front electric motor (motor 2) is analogously the same as the replacement of the rear electric motor (motor 1), refer to section 3.3.5 on page 3-22.

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3.3.6

Electric Motors

FINAL ALIGNMENT OF THE ELECTRIC MOTORS

Special tools:

n/a

Additional equipment:

2 x Dial gauge Laser alignment set (recommended), PN 232 713 40 + PN 232 714 40

For the alignment procedure the following preconditions are considered: A new electric motor is installed. The new motor is jacked up by the jacking bolts. The flexible coupling is not installed yet. The coupling’s hubs are already installed at the motor shaft and at the PTO shaft. NOTE: Due to higher accuracy, it is recommended to make all measurements in the alignment procedure with a laser alignment set instead of dial gauges. Observe the instructions given in the manual of the laser alignment set. z

Rotate the rotor of the electric motor and check the axial clearance.

NOTE: The sleeve bearings of the motor must be lubricated properly before turning the rotor. Rough adjustment z

Move the motor (Fig. 3-16, Pos. 1) by using the adjusting bolts (Fig. 3-16, Pos.3) and the jacking bolts (Fig. 3-18, Pos.1), until the drive shaft centerline and the centerline at the PTO drive shaft are aligned roughly.

z

Adjust the desired distance between the hubs by using the adjusting bolts (Fig. 3-16, Pos.3). For the proper distance for the coupling, refer to the PARTS & SERVICE NEWS No. "AH01523".

NOTE: Leave all adjusting screws tightened slightly. Fig. 3-16 Run-out check The alignment procedure is started by measuring the run-out of the coupling hubs. This measurement will show any inaccuracy of the shaft and / or hubs. z

The run-out of the coupling hub in respect to the bearing housing of the motor is measured.

z

Place the dial gauges according to Fig. 3-17 to measure the run-out at the coupling half.

z

Similarly check the run-out of the coupling hub at the PTO drive shaft in respect to its bearing housing.

Fig. 3-17

NOTE: A simple lever arm is needed to turn the rotor of the electric motor.

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Superstructure

Fig. 3-18 Alignment of the electric motor Final alignment z

Mount the dial gauges as shown in Fig. 3-19.

NOTE: It is practical to adjust the dial gauges in such way that approximately half of the scale is available in either direction. Check the rigidity of the gauge brackets in order to eliminate the possibility of sag. z

Measure and record readings for parallel (Fig. 3-19, Pos. 1), angular (Fig. 3-19, Pos. 2) and axial misalignment in four different positions: top, bottom, right and left, i.e. every 90°, while both shafts are turned simultaneously.

NOTE: For the permissible alignment tolerances for the coupling, refer to the PARTS & SERVICE NEWS No. "AH01523".

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Fig. 3-19

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Electric Motors

z

Align the motor vertically by turning the jacking bolts (Fig. 3-18, Pos. 1).

z

Measure the distance between the bottom of the motor stand and the power frame.

z

Manufacture corresponding compensation plates (Fig. 3-18, Pos. 5) and position the compensation plates between power frame and motor stand.

z

Loosen the jacking bolts and tighten the fixing bolts /nuts (Fig. 3-18, Pos. 2 and 3) to the specified torque: Tightening torque for motor fixing bolts and nuts (Fig. 3-18, Pos. 2 and 3): 3100 Nm

z

Check the alignment again. Make corrections if necessary.

z

Record the data for future checks.

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Electric Motors

3.3.7

Superstructure

CAPACITOR ASSEMBLIES

Fig. 3-20 Capacitors (1)

Capacitor assembly

(2)

Motor connection box

(3)

Motor cooling air intake

(4)

High voltage cable

(5)

Cable clamp

(6)

Capacitor assembly bed-plate

(7)

Mounting bolt with resilient sleeve

(8)

Machinery housing door (left side of machine)

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3.3.7.1 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 1) Special tools:

n/a

Additional equipment:

Crane Capacitor assembly:125 kg

Dogman/rigger Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane or forklift.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

z

Open the outer door (Fig. 3-20, Pos. 8) of motor 1 (rear motor) on the left side of the machine. WARNING

Do not carry out the following work on a hot capacitor. Wait until the temperature of the capacitor is below 50 °C. Disobedience may result in personal injury from heated parts.

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Electric Motors

z

Superstructure

Open the cover of the capacitor connection box (Fig. 3-21, Pos. 1) and disconnect the cable (Fig. 3-21, Pos. 3) and the wires (Fig. 3-21, Pos. 2) from the capacitors.

Fig. 3-21 z

Open the cable clamp (Fig. 3-22, Pos. 3) and remove the cable (Fig. 3-22, Pos. 2).

z

Sling the capacitor assembly (Fig. 3-22, Pos. 1) to a crane with two slings.

z

Remove the capacitor fixing bolts (Fig. 3-22, Pos. 7) and resilient sleeves (Fig. 3-22, Pos. 6) from the bed-plate (Fig. 3-22, Pos. 5).

z

Lift the capacitor assembly off the shock absorbers (Fig. 3-22, Pos. 4) with the crane, and place it on the ground. DANGER

Fig. 3-22

Risk of falling weights! Death or serious injury may result. When lifting the capacitor, make sure that nobody steps below the weight.

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Electric Motors

3.3.7.2 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 1) Special tools:

n/a

Additional equipment:

Crane Capacitor assembly:125 kg

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Carry out installation in reverse order to removal. CAUTION

Before starting the motors, pay attention to the hydraulic oil temperature. Refer to the Operation & Maintenance Manual, chapter 3, section "Starting the main drive motors".

3.3.7.3 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 2) The removal of the capacitor assembly of motor 2 (front motor) is analogously the same as the removal of the capacitor assembly of motor 1 (rear motor), refer to section 3.3.7.1 on page 3-27.

3.3.7.4 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 2) The replacement of the capacitor assembly of motor 2 (front motor) is analogously the same as the removal of the capacitor assembly of motor 1 (rear motor), refer to section 3.3.7.2 on page 3-29.

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Batteries

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3.4

BATTERIES

3.4.1

REMOVAL OF THE BATTERIES

Special tools:

n/a

Additional equipment:

Crane or forklift Battery: 62 kg each

Dogman/rigger Certified electrician

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane or forklift.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

Remove the keys from the battery main switches (Fig. 3-23, Pos. 1).

NOTE: The batteries are located below the hinged floor plats (Fig. 3-23, Pos. 2) in separate boxes. DANGER Danger of explosion due to hydrogen gas! Blindness, serious injury, permanent disfigurement, and scaring may result. Never allow sparks or open flame near the batteries! DO NOT short circuit or ground any terminals of the batteries!

z

Remove floor plate fastening bolts and open the hinged floor plates (Fig. 3-23, Pos. 2).

NOTE: Wash the dirt of the floor plates (Fig. 3-23, Pos. 2) as they can be very heavy. Fig. 3-23 z

Secure the open floor plates against falling down using the safety chains provided.

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z

Batteries

Disconnect the cables from the batteries (Fig. 3-24, Pos. 1). DANGER

Risk of electrical and fire hazard! Death, serious injury, shock, or burns may result. Disconnecting the batteries has to be done by a certified electrician only. Disconnect the ground cables (-) of both batteries first.

z

Remove the angles (Fig. 3-24, Pos. 2) from the batteries.

z

Take the batteries out of the battery boxes.

Fig. 3-24

WARNING Use the provided loops to carry the batteries. Do not drop the battery.

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Batteries

3.4.2

Superstructure

REPLACEMENT OF THE BATTERIES

Special tools:

n/a

Additional equipment:

n/a Battery: 62 kg each

Dogman/rigger Certified electrician If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out installation in reverse order to removal. DANGER

Risk of electrical and fire hazard! Death, serious injury, shock, or burns may result. Clean hands or clothing immediately if electrolyte was spilled. Connecting the batteries has to be done by a certified electrician only. Connect the positive cables (+) of the batteries first.

WARNING Avoid spilling any electrolyte on hands or clothing. Repair or replace all broken wires immediately. All terminals must be clean and securely fastened. Never paint connections.

DANGER Danger of explosion due to hydrogen gas! Blindness, serious injury, permanent disfigurement, and scaring may result. Never allow sparks or open flame near the batteries! DO NOT short circuit or ground any terminals of the batteries!

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Flexible coupling

Superstructure

3.5

FLEXIBLE COUPLING

3.5.1

VULKAN COUPLING

Fig. 3-25 Vulkan coupling Description The Vulkan coupling is a torsionally flexible rubber coupling, that compensates axial, angular and, to a certain degree, radial displacement of the connected machines. The Vulkan coupling transfers the torque without any slippage. The disc-shaped elastic element with a "plug-in" teeth at the outer radius (PTO side) can be replaced without dismantling the motor and the pump distributor gearbox (PTO) respectively.

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Flexible coupling

Legend for Fig. 3-25: (1)

Bolt

(2)

Nut

(3)

Coupling half, PTO side

(4)

PTO flange

(5)

Bolt

(6)

Coupling element

(7)

Bolt

(8)

Elastic element

(9)

Bolt

(10)

Coupling input hub, motor side

(11)

Bolt

(12)

Housing ring

3.5.1.1 REMOVAL OF THE VULKAN COUPLING Special tools:

n/a

Additional equipment:

Chain hoist Coupling element: 47 kg Coupling housing ring: 94 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

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Flexible coupling

Superstructure

NOTE: Check if a lifting eye (Fig. 3-26, Pos. 1) is installed at the roof plate over the coupling. Use the lifting eye to hook a chain hoist. If no lifting eye is installed, it has to be welded to the roof plate. WARNING For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS" and refer to PARTS & SERVICE NEWS No. "AH08507". Fig. 3-26

WARNING Do not carry out the following work on a hot motor. Wait until the temperature of the motor is below 50 °C. Disobedience may result in personal injury from heated parts.

z

Remove the bolts (Fig. 3-27, Pos. 3), resilient sleeves (Fig. 3-27, Pos. 4), and nuts (Fig. 3-27, Pos. 2).

z

Remove the protective cover (Fig. 3-27, Pos. 1).

Fig. 3-27 z

Remove the vulkan coupling according to PARTS & SERVICE NEWS No. "AH01523". DANGER

Risk of falling weights! Death or serious injury may result. When lifting the motor, make sure that nobody steps below the weight.

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Flexible coupling

NOTE: Fig. 3-28 shows the parts for mounting the coupling as they are delivered already installed to the motor power take-off shaft (Fig. 3-28, Pos. 8) and the PTO flange (Fig. 3-28, Pos. 5) respectively. z

Carry out the following step only if required: z

Remove the bolts (Fig. 3-28, Pos. 3) and take the coupling half (Fig. 3-28, Pos. 4) off the PTO flange (Fig. 3-28, Pos. 5).

NOTE: The coupling hub (Fig. 3-28, Pos. 1) should not be drawn-off the motor shaft (Fig. 3-28, Pos. 8), as the motor is balanced along with the hub.

Fig. 3-28

3.5.1.2 REPLACEMENT OF THE VULKAN COUPLING Special tools:

n/a

Additional equipment:

Chain hoist Coupling element: 47 kg Coupling housing ring: 94 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out the following step only if required. z

Install the coupling half (Fig. 3-29, Pos. 4) to the PTO flange (Fig. 3-29, Pos. 5) and install the bolts (Fig. 3-29, Pos. 3).

NOTE: Always use new mounting bolts.

Fig. 3-29 z

Install the new coupling element and the housing ring of the Vulkan coupling according to PARTS & SERVICE NEWS No. "AH01523".

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PTO

Superstructure

3.6

PTO

3.6.1

MAIN PUMPS

Fig. 3-30 Main pumps assembly

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Legend for Fig. 3-30: (1)

Main pump 1

(2)

Main pump 2

(3)

Main pump 3

(4)

Main pump 4

(5)

Main pump 5

(6)

Main pump 6

(7)

Pump distributor gearbox (motor 1)

(8)

Pump distributor gearbox (motor 2)

(9)

O-ring

The rotative energy from each main motor or engine propels the gears in the pump distributor gearboxes (Fig. 3-30, Pos. 7, Pos. 8) and the gears propel the main and auxiliary pumps. The pumps create a hydraulic oil flow to the cylinders or hydraulic motors. The main high pressure hydraulic circuits are supplied from six swash plate type variable displacement pumps (Fig. 3-30, Pos. 1 to 6). All Main pumps are additionally equipped with gear pumps.

3.6.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL Special tools:

n/a

Additional equipment:

4 x swivel hoist rings: M16 Crane Roof plate, PTO side: 355 kg Roof plate, cooling air outlet: 483 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

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PTO

Superstructure

z

Close the hand wheel (Fig. 3-31, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

To accelerate the draining of oil from the pumps, loosen the vent plugs on the main pumps, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP". Fig. 3-31

NOTE: The following steps indicate the standard procedure for main pump removal. It is also possible to access the main pump assemblies with a crane by opening the PVG sound silencer gate on the right side of the engine house. Carry out the following steps only if you refer to the standard procedure. z

Remove all cables which lead through the roof plates over the pumps. WARNING

Pay attention to the Fire Detection and Suppression System. Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression System" The wires of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional.

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PTO

Fig. 3-32 Roof plate removal

z

(1)

Roof plate, PTO side

(2)

Resilient sleeve

(3)

Bolt

(4)

Bolt

(5)

Washer

(6)

Sealing

(7)

Roof plate, cooling air outlet

Remove the roof plates (Fig. 3-32, Pos. 1 and 7) above the main pumps, refer to section 3.3.1 on page 3-9.

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PTO

Superstructure

3.6.1.2 REMOVAL OF MAIN PUMPS Special tools:

n/a

Additional equipment:

Crane Oil drain pans Main pump assembly with flanged gear pump: 362.4 kg each

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

NOTE: The removal of all main pumps (Fig. 3-33, Pos. 1 - 6) is analogously always the same.

Fig. 3-33 z

Carry out the preparatory work, refer to section 3.6.1.1 on page 3-39.

z

If equipped with, remove fasteners for hoses of the main pump assembly to be removed.

z

Mark all pipes and hoses at that main pump assembly of the main pump to be removed. DANGER

Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

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PTO

Drain the drive shaft housing oil, approx. 1.5 liters by removing the drain plug (Fig. 3-34, Pos. 3) of the main pump to be removed. Remove the level plug opening (Fig. 3-34, Pos. 2) to speed up the draining procedure.

NOTE: When the plugs are removed, the oil inside the drive shaft housing will flow out. Catch it in an oil pan.

Fig. 3-34 WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Disconnect the SAE flanges of the pressure hose and the suction hose from the gear pump (Fig. 3-35, Pos. 4) of the main pump to be removed.

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the leak oil hose and all control hoses from the control block (Fig. 3-35, Pos. 1).

z

Disconnect the bearing flushing/lubrication hose from the right side of the pump mounting flange.

z

Disconnect the high pressure hose (Fig. 3-35, Pos. 2) from the main pump assembly.

z

Disconnect the suction hose (Fig. 3-35, Pos. 3) at the bottom side of the pump.

Fig. 3-35

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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PTO

Superstructure

z

Sling pump assembly as shown in Fig. 3-36.

z

Remove mounting bolts. Then remove pump assembly by pulling it out of the pump distributor gearbox. DANGER

Risk of falling weights! Death or serious injury may result. When removing the main pump assembly, make sure that nobody steps below the weight.

NOTE: To simplify the removal, move the pump assembly lightly up and down.

Fig. 3-36

When the pump assembly is removed, oil will flow out of the spline shaft housing. Catch it in an oil pan. z

Check the O-ring (Fig. 3-36, Pos. 1) at the pump assembly flange and replace it if required.

3.6.1.3 REPLACEMENT OF MAIN PUMPS Special tools:

n/a

Additional equipment:

Crane Paste Optimol White, PN 999 039 Main pump assembly with flanged gear pump: 362.4 kg each

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: When mounting a new pump, activate the external flushing of bearing. Refer to PARTS & SERVICE NEWS No. "AH05510". z

Carry out installation in reverse order to removal.

NOTE: Use "Optimol White" on the spline shaft of the pump. Use new bolts with grade 8.8 at the mounting flanges of the main pump. Tighten the bolts to the specified tightening torque. Tightening torque for the main pump mounting bolts: 360 Nm

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PTO

NOTE: For connecting the suction hose, refer to PARTS & SERVICE NEWS No. "AH05525". NOTE: Always use new O-rings at the SAE flange connections and hose fittings. Refill lubricant in the drive shaft housing approx. 1.5 liters, refer to Operation & Maintenance Manual, chapter 4, section "PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL". Fill up to lower edge of level plug opening (Fig. 3-37, Pos. 2). For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

Fig. 3-37 z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

z

Adjust main pump, refer to the Service Manual for further information and refer to PARTS & SERVICE NEWS No. "AH06542".

z

Check for leaks and proper operation.

z

Check the hydraulic oil level again and correct the oil level if required.

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PTO

3.6.2

Superstructure

PTO OIL PUMP (AUXILIARY PUMP)

The gear oil pumps (Fig. 3-38, Pos. 1) for the PTO gear lubrication aspirate gear oil from the PTO gearboxes sump and pumps it through filters and coolers back to the PTOs. The gear oil pumps are attached at the main pump 1 assembly or, respectively, at main pump 4 assembly.

Fig. 3-38

3.6.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP) Special tools:

n/a

Additional equipment:

Oil drain pan PTO oil pump: 25 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Disconnect the SAE flanges of pressure hose and suction hose from the PTO oil pump (Fig. 3-38, Pos. 1) to be removed.

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PTO

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the two bolts (Fig. 3-39, Pos. 1) and pull the PTO oil pump (Fig. 3-39, Pos. 7) out of the adapter (Fig. 3-39, Pos. 2).

z

Remove the four bolts (Fig. 3-39, Pos. 6) and disconnect the adapter (Fig. 3-39, Pos. 2) from the main pump assembly (Fig. 3-39, Pos. 5).

z

Discard the O-ring (Fig. 3-39, Pos. 4).

NOTE: Check the joint element (Fig. 3-39, Pos. 3) for wear and replace it if required.

Fig. 3-39

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PTO

Superstructure

3.6.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP) Special tools:

Hydraulic testing kit, PN 232 591 40

Additional equipment:

Paste "Optimol White" PN 999 039 PTO oil pump: 25 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Check PTO oil pump before installing, refer to PARTS & SERVICE NEWS No. "AH03511" and "AH03512".

z

Remove the two bolts (Fig. 3-39, Pos. 1) at the new PTO oil pump and disconnect the new adapter (Fig. 3-39, Pos. 1) carefully.

z

To avoiding of corrosion coat the adapter surfaces and the pump surface with Optimol White, refer to PARTS & SERVICE NEWS No. "AH06543".

z

Carry out installation in reverse order to removal.

NOTE: Use "Optimol White" on the spline shaft of the pump and use a new O-ring (Fig. 3-39, Pos. 4). NOTE: Use new mounting bolts with grade 8.8 at the mounting flanges of the pump and adapter. Tighten the bolts to the specified tightening torque. Tightening torque for the mounting bolts: 74 Nm z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

z

Run machine to warm, test pressure of the PTO oil pump and adjust if required. Refer to Service Manual.

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3.6.3

PTO

OIL CIRCULATION PUMP (AUXILIARY PUMP)

The oil circulation pumps (Fig. 3-40, Pos. 1) together with back pressure valves prevent cavitation in the swing motors during the swing down phases. For further information refer to section 3.8.4 on page 3-180 and the Service Manual. The oil circulation pumps are attached at the main pump 2 assembly or, respectively, at the main pump 5 assembly.

Fig. 3-40

3.6.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP) Special tools:

n/a

Additional equipment:

Oil drain pan Oil circulation pump: 25 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Disconnect the SAE flanges of pressure hose and suction hose from the circulation pump (Fig. 3-40, Pos. 1) to be removed.

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PTO

Superstructure

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the two bolts (Fig. 3-41, Pos. 1) and pull the oil circulation pump (Fig. 3-41, Pos. 7) out of the adapter (Fig. 3-41, Pos. 2).

z

Remove the four bolts (Fig. 3-41, Pos. 6) and disconnect the adapter (Fig. 3-41, Pos. 2) from the main pump assembly (Fig. 3-41, Pos. 5).

z

Discard the O-ring (Fig. 3-41, Pos. 4).

z

Check the joint element (Fig. 3-41, Pos. 3) for wear and replace it if required.

Fig. 3-41

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3.6.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) Special tools:

Hydraulic testing kit, PN 232 591 40

Additional equipment:

Paste "Optimol White" PN 999 039 Oil circulation pump: 25 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Check the oil circulation pump before installing, refer to PARTS & SERVICE NEWS No. "AH03511" and "AH03512".

z

Remove the two bolts (Fig. 3-41, Pos. 1) at the new oil circulation pump and disconnect the new adapter (Fig. 3-39, Pos. 1) carefully.

z

To avoiding of corrosion coat the adapter surfaces and the pump surface with Optimol White, refer to PARTS & SERVICE NEWS No. "AH06543".

z

Carry out installation in reverse order to removal.

NOTE: Use "Optimol White" on the spline shaft of the pump and use a new O-ring (Fig. 3-41, Pos. 4). NOTE: Use new mounting bolts with grade 8.8 at the mounting flanges of the pump and adapter. Tighten the bolts to the specified tightening torque. Tightening torque for the mounting bolts: 74 Nm z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

z

Run machine to warm, test pressure of the oil circulation pump and adjust if required. Refer to Service Manual.

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PTO

3.6.4

Superstructure

PUMP DISTRIBUTOR GEARBOX (PTO)

Fig. 3-42 Pump distributor gearbox

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PTO

Legend for Fig. 3-42: (1)

Oil level gauge

(2)

Oil filler plug

(3)

Breather filter

(4)

Oil collector reservoir for auxiliary pump drive shaft housing

(5)

Breather filter with oil level gauge (drive shaft housing)

(6)

Main pump drive shaft housings

(7)

Oil level plug of main pump drive shaft housing

(8)

Oil filler plug with breather pipe of main pump drive shaft housing

(9)

Oil drain plug of main pump drive shaft housing

(10)

Oil drain plug of PTO gear

(11)

Flange for heater studs

(12)

Gear oil temperature sensor mounting bore

(14)

Suction port to PTO lubrication pump

(16)

Return line connection from gear oil cooler

(D)

Drive flange

(M)

Power take off for main pumps

(R)

Power take off Not used at machines with electric drives

(C)

Power take off for hydraulic oil cooler fan drive pump

The pump distribution gear (PTO gear) is from a spur gear design and driven by an electric motor. It is equipped with an external lubrication/cooling system. The PTO gear runs in anti friction bearings and has been provided with a splash lubrication system. The oil supply of the bearings and tooth contacts takes place by an injection. The gearwheels are of case-hardened steel. The hydraulic pumps are directly attached to the gearbox. The O-rings included in the delivery seal the unit statically and reliably. The gearbox housing is a one-piece design and made of grey cast iron. The gearbox design with a drive flange allows a direct connection of a flexible coupling, which is installed between the electric motor and the PTO gearbox. The gearbox has been provided with connections for a separate cooling system or for a preheating system. Always check gearbox oil level with unlocked dip stick and stopped electric motor.

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PTO

Superstructure

3.6.4.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) Special tools:

n/a

Additional equipment:

Crane Oil drain pans PTO: 1900 kg each Control- and filter plate assembly: 260 kg each

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Carry out the preparatory work, refer to section 3.6.1.1 on page 3-39.

NOTE: The removal of the pump distributor gearbox 1 (Fig. 3-43, Pos. 7) and pump distributor gearbox 2 (Fig. 3-43, Pos. 8) is analogously the same. Drain the gear oil of the PTO to be removed, approx. 95 liters. Refer to Operation & Maintenance Manual, chapter 4, section "PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL". z

Remove main pump assemblies 1-3 (Fig. 3-43, Pos. 1-3) respectively main pump assemblies 4-6 (Fig. 3-43, Pos. 4-6), refer to section 3.6.1 on page 3-38. Fig. 3-43

z

Remove the hydraulic cooler fan drive pump of the PTO to be removed, refer to section 3.7.1.1 on page 3-60.

z

Relieve pilot pressure at the pressure check point M40 for accumulator, refer to the Service Manual.

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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PTO

Fig. 3-44 PTO 1+2 with control- and filter plates (1)

Pump distributor gearbox (PTO), engine 1

(2)

Pump distributor gearbox (PTO), engine 2

(3)

Control- and filter plate (engine 1)

(4)

Control- and filter plate (engine 2)

z

Mark and disconnect all hydraulic lines and electrical wires leading to the control- and filter plate assembly of the PTO to be removed (Fig. 3-44, Pos. 3 and Fig. 3-44, Pos. 4 respectively).

z

Sling the control- and filter plate assembly of the PTO to be removed (Fig. 3-44, Pos. 3 and Fig. 3-44, Pos. 4 respectively) to a crane.

z

Remove mounting bolts (Fig. 3-45, Pos. 1) with resilient sleeves (Fig. 3-45, Pos. 2).

z

Remove the control- and filter plate assembly (Fig. 3-45, Pos. 3) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the control- and filter plate assembly, make sure that nobody steps below the weight. Fig. 3-45

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PTO

z

Superstructure

Disconnect all hydraulic hoses from the PTO.

NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect all retainers for hydraulic hoses and electrical wires at the PTO.

Fig. 3-46 z

Disconnect the temperature sensor (Fig. 3-47, Pos. 1).

z

Disconnect the heating and the thermo switch, if equipped.

z

Remove the coupling (Fig. 3-47, Pos. 2), refer to section 3.5.1.1 on page 3-35.

Fig. 3-47 z

Attach the PTO to a crane, using the lifting eyes (Fig. 3-48, arrows).

Fig. 3-48

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z

PTO

Remove the bolts (Fig. 3-49, Pos. 2) with resilient sleeves (Fig. 3-49, Pos. 3) attaching the PTO (Fig. 3-49, Pos. 1) to the supports (Fig. 3-49, Pos. 4).

Fig. 3-49 z

Lift the PTO out of the machinery house using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the PTO, make sure that nobody steps below the weight.

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PTO

Superstructure

3.6.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO) Special tools:

Hydraulic testing kit, PN 232 591 40

Additional equipment:

Crane Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 PTO: 1900 kg each Control- and filter plate assembly: 260 kg each

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

If required, install the temperature sensor, the heating, and the thermo switch to the replacement PTO.

z

Carry out installation in reverse order to removal.

NOTE: Before connecting the flexible coupling, check the alignment of the electric motor with the pump distributor gearbox (PTO). Always use new O-rings at all SAE flange connections. NOTE: Use new PTO mounting bolts (Fig. 3-50, Pos. 2) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on the PTO mounting bolts, and tighten the PTO mounting bolts to the specified tightening torque: Tightening torque for the PTO mounting bolts: 1770 Nm

Fig. 3-50

Refill gear oil of the PTO, approx. 95 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL". z

Run machine to warm, test pressure of the circulation pump and adjust if required. Refer to Service Manual for further information.

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3.7

HYDRAULICS

3.7.1

HYDRAULIC COOLER FAN DRIVE PUMP

The hydraulic cooler fan drive pump is a fixed displacement pump with variable setting. The pump of the type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft. The right hydraulic pump on PTO 1 (Fig. 3-51, Pos. 1) supplies the lower and the right hydraulic pump on PTO 2 (Fig. 3-51, Pos. 2) supplies the upper hydraulic fan motor. The fans are mounted directly to the hydraulic motors drive shaft.

Fig. 3-51 Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of an adjusting screw. z

With an increase in the swivel angel, the pump output increases together with the necessary drive torque.

z

With an decrease in the swivel angel, the pump output decreases together with the necessary drive torque.

NOTE: When increasing to maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motor.

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3.7.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP Special tools:

n/a

Additional equipment:

Chain hoist Crane Oil drain pan Hydraulic cooler fan drive pump: 40 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-52, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-52

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NOTE: Check if a lifting eye (Fig. 3-53, Pos. 1) is installed at the roof plate over the pump. Use the lifting eye to hook a chain hoist. If no lifting eye is installed, it has to be welded to the roof plate. WARNING For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS" and refer to PARTS & SERVICE NEWS No. "AH08507". Fig. 3-53

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50°C. Disobedience may result in personal injury from heated oil.

z

Dismantle the hose mounting plate (Fig. 3-54, Pos. 1).

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the pressure hose (Fig. 3-54, Pos. 2) and the suction hose (Fig. 3-54, Pos. 3) from the hydraulic cooler fan drive pump (Fig. 3-54, Pos. 5).

z

Sling the pump, remove the bolts (Fig. 3-54, Pos. 4), and remove the hydraulic cooler fan drive pump (Fig. 3-54, Pos. 5) by pulling it out of the PTO using a chain hoist.

Fig. 3-54

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Superstructure

NOTE: To simplify the removal, move the pump assembly lightly up and down. When the pump assembly is removed, oil will flow out of the spline shaft housing. Catch it in an oil pan. z

Check the O-ring at the pump flange and replace it if required.

z

Remove the hydraulic cooler fan drive pump through the PVG sound silencer gate using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic cooler fan drive pump through the PVG sound silencer gate, make sure that nobody steps below the weight.

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3.7.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP Special tools:

Rotational speed infrared probe DS03, PN 793 788 73

Additional equipment:

Crane Chain Hoist Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Hydraulic cooler fan drive pump: 40 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out installation in reverse order to removal.

NOTE: Use "Optimol White" on the spline shaft of the pump. Always use new O-rings at the SAE flange connections. Use new bolts (Fig. 3-54, Pos. 4) of grade 8.8 at the mounting flanges. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified tightening torque. Tightening torque for the mounting bolts: 74 Nm

Refill the oil collector reservoir (Fig. 3-55, Pos. 1) for the spline shaft housing. For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513". Fig. 3-55

z

Add hydraulic oil up to the specified level.

z

Check and adjust the speed of the hydraulic cooler fan, refer to the Operation and Maintenance Manual, chapter 3, section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS".

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3.7.2

Superstructure

HYDRAULIC COOLER FAN ASSEMBLY

There are four (temperature range up to 40 °C) hydraulic oil coolers in front of the hydraulic oil reservoir on the right-hand side of the platform. Two cooler elements are mounted in one frame at a time, one above the other. So two frames are installed with two cooler elements installed in each frame. The air stream needed for the cooling is produced by hydraulically driven fans. The air flows from inside to outside through the coolers. For better cleaning, the cooler frames are mounted via hinges to the cooler support so the cooler frames can be opened. ("swing out cooler"). The two cooler fans are driven by hydraulic motors. Each motor is supplied by one hydraulic pump. The right hydraulic pump on PTO 1 (Fig. 3-56, Pos. 1) supplies the lower and the right hydraulic pump on PTO 2 (Fig. 3-56, Pos. 2) supplies the upper hydraulic fan motor. The fans are mounted directly to the hydraulic motors drive shaft.

Fig. 3-56

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3.7.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY Special tools:

n/a

Additional equipment:

Oil drain pan Crane Hydraulic cooler fan assembly: 117.4 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

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Fig. 3-57 Position of the hydraulic cooler fan assembly z

Open the hydraulic fan guard (Fig. 3-57, Pos. 1) WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

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z

Hydraulics

Disconnect the hydraulic pressure hoses (Fig. 3-57, Pos. 3) and the leak oil hose (Fig. 3-57, Pos. 2) from the hydraulic motor.

NOTE: When the hoses are removed, the oil inside the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic cooler fan assembly (Fig. 3-58, Pos. 1) from the main cooler frame support, supported using a crane. WARNING

Fan blades could have sharp edges. Use gloves!

CAUTION Remove the assembly carefully in order not to damage the oil cooler or the fan blades.

Fig. 3-58

DANGER Risk of falling weights! Death or serious injury may result. When removing the hydraulic cooler fan assembly, make sure that nobody steps below the weight.

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Hydraulics

Superstructure

3.7.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY Special tools:

Rotational speed infrared probe DS03, PN 793 788 73

Additional equipment:

Crane Hydraulic cooler fan assembly: 117.4 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out installation in reverse order to removal. Refer to PARTS & SERVICE NEWS No. "AH03506". WARNING

Fan blades could have sharp edges. Use gloves!

CAUTION Install the assembly carefully in order not to damage the oil cooler or the fan blades.

z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS "AH01513".

z

Add hydraulic oil up to the specified level.

z

Check and adjust the speed of the hydraulic cooler fan, refer to the Operation and Maintenance Manual, chapter 3, section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS".

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3.7.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR Special tools:

n/a

Additional equipment:

Oil drain pan Fan: 19 kg Hydraulic cooler fan mounting assembly: 72 kg Hydraulic motor assembly: 26.4 kg

Dogman/rigger

z

Remove the hydraulic cooler fan assembly, refer to section 3.7.2.1 on page 3-65.

Fig. 3-59 Hydraulic cooler fan assembly

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Legend for Fig. 3-59: (1)

Bolt

(2)

Locking plate

(3)

Cooler fan

(4)

Drive shaft

(5)

Shaft protecting sleeve

(6)

Drive shaft seal

(7)

Bearing

(8)

Distance sleeve

(9)

Bearing group carrier

(10)

Bearing

(11)

Circlip

(12)

O-ring

(13)

Hydraulic motor

(14)

Bolt

WARNING Fan blades could have sharp edges. Use gloves!

NOTE: Carry out the two following two steps only if cooler fan needs to be removed.

z

z

Remove the attaching bolts (Fig. 3-59, Pos. 1) with the locking plates (Fig. 3-59, Pos. 2). Discard the locking plates.

z

Remove the cooler fan (Fig. 3-59, Pos. 3) from the drive shaft (Fig. 3-59, Pos. 4).

Remove the four bolts (Fig. 3-59, Pos. 14) and remove the hydraulic motor (Fig. 3-59, Pos. 13) from the bearing group carrier (Fig. 3-59, Pos. 9). Discard the O-ring (Fig. 3-59, Pos. 12).

NOTE: When the hydraulic motor is disconnected from the bearing group carrier, the oil inside the bearing group carrier will flow out. Catch it in an oil pan. z

If required remove the circlip (Fig. 3-59, Pos. 11), extract the drive shaft (Fig. 3-59, Pos. 4) out of the bearing group carrier (Fig. 3-59, Pos. 9), and remove the drive shaft seal (Fig. 3-59, Pos. 6), the bearings (Fig. 3-59, Pos. 7 and 10), and the sleeves (Fig. 3-59, Pos. 5 and 8).

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3.7.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR Special tools:

n/a

Additional equipment:

n/a Fan: 19 kg Hydraulic cooler fan mounting assembly: 72 kg Hydraulic motor assembly: 26.4 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

Fig. 3-60 Hydraulic cooler fan assembly z

Carry out installation in reverse order to removal. Refer to PARTS & SERVICE NEWS No. "AH03506".

NOTE: If the drive shaft (Fig. 3-60, Pos. 4) is removed, check the drive shaft. Check drive shaft seal (Fig. 3-60, Pos. 6) for wear and damage. Replace if required. NOTE: Use a new O-ring (Fig. 3-60, Pos. 12) and new locking plates (Fig. 3-60, Pos. 2).

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WARNING Fan blades could have sharp edges. Use gloves!

z

Install the hydraulic cooler fan assembly, refer to section 3.7.2.2 on page 3-68.

NOTE: Check the oil level in the bearing group carrier (Fig. 3-60, Pos. 9) and add oil if required, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER". z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

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Superstructure

HYDRAULIC OIL COOLERS

Fig. 3-61 Hydraulic oil cooler circuit 3 - 74

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Legend for Fig. 3-61: (1)

Back pressure valve

(2)

Solenoid valve (4/2-directional control valve)

(3)

Return lines from control blocks

(4)

Return oil collector tube

(5)

Restrictor (shock absorbers for the hydraulic oil cooler)

(6)

Lines to cooler (hot oil)

(7)

Hydraulic oil cooler

(8)

Lines to hydraulic oil reservoir

(9)

Hydraulic oil reservoir

The returning oil from the system flows via the lines (Fig. 3-61, Pos. 3) into the collector tube (Fig. 3-61, Pos. 4). On the top side of it the back pressure valve (Fig. 3-61, Pos. 1) is installed. The back pressure valve causes a back pressure which forces most of the relative hot oil via the lines (Fig. 3-61, Pos. 6) to the cooler (Fig. 3-61, Pos. 7). On the flow to the cooler the hydraulic oil passes the restrictor, gets cooled in the cooler and then flows through the lines (Fig. 3-61, Pos. 8) into the filter chamber of the hydraulic oil reservoir (Fig. 3-61, Pos. 9). The restrictors acts as shock absorbers to prevent cooler cracks created from pressure peaks. Besides the back pressure valve acts as an oil flow control valve as far as the oil temperature has not reached its steady temperature. During the warm up period (1/2 Qmax) the back pressure valve (Fig. 3-61, Pos. 1) is wide open, because the solenoid valve (Fig. 3-61, Pos. 2) is energized, which results in less oil flow through the cooler which causes the oil getting its optimum operating temperature quicker. With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously the solenoid valve (Fig. 3-61, Pos. 2) will be de-energized, so that the valve piston will be closed further by the force of the spring resulting in more oil passing the cooler. NOTE: Each oil cooler contains the hydraulic oil cooler and PTO gear oil cooler. The machine is equipped with four oil coolers.

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3.7.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane Mobile elevator working platform Oil drain pans Hydraulic oil cooler: 275 kg each

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM"

z

Isolate the machine according to local regulations. WARNING

z

Always wear a safety harness when working at the hydraulic oil coolers.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

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z

Close the hand wheel (Fig. 3-62, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

z

Open the hydraulic oil cooler door. Refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY". WARNING

Fig. 3-62

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Disconnect the hoses (Fig. 3-63, Pos. 1 and 2) from the PTO gear oil cooler.

NOTE: When the hoses are removed, oil will flow out of the oil coolers. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-63

z

Disconnect all inlet hoses (Fig. 3-64, Pos. 2) and outlet hoses (Fig. 3-64, Pos. 1) from the hydraulic oil cooler.

NOTE: When the hoses are removed, oil will flow out of the oil coolers. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-64

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z

Superstructure

Sling the oil cooler (Fig. 3-65).

Fig. 3-65

Fig. 3-66 Removal of the oil cooler z

Remove the bolts (Fig. 3-66, Pos. 2), the washers (Fig. 3-66, Pos. 3) and locking plates (Fig. 3-66, Pos. 4), and clear the oil cooler (Fig. 3-66, Pos. 1) from the angle (Fig. 3-66, Pos. 8).

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z

Hydraulics

Lift the oil cooler (Fig. 3-66, Pos. 1) out of the radiator mounting (Fig. 3-66, Pos. 9) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic oil cooler, make sure that nobody steps below the weight.

NOTE: Discard locking plates (Fig. 3-66, Pos. 4). Check condition of buffer elements (Fig. 3-66, Pos. 10), and replace them if required.

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3.7.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane Mobile elevator working platform Glue PN 256 952 40 Hydraulic oil cooler: 275 kg each

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

Fig. 3-67 Installation of the oil cooler

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WARNING Always wear a safety harness when working at the hydraulic oil coolers.

z

Exchange the restrictor (Fig. 3-61, Pos. 5) from the old oil cooler to the new oil cooler.

z

Apply glue PN 256 952 40 to the profiled joints (Fig. 3-67, Pos. 5 to 7) and attach them in the same manner as they were fixed to the old oil cooler.

z

Carry out further installation in reverse order to removal.

NOTE: Use new locking plates (Fig. 3-67, Pos. 4). z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No."AH01513".

z

Add hydraulic oil up to the specified level.

z

Add PTO gear oil to the specified level.

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3.7.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane 2 x swivel hoist rings: M36 Mobile elevator working platform Oil drain pans Hydraulic oil cooler frame: 3950 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-68, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

z

Open the hydraulic oil cooler door. Refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY". Fig. 3-68

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WARNING z

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Always wear a safety harness when working at the hydraulic oil cooler frame.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Disconnect all wiring harness connectors from the hydraulic oil cooler frame.

z

If required, remove the following parts from the hydraulic oil cooler frame (Fig. 3-69, Pos. 4):

1. Plate (Fig. 3-69, Pos. 1) 2. Rail (Fig. 3-69, Pos. 2) 3. Rail (Fig. 3-69, Pos. 3)

Fig. 3-69 z

Disconnect hydraulic inlet hoses (Fig. 3-70, Pos. 1) from the hydraulic cooler fan motor (Fig. 3-70, Pos. 2).

NOTE: When the hoses are disconnected, oil will flow out of the hoses. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-70

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z

Superstructure

Disconnect the return hose (Fig. 3-71, Pos. 1) and the leak oil hose (Fig. 3-71, Pos. 2) from the hydraulic cooler fan motor.

NOTE: When the hoses are disconnected, oil will flow out of the hoses. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-71 z

Disconnect hydraulic hoses (Fig. 3-72, Pos. 1 and 2) at the shown joints.

NOTE: When the hoses are disconnected, oil will flow out of the hoses. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-72 z

Disconnect PTO oil hoses (Fig. 3-73, Pos. 1 and 2).

NOTE: When the hoses are disconnected, oil will flow out of the hoses. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-73

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z

Insert the swivel hoist rings (M36) into the threads (Fig. 3-74, Pos. 1) of the hydraulic oil cooler frame (Fig 3-74, Pos. 2).

z

Sling hydraulic oil cooler frame (Fig. 3-74, Pos. 2) at the hoist rings.

Fig. 3-74 z

Remove mounting bolts (Fig. 3-75, Pos. 2 and 3) and remove the hydraulic oil cooler frame (Fig. 3-75, Pos. 1) from the superstructure using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic oil cooler, make sure that nobody steps below the weight.

z

Rest the hydraulic oil cooler frame on the ground on an appropriate stand and carry out the following steps if required.

Fig. 3-75 z

If required, remove the hydraulic oil cooler from the hydraulic oil cooler frame, refer to section 3.7.3.1 on page 3-76.

z

If required, remove the cooler fan assembly from the hydraulic oil cooler frame, refer to section 3.7.2.1 on page 3-65.

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3.7.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 2 x swivel hoist rings: M36 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Hydraulic oil cooler frame: 3950 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING Always wear a safety harness when working at the hydraulic oil cooler frame.

z

Carry out installation in reverse order to removal.

NOTE: Use new mounting bolts (Fig. 3-76, Pos. 2 and 3) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque: Tightening torque for mounting bolts (Fig. 3-76, Pos. 2 and 3): 1770 Nm

Fig. 3-76 z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

z

Add PTO gear oil to the specified level.

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Hydraulics

MAIN RELIEF VALVES (MRV)

MRV (main relief valves) are pilot operated relief valves. The MRV limit the maximum pump supply line pressure. The valves are designed with an opening characteristic. That means, if the valve is activated after the response procedure, no further pressure increase is possible and damage is avoided. The valves are installed in the main control valve blocks.

3.7.4.1 REMOVAL OF THE MRV Special tools:

36 mm Socket wrench, PN 232 374 40

Additional equipment:

n/a

NOTE: For additional information about the MRV on the main control valve blocks, refer to section 3.7.8 on page 3-105. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-77, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-77

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Remove the MRV (Fig. 3-78, Pos. 1, 2 or 3) from the main control valve block.

NOTE: When the MRV is removed, oil will flow out of the main control valve block. Catch it in an oil pan. Fig. 3-78

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3.7.4.2 REPLACEMENT OF THE MRV Special tools:

36 mm Socket wrench, PN 232 374 40 Hydraulic testing kit, PN 232 591 40

Additional equipment:

n/a

NOTE: Fit new O-rings to the MRV. z

Carry out installation in reverse order to removal.

NOTE: Tighten the MRV to the specified torque. Tightening torque for MRV: 300 Nm z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

z

Check and adjust the MRV. Refer to Service Manual. WARNING

Wear ear protection when checking the relief pressure.

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PILOT OIL PUMP (GEAR PUMP)

3.7.5.1 REMOVAL OF THE PILOT OIL PUMP Special tools:

n/a

Additional equipment:

n/a Pilot oil pump: 27.4 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-79, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-79

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z

The pilot oil pumps (Fig. 3-80, Pos. 1) generate the pilot pressure that is used for all hydraulic control operations.

z

The pilot oil pumps are attached to both PTOs.

z

Disconnect the SAE flanges of pressure hose and suction hose from the pilot oil pump(s) (Fig. 3-80, Pos. 1).

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Fig. 3-80 z

Remove the two bolts (Fig. 3-81, Pos. 1) and pull the pilot oil pump (Fig. 3-81, Pos. 7) out of the adapter (Fig. 3-81, Pos. 2).

z

Remove the four bolts (Fig. 3-81, Pos. 6) and disconnect the adapter from the main pump assembly (Fig. 3-81, Pos. 5).

z

Discard the O-ring (Fig. 3-81, Pos. 4).

NOTE: Check the joint element (Fig. 3-81, Pos. 3) for wear, and replace it, if required.

Fig. 3-81

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3.7.5.2 REPLACEMENT OF THE PILOT OIL PUMP Special tools:

Hydraulic testing kit, PN 232 591 40

Additional equipment:

Paste "Optimol White" PN 999 039 Pilot oil pump: 27.4 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Check the pilot oil pump before installing, refer to PARTS & SERVICE NEWS No. "AH03511" and "AH03512".

z

Remove the two bolts (Fig. 3-82, Pos. 1) at the new pilot oil pump, and disconnect the adapter (Fig. 3-82, Pos. 2) carefully.

z

To avoiding of corrosion, coat the adapter surfaces and the pump surface with Optimol White, refer to PARTS & SERVICE NEWS No. "AH06543".

z

Carry out installation in reverse order to removal, refer to PARTS & SERVICE NEWS No. "AH05520".

Fig. 3-82 NOTE: Use "Optimol White" on the spline shaft of the pump. Use a new O-ring (Fig. 3-82, Pos. 4) and new mounting bolts (Fig. 3-82, Pos. 1 and Pos. 6) with grade 8.8 at the mounting flanges of the pump and the adapter. Tighten the mounting bolts to the specified tightening torque. Tightening torque for the mounting bolts: 74 Nm z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

NOTE: Check and adjust the pilot pressure, if required. Refer to Service Manual. Version 2010/1

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3.7.6

Superstructure

MAIN GATE VALVE

The connection between the suction reservoir and the hydraulic oil reservoir can be closed with the main gate valve to prevent oil flow during repairs. This unit is monitored by the switch S31. It makes sure that an engine start is not possible with a closed main gate valve. Fault message „Start blocked because of main shut-off (gate) valve“ is displayed on the operator’s dashboard.

3.7.6.1 REMOVAL OF THE MAIN GATE VALVE Special tools:

n/a

Additional equipment:

Oil tank (4450 liters) Main gate valve: 12.3 kg

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-83, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-83

Drain hydraulic oil from the hydraulic oil reservoir, approx. 4450 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

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z

Disconnect the harness connector S31 from the proximity switch at the main gate valve. Refer to Fig. 3-92 on page 3-99.

z

Remove the bolts (Fig. 3-84, Pos. 1), dismantle the compensator (Fig. 3-84, Pos. 2), and the main gate valve (Fig. 3-84, Pos. 3).

NOTE: When the main gate valve (Fig. 3-84, Pos. 3) and the compensator (Fig. 3-84, Pos. 2) are removed some oil inside the piping will flow out. Catch it in an oil pan. Check condition of the compensator (Fig. 3-84, Pos. 2) and replace as necessary.

Fig. 3-84

3.7.6.2 REPLACEMENT OF THE MAIN GATE VALVE Special tools:

n/a

Additional equipment:

Oil tank (4450 liters) Main gate valve: 12.3 kg If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

z

Carry out installation in reverse order to removal. Fill hydraulic oil into the hydraulic oil reservoir, approx. 4450 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

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3.7.7

Superstructure

HYDRAULIC OIL RESERVOIR

Fig. 3-85 Hydraulic oil reservoir

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Legend for Fig. 3-85: (A)

View from machine center

(B)

View from pump compartment

(C)

Top view

(1)

Main hydraulic oil reservoir

(2)

Oil level sight gauge

(3)

Auxiliary return oil connections

(4)

Breather filter

(5)

Leakage oil line connections

(6)

Back-pressure valve, temperature controlled

(7)

Return oil collector tube with strainer

(8)

Oil reservoir outlet (suction pipe)

(9)

Main gate valve

(10)

Drain coupling an collector pipe

(11)

Mounting brackets

(12)

Compensator

(13)

Drain coupling, main oil reservoir

(14)

Access cover

(15)

Return oil filters (four)

(16)

Refill plug

(17)

Leakage oil filter (one)

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3.7.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR Special tools:

Socket wrench 46 mm, PN 232 377 40

Additional equipment:

Safety harness in conformity with EN 361 Crane Mobile elevator working platform 4 x swivel hoist rings: M 36 Hydraulic oil reservoir incl. back pressure valve: 3465 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. WARNING

z

Always wear a safety harness when working at the hydraulic oil reservoir.

z

The following operations require the use of men safety cages on elevator working platforms.

Drain hydraulic oil from the hydraulic oil reservoir, approx. 4450 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

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z

Remove the main gate valve, refer to section 3.7.6.1 on page 3-92.

z

Remove the plates (Fig. 3-86, Pos. 1) beside the threads (Fig. 3-86, Pos. 2).

z

Insert swivel hoist rings (M 36) into the threads (Fig. 3-86, Pos. 2).

Fig. 3-86 z

Remove the rails (Fig. 3-87, Pos. 1) from the hydraulic oil reservoir (Fig. 3-87, Pos. 2).

Fig. 3-87 z

Disconnect the hydraulic outlet hoses (Fig. 3-88, Pos. 1), leading from the hydraulic coolers, from the hydraulic oil reservoir.

z

Disconnect the hydraulic inlet hoses (Fig. 3-88, Pos. 2), leading to the hydraulic coolers, from the hydraulic oil reservoir.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-88

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z

Loosen all clamps (Fig. 3-89, Pos. 2) mounted at the hydraulic oil reservoir to clear all hydraulic lines from the hydraulic oil reservoir (Fig. 3-89, Pos. 3).

z

Mark and disconnect all hydraulic lines (Fig. 3-89, Pos. 1) from the hydraulic oil reservoir.

NOTE: When the hydraulic hoses/pipes are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-89

z

Disconnect the electrical wiring (Fig. 3-90, Pos. 1) from the transfer pump (Fig. 3-90, Pos. 7) and the hydraulic oil reservoir.

z

Shut the cock valves at the hydraulic hoses (Fig. 3-90, Pos. 3) and disconnect the hydraulic hoses from the union (Fig. 3-90, Pos. 4).

z

Clear all hydraulic hoses from the hydraulic oil reservoir.

z

Disconnect all hydraulic lines from the standpipe (Fig. 3-90, Pos. 5).

NOTE: When the hydraulic hoses/pipes are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the grating (Fig. 3-90, Pos. 6).

z

Disconnect all hydraulic lines (Fig. 3-91, Pos. 1) from the standpipe below the hydraulic oil reservoir.

Fig. 3-90

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Loosen all clamps (Fig. 3-91, Pos. 2) below the hydraulic oil reservoir to clear all hydraulic lines from the hydraulic oil reservoir.

Fig. 3-91

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z

Disconnect all wiring harness connectors (Fig. 3-92, Pos. Bxx, Y101) and the head light assembly (Fig. 3-92, Pos. H49b).

z

Remove the wiring harnesses from the hydraulic oil reservoir.

Fig. 3-92 z

Attach the hydraulic oil reservoir to a crane.

z

Remove two mounting bolts (Fig. 3-93, Pos. 1) from each mounting flange (Fig. 3-93, Pos. 3) of the hydraulic oil reservoir (Fig. 3-93, Pos. 2).

z

Lift the hydraulic oil reservoir (Fig. 3-93, Pos. 2) off the superstructure using the crane and place it on the ground. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic oil reservoir, make sure that nobody steps below the weight.

Fig. 3-93

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Fig. 3-94 Filter assembly/provided parts

z

(R)

Return oil filter location

(L)

Leakage oil filter location

(1)

Mounting bolt

(2)

Filter cover retainer

(3)

Filter cover assembly

(4)

Return and leakage filter unit

(5)

Oil filler plug

(6)

Gasket

(7)

Cover

(8)

Breather filter

Remove filters and all provided parts (Fig. 3-94, Pos. 1…8) from the top of the old hydraulic oil reservoir if required.

NOTE: Check O-rings and replace if required. Discard the gasket (Fig. 3-94, Pos. 6).

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z

Hydraulics

Carry out the following steps only if required: z

Remove the back pressure valve (Fig. 3-95, Pos. 2) and discard the gaskets (Fig. 3-95, Pos. 1 and 3).

z

Remove the whole standpipe (Fig. 3-95, Pos. 4).

z

Remove all covers (Fig. 3-95, Pos. 5).

z

Remove all plugs (Fig. 3-95, Pos. 6).

z

Remove the oil level plate (Fig. 3-95, Pos. 8) and hydraulic oil level sight gauge (Fig. 3-95, Pos. 7).

z

Remove all other equipment (clamps, bolts, etc.), if required.

Fig. 3-95

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3.7.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR Special tools:

Socket wrench 46 mm, PN 232 377 40 Hydraulic testing kit, PN 232 591 40

Additional equipment:

Safety harness in conformity with EN 361 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Hydraulic oil reservoir incl. back pressure valve: 3465 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING Always wear a safety harness when working at the hydraulic oil reservoir.

z

If required, install all provided parts (Fig. 3-94, Pos. 1 - 8) at the new hydraulic oil reservoir.

NOTE: Use new gasket (Fig. 3-94, Pos. 6) at the cover (Fig. 3-94, Pos. 7). Use new filter units (Fig. 3-94, Pos. 4). Check O-rings and replace if required. z

Replace the return oil strainer (Fig. 3-96, Pos. 1).

NOTE: Use new gaskets (Fig. 3-96, Pos. 2).

Fig. 3-96 z

If required, install all provided parts (Fig. 3-95, Pos. 1 - 8) at the new hydraulic oil reservoir.

NOTE: Use new gaskets (Fig. 3-95, Pos. 1 and 3) at the back pressure valve (Fig. 3-95, Pos. 2). Check O-rings and replace if required.

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z

Hydraulics

Carry out further installation in reverse order to removal.

NOTE: Use new bolts (Fig. 3-97, Pos. 1) of grade 10.9 at the mounting flanges (Fig. 3-97, Pos. 3) of the hydraulic oil reservoir (Fig. 3-97, Pos. 2). Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts (Fig. 3-97, Pos. 1) and tighten them to the specified tightening torque. Tightening torque for the mounting bolts: 1770 Nm

Fill hydraulic oil into the hydraulic oil reservoir, approx. 4450 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

z

Check and adjust the back pressure if required, refer to Service Manual. Fig. 3-97

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Superstructure

This page was left blank intentionally.

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3.7.8

Hydraulics

MAIN CONTROL VALVE BLOCKS

Fig. 3-98 Main control valve blocks overview (1)

Main control valve block I

(2)

Main control valve block II

(3)

Main control valve block III

(4)

Swing control valve block IV

(5)

High pressure filter 1

(6)

High pressure filter 2

(7)

High pressure filter 3

(8)

High pressure filter 4

There are three main control valve blocks (I - III) and one swing control valve block (IV) on each control and filter panel. Individual valve plugs are mounted on each main control valve block. These valves are anti-cavitation valves (ACV), service line relief valves (SRV), or main relief valves (MRV).

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Fig. 3-99 Main control valve blocks 1 and 2 (BHA)

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Legend for Fig. 3-99: Main control valve block I (BHA) (L.H. Travel, stick, bucket, boom) (46.1)

High pressure filter, pump 2 and 5

(31.1)

SRV Travel motors left backward

(32.1)

ACV Travel motors left backward

(31.2)

SRV Travel motors left forward

(32.2)

ACV Travel motors left forward

(33.1)

SRV Stick cylinder piston side

(32.3)

ACV Stick cylinder piston side

(32.4)

AVC Stick cylinder rod side

(32.5)

ACV Bucket cylinder rod side

(32.6)

ACV Bucket cylinder piston side

(32.7)

ACV Boom cylinder rod side

(32.8)

ACV Boom cylinder piston side

Main control valve block II (BHA) (Bucket, Boom, Reserved, Stick) (44.2)

High pressure filter, pump 4

(32.9)

ACV Bucket cylinder rod side

(32.10)

ACV Bucket piston side

(33.6)

SRV Boom cylinder rod side

(32.11)

ACV Boom cylinder rod side

(32.12)

ACV Boom cylinder piston side

(33.5)

SRV Stick cylinder piston side

(32.15)

ACV Stick cylinder piston side

(32.16)

ACV Stick cylinder rod side

NOTE: The numbers in brackets are component numbers for the hydraulic diagram. NOTE: There is one MRV in each control block.

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Fig. 3-100 Main control valve blocks 3 and 4 (BHA)

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Legend for Fig. 3-100: Main control valve block III (BHA) (R.H. Travel, boom, bucket, stick) (46.2)

High pressure filter, pump 1 and 6

(31.3)

SRV Travel motors right backward

(32.17)

ACV Travel motors right backward

(31.4)

SRV Travel motors right forward

(32.18)

ACV Travel motors right forward

(32.19)

ACV Boom cylinder rod side

(32.20)

ACV Boom cylinder piston side

(32.21)

ACV Bucket cylinder rod side

(32.22)

ACV Bucket cylinder piston side

(32.23)

ACV Stick cylinder rod side

(32.24)

ACV Stick cylinder piston side

Main control valve block IV (BHA) (Single spool for swing) (44.1)

High pressure filter, pump 3

NOTE: The numbers in brackets are component numbers for the hydraulic diagram. NOTE: There is one MRV in each control block.

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Fig. 3-101 Main control valve blocks 1 and 2 (FSA)

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Legend for Fig. 3-101: Main control valve block I (FSA) (L.H. Travel, stick, bucket, boom) (46.1)

High pressure filter, pump 2 an 5

(31.1)

SRV Travel motors left backward

(32.1)

ACV Travel motors left backward

(31.2)

SRV Travel motors left forward

(32.2)

ACV Travel motors left forward

(33.1)

SRV Stick cylinder rod side

(32.3)

ACV Stick cylinder rod side

(32.4)

ACV Stick cylinder piston side

(32.5)

ACV Bucket cylinder rod side

(33.2)

SRV Bucket cylinder rod side

(32.6)

ACV Bucket cylinder piston side

(32.7)

ACV Boom cylinder rod side

(32.8)

ACV Boom cylinder piston side

Main control valve block II (FSA) (Bucket, boom, reserved, stick) (44.2)

High pressure filter, pump 4

(32.9)

ACV bull clam cylinder rod side

(32.10)

ACV bull clam cylinder piston side

(30)

SRV bull clam cylinder piston side

(33.6)

SRV Bucket cylinder rod side

(32.11)

ACV Bucket cylinder rod side

(32.12)

ACV Bucket cylinder piston side

(32.13)

ACV Boom cylinder rod side

(33.4)

SRV Boom cylinder rod side

(32.14)

ACV Boom cylinder piston side

(32.15)

ACV Stick cylinder piston side

(191)

SRV (pressure increasing valve) Stick cylinder rod side

(32.16)

ACV Stick cylinder piston side

NOTE: The numbers in brackets are component numbers for the hydraulic diagram. NOTE: There is one MRV in each control block.

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Fig. 3-102 Main control valve blocks 3 and 4 (FSA)

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Legend for Fig. 3-102: Main control valve block III (FSA) (R.H. Travel, boom, bucket, stick) (46.2)

High pressure filter, pump 1 and 6

(31.3)

SRV Travel motors right forward

(32.17)

ACV Travel motors right forward

(31.4)

SRV Travel motors right backward

(32.18)

ACV Travel motors right backward

(32.19)

ACV Boom cylinder rod side

(32.20)

ACV Boom cylinder piston side

(32.21)

ACV Bucket cylinder rod side

(32.22)

ACV Bucket cylinder piston side

(32.23)

ACV Stick cylinder rod side

(32.24)

ACV Stick cylinder piston side

Main control valve block IV (FSA) (Single spool for swing) (44.1)

High pressure filter, pump 3

NOTE: The numbers in brackets are component numbers for the hydraulic diagram. NOTE: There is one MRV in each control block.

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3.7.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS Special tools:

n/a

Additional equipment:

Crane Oil drain pan Main control valve block I: 717 kg Main control valve block II: 726 kg High pressure filter (main control block II): 44.6 kg Main control valve block III: 713kg Main control valve block IV: 143 kg High pressure filter (main control block IV): 15 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-103, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-103

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WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Remove all SRVs from the main control valve block, refer to section 3.7.9.1 on page 3-121.

z

Remove all ACVs from the main control valve block, refer to section 3.7.10.3 on page 3-133.

z

If required, remove the load holding valves from the main control valve block.

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Fig. 3-104 z

Disconnect all hydraulic lines (Fig. 3-104, Pos. 3) at the respective main control valve block.

z

Disconnect all pilot lines from the spool valves (Fig. 3-104, Pos. 1) at the respective main control valve block.

NOTE: When the hydraulic lines are removed, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Discard the O-rings (Fig. 3-104, Pos. 2) of the SAE flanges.

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z

Hydraulics

Disconnect the return line (Fig. 3-105, Pos. 1) at the respective main control valve block (I - IV) and discard the O-ring (Fig. 3-219, Pos. 2) of the SAE flange.

NOTE: When the return line is removed, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-105 Removal of the Main control valve blocks I and III z

Disconnect the pressure line (Fig. 3-106, Pos. 1) at the respective main control valve block (I or III) and discard the O-ring (Fig. 3-106, Pos. 2) of the SAE flange.

NOTE: When the pressure line is removed, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the harness connectors and clear the wiring harness from the main control valve block.

Fig. 3-106 z

Wind a lifting belt around the spool valves (Fig. 3-104, Pos. 1) and sling the main control valve block at the lifting belt as shown in Fig. 3-107.

z

Remove the mounting bolts, and dismantle the main control valve block from the control valve carrier using a crane.

Fig. 3-107 WARNING Risk of falling weights! May result in death or serious injury. When removing the main control valve blocks, make sure that nobody steps below the weight.

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Removal of the main control valve block II z

Remove the pressure filter (Fig. 3-108, Pos. 3) from the main control valve block II (Fig. 3-108, Pos. 1).

z

If required, disconnect the pressure lines (Fig. 3-108, Pos. 6) from the pressure filter (Fig. 3-108, Pos. 3) and discard the Oring (Fig. 3-106, Pos. 2) at the pressure filter side (Fig. 3-108, Pos. 3) and the quad ring (Fig. 3-108, Pos. 4) at the block side (Fig. 3-108, Pos. 5).

NOTE: When the pressure lines are removed, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the harness connectors, and clear the wiring harness from the main control valve block.

z

Wind a lifting belt around the spool valves, and sling the main control valve block at the lifting belt as shown in Fig. 3-109.

z

Remove the mounting bolts, and dismantle the main control valve block from the control valve carrier using a crane.

Fig. 3-108

Fig. 3-109 WARNING Risk of falling weights! May result in death or serious injury. When removing the main control valve blocks, make sure that nobody steps below the weight.

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Removal of the main control valve block IV z

Disconnect the pressure line (Fig. 3-110, Pos. 3) at the main control valve block (Fig.3-110, Pos.1), and discard the O-ring (Fig. 3-110, Pos. 2) of the SAE flange.

z

Remove the pressure filter (Fig. 3-110, Pos. 4) from the main control valve block (Fig. 3-110, Pos. 1), and discard the O-ring (Fig. 3-110, Pos. 2) at the pressure filter.

z

If required, disconnect the pressure line (Fig. 3-110, Pos. 5) from the pressure filter (Fig. 3-110, Pos. 4), and discard the O-ring (Fig. 3-110, Pos. 2) of the SAE flange.

NOTE: When the pressure lines are removed, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the harness connectors, and clear the wiring harness from the main control valve block.

z

Sling main control valve block using suitable sling accessory.

z

Remove the mounting bolts, and dismantle the main control valve block from the control valve carrier using a crane.

Fig. 3-110

WARNING Risk of falling weights! May result in death or serious injury. When removing the main control valve blocks, make sure that nobody steps below the weight.

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3.7.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS Special tools:

Hydraulic testing kit, PN 232 591 40

Additional equipment:

Crane Compound "KP2K", PN 324 969 40 Main control valve block I: 717 kg Main control valve block II: 726 kg High pressure filter (main control block II): 44.6 kg Main control valve block III: 713kg Main control valve block IV: 143 kg High pressure filter (main control block IV): 15 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings. z

Carry out installation in reverse order to removal.

NOTE: Use new mounting bolts (Fig. 3-111, Pos. 1 and 2) of grade 10.9 and new screw nuts (Fig. 3-111, Pos. 4) for the respective main control valve block (I - III). Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque. Tightening torques for the mounting bolts (Fig. 3-111, Pos. 1 and 2) at the main control valve blocks: 510 Nm NOTE: Use new mounting bolts (Fig. 3-111, Pos. 3) of grade 10.9 for main control valve block IV. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque.

Fig. 3-111

Tightening torques for the mounting bolts (Fig. 3-111, Pos. 3) at the main control valve block IV: 265 Nm z

Mount the pressure filter at main control block II (Fig.3-108, Pos. 3). If required, install the pressure lines using new bolts, a new O-ring (Fig.3-108, Pos.2) and a new quad ring (Fig 3-108, Pos. 4).

z

Mount the pressure filter at main control block IV (Fig.3-110, Pos. 4). If required, install the pressure lines using new bolts and a new O-rings (Fig.3-110, Pos. 2).

NOTE: Refer to PARTS & SERVICE NEWS No. "AH05501".

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z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

z

Check pressure of all circuits of the control valve block (use 400 bar gauge).

3.7.9

SERVICE LINE RELIEF VALVES (SRV)

The service relief valves are pilot operated relief valves. The SRV limit the maximum possible pressure in the service lines created by external force. The valves are designed with an opening characteristic. That means, if the valve is activated after the response procedure, no further pressure increase is possible and damage is avoided. Service relief valves are located on the main control valve blocks on the manifold build and in the throttle check valves, refer to section 3.7.11.1 on page 3-140. NOTE: SRVs are also installed in the travel system, refer to section 4.2.8.1 on page 4-41.

3.7.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK Special tools:

n/a

Additional equipment:

Oil drain pan

NOTE: For additional information about the SRV on the main control valve blocks, refer to section 3.7.8 on page 3-105. z

Relieve the pressure in the hydraulic system. Refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-112, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir. Refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-112

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Fig. 3-113 SRV on the main control valve blocks (BHA)

Fig. 3-114 SRV on the main control valve blocks (FSA)

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WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Disconnect the hose from the SRV.

z

Remove the four bolts (Fig. 3-113 or Fig. 3-114, Pos. 1) attaching the SRV to the main control valve block.

z

Remove the SRV (Fig. 3-113 or Fig. 3-114, Pos. 2), and cap the openings with blind plugs to avoid contamination.

z

Remove the O-rings (Fig. 3-115, Pos. 1) and discard them.

NOTE: Carry out the following steps only if required: z

Remove the support rings (Fig. 3-115, Pos. 2) from the valve body (Fig. 3-115, Pos. 4).

z

Remove the pressure relief valve (Fig. 3-115, Pos. 3) from the valve body (Fig. 3-115, Pos. 4). CAUTION

Different SRVs with different pressures are installed. If removing more than one SRV at the same time, mark the SRV and the position where it is installed.

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3.7.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS Special tools:

Hydraulic testing kit, PN 232 591 40

Additional equipment:

n/a If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Fit new O-rings (Fig. 3-115, Pos. 1) to the SRV.

z

Carry out installation in reverse order to removal.

NOTE: If the pressure relief valve (Fig. 3-115, Pos. 3) was removed from the valve body (Fig. 3-115, Pos. 4) tighten it to the specified torque: Tightening torque for the built-in SRV: 300 Nm z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

z

Check and adjust the SRV. Refer to Service Manual.

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3.7.10 ANTI-CAVITATION VALVES (ACV)

Fig. 3-116 Anti cavitation valve (ACV) (1)

ACV housing

(2)

Valve cone

(3)

Spring

(4)

O-ring

(5)

Control leak oil bore

(6)

Cap screw (torque 900 Nm)

(S)

Supply line

(A/B)

Line connections

The anti-cavitation valves (ACV) are installed to avoid cavitation damages on users (hydraulic cylinders) by compensating a lack of oil when the SRV at the opposite side of the cylinder opens. See hydraulic circuit diagram. The circuit pressure in the line (Fig. 3-116, Pos. A/B) hold the valve cone (Fig. 3-116, Pos. 2) closed. The pressure of the supply line (Fig. 3-116, Pos. S) forces onto the valve cone. The valve cone opens, whenever the pressure at the A and B side is lower than the back pressure at return oil port S, to allow necessary oil supply into circuit.

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The ACVs are installed at the attachment manifold and at the main control valve blocks.

3.7.10.1 REMOVAL OF ACV ON MANIFOLD Special tools:

n/a

Additional equipment:

Crane Oil drain pan Single-anti cavitation valve: 15 kg Double-anti cavitation valve: 44.6 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-117, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-117

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Fig. 3-118 Positions of the ACV at the BHA manifold NOTE: The numbers (Fig.3-118, Pos.140.1 - 140.9) are component numbers for the hydraulic diagram. NOTE: For further information about the ACV at the BHA manifold, refer to the hydraulic diagram and the Service Manual.

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Fig. 3-119 Positions of the ACV at the FSA manifold NOTE: The numbers (Fig.3-119, Pos.140.1 - 140.10) are component numbers for the hydraulic diagram. NOTE: For further information about the ACV at the FSA manifold, refer to the hydraulic diagram and the Service Manual.

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NOTE: In the following steps one ACV of the of the FSA manifold is removed exemplarily. The procedure is identical for all the ACV, except for the valves with other valves attached, so carry out the following four steps only if required: WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50°C. Disobedience may result in personal injury from heated oil.

z

If required, remove the throttle check valve to gain access to the anti-cavitation valve, refer to section 3.7.11.1 on page 3-140.

If required, remove the non return valve (analogously to throttle check valve removal) to gain access to the anti-cavitation valve, refer to section 3.7.11.1 on page 3-140. z

Remove the four bolts attaching the oil pipe (Fig. 3-120, Pos. 3) to the main control valve block and the four bolts (Fig. 3-120, Pos. 2) at the ACV (Fig. 3-120, Pos. 1) end.

z

Remove the oil pipe and the two flange seals (Fig. 3-120, Pos. 4). Discard the seals.

NOTE: When the pipe is disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-120 z

Disconnect the flex hoses (Fig. 3-121, Pos. 2) and remove the joint (Fig. 3-121, Pos. 3) from the anti-cavitation valve (Fig. 3-121, Pos. 1).

NOTE: When the flex hose is disconnected, the oil inside the hose and the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination

Fig. 3-121

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z

Remove the four bolts (Fig. 3-122, Pos. 1) attaching the ACV to the manifold.

z

Remove the ACV (Fig. 3-122, Pos. 2) and the O-ring (Fig. 3-122, Pos. 3). Discard the O-ring.

z

If required, repeat the procedure to remove the other ACV from the manifold.

Fig. 3-122

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3.7.10.2 REPLACEMENT OF THE ACV ON MANIFOLD Special tools:

n/a

Additional equipment:

Crane Compound "KP2K", PN 324 969 40 Single-anti cavitation valve: 15 kg Double-anti cavitation valve: 44.6 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Fit a new O-ring (Fig. 3-123, Pos. 3) to the new ACV (Fig. 3-123, Pos. 2).

z

Apply compound "KP2K", PN 324 969 40 on threads of the mounting bolts (Fig. 3-123, Pos. 1).

z

Align the new ACV to the manifold and insert the mounting bolts.

Fig. 3-123 z

Carry out further installation in reverse order to removal.

NOTE: Carry out the following four steps only if required: z

If required, install the throttle check valve onto the ACV, refer to section 3.7.11.2 on page 3-143.

z

If required, install the non return valve (analogously to the throttle check valve installation), refer to section 3.7.11.2 on page 3-143.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

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3.7.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS Special tools:

n/a

Additional equipment:

Oil drain pan

NOTE: For additional information about the ACV on the main control valve blocks, refer to section 3.7.8 on page 3-105. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-124, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-124

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Fig. 3-125 ACV on the main control valve blocks (BHA)

Fig. 3-126 ACV on the main control valve blocks (FSA)

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NOTE: The numbers (Fig. 3-125 or Fig. 3-126, Pos. 32.1 - 32.24) are component numbers for the hydraulic diagram. NOTE: For further information about the ACV at the main control valve blocks, refer to the hydraulic diagram and the Service Manual. WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50°C. Disobedience may result in personal injury from heated oil.

z

Remove the four bolts (Fig. 3-125 or Fig. 3-126, Pos. 1) attaching the ACV to the main control valve block.

z

Remove the ACV (Fig. 3-125 or Fig. 3-126, Pos. 2).

NOTE: When the ACV is removed, the oil inside the valves will flow out. Catch it in an oil pan. Cap the openings to avoid contamination. z

Remove the O-rings (Fig. 3-127, Pos. 1) and discard them.

z

Remove the support rings (Fig. 3-127, Pos. 2) from the valve body (Fig. 3-127, Pos. 3) only if required.

Fig. 3-127

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3.7.10.4 REPLACEMENT OF THE ACV ON MAIN CONTROL VALVE BLOCKS Special tools:

n/a

Additional equipment:

n/a If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings to the ACV (Fig. 3-127, Pos. 1). z

Carry out installation in reverse order to removal.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

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3.7.11 THROTTLE CHECK VALVES

Fig. 3-128 Throttle check valve with built-in SRV

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Legend for Fig. 3-128: NOTE: The illustration shows the valve block up side down (1)

Throttle adjustment pin

(2)

Back-up ring

(3)

O-ring

(4)

Retainer

(5)

Back-up ring

(6)

O-ring

(7)

Spring

(8)

Spring cup

(9)

Throttle valve sleeve

(9.1)

Adjustable throttle holes

(9.2)

Permanent throttle holes (safety channel)

(10)

O-ring

(11)

Housing

(12)

Return line port, T

(13)

SRV

(14)

Bolt

(15)

Clip ring

(16)

Lock nut

(A)

Line ports from the control valve

(B)

Line port to the cylinder

(M)

Pressure check point

(Y)

Control oil drain port

The maximum permissible cylinder speed is set by the pin (Fig. 3-128, Pos.1). Depending on the pin setting, the radial holes (Fig. 3-128, Pos. 9.1) in the valve sleeve (Fig. 3-128, Pos. 9) will be opened partially to achieve the required throttling of the oil flow. The safety holes (Fig. 3-128, Pos. 9.2) prevent the valve from becoming completely closed. For the lifting operation the valve sleeve which is guided by the spindle (Fig. 3-128, Pos. 1) is pressed against the spring (Fig. 3-128, Pos. 7) so that the valve will be completely open. The build-in SRV (Fig. 3-128, Pos. 13) limits the maximum system pressure from the cylinder and relieves oil to the tank line when the pressure reaches the valve setting.

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3.7.11.1 REMOVAL OF THROTTLE CHECK VALVES Special tools:

n/a

Additional equipment:

Crane Oil drain pan Throttle check valve (long version): 31 kg Throttle check valve (short version): 28 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

Fig. 3-129 Positions of the throttle check valves BHA NOTE: The numbers (Fig. 3-129, Pos. 138.1 - 145.5) are component numbers for the hydraulic diagram. For further information about the SRV at the BHA manifold, refer to the hydraulic diagram and the Service Manual.

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Fig. 3-130 Positions of the throttle check valves FSA NOTE: The numbers (Fig. 3-130, Pos. 141.1 - 158) are component numbers for the hydraulic diagram. For further information about the SRV at the FSA manifold, refer to the hydraulic diagram and the Service Manual. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

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z

Close the hand wheel (Fig. 3-131, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP". WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Disconnect the flex hose (Fig. 3-132, Pos. 5) from the throttle check valve (Fig. 3-132, Pos. 1).

z

Remove the four bolts (Fig. 3-132, Pos. 2) and remove the pipe (Fig. 3-132, Pos. 3) from the throttle check valve (Fig. 3-132, Pos. 1).

Fig. 3-131

NOTE: When the hydraulic lines are removed, the oil inside the piping and the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-132 z

Remove the four bolts (Fig. 3-133, Pos. 5) attaching the throttle check valve (Fig. 3-133, Pos. 1) to the manifold (Fig. 3-133, Pos. 2).

z

Remove the throttle check valve (Fig. 3-133, Pos. 1) and the O-ring (Fig. 3-133, Pos. 3). Discard the O-ring.

NOTE: When the throttle check valve is removed, the oil inside the valve and the manifold will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

If required, remove the adaptor (Fig. 3-133, Pos. 4) from the throttle check valve. Fig. 3-133

z

If required, repeat the procedure to remove the other throttle check valves from the manifold.

z

If required, remove the built-in SRV (Fig. 3-128, Pos. 13) from the throttle check valve’s housing (Fig. 3-128, Pos. 11).

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3.7.11.2 REPLACEMENT OF THROTTLE CHECK VALVES Special tools:

n/a

Additional equipment:

Crane Compound "KP2K", PN 324 969 40 Throttle check valve (long version): 31 kg Throttle check valve (short version): 28 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit a new O-ring (Fig. 3-133, Pos. 3) to the throttle check valve (Fig. 3-133, Pos. 1). z

Carry out installation in reverse order to removal.

NOTE: If the built-in SRV (Fig. 3-128, Pos. 13) has been removed from the housing (Fig. 3-128, Pos. 11), tighten it to the specified tightening torque: Tightening torque for the built-in SRV: 300 Nm NOTE: Apply compound "KP2K", PN 324 969 40 on heads and threads of the throttle check valve mounting bolts (Fig. 3-133, Pos. 5). z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, section 4.13.

z

Add hydraulic oil up to the specified level.

z

Check and adjust the throttle check valve. Refer to the Service Manual, section 8.1.11.

z

Check and adjust the built-in SRV in the throttle check valves if required. Refer to the Service Manual, section 8.1.10.

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3.7.12 MANIFOLD 3.7.12.1 REMOVAL OF THE MANIFOLD Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane Oil drain pan Manifold BHA incl. ACVs and SRVs: 921.2 kg Manifold FSA incl. ACVs and SRVs: 893.2 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-134, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-134

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WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50°C. Disobedience may result in personal injury from heated oil.

z

Disconnect all hydraulic hoses (Fig. 3-135, Pos. 1) leading to the attachment, refer to section 5.1.6.1 on page 5-58 (BHA) or refer to section 5.2.6.1 on page 5-142 (FSA). WARNING

Always wear a safety harness when working at the front side of the manifold.

z

Disconnect the hydraulic piping (Fig. 3-135, Pos. 2) at the front of the manifold.

NOTE: When the hydraulic lines are removed, the oil inside the hydraulic lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the manifold.

z

Remove four mounting bolts (Fig. 3-135, Pos. 3).

z

Remove the manifold using a crane.

z

Remove the anti cavitation valves (ACV) from the manifold, refer to section 3.7.10.1 on page 3-127.

z

Remove the throttle check valves from the manifold, refer to section 3.7.11.1 on page 3-140.

Fig. 3-135

DANGER Risk of falling weights! May result in death or serious injury When removing the manifold, make sure that nobody steps below the weight.

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3.7.12.2 REPLACEMENT OF THE MANIFOLD Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane Compound "KP2K", PN 324 969 40 Manifold BHA incl. ACVs and SRVs: 921.2 kg Manifold FSA incl. ACVs and SRVs: 893.2 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings to the SAE flanges. Apply compound "KP2K", PN 324 969 40 on heads and threads of the manifold mounting bolts (Fig. 3-135, Pos. 3) and tighten them to the specified tightening torque. WARNING Always wear a safety harness when working at the front side of the manifold.

z

Carry out installation in reverse order to removal.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

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Slew system

SLEW SYSTEM

Fig. 3-136 The PC5500-6 is equipped with two slew gear arrangements. For further information, refer to the Service Manual. Multi disc brakes (Fig. 3-136, Pos. 3) are installed between the swing motors (Fig. 3-136, Pos. 2) and the gearboxes (Fig. 3-136, Pos. 4). These brakes are safety brakes, applied by spring force and released by oil pressure. To operate the rotary motion, slew brake valves (Fig. 3-136, Pos. 1) are directly flanged to the swing motor heads. For further information, refer to the Service Manual.

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Superstructure

SLEW GEAR

Fig. 3-137 Slew gear unit (Siebenhaar) NOTE: The machine can be equipped either with a slew gear of manufacturer "L&S" or of manufacturer "Siebenhaar". The removal and the replacement of the slew gear by different manufacturer are analogously the same. Refer to the data plate on each slew gear housing to find out the manufacturer of the slew gear. 3 - 148

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3.8.1.1 REMOVAL OF THE SLEW GEAR Special tools:

n/a

Additional equipment:

Crane 4 x swivel hoist rings: M16 Swing motor with attached slew service brake valve: 292.5 Slew gear (Siebenhaar): 1700 kg Slew gear (L&S): 1880 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-138, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP".

Fig. 3-138 z

Remove the swing motor (Fig. 3-137, Pos. 2) from the slew gearbox (Fig. 3-137, Pos. 3), refer to section 3.8.2.1 on page 3-159. Leave the hydraulic hoses and the slew service brake valve (Fig. 3-137, Pos. 1) attached to the swing motor if possible. If not disconnect the hydraulic lines.

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z

Superstructure

Remove the bleeder valves (Fig. 3-139, Pos. 1) Drain the gear oil from the slew gear (Fig. 3-139, Pos. 3 respectively Pos. 5) at the drain coupling (Fig. 3-139, Pos. 2), • approx 60 liters (Siebenhaar), • approx. 42 liters (L&S), refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL"

z

Remove the oil drain coupling (Fig. 3-139, Pos. 2), and, if equipped with, remove the union (Fig. 3-139, Pos. 4) from the slew gear (Fig. 3-139, Pos. 3 respectively Pos. 5).

Fig. 3-139 DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the oil pressure line from the slew parking brake.

NOTE: When the hydraulic lines are disconnected, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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z

Slew system

Removing the rear slew gear, the hydraulic line (Fig. 3-140, Pos. 2) and the mounting (Fig. 3-140, Pos. 1) for hydraulic hoses have to be removed.

NOTE: When the hydraulic line is disconnected, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-140

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Fig. 3-141 Slew gear (Siebenhaar) z

Remove the protection caps (Fig. 3-141, Pos. 1) from the bolt heads and remove the slew gear mounting bolts (Fig. 3-141, Pos. 2) and washers (Fig. 3-141, Pos. 3). Discard the bolts.

z

Disconnect the lubrication lines below the slew gear.

z

Install four swivel hoist rings (M16) displaced by 90° into the threaded bores for the swing motor mounting bolts and attach a crane.

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z

Slew system

Remove the slew gear using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the slew gear, make sure that nobody steps below the weight.

3.8.1.2 REPLACEMENT OF THE SLEW GEAR Special tools:

Feeler gauge (customary)

Additional equipment:

Crane 4 x swivel hoist rings: M16 Compound "KP2K", PN 324 969 40 Swing motor with attached slew service brake valve: 292.5 Slew gear (Siebenhaar): 1700 kg Slew gear (L&S): 1880 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING New slew gears are delivered without gear oil

NOTE: The machine can be equipped either with a slew gear of manufacturer "Siebenhaar" or of manufacturer "L&S". Refer to the data plate on each slew gear housing to find out the manufacturer of the slew gear. Both slew gears are replaceable using of a special modification kit. Refer to PARTS & SERVICE NEWS No. "AH05535". NOTE: Ensure that the mating surfaces are clean and free of paint before assembly.

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Fig. 3-142 Slew gear unit (Siebenhaar)

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z

Install four swivel hoist rings (M16) displaced by 90° into the threaded bores for the swing motor mounting bolts and attach a crane.

z

Insert the new slew gear (Fig. 3-142, Pos. 3) and mount it to the superstructure with the mounting bolts (Fig. 3-142, Pos. 1) and the washers (Fig. 3-142, Pos. 2).

NOTE: Use new slew gear mounting bolts (Fig. 3-142, Pos. 1) of grade 12.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque.. Tightening torque for the slew gear mounting bolts: 1030 Nm

z

Install the oil drain coupling (Fig. 3-143, Pos. 2) with the union (Fig. 3-143, Pos. 4) if equipped, at the new slew gear (Fig. 3-143, Pos. 3 respectively Pos. 5).

z

Clean the bleeder valves (Fig. 3-143, Pos. 1) with compressed air from inside to outside and reinstall at the new slew gear (Fig. 3-143, Pos. 3 respectively Pos. 5).

Fig. 3-143 z

Connect the lubrication lines.

z

Carry out further installation in reverse order to removal. WARNING

Make sure to use the specified bolts and tightening torque for the swing motor mounting bolts, refer to section 3.8.2.2 on page 3-162.

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Fill gear oil into the slew gear, • approx. 60 liters (Siebenhaar), • approx. 42 liters (L&S). Fill oil into the motor adapter housing, • approx. 0.6 liters (L&S), • up to level gauge marking (Siebenhaar). Fill oil into the brake housing (Siebenhaar only), approx. 0.2 liters. NOTE: Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS". z

Check the tooth backlash between slew ring and slew pinion with a feeler gauge. Refer to PARTS & SERVICE NEWS No. "AH00511".

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3.8.2

Superstructure

SWING MOTOR

Fig. 3-144 Swing motor assembly (1)

Bolt

(12)

Bolt (only Siebenhaar)

(2)

Slew brake valve

(13)

Washer (only Siebenhaar)

(3)

O-ring

(14)

Expansion tank of the slew gear (only Siebenhaar)

(4)

Bolt

(15)

Sleeve (only Siebenhaar)

(5)

Intermediate plate

(6)

O-ring

(7)

Bolt

(8)

Washer

(9)

Swing motor

(10)

O-ring

(11)

Slew gear

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3.8.2.1 REMOVAL OF THE SWING MOTOR Special tools:

n/a

Additional equipment:

Crane Oil drain pan Swing motor: 170 kg Slew brake valve: 97 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-145, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP".

Fig. 3-145 WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50°C. Disobedience may result in personal injury from heated oil.

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Drain gear oil from the motor adapter housing. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL" z

Disconnect all hydraulic hoses (Fig. 3-146, Pos. 1), attached to the swing motor (Fig. 3-146, Pos. 2).

NOTE: When the hydraulic hoses are disconnected, hydraulic oil from inside the hoses and the swing motor will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-146

Fig. 3-147 Removal of the swing motor

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z

Slew system

Remove the four mounting bolts (Fig. 3-147, Pos. 1) and take the slew brake valve (Fig. 3-147, Pos. 2) off. Discard the O-ring (Fig. 3-147, Pos. 3). For further information, refer to section 3.8.4.1 on page 3-183.

NOTE: The hydraulic hoses remain at the slew brake valve. When the slew brake valve is removed, the oil inside the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the mounting bolts (Fig. 3-147, Pos. 4) and take off the intermediate plate (Fig. 3-147, Pos. 5). Discard the O-ring (Fig. 3-147, Pos. 6).

z

Only slew gear (Siebenhaar): Remove the bolts (Fig. 3-147, Pos. 12), with washers (Fig. 3-147, Pos. 13), and the sleeves (Fig. 3-147,Pos. 15). Put the expansion tank (Fig. 3-147, Pos. 14) of the slew gear aside. Discard the bolts.

z

Remove the bolts (Fig. 3-147, Pos. 7) and the washers (Fig. 3-147, Pos. 8). Discard the bolts.

z

Sling the swing motor (Fig. 3-147, Pos. 9).

z

Pull the swing motor out of the slew gear (Fig. 3-147, Pos. 11) using a crane. Place the swing motor on the ground. DANGER

Risk of falling weights! May result in death or serious injury. When removing the swing motor, make sure that nobody steps below the weight.

z

Discard the O-ring (Fig. 3-147, Pos. 10).

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3.8.2.2 REPLACEMENT OF THE SWING MOTOR Special tools:

Hydraulic testing kit, PN 232 591 40

Additional equipment:

Crane Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Swing motor: 170 kg Slew brake valve: 97 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

Fig. 3-148 Installation of the swing motor

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NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings (Fig. 3-148, Pos. 3, Pos. 6 and Pos. 10). z

Apply "Optimol White" to the spline shaft of the motor.

z

Carry out installation in reverse order to removal.

NOTE: Use new swing motor mounting bolts (Fig. 3-148, Pos. 7 and 12) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified torque. Tightening torque for the swing motor mounting bolts: 265 Nm z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level. Fill oil into the motor adapter housing, • approx. 0.6 liters (L&S), • up to level gauge marking (Siebenhaar). Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

z

Check the adjustments of the swing motors. Refer to the Service Manual for further information.

z

Check the slew brake valve and adjust it if required. Refer to the Service Manual for further information.

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3.8.3

Slew system

SLEW PARKING BRAKE

NOTE: The machine can be equipped either with a slew parking brake of manufacturer "Siebenhaar" or of manufacturer "L&S". For the removal and the replacement, the "L&S" slew parking brake has to be disassembled/assembled. The "Siebenhaar" slew parking brake assembly can be exchanged completely.

Slew parking brake (L&S) (1)

Disc housing

(10)

Thrust washer

(2)

Thrust washer

(11)

Circlip

(3)

Inner discs

(12)

Drive shaft

(4)

Outer discs

(13)

Oil pressure port

(5)

Sinus spacer ring

(14)

Bolt

(6)

Piston

(15)

Bearing ring

(7)

Quad ring with back up ring

(16)

Rotary shaft seal

(8)

Quad ring with back up ring

(17)

Cylinder assembly

(9)

Springs

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General: Brake applied: The outer disks engaged to the housing by serration and the inner disks in serrated connection with the drive shaft are pressed together by the springs. This results in a fixed connection between housing and drive shaft due to the friction between the spring pressurized discs. Brake released: Oil pressure via the pilot port reaches the bottom of the piston and forces the piston upwards against the thrust washer and the spring force. This eliminates the spring force towards the disks so that the friction between the discs is released and the inner shaft can rotate. Only the brake of the L&S gearbox uses an additional spacer ring (sinus ring) to keep the discs apart. It should reduce the friction in released condition. The minimum release pressure is 19 - 20 bar. In normal working conditions, the releasing pressure is about 60 bar. NOTE: The slew parking brake must only be applied with the superstructure at a complete standstill. Applying the parking brake with superstructure still slewing may result in severe damage to the brake. WARNING z

Only use the slew parking brake in emergency situations to stop the rotating superstructure.

z

If the parking brake has been used for an emergency stop, it is necessary to shut down the excavator and to have the parking brake of each swing gear inspected and repaired if necessary. Contact your Komatsu dealer for repairing the brakes.

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3.8.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) Special tools:

n/a

Additional equipment:

Crane 4 x swivel hoist rings: M16 Swing motor with attached slew service brake valve: 292.5 kg Bearing ring: 32 kg

Dogman/rigger

NOTE: The slew parking brake is attached to the slew gear with eight hexagon socket bolts. It is removed by disassembling it. z

Remove the swing motor from the slew gear, refer to section 3.8.2.1 on page 3-159. Leave the hydraulic hoses and the slew service brake valve attached to the swing motor.

NOTE: For further information relating the parking brake, refer to PARTS & SERVICE NEWS No. "AH03509". z

Install four swivel hoist rings (M16) displaced by 90° into the threaded bores for the swing motor mounting bolts and attach a crane.

z

Remove the mounting bolts (Fig. 3-149, Pos. 1) at the swing motor flange.

z

Remove the inner snap ring (Fig. 3-149, Pos. 2).

z

Dismantle the bearing ring (Fig. 3-149, Pos. 3) from the slew gearbox using a crane.

Fig. 3-149

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Fig. 3-150 Slew parking brake (L&S) z

Check rotary shaft seal (Fig. 3-150, Pos. 16) for wear and damage. Replace it if required.

z

Disconnect the pressure hose from the oil pressure port (Fig. 3-150, Pos. 13).

NOTE: When the pressure hose is removed, the oil inside the hose and the cylinder (Fig. 3-150, Pos. 17) will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. WARNING The piston (Fig. 3-150, Pos. 6) of the break assembly is spring loaded.

z

Remove the two socket head cap bolts (Fig. 3-150, Pos. 14) and relieve the spring load of the springs (Fig. 3-150, Pos. 9) on the piston (Fig. 3-150, Pos. 6).

z

Take off the cylinder assembly (Fig. 3-150, Pos. 17).

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z

Dismount 10 inner discs (Fig. 3-150, Pos. 3), 11 outer discs (Fig. 3-150, Pos. 4), and 10 sinus spacer rings (Fig. 3-150, Pos. 5) from the disc housing (Fig. 3-150, Pos. 1).

z

Remove the drive shaft (Fig. 3-150, Pos. 12).

z

Remove the thrust washer (Fig. 3-150, Pos. 2) from the disc housing (Fig. 3-150, Pos. 1).

z

Check the inner discs (Fig. 3-150, Pos. 3), the outer discs (Fig. 3-150, Pos. 4), the sinus spacer rings (Fig. 3-150, Pos. 5), and the thrust washer (Fig. 3-150, Pos. 2) for wear and damage. Replace if required.

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Superstructure

3.8.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) Special tools:

n/a

Additional equipment:

Crane Paste "Optimol White" PN 999 039 Hydraulic power unit (60 bar) with fitting (M18 x 1.5) Swing motor with attached slew service brake valve: 292.5 kg Bearing ring: 32 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

Fig. 3-151 Slew parking brake (L&S)

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NOTE: Replace all O-rings. For further information relating the parking brake, refer to PARTS & SERVICE NEWS No. "AH03509". z

Install the thrust washer (Fig. 3-151, Pos. 2).

z

Install the drive shaft (Fig. 3-151, Pos. 12).

NOTE: Apply "Optimol White" to the spline shaft. z

Install new discs according to the following order: At first an outer disc (Fig. 3-151, Pos. 4), then an inner disc (Fig. 3-151, Pos. 3), and then a sinus spacer ring (Fig. 3-151, Pos. 5). Apply oil to the discs.

NOTE: Before reinstallation, apply pressure (max. 60 bar) to the cylinder assembly (Fig. 3-151, Pos. 17), otherwise the two socket head cap bolts (Fig. 3-151, Pos. 14) are prestressed (spring loaded). z

Install the cylinder assembly (Fig. 3-151, Pos. 17).

z

Carry out further installation in reverse order to removal. WARNING

Make sure to use the specified bolts and torque for the swing motor mounting bolts, refer to section 3.8.2.2 on page 3-162.

Fill oil into the motor adapter housing, approx. 0.6 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS". z

Add hydraulic oil up to the specified level.

z

Check slew parking brake for proper function. Refer to the Service Manual.

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3.8.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) Special tools:

n/a

Additional equipment:

Crane 2 x swivel hoist rings: M16 Swing motor with attached slew service brake valve: 292.5 kg Slew parking brake assembly: 115 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. NOTE: There can be two different types of "Siebenhaar" slew parking brake assemblies installed at the machines (depending on gear type): Old type: PN 925 864 40 New type: PN 936 540 40 If an old type is installed, it is recommended by KOMATSU to rebuild the brake assembly according to the PARTS & SERVICE NEWS No. "AH07509". Only the removal of the "new type" slew parking brake is described below. z

Remove the swing motor from the slew parking brake, refer to section 3.8.2.1 on page 3-159. Leave the hydraulic hoses and the slew service brake valve (Fig. 3-137, Pos. 1) attached to the swing motor. Drain oil of the brake housing, approx. 0.2 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL".

NOTE: After draining the oil of the brake housing, cap the openings with blind plugs to avoid contamination. DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the pilot oil pressure line from the slew parking brake.

NOTE: When the pilot oil pressure line is disconnected, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Version 2010/1

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z

Superstructure

Remove all hydraulic pipes (Fig. 3-152, Pos. 3) from the slew parking brake (Fig. 3-152, Pos.23) and cap the openings with blind plugs to avoid contamination. DANGER

Danger of parts blasting off! Serious injury, permanent disfigurement and scarring, or death may result! The piston of the slew parking break assembly is spring loaded. It is necessary to release the brake manually (see following procedure) before removing the mounting bolts (Fig. 3-152, Pos. 1) attaching the complete slew parking brake (Fig. 3-152, Pos. 2) to the slew gearbox (Fig. 3-152, Pos. 4). Never open the brake by removing the flange mounting bolts (Fig. 3-153, Pos. 3) before the slew parking brake is manually released!

Fig. 3-152

Fig. 3-153 Slew parking brake (Siebenhaar), drawn released

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Releasing the slew parking brake manually: z

Insert two crews (Fig. 3-154, Pos. 1) of suitable length with nuts (Fig. 3-154, Pos. 3) in the threaded borings (Fig. 3-153, Pos. 2) of the piston (Fig. 3-154, Pos. 2) opposed to each other.

z

Tighten each nut (Fig. 3-154, Pos. 3) alternately with a half turn, to withdraw the piston Fig. 3-154, Pos. 2) to the flange (Fig. 3-154, Pos. 4).

NOTE: Avoid tilting the piston! z

Only remove the mounting bolts (Fig. 3-152 and 3-153, Pos. 1) attaching the complete slew parking brake (Fig. 3-154, Pos. 2) to the slew gearbox.

Fig. 3-154

DANGER Danger of parts blasting off! Serious injury, permanent disfigurement and scarring, or death may result! The piston of the slew parking break assembly is spring loaded. Never open the brake by removing the flange mounting bolts (Fig. 3-153, Pos. 3) before the slew parking brake is manually released!

z

Insert swivel hoist rings (M16) displaced by 180° into the threads of the swing motor mounting bolts and attach a crane.

z

Remove the slew parking brake (Fig. 3-152, Pos. 2) from the slew gearbox (Fig. 3-152, Pos. 4), using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the slew gear, make sure that nobody steps below the weight.

z

Discard the O-ring (Fig. 3-152, Pos. 5).

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3.8.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) Special tools:

n/a

Additional equipment:

Crane 2 x swivel hoist rings: M16 Paste "Optimol White", PN 999 039 Swing motor with attached slew service brake valve: 292.5 kg Slew parking brake assembly: 115 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: There can be two different types of "Siebenhaar" slew parking brake assemblies installed at the machines (depending on gear type): Old type: PN 925 864 40 New type: PN 936 540 40 If an old type is installed, it is recommended by KOMATSU to rebuild the brake assembly according to the PARTS & SERVICE NEWS No. "AH07509". Only the replacement of the "new type" slew parking brake is described below.

Fig. 3-155 Slew parking brake (Siebenhaar), drawn released

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DANGER Danger of parts blasting off! Serious injury, permanent disfigurement and scarring, or death may result! The piston of the slew parking break assembly is spring loaded. Never open the brake by removing the flange mounting bolts (Fig. 3-155, Pos. 3) before the slew parking brake is manually released!

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Apply paste "Optimol White" on the spline shaft at the adapter cover (Fig. 3-156, Pos. 4) of the gearbox.

z

Install swivel hoist rings (M16) on the new pre-assembled slew parking brake, displaced by 180° into the threads of the swing motor mounting bolts and attach the brake assembly to a crane.

z

Insert a new O-Ring (Fig. 3-156, Pos. 3).

z

Centre the new pre-assembled slew parking brake (Fig. 3-156, Pos. 2) onto the adapter cover (Fig. 3-156, Pos. 4) of the gearbox. DANGER

Fig. 3-156

Risk of falling weights! May result in death or serious injury. When removing the slew gear, make sure that nobody steps below the weight.

Releasing the slew parking brake manually: z

Insert two bolts (Fig. 3-157, Pos. 1) of suitable length with nuts (Fig. 3-157, Pos. 3) in the threaded borings (Fig. 3-155, Pos. 2) of the piston (Fig. 3-157, Pos. 2) opposed to each other.

z

Tighten each nut (Fig. 3-157, Pos. 3) alternately with a half turn, to withdraw the piston Fig. 3-157, Pos. 2) to the flange (Fig. 3-157, Pos. 4).

NOTE: Avoid tilting the piston! z

Turn the slew parking brake (Fig. 3-156, Pos. 2) until the bores in slew parking brake are aligned to threads in the adapter cover (Fig. 3-156, Pos. 3).

z

Insert new mounting bolts (Fig. 3-156, Pos. 1) and tighten them crosswise.

z

Remove the release bolts (Fig. 3-157, Pos. 1) with nuts alternately stepwise to prevent the piston from tilting.

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z

Superstructure

Carry out further installation in reverse order to removal. WARNING

Make sure to use the specified bolts and torques for the swing motor mounting bolts, refer to section 3.8.2.2 on page 3-162.

Fill oil into the motor adapter housing, up to level gauge marking. Fill oil in the brake housing approx. 0.2 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS". z

Add hydraulic oil up to the specified level.

z

Check slew parking brake for proper function. Refer to the Service Manual.

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3.8.4

Superstructure

DYNAMIC SLEW BRAKE

Fig. 3-158 Slew brake valve

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Legend for Fig. 3-158: (1)

Pressure increasing valve

(2)

Check valve circuit A

(3)

Check valve circuit B

(4)

Anti-cavitation valve circuit B (check valve)

(5)

Anti cavitation valve circuit A (check valve)

(6)

Jet bore of main relief valve spool

(7)

Spring of main relief valve spool

(8)

Jet bore pilot relief valve

(9)

Valve cone of pilot relief valve

(10)

Spring of pilot relief valve

(11)

Intermediate pin

(12)

Control piston for pressure increase

(13)

Main relief valve spool

(X)

Pilot control port for pressure increase

(Y)

Leak oil, pilot valve drain

(T)

Return oil to tank / reservoir

(A)

Service line from main control valve block

(A’)

Service line to the motor

(B)

Service line from main control valve block

(B’)

Service line to the motor

(MA)

Check point circuit A

(MB)

Check point circuit B

When ever a swing motion is carried out or the foot brake is used, pilot pressure is present at port X of the pressure increase valve (Fig. 3-158, Pos. 1). The pilot pressure preloads the relief valve. The oil for the hydraulic motor from the main control valve block feeds the service line port A or B depending of the slew direction left or right. The ports A and B are internally connected to the ports A’ and B’ and these ports in turn with the hydraulic motor. The operating pressure at either port A or B closes the anti-cavitation valves (Fig. 3-158, Pos. 4 and 5) and opens the check valves (Fig. 3-158, Pos. 2 and 3). That means the service lines are connected to the pressure increase valve by the check valves (Fig. 3-158, Pos. 2 and 3). When ever the pressure is higher than the setting of the pressure increase valve, the valve opens and dumps oil into the return line T to the reservoir. If the superstructure is slewing by dynamical momentum, the motor is driven by the slew gear and acts as a pump. The pressure in the service lines to the motor changes.

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The low pressure return line becomes pressurized and the pressurized service line changes to suction line. The service line is closed at the main control valve block so the oil can only circulate through the brake valve block’s pressure increase valve.

Fig. 3-159 Pressure increase valve Whenever a swinging motion is carried out or the foot brake is used, pilot pressure is present at port X of the pressure increasing valve. The pilot pressure preloads the relief valve. By applying pilot pressure via the external port X to piston (Fig. 3-159, Pos. 12), the pretension of the spring (Fig. 3-159, Pos. 10) is increased by the amount of the piston stroke S which results in a higher pressure setting for the pilot valve. The system pressure is present at the main piston (Fig. 3-159, Pos. 13) and via the jet bore (Fig. 3-159, Pos. 6) in the chamber of the spring (Fig. 3-159, Pos. 7) as well. System pressure also is present at the pressure relief valve cone (Fig. 3-159, Pos. 9) via the jet bore (Fig. 3-159, Pos. 8). Due to the force balance, the piston (Fig. 3-159, Pos. 13) is kept in its position, supported by the spring (Fig. 3-159, Pos. 7). If the system pressure is higher than the setting of the valve (Fig. 3-159, Pos. 9) the valve opens a channel to the drain port Y. Due to the drop of pressure, the piston (Fig. 3-159, Pos. 13) is moved by the spring (Fig. 3-159, Pos. 7). The pressure line is connected to the return line T. Dampened opening and closing is obtained by the throttled volumetric change that is caused by the jet bores.

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3.8.4.1 REMOVAL OF THE SLEW BRAKE VALVE Special tools:

n/a

Additional equipment:

Crane Slew brake valve: 97 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Close the hand wheel (Fig. 3-160, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP".

Fig. 3-160

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WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Disconnect the service hoses (Fig. 3-161, Pos. 2), the return hose (Fig. 3-161, Pos. 3), the leak oil hose (Fig. 3-161, Pos. 4), and the pilot hose (Fig. 3-161, Pos. 5) from the slew brake valve (Fig. 3-161, Pos. 6).

NOTE: When the hydraulic hoses are removed, hydraulic oil from inside the valve and the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the slew brake valve (Fig. 3-161, Pos. 6).

z

Remove the four mounting bolts (Fig. 3-161, Pos. 1) and demount the slew brake valve (Fig. 3-161, Pos. 6) from the swing motor (Fig. 3-161, Pos. 7), using a crane.

Fig. 3-161

DANGER Risk of falling weights! May result in death or serious injury. When removing the slew brake valve, make sure that nobody steps below the weight.

z

Discard the O-ring from below the slew brake valve (Fig. 3-161, Pos. 6).

NOTE: When the slew brake valve is removed, hydraulic oil from inside the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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3.8.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE Special tools:

Hydraulic testing kit, PN 232 591 40

Additional equipment:

n/a Slew brake valve: 97 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings below the slew brake valve and the SAE flanges. z

Carry out installation in reverse order to removal.

z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

z

Check and adjust the slew brake valve. Refer to the Service Manual.

z

Check dynamic slew brake for proper function. Refer to the Service Manual.

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3.8.5

Superstructure

SWING CIRCLE

Fig. 3-162 Slew ring assembly

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Legend for Fig. 3-162: (1)

Superstructure

(2)

Swing circle

(3)

Bolt

(4)

Washer

(5)

Swing circle protection covers

(6)

Washer

(7)

Bolt

(8)

Car body

(9)

Bolt

(10)

Resilient sleeve

The swing circle is the movable connection between the superstructure and the car body. The swing circle bearing is connected to the central lubrication system. The outer ring gear is lubricated by an own lubrication system SLS which uses a special open gear lubricant. NOTE: For wear limits, refer to PARTS & SERVICE NEWS No. "AH02513". For additional information, refer to PARTS & SERVICE NEWS No. "AH00511" last edition.

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3.8.5.1 REMOVAL OF THE SWING CIRCLE

Special tools:

Mounting cross, PN 477 577 40 Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40

Additional equipment:

2 x Crane (2nd. crane for superstructure lifting) Swing circle: 10,000 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

Remove the superstructure from the car body (counterweight, fluids and attachment removed), refer to section 3.14.1 on page 3-256.

z

Place the superstructure on appropriate supports, high enough to handle the mounting cross underneath the swing circle. CAUTION

Supports need to be substantial enough to carry total weight of the superstructure (without counterweight, fluids and attachment), total weight 137,215 kg.

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z

Before removing swing circle, mark location of both slew rings to superstructure and the car body as well for further investigations.

z

Disconnect all slew ring bearing lubrication hoses (Fig. 3-163, Pos. 1) from the inner slew ring (Fig. 3-163, Pos. 3), removing the unions (Fig. 3-163, Pos. 2).

Fig. 3-163 z

Position the mounting cross, PN 477 577 40 underneath the swing circle.

z

Connect the lifting device to a crane.

NOTE: In order to avoid damage to the sling accessory, use edge protection at all sharp edges. The lifting device is accessible from the centre of the machine (Fig. 3-164, arrow). CAUTION Move the sling accessory carefully between the pipe work/ hoses at the manifold to prevent the pipe work from being damaged or ripped off. Fig. 3-164

z

Lift the mounting cross (Fig. 3-165, Pos. 1) to place it under the swing circle (Fig. 3-165, Pos. 2).

z

Remove the mounting bolts of the inner slew ring to dismount the swing circle (Fig. 3-165, Pos. 2) from the superstructure (Fig. 3-165, Pos. 3).

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges.

Fig. 3-165

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z

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Lower the mounting cross with the swing circle (Fig. 3-166, Pos. 3) resting on it to the ground.

NOTE: The guides (Fig. 3-166, Pos. 2) ensure that the swing circle is aligned accurately with the superstructure (Fig. 3-166, Pos. 1) while it is removed and installed respectively. Do not loosen nor remove the guides, if the swing circle will be re-installed.

Fig. 3-166 z

Install four swivel hoist rings evenly distributed at the inner slew ring and remove the swing circle from the mounting cross using a crane. DANGER

Risk of falling weights! Death or serious injury result. When removing the swing circle, make sure that nobody steps below the weight.

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3.8.5.2 REPLACEMENT OF THE SWING CIRCLE

Special tools:

Mounting cross, PN 477 577 40 Measuring jaw, PN 376 792 40 8 x Measuring bolt, PN 409 437 40 and 8 x measuring bolt (cold weather) respectively, PN 409 484 40 Test block, PN 379 077 40 Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40

Additional equipment:

2 x Crane (2nd. crane for superstructure lifting) Laser device for checking the level of bearing area Compound "KP2K", PN 324 969 40 Swing circle: 10,000 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Check the wear of the swing circle pinions at the slew gears, refer to PARTS & SERVICE NEWS No. "AH05518".

z

Check the level of bearing area with a laser device before installing a new slew ring. Refer to PARTS & SERVICE NEWS No. "AH00511".

z

Check the outer diameter of the new slew ring top surface and compare with the outer diameter of the factory machined surface of the superstructure. Refer to PARTS & SERVICE NEWS No. "AH00511" last edition. Remove the shoulder by machining if necessary. WARNING

z

Shocks to the swing circle (especially radial shocks) must be avoided.

z

Transport and store the new swing circle exclusively with transport star fitted.

z

It is strictly forbidden to hook up the new swing circle at the transport star.

z

Hang up and/or transport and store the swing circle only horizontally. If a special attachment is available, the transportation and storage in inclined position may be carried out.

z

Only hang swing circle at four swivel hoist rings evenly distributed in screw circle of the inner slew ring.

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NOTE: When replacing the swing circle, all fastening bolts must also be replaced. z

Install four swivel hoist rings evenly distributed at the inner slew ring and lift it using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the swing circle, make sure that nobody steps below the weight.

z

Place the swing circle (Fig. 3-167, Pos. 2) onto the mounting cross (Fig. 3-167, Pos. 1).

z

Centre the swing circle (Fig. 3-167, Pos. 2) on the mounting cross (Fig. 3-167, Pos. 1) using the transport star.

z

Position the mounting cross with the swing circle resting on it under the superstructure (Fig. 3-167, Pos. 3) and connect the mounting cross to a crane.

Fig. 3-167 NOTE: In order to avoid damage to the sling accessory, use edge protection at all sharp edges. The lifting device is accessible from the centre of the machine (Fig. 3-164, arrow). CAUTION Move the sling accessory carefully between the pipe work/ hoses at the manifold to prevent the pipe work from being damaged or ripped off.

Fig. 3-168

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Fig. 3-169 Swing circle installation z

Mating surfaces between superstructure platform (Fig. 3-169, Pos. 6) and swing circle (Fig. 3-169, Pos. 5) must be absolutely fat-free. Even the solvent must be rinsed away before assembling.

z

Check flatness of the mating surfaces.

z

Prepare new bolts (Fig. 3-169, Pos. 3) and washers (Fig. 3-169, Pos. 4). Lubricate the threads and the head surface of the bolts with compound "KP2K", PN 324 969 40.

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z

Slew system

Align the "S-spots".

NOTE: The unhardened spot of race surfaces (changeover area between beginning and end of hardening process) is punch-marked with an "S" at the inner resp. outer side of each slew ring (Fig. 3-169, Pos. 1 and 2). These spots "S" must not be placed within the main load area of the swing circle. Hence, the unhardened spot "S" has to be turned in an angle of 90° to the main load area refer to Fig. 3-169. z

Align the teeth of the outer slew ring with the lubrication pinions and the pinions of the slew gears.

z

Lift the swing circle (Fig. 3-170, Pos. 3) to approx. 10 mm below the superstructure platform (Fig. 3-170, Pos. 1) by means of the mounting cross.

z

Align the holes in the inner slew ring with the treads in the superstructure platform (observe the unhardened "S-spots").

NOTE: When re-installing the swing circle, the guides (Fig. 3-170, Pos. 2) ensure that the swing circle is aligned accurately into its original mounting position, so no adjusting of the tooth backlash is required. When installing a new swing circle, it could be necessary to loosen the guides due to disparities in the inner diameter of the inner slew ring of the swing circle.

Fig. 3-170

Do not remove the guides after installation. z

Install the mounting bolts (Fig. 3-169, Pos. 3) with washers (Fig. 3-169, Pos. 4) to the inner slew ring.

z

Join the swing circle (Fig. 3-169, Pos. 5) on to the supporting surface at the superstructure platform (Fig. 3-169, Pos. 6) by tightening the bolts crosswise manually.

z

Remove the mounting cross.

z

Connect all lubrication lines (Fig. 3-171, Pos. 1) to the unions (Fig. 3-171, Pos. 2) at the inner slew ring (Fig. 3-171, Pos. 3).

Fig. 3-171

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z

Superstructure

Check the tooth backlash between slew ring and slew pinions with a feeler gauge and adjust it if required. Refer to PARTS & SERVICE NEWS No. "AH00511". Tighten all bolts (Fig. 3-169, Pos. 3) of the inner slew ring crosswise to the required torque, refer to PARTS & SERVICE NEWS No. "AH00511" last edition.

NOTE: The procedure of tightening has to be performed twice or three times, to ensure a setting of the bolts. Refer to PARTS & SERVICE NEWS No. "AH00511" last edition. z

After tightening all bolts (Fig. 3-169, Pos. 3) the tooth back lash has to be checked once more at 4 points. Refer to PARTS & SERVICE NEWS No. "AH00511" last edition. If necessary, repeat adjustment.

z

Make sure that the guides (Fig. 3-170, Pos. 2) are in touch with the inner diameter surface of the inner slew ring.

z

Lift the superstructure and install it onto the undercarriage, refer to section 3.14.2 on page 3-261. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the superstructure, make sure that nobody steps below the weight.

z

Carry out further installation in reverse order to removal.

z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

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3.9

LUBRICATION SYSTEM

3.9.1

SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL)

Fig. 3-172 Slew ring lubrication 3 - 198

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Lubrication system

Legend for Fig. 3-172: (1)

Lubrication pump station (SLS)

(2)

Lubricant supply line from pump to injector

(3)

Injectors

(4)

End line pressure switch

(5)

Lubricant feed line from injector to lubrication pinion

(6)

Lubrication pinion

(7)

Slew ring

(8)

Lubrication pinion

(9)

Lubricant outlet

(10)

Lubrication pinion center shaft with distributing drillings

The Swing circle lubrication system (SLS) lubricates the open gear of the outer slew ring with special open gear lubricant. The lubricant pump station (Fig. 3-172, Pos. 1) is identical with the central lubrication system (CLS), refer to section 3.9.2 on page 3-204. To apply the lubricant equably to the outer slew ring teeth (Fig. 3-172, Pos. 7), a special lubrication pinion (Fig. 3-172, Pos. 8) is mounted near the drive pinion of the front slew gear. The lubrication pinion (Fig. 3-172, Pos. 8) distributes the lubricant from the injectors (Fig. 3-172, Pos. 3) evenly to the teeth. Normally two or more small SL1 injectors (Fig. 3-172, Pos. 3) are parallel connected to supply the required amount of lubricant to the lubrication pinion. NOTE: The pinion center shaft (Fig. 3-172, Pos. 10) acts as a rotary joint and distributes lubricant through radial drillings only to the teeth, witch are in contact with the outer slew ring gear teeth. Outlet bores (Fig. 3-172, Pos. 9 on different position of the pinion gear distribute the lubricant equably to the outer slew ring teeth (Fig. 3-172, Pos. 7).

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3.9.1.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform Pinion cover: 11.6 kg Lubrication pinion assembly: 18.2 kg

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and mobile working platform.

z

Park the machine on the prepared flat ground area with the lubrication pinion placed between the crawler carriers, so that the lubrication pinion can be accessed by a mobile working platform.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. WARNING

Before maintenance, set the key-operated main switch to "OFF" and the maintenance safety switch (Fig. 3-173, Pos. 1) to "0" position to prevent operation of the electric motors during work. Fold up flap (Fig. 3-173, Pos. 2) and secure this position by inserting a padlock into the holes (Fig. 3-173, Pos. 4) of the flap and the safety switch. Assure that the system pressure of the lubrication system is relieved before maintenance. Fig. 3-173 z

Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-181, Pos. 2) by hand, refer to PARTS & SERVICE NEWS No. "AH05546". WARNING

Always wear a safety harness when working at the lubrication pinion.

NOTE: A second person is required for the work at the lubrication pinion.

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Fig. 3-174 Lubrication pinion assembly, removal and replacement z

Remove the mounting bolts (Fig. 3-174, Pos. 6) with sleeves (Fig. 3-174, Pos. 7) and remove the pinion cover (Fig. 3-174, Pos. 1).

NOTE: A second person is required for this work. z

Disconnect the lubrication lines (Fig. 3-174, Pos. 4).

z

Remove the nuts (Fig. 3-174, Pos. 5) and take the lubrication pinion assembly (Fig. 3-174, Pos. 3) with connector plate (Fig. 3-174, Pos. 2) off the superstructure.

NOTE: A second person is required for this work.

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3.9.1.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform Pinion cover: 11.6 kg Lubrication pinion assembly: 18.2 kg If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING Always wear a safety harness when working at the lubrication pinion.

z

Carry out installation in reverse order to removal.

NOTE: A second person is required for this work. z

After installation is complete, the swing circle lubrication system has to be activated manually, refer to the Operation & Maintenance Manual, chapter 3, section "SWING CIRCLE PINION LUBRICATION SYSTEM SLS”. Activate the switch S26 at the dash board until the correct pressure is reached.

z

Reset the lubrication cycle counter of the slew ring lubrication system. Refer to the Operation & Maintenance Manual, chapter 3, section "SWING CIRCLE PINION LUBRICATION SYSTEM SLS”.

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3.9.2

Superstructure

LUBRICATION PUMP STATION

Fig. 3-175 Lubrication pump station (old version)

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Legend for Fig. 3-175: (1)

Coupling on service arm for filling up the grease container (3) of the swing circle lubrication system (SLS)

(2)

Grease filter of the swing circle lubrication system (SLS)

(3)

Grease container of the swing circle lubrication system (SLS)

(4)

Hydraulic motor with pump unit

(5)

Grease pressure gauge for SLS

(6)

Receiver panel on service arm

(7)

Coupling on service arm for filling the grease container (9) of the central lubrication system (CLS)

(8)

Grease filter of the central lubrication system (CLS)

(9)

Grease container of the central lubrication system (CLS)

(10)

Hydraulic motor with pump unit

(11)

Grease pressure gauge for CLS

(12)

Mounting bolts of the grease pump station

The lubrication includes two single lubrication pumps and a grease container for each lubrication pump. Each lubrication pump has its own lubrication system: –

One lubrication pump of the central lubrication system (CLS).

–

One lubrication pump of the swing circle pinion lubrication system (SLS).

The lubrication pump is a hydraulically driven seal-free differential piston pump. The pump pumps lubricant during the up and down stroke but sucks lubricant only during the up stroke. The scoop piston at the pump bottom supports the main pump with high viscosity lubricants. There is only one dynamic seal at the piston rod on top of the pump pipe. The lubrication pump is divided in two main components, the pump drive’s hydraulic cylinder and the pump. The pump drive and only the pump outlet are outside on top of the lubricant container, the pump itself is inside and reaches into the lubricant.

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Fig. 3-176 Lubrication pump station (actual version)

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Legend for Fig. 3-176: (1)

Grease container of the swing circle lubrication system (SLS)

(2)

Grease container of the central lubrication system (CLS) for the lubrication of the swing connection bearing and of the boom cylinder foot bearing

(3)

Grease container of the central lubrication system (CLS) for the lubrication of the attachment

(4)

Hydraulic motor with pump unit

(5)

Grease filter of the swing circle lubrication system (SLS)

(6)

Grease filter of the central lubrication system (CLS)

(7)

Grease pressure gauge

(8)

In-line high pressure grease filters

The lubrication pump station includes three single lubrication pumps and a grease container for each lubrication pump. Each lubrication pump provides different group of components with grease: –

One lubrication pump for the lubrication of the attachment (CLS).

–

One lubrication pump for the lubrication of the swing connection bearing and of the boom cylinder foot bearing (CLS).

–

One lubrication pump of the swing circle pinion lubrication system (SLS).

NOTE: The grease containers (Fig. 3-179, Pos. 1 and 2) are linked together by an opening in the upper part of the of the containers. This is for grease level compensation during refilling.

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3.9.2.1 REMOVAL OF THE LUBRICATION PUMP STATION Special tools:

n/a

Additional equipment:

Crane Double lubrication pump station: 415 kg Triple lubrication pump station: 618 kg

Dogman/rigger

NOTE: The removal of the triple lubrication station is analogously the same. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. WARNING

Before maintenance, set the key-operated main switch to "OFF" and the maintenance safety switch (Fig. 3-177, Pos. 1) to "0" position to prevent operation of the electric motors during work. Fold up flap (Fig. 3-177, Pos. 2) and secure this position by inserting a padlock into the holes (Fig. 3-177, Pos. 4) of the flap and the safety switch. Assure that the system pressure of the lubrication system is relieved before maintenance. Fig. 3-177 z

Relieve system pressure of the lubrication system by actuating the vent valve by hand, refer to PARTS & SERVICE NEWS No. "AH05546".

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z

Disconnect all hydraulic and grease lines (Fig. 3-178, Pos.1) from the front roof plate.

z

Disconnect the wire harnesses from the end of line pressure switches B43, B46, and B174 (only triple pump). Clear the harnesses from the lubrication pump station.

z

Sling the lubrication pump station (Fig. 3-178, Pos. 3) at the lifting eyes (Fig. 3-178, see arrows).

z

Remove the bolts (Fig. 3-178, Pos. 2) and remove the lubrication pump station from the roof using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the lubrication pump station, make sure that nobody steps below the weight.

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3.9.2.2 REPLACEMENT OF THE LUBRICATION PUMP STATION Special tools:

n/a

Additional equipment:

Crane Double lubrication pump station: 415 kg Triple lubrication pump station: 618 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: The replacement of the triple lubrication station is analogously the same as of the double station. z

Carry out installation in reverse order to removal.

z

If required, bleed the pump at the breather port (Fig. 3-178, Pos. 1).

NOTE: Make sure that the grease hoses are filled with grease. Therefore it may be necessary to carry out some lubrication cycles manually. z

Make sure that the end of line pressure switches (see following table) are pressurized. If not, start a lubrication cycle of the corresponding lubrication pump by actuating the appropriate switch at the operator’s console, see following table:

Fig. 3-179

Switch

Pressure switch

Lubrication system

S24

B43

CLS

S26

B46

SLS

S99

B174

Separate attachment lubrication pump (CLS, triple pump station only)

NOTE: There may be a time gap of up to 11 minutes until the next manually started cycle is carried out. Refer to the time table in the flowchart. z

Adjust the lubrication pump speed and pressure. Refer to the Service Manual.

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Lubrication system

REMOVAL OF THE LUBRICATION PUMP

Special tools:

n/a

Additional equipment:

Crane Lubrication pump: 28 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. WARNING

Before maintenance, set the key-operated main switch to "OFF" and the maintenance safety switch (Fig. 3-180, Pos. 1) to "0" position to prevent operation of the electric motors during work. Fold up flap (Fig. 3-180, Pos. 2) and secure this position by inserting a padlock into the holes (Fig. 3-180, Pos. 4) of the flap and the safety switch. Assure that the system pressure of the lubrication system is relieved before maintenance. Fig. 3-180

z

Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-181, Pos. 1) by hand, refer to PARTS & SERVICE NEWS No. "AH05546".

z

Disconnect the hydraulic lines (Fig. 3-181, Pos. 2) from the lubrication pump.

z

Disconnect the quick coupling from the grease feeding line (Fig. 3-181, Pos. 3).

Fig. 3-181

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z

Superstructure

Disconnect the grease feeding line (Fig. 3-182, Pos. 1) from the lubrication pump.

Fig. 3-182 z

Remove the bolt (Fig. 3-183, Pos. 1).

Fig. 3-183

z

Sling the lubrication pump (Fig. 3-183, Pos. 1) at the installed lifting eye (Fig. 3-183, Pos. 1) and pull the lubrication pump out of the grease container.

Fig. 3-184

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Lubrication system

REPLACEMENT OF THE LUBRICATION PUMP

Special tools:

n/a

Additional equipment:

Crane Lubrication pump: 28 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out installation in reverse order to removal.

z

After replacement, bleed the pump at the breather port (Fig. 3-185, Pos. 1).

Fig. 3-185 z

Adjust the lubrication pump speed and pressure. Refer to the Service Manual.

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3.10 OPERATOR’S CAB

Fig. 3-186 Operator’s cab overview 3 - 214

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Legend for Fig. 3-186: A

Rear View of Operator’s Cab

(1)

Door handle

(2)

Door latch (with door fully opened)

(3)

Door locking pin, engages into latch when the cab door is fully opened

(4)

Light switch for access area lighting

(5)

Light switch for interior cab lighting

(6)

Air conditioner door

(7)

Outside mirrors with integrated heaters, both mirrors are adjusted electrically via a control switch on the instrument panel

(8)

Main working lights

(9)

Adapter for warning beacon

B

Front View of Operator’s Cab

(10)

Release lever for door lock (2 - 3)

(11)

Door opener push button

(12)

Lock lever

(13)

Control levers for working attachment

(14)

Operator’s seat

(15)

Upper windshield wiper

(16)

Lower windshield wiper

WARNING The operator’s cab is equipped with an integrated Falling Object Protective Structure (FOPS) that meets the requirements of ISO 3449. Any modifications on the steel structure of the cab are inadmissible. Repairs on the FOPS must only be carried out by specialists having the authorization for repair work on Falling Object Protective Structures and in accordance with the manufacturer’s repair instructions.

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3.10.1 REMOVAL OF THE OPERATOR’S CAB Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane Mobile elevator working platform Operator’s cab: 3785 kg Dogman/rigger Air condition service specialist Electrician with permission to work on high voltage systems For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. The following safety measures have to be carried out before any work on the high voltage system by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

z

Remove the keys from the battery main switches. WARNING

Always wear a safety harness when working at the operator’s cab.

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z

Superstructure

Dismount the grommet plate (Fig. 3-187, Pos. 1) inside the cab base. If the machine is equipped with harness connectors: z

Disconnect all harness connectors at the back side of the grommet plate.

z

Disconnect all other harnesses leading to the operator’s cab from the X2-board and pull it out of the grommet plate.

If the machine is not equipped with harness connectors: z

z

Disconnect all harnesses leading to the operator’s cab Fig. 3-187 from the X2C-board and remove the cable transfer elements.

Dismount the grommet plate (Fig. 3-188, Pos. 1) above the X2-board inside the cab base. If the machine is equipped with harness connectors: z

Disconnect all harness connectors of the manipulators at the back side of the grommet plate.

If the machine is not equipped with harness connectors: z

Disconnect all harnesses leading to the operator’s cab from the X2-board and remove the cable transfer elements. Fig. 3-188

z

Remove the ground cable (Fig. 3-189, Pos. 1) in the cab base (Fig. 3-189, Pos. 2) from the left lower fixing bolt at the X2-board and pull it out of the grommet plate.

Fig. 3-189

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z

Remove the cover (Fig. 3-190, Pos. 1) inside the cab base.

z

Disconnect the hose (Fig. 3-190, Pos. 2) between cab support and operator’s cab from the upper side of the cover.

Fig. 3-190

WARNING The air conditioning must be serviced by authorized service specialists only.

z

Aspirate the refrigerant from the air condition system.

z

Disconnect the refrigerant lines (Fig. 3-191, Pos. 2) from the air conditioning unit (Fig. 3-191, Pos. 1).

NOTE: Cap the openings with blind plugs to avoid contamination of the air conditioning system. z

Disconnect the condensate lines (Fig. 3-191, Pos. 3) from the air conditioning unit (Fig. 3-191, Pos. 1).

z

Clear all hoses from the operator’s cab.

z

Sling the operator’s cab (Fig. 3-192, Pos. 2) at the lifting eye bolts (Fig. 3-192, Pos. 1) delivered with the cab.

Fig. 3-191

Fig. 3-192

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Fig. 3-193 Removal of the operator’s cab, overview z

Remove the hose (Fig. 3-193, Pos. 7) of the operator’s cab water supply.

z

Open the hose clips (Fig. 3-193, Pos. 5) and remove the water hoses (Fig. 3-193, Pos. 6).

z

Remove the gratings (Fig. 3-193, Pos. 8) from the cab support (Fig. 3-193, Pos. 9).

z

Remove the bolts (Fig. 3-193, Pos. 2) and resilient sleeves (Fig. 3-193, Pos. 3) from the viscous mounts (Fig. 3-193, Pos. 4).

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z

Operator’s cab

Remove operator’s cab (Fig. 3-193, Pos. 1) using a crane.

NOTE: Lift the operator´s cab slowly while using a second person inside the cab base to guide the harnesses through the grommet plates. DANGER Risk of falling weights! Death or serious injury may result. When lifting the operator’s cab make sure that nobody steps below the weight.

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3.10.2 REPLACEMENT OF THE OPERATOR’S CAB Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Operator’s cab: 3785 kg Dogman/rigger Air condition service specialist Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

Fig. 3-194 Replacement of the operator’s cab, overview

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WARNING z

Always wear a safety harness when working at the operator’s cab.

z

Ensure no one stands between the cabin and the cab base during lowering.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the operator’s cab make sure that nobody steps below the weight.

z

Carry out installation in reverse order to removal.

NOTE: Use new bolts (Fig. 3-194, Pos. 2) of the grade 10.9 at the viscous mounts (Fig. 3-194, Pos. 4). Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified torque. Tightening torque for the mounting bolts (Fig. 3-194, Pos. 2): 880 Nm NOTE: When lowering the operator’s cab have a second person inside the cab base to guide the harnesses through the grommet plates. z

Evacuate the air conditioning system and add refrigerant. WARNING

The air conditioning must be filled with refrigerant "R134a" by authorized service specialists only.

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3.10.3 VISCOUS CAB-MOUNTS 3.10.3.1 REMOVAL OF THE VISCOUS CAB-MOUNTS Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane Mobile elevator working platform Operator’s cab: 3785 kg Viscous mount: 4 kg Absorber plate incl. 2 viscous mounts: 11.9 kg Absorber plate incl. 3 viscous mounts: 17.4 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. WARNING

Always wear a safety harness when working at the operator’s cab.

z

Sling the operator’s cab (Fig. 3-192, Pos. 2) at the lifting eye bolts (Fig. 3-192, Pos. 1) delivered with the cab.

Fig. 3-195

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Fig. 3-196 Removal of the viscous cab-mounts, overview z

Remove the gratings (Fig. 3-196, Pos. 8) from the cab support (Fig. 3-196, Pos. 9).

z

Remove the bolts (Fig. 3-196, Pos. 2) and resilient sleeves (Fig. 3-196, Pos. 3) from the viscous mounts (Fig. 3-193, Pos. 4).

z

Raise the operator’s cab (Fig. 3-193, Pos. 1) only a few millimeters, just enough to clear the viscous mounts (Fig. 3-193, Pos. 4).

z

Remove the bolts (Fig. 3-196, Pos. 5) from the absorber plate (Fig. 3-196, Pos. 6) and remove the absorber plate with the viscous mounts.

z

Remove the bolts (Fig. 3-196, Pos. 7) and dismount the viscous mounts (Fig. 3-193, Pos. 4) from the absorber plate (Fig. 3-196, Pos. 6).

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3.10.3.2 REPLACEMENT OF THE CAB-MOUNTS Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Operator’s cab: 3785 kg Viscous mount: 4 kg Absorber plate incl. 2 viscous mounts: 11.9 kg Absorber plate incl. 3 viscous mounts: 17.4 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

Fig. 3-197 Replacement of the cab-mounts, overview

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WARNING Always wear a safety harness when working at the operator’s cab.

z

Carry out installation in reverse order to removal.

NOTE: Always use new mounting bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified torque. Tightening torque for the mounting bolts (Fig. 3-197, Pos. 7) at the cab mounts (Fig. 3-197, Pos. 4): 180 Nm Tightening torque for the mounting bolts (Fig. 3-197, Pos. 5) at the absorber plates (Fig. 3-197, Pos. 6): 880 Nm Tightening torque for the operator’s cab mounting bolts (Fig. 3-197, Pos. 2): 880 Nm

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3.10.4 FRONT WINDOW (WINDSCREEN) 3.10.4.1 REMOVAL OF THE FRONT WINDOW Special tools:

n/a

Additional equipment:

Suction lifters with hoist rings Safety harness in conformity with EN 361 Crane Mobile elevator working platform Front window: 112 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. WARNING

Always wear a safety harness when working at the operator’s cab.

z

Remove the wiper arms (Fig. 3-198, Pos. 1).

z

Use suction lifters with hoist rings at the front window (Fig. 3-198, Pos. 4) to sling the front window.

z

Remove the bolts (Fig. 3-198, Pos. 2). Hold nut (Fig. 3-198, Pos. 3) from inside the cab.

z

Remove the front window (Fig. 3-198, Pos. 4) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the front window, make sure that nobody steps below the weight. Fig. 3-198

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3.10.4.2 REPLACEMENT OF THE FRONT WINDOW Special tools:

n/a

Additional equipment:

Suction lifters with hoist rings Safety harness in conformity with EN 361 Crane Mobile elevator working platform Front window: 112 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING Always wear a safety harness when working at the operator’s cab.

z

Carry out installation in reverse order to removal.

NOTE: A different holes pattern is used since January 2007 for the frame of the front window. KOMATSU recommends to use front windows with new holes pattern in the frame, also for shovels, delivered before 2007. For further information refer to the PARTS & SERVICE NEWS No. "AH08504". z

Check the correct end position of the wiper arm(s) after installation of the front window.

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3.10.5 OPERATOR’S SEAT 3.10.5.1 REMOVAL OF THE OPERATOR’S SEAT Special tools:

n/a

Additional equipment:

Crane Operator’s seat: 62 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

Disconnect the wire harness connector (Fig. 3-199, Pos. 1) of the air suspension.

z

Remove both control lever carriers (Fig. 3-199, Pos. 2 and 8).

z

Remove all mounting bolts (Fig. 3-199, Pos. 6) from the cover plate (Fig. 3-199, Pos. 7) on the heating console (Fig. 3-199, Pos. 5).

z

Remove the cover plate (Fig. 3-199, Pos. 5) from the operator’s seat (Fig. 3-199, Pos. 9) by removing all mounting bolts (Fig. 3-199, Pos. 4) and lock washers (Fig. 3-199, Pos. 3).

NOTE: A second person is required to carry the operator’s seat out of the operator’s cab.

Fig. 3-199

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z

Operator’s cab

Sling the operator’s seat and lift it off the machine using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the operator’s seat, make sure that nobody steps below the weight.

3.10.5.2 REPLACEMENT OF THE OPERATOR’S SEAT Special tools:

n/a

Additional equipment:

Crane Operator’s seat: 62 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Remove both control lever carriers from the new seat.

z

Carry out installation in reverse order to removal. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the operator’s seat, make sure that nobody steps below the weight.

NOTE: A second person is required to carry the operator’s seat into the operator’s cab.

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Superstructure

3.10.6 ECS 3.10.6.1 REMOVAL OF THE ECS TEXT DISPLAY Special tools:

n/a

Additional equipment:

n/a

z

Isolate the machine according to local regulations.

z

Remove the keys from the battery main switches.

z

Open the operator’s console.

z

Disconnect the data cables (Fig. 3-200, Pos. 1 and 2) from the ECS text display (Fig. 3-200, Pos. 4).

z

Remove the wing nuts (Fig. 3-200, Pos. 3) and take the ECS text display (Fig. 3-200, Pos. 4) out of the operator’s console.

Fig. 3-200

3.10.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY Special tools:

n/a

Additional equipment:

n/a

z

Carry out installation in reverse order to removal.

z

Set time, date and operating hours, refer to the Operation & Maintenance Manual, chapter 3, section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS".

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3.11 CAB BASE (MEDIUM VOLTAGE SWITCH CABINET) 3.11.1 REMOVAL OF THE CAB BASE Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform Crane Forklift Support frame: 987 kg Cab base: 4000 kg Emergency exit ladder: 56 kg Dogman/rigger Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, elevator working platform and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

z

Remove the keys from the battery main switches. WARNING

Always wear a safety harness when working at the cab base.

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Superstructure

z

Remove the operator’s cab (Fig. 3-201, Pos. 1), refer to section 3.10.1 on page 3-217.

z

Remove the emergency exit ladder (Fig. 3-201, Pos. 2).

NOTE: For safety reasons, the handrails at the cab support frame (Fig. 3-201, Pos. 3) remain mounted.

Fig. 3-201 z

Disconnect all wire harnesses leading to the cab base inside the cab base.

z

Clear all wire harnesses from the cable channel underneath the cab base.

z

Disconnect the extinguishing agent hose (Fig. 3-202, Pos. 1) of the fire suppression system between the cab base (Fig. 3-202, Pos. 3) and the high voltage switch (Fig. 3-202, Pos. 2) cabinet from the union at the cab base.

z

If equipped, disconnect the extinguishing agent hose of the fire suppression system between the cab base and the slip ring assembly (Fig. 3-202, Pos. 4) from the union at the cab base.

Fig. 3-202 z

Sling the support frame (Fig. 3-203, Pos. 2).

z

Remove the bolts (Fig. 3-203, Pos. 1) from within the cab base (Fig. 3-203, Pos. 3) and remove the support frame (Fig. 3-203, Pos. 2) using a crane.

Fig. 3-203

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z

Install four swivel hoist rings (M36) and sling the cab base (Fig. 3-204, Pos. 1) at the installed hoist rings, refer to Fig. 3-205.

z

Remove bolts (Fig. 3-204, Pos. 2 and 3) attaching the cab base to the superstructure (Fig. 3-204, Pos. 4).

Fig. 3-204 z

Remove the cab base using a crane. DANGER

Risk of falling weights! May result in death or serious injury When moving cab base, make sure that nobody steps below the lifted cab base.

Fig. 3-205

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Superstructure

3.11.2 REPLACEMENT OF THE CAB BASE Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform Crane Compound "Epple 28", PN 592 199 40 Compound "Loctite 222", PN 414 299 40 Compound "KP2K", PN 324 969 40 Support frame: 987 kg Cab base: 4000 kg Emergency exit ladder: 56 kg Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING Always wear a safety harness when working at the cab base.

z

Install four swivel hoist rings (M36) and sling the new cab base at the hoist rings.

z

Lift the cab base and align it with the superstructure using a crane (Fig. 3-206). DANGER

Risk of falling weights! May result in death or serious injury When lifting the cab base, make sure that nobody steps below the weight. Fig. 3-206

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z

Cab base (medium voltage switch cabinet)

Install the bolts (Fig. 3-207, Pos. 2 and 3) attaching the cab base (Fig. 3-207, Pos. 1) to the superstructure (Fig. 3-207, Pos. 4).

NOTE: Use new mounting bolts (Fig. 3-207, Pos. 2) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque. Tightening torque for cab base mounting bolts (Fig. 3-207, Pos. 2 and 3): 3100 Nm

Fig. 3-207 z

Apply sealing compound "Epple 28" onto the whole contact surfaces (Fig. 3-208, arrows) of the cab base.

z

Install the support frame (Fig. 3-208, Pos. 2) using a crane.

z

Install bolts (Fig. 3-208, Pos. 1) attaching the support frame (Fig. 3-208, Pos. 2) to the cab base (Fig. 3-208, Pos. 3).

NOTE: Use new mounting bolts (Fig. 3-208, Pos. 1) of grade 10.9. Apply compound "Loctite 222" on the threads of all bolts (Fig. 3-208, Pos. 1), and tighten the mounting bolts to the specified tightening torque. Tightening torque for support frame mounting bolts (Fig. 3-208, Pos. 1): 265 Nm

z

Fig. 3-208

Carry out further installation in reverse order to removal.

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3.11.3 PUMP CONTROLLER 3.11.3.1 REMOVAL OF THE PUMP CONTROLLER Special tools:

n/a

Additional equipment:

n/a

Electrician with permission to work on high voltage systems

z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

z

Remove the wiring harness connector X14 (Fig. 3-209, Pos. 2) from the electronic pump controller RC4 (Fig. 3-209, Pos. 3).

z

Remove four bolts and remove the pump controller RC4 from the wall of the cab base (Fig. 3-209, Pos. 1).

Fig. 3-209

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3.11.3.2 REPLACEMENT OF THE PUMP CONTROLLER Special tools:

n/a

Additional equipment:

n/a

Electrician with permission to work on high voltage systems

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out installation in reverse order to removal.

z

Check and adjust the parameters of the pump controller. Refer to the Service Manual for further information.

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Superstructure

3.12 ACCESS LADDER

Fig. 3-210 Access ladder assembly

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Legend for Fig. 3-210: (1)

Access ladder

(2)

Pin

(3)

Pin

(4)

Access ladder cylinder

(5)

Cotter pin

(6)

Washer

(7)

Socket

(8)

Hydraulic hose

(9)

Hydraulic hose

(10)

Self-locking nut

(11)

Distance sleeve

(12)

Bearing

(13)

Shaft seal

(14)

Dowel Screw

(15)

Ladder bearing assembly

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Fig. 3-211 Access ladder removal

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3.12.1 REMOVAL OF THE ACCESS LADDER Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder: 167 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Lower the access ladder (Fig. 3-211, Pos. 1) to the ground.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulation.

NOTE: Relieve the remaining pilot pressure at the Minimess test point M40 on the control and filter plate at motor 2. WARNING z

Provide an adequate working platform for safe access to the access ladder bearing.

z

Always wear a safety harness when working at the access ladder assembly.

z

Secure the access ladder cylinder (Fig. 3-211, Pos. 4) in its position.

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Access ladder

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Fig. 3-212 Access ladder replacement

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CAUTION Assure that the pressure in the hydraulic system is completely relieved before removing the pivot pin (Fig. 3-212, Pos. 2).

z

Clear the access ladder (Fig. 3-212, Pos. 1) by removing the pin (Fig. 3-212, Pos. 2) from the access ladder cylinder moving rod.

z

Sling the access ladder and remove the self locking nuts (Fig. 3-212, Pos. 10) from the ladder bearing assemblies (Fig. 3-212, Pos. 15).

z

Remove the ladder bearing assemblies and the ladder. Rest it on the ground.

3.12.2 REPLACEMENT OF THE ACCESS LADDER Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Crane Mobile elevator working platform Access ladder: 167 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Provide an adequate working platform for safe access to the access ladder bearing.

z

Always wear a safety harness when working at the access ladder assembly.

NOTE: Apply grease to the pin (Fig. 3-212, Pos. 2) at the access ladder cylinder moving rod. z

Carry out installation in reverse order to removal.

NOTE: Always use new self-locking nuts (Fig. 3-212, Pos. 10). Tightening procedure for the self-locking nuts (Fig. 3-212, Pos. 10): 1000 Nm

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Access ladder

Superstructure

Fig. 3-213 Access ladder cylinder removal

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3.12.3 REMOVAL OF THE ACCESS LADDER CYLINDER Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder cylinder: 23 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and elevator working platform.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Lower the access ladder (Fig. 3-213, Pos. 1) to the ground.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

NOTE: Relieve the remaining pilot pressure at the Minimess test point M40 on the control and filter plate at motor 2. WARNING z

Provide an adequate working platform for safe access to the access ladder bearing.

z

Always wear a safety harness when working at the access ladder assembly.

z

Assure that the pressure in the hydraulic system is completely relieved before removing the pivot pin (Fig. 3-213, Pos. 10) or disconnecting any hydraulic hoses.

z

Remove hydraulic hoses (Fig. 3-213, Pos. 8 and 9) with the socket (Fig. 3-213, Pos. 8) from the access ladder cylinder (Fig. 3-213, Pos. 4).

NOTE: When the hydraulic hoses are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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Access ladder

Superstructure

Fig. 3-214 Access ladder cylinder installation

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z

Support the access ladder cylinder (Fig. 3-214, Pos. 4) from the bottom side.

z

Remove the pins (Fig. 3-214, Pos. 2 and 3) and remove the access ladder cylinder (Fig. 3-214, Pos. 4).

3.12.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER Special tools:

n/a

Additional equipment:

Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder cylinder: 23 kg If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Provide an adequate working platform for safe access to the access ladder bearing.

z

Always wear a safety harness when working at the access ladder assembly.

z

Carry out installation in reverse order to removal.

NOTE: Apply grease to the pins (Fig. 3-214, Pos. 2 and 3). z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

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Counterweight

Superstructure

3.13 COUNTERWEIGHT DANGER Risk of explosion! Blindness, serious injury, permanent disfigurement and scarring, or death may result. Do not weld, flame-cut, grind, or drill at the counterweight! Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers!

NOTE: The chambers of the counterweight are filled with a mixture of concrete, granulated ore and steel pellets. This mixture can create explosive gases which will accumulate in the chambers of the counterweight. Before any welding, flame-cutting, grinding, or drilling procedures are carried out on the counterweight, it is vital to expel these gases from the counterweight chambers. Failure to properly expel the gases from the counterweight chambers can result in an explosion with serious personal injury or death. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.

3.13.1 REMOVAL OF THE COUNTERWEIGHT Special tools:

Hydraulic torque wrench, PN 793 374 73 Electro-hydraulic pump aggregate, PN 793 375 73 75 mm hexagon impact socket wrench (1 1/2"), PN 232 805 40

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform Crane Counterweight: 42,000 kg (BHA) / 46,000 kg (FSA)

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

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Counterweight

Park the machine on the prepared flat area and position the bucket on the ground.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. WARNING

Always wear a safety harness when working at the counterweight.

z

Remove the rails (Fig. 3-215, Pos. 1) from the counterweight.

z

Remove all additional equipment from the counterweight, if required.

z

Remove the tanks (Fig. 3-215, Pos. 2) and wires of the Fire Detection and Suppression System, if equipped. WARNING

Pay attention to the Fire Detection and Suppression System. Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression System" The wires of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional.

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Counterweight

Superstructure

Fig. 3-216 Counterweight (1)

Counterweight

(2)

Lifting situation for horizontal transport

(3)

Lifting situation for vertical transport

(4)

Lifting situation for raising up the counterweight

(5)

Bolt

(6)

Washer

WARNING Make sure that the maximum rope angle depending on the lifting situation (Fig. 3-216, Pos. 2 to 4) is not exceeded.

z

Sling the counterweight (Fig. 3-216, Pos. 1) at the installed lifting eyes.

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z

Remove all mounting bolts (Fig. 3-216, Pos. 5).

z

Remove the counterweight using the crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the counterweight, make sure that nobody steps below the lifted counterweight.

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Counterweight

Superstructure

3.13.2 REPLACEMENT OF THE COUNTERWEIGHT Special tools:

Hydraulic torque wrench, PN 793 374 73 Electro-hydraulic pump aggregate, PN 793 375 73 75 mm hexagon impact socket wrench (1 1/2"), PN 232 805 40

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform Crane Compound "KP2K", PN 324 969 40 Counterweight: 42,000 kg (BHA) / 46,000 kg (FSA)

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING Always wear a safety harness when working at the counterweight.

NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. z

Carry out installation in reverse order to removal. WARNING

Make sure that the maximum rope angle of 40° is not exceeded. Refer to Fig. 3-216, Pos. 3.

NOTE: Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts. Tighten the mounting bolts to the specified tightening torque. Tightening torque for the counterweight mounting bolts: 7500 Nm

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Superstructure

3.14 SUPERSTRUCTURE LIFTING 3.14.1 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform 2 x crane Superstructure without counterweight, attachment and fluids: 150,000 kg Dogman/rigger Crane operators trained in dual crane lift Electrician with permission to work on high voltage systems For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

z

Park the machine on the prepared flat area and position the bucket on the ground.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

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z

Superstructure lifting

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 3-217, Pos. 1) at the track tensioning valve block (Fig. 3-217, Pos. 2) inside the car body.

Fig. 3-217 z

Close the hand wheel (Fig. 3-218, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP". WARNING

Always wear a safety harness when working in height. Fig. 3-218

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Superstructure lifting

Superstructure

Fig. 3-219 Superstructure lifting z

Remove the counterweight from the superstructure, refer to section 3.13.1 on page 3-250.

z

Install shackles (Fig. 3-219, Pos. 6) delivered with the machine to the flanges of the counterweight using the mounting bolts of the counterweight. Tighten the mounting bolts to the specified tightening torque. Tightening torque for the mounting bolts: 7500 Nm

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Superstructure lifting

z

Remove the complete attachment, refer to section 5.1 on page 5-2.

z

Remove the slip ring unit, refer to section 3.16.1 on page 3-275.

z

Disconnect all hydraulic hoses leading to the superstructure from the rotary joint, refer to section 4.3.5.1 on page 4-98. If the machine is equipped with slew ring protection covers (Fig. 3-219, Pos. 9): z

Remove all bolts (Fig. 3-219, Pos. 7) and resilient sleeves (Fig. 3-219, Pos. 8) attaching the protection covers to the superstructure (Fig. 3-219, Pos. 4).

z

If equipped, remove the rotation direction sensors B98 and B99 from the slew ring protection cover. WARNING

Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

z

Attach the superstructure to two cranes.

z

Remove all bolts (Fig. 3-219, Pos. 1) and washers (Fig. 3-219, Pos. 2) attaching the slew ring to the undercarriage (Fig. 3-219, Pos. 5).

z

Lift off the superstructure using the two cranes and rest it on appropriate supports on the ground. DANGER

Risk of falling weights! Death or serious injury may result. When moving the superstructure, make sure that nobody steps below the lifted weight.

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Superstructure lifting

Superstructure

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Superstructure lifting

3.14.2 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE

Special tools:

Measuring jaw, PN 376 792 40 Measuring bolt, PN 409 437 40 or measuring bolt (cold weather design), PN 409 484 40 Gauge device (test block) for bolts M36, PN 379 077 40 Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform 2 x Crane Compound "KP2K", PN 324 969 40 2 thread pins (M 36 x 250) Superstructure without counterweight, attachment and fluids: 150,000 kg Dogman/rigger Crane operators trained in dual crane lift Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING Always wear a safety harness when working in height.

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation.

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Superstructure

Fig. 3-220 Superstructure lifting

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z

Superstructure lifting

Clean the contact surfaces of the slew ring (Fig. 3-220, Pos. 3) and the undercarriage (Fig. 3-220, Pos. 5) very carefully and thoroughly.

NOTE: Check the level of the bearing area with a laser device before installing a new slew ring. Refer to PARTS & SERVICE NEWS No. "AH00511" z

Remove the torque support lever of the rotary joint before installing the superstructure, refer to section 4.3.5.1 on page 4-98. WARNING

Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

z

Attach the superstructure to two cranes and lift it up. Refer to Fig. 3-220. DANGER

Risk of falling weights! May result in death or serious injury When moving superstructure, make sure that all personnel are clear.

NOTE: The unhardened spot of race surfaces (changeover area between beginning and ending of hardening process) is punch-marked with an "S" at the inner resp. outer side of each slew ring (Fig. 3-221, Pos. 1 and 2). Refer to PARTS & SERVICE NEWS No. "AH00511". z

Align the spots (Fig. 3-221, Pos. S) to each other.

z

Prepare new bolts, washers and sleeves. Lubricate the threads and the head surface of the bolts with compound "KP2K", PN 324 969 40.

Fig. 3-221 z

Align the superstructure to the undercarriage and lower the superstructure.

z

To simplify the alignment of the slew ring to the undercarriage, install two thread pins (M36 x 250) displaced by 180° at the outer slew ring.

z

Insert 4 bolts (Fig. 3-220, Pos. 1) with washers (Fig. 3-220, Pos. 2) displaced by 90° and lower the superstructure.

z

Remove the two thread pins from the outer slew ring.

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z

Superstructure

Install all remaining bolts and tight them manually. Tighten all bolts crosswise to the required torque, refer to PARTS & SERVICE NEWS No. "AH00511".

NOTE: If approx. 10 bolts (front and rear) are tightened the superstructure can be unhooked from the crane. z

Reinstall the torque support lever of the rotary joint, refer to section 4.3.5.2 on page 4-101.

z

Reinstall the slip ring unit, refer to section 3.16.2 on page 3-277. WARNING

Make sure to use the specified bolts and torque for the torque support lever mounting bolts, refer to section 4.3.5.2 on page 4-101.

z

Carry out further installation in reverse order to removal.

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High voltage switch cabinet

Superstructure

3.15 HIGH VOLTAGE SWITCH CABINET

Fig. 3-222 High voltage switch cabinet, overview

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Superstructure

High voltage switch cabinet

Legend for Fig. 3-206: (1)

High voltage switch cabinet

(2)

Bolt

(3)

Wing nut (plastic)

(4)

Grating

(5)

Threaded block

(6)

Bolt with washer

(7)

Cable channel

(8)

Bolt

(9)

Superstructure platform

(10)

Bolt

(11)

Cover

(12)

Bolt

(13)

Nut

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High voltage switch cabinet

Superstructure

3.15.1 REMOVAL OF THE HIGH VOLTAGE SWITCH CABINET Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform 4 x Swivel hoist ring (M36) Forklift Crane High voltage switch cabinet: 6200 kg Emergency exit ladder: 56 kg Platform: 150 kg Support frame (operator’s cab): 987 kg Dogman/rigger Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area and position the bucket on the ground.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. The following safety measures have to be carried out before any work on the high voltage system by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28. WARNING

Always wear a safety harness when working at the high voltage cabinet.

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High voltage switch cabinet

z

Remove the operator’s cab (Fig. 3-223, Pos. 1), refer to section 3.10.1 on page 3-217.

z

Remove the mounting bolts attaching the emergency ladder (Fig. 3-223, Pos. 2) to the operator’s cab support frame (Fig. 3-223, Pos. 3).

Fig. 3-223 z

If equipped, remove the platform (Fig. 3-224, Pos. 1): z

Support the platform (Fig. 3-224, Pos. 1) with a forklift.

z

Remove the grating (Fig. 3-224, Pos. 3).

z

Remove the bolts (Fig. 3-224, Pos. 4) and resilient sleeves (Fig. 3-224, Pos. 5).

z

Lower the platform to the ground.

Fig. 3-224 z

Clear all hoses and wire harnesses from the support frame (Fig. 3-225, Pos. 2).

z

Sling the support frame.

z

Remove the bolts (Fig. 3-225, Pos. 1) from within the cab base (Fig. 3-225, Pos. 3) and remove the support frame (Fig. 3-225, Pos. 2) using a crane.

Fig. 3-225

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High voltage switch cabinet

z

Superstructure

Disconnect the extinguishing agent hose (Fig. 3-226, Pos. 2) of the fire suppression system at the pipework attached to the high voltage switch cabinet (Fig. 3-226, Pos. 1).

Fig. 3-226 z

Disconnect the wire harnesses between the high voltage cabinet and the cab base inside the high voltage cabinet.

z

Pull the disconnected wire harnesses out of the high voltage cabinet.

z

Disconnect the high voltage power supply cable between the slip ring and the high voltage cabinet from the load cut-off switch inside the high voltage switch cabinet.

z

Disconnect the high voltage power supply cables leading to the electric motors inside the high voltage switch cabinet.

z

Pull the disconnected high voltage cables out of the high voltage switch cabinet.

z

Open the cable channel underneath the high voltage switch cabinet and clear all wire harnesses and hoses from the high voltage switch cabinet.

z

Insert 4 swivel hoist rings at the top of the high voltage switch cabinet.

z

Attach the high voltage cabinet to a crane.

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z

High voltage switch cabinet

Remove the mounting bolts (Fig. 3-227, Pos. 2 and 3) and lift the high voltage cabinet (Fig. 3-227, Pos. 1) off the superstructure (Fig. 3-227, Pos. 4). DANGER

Risk of falling weights! Death or serious injury may result. When lifting the high voltage switch cabinet, make sure that nobody steps below the weight.

NOTE: Discard the mounting bolts (Fig. 3-227, Pos. 2 and 3).

Fig. 3-227 z

Dismantle the handrails and all other parts from the high voltage switch cabinet.

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High voltage switch cabinet

Superstructure

3.15.2 REPLACEMENT OF THE HIGH VOLTAGE CABINET Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40

Additional equipment:

Safety harness in conformity with EN 361 Mobile elevator working platform Crane Compound "KP2K", PN 324 969 40 High voltage switch cabinet: 6200 kg Emergency exit ladder: 56 kg Platform: 150 kg Support frame (operator’s cab): 987 kg Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING Always wear a safety harness when working at the high voltage cabinet.

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

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z

High voltage switch cabinet

Carry out installation in reverse order to removal. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the high voltage cabinet, make sure that nobody steps below the weight.

NOTE: Use new mounting bolts (Fig. 3-228, Pos. 2 and 3) of grade 10.9 to attach the high voltage switch cabinet (Fig. 3-228, Pos. 1) to the superstructure platform (Fig. 3-228, Pos. 4). Apply compound "KP2K", PN 324 969 40 to the heads and threads of the mounting bolts, and tighten the mounting bolts to the specified tightening torque: Tightening torque for high voltage switch cabinet mounting bolts (Fig. 3-228, Pos. 2 and 3): 3100 Nm

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Fig. 3-228

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Slip ring unit

Superstructure

3.16 SLIP RING UNIT

Fig. 3-229 Slip ring unit, overview (1)

Slip ring unit

(2)

Carrier

(3)

Cam

(4)

Rotary joint

(5)

Bolt

(6)

Washer

(7)

Nut

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Slip ring unit

3.16.1 REMOVAL OF THE SLIP RING UNIT Special tools:

n/a

Additional equipment:

Crane Slip ring unit: 355 kg

Dogman/rigger Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

z

Remove the boom arc hoses over the slip ring unit, refer to section 5.1.6.1 on page 5-58 (BHA) or refer to section 5.2.6.1 on page 5-142 (FSA).

z

Open the slip ring unit (Fig. 3-230, Pos. 1) and disconnect the high voltage power supply cables and wiring leading into the slip ring unit.

z

If equipped, disconnect the extinguishing agent hose (Fig. 3-230, Pos. 2) of the fire suppression system from the slip ring unit.

z

Sling the slip ring unit at the installed hoist rings to a crane.

Fig. 3-230

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Slip ring unit

Superstructure

Fig. 3-231 z

Remove the nuts (Fig. 3-231, Pos. 7), washers (Fig. 3-231, Pos. 6), and the mounting bolts (Fig. 3-231, Pos. 5) attaching the slip ring unit to the carriers (Fig. 3-231, Pos. 2) fixed at the superstructure.

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z

Slip ring unit

Lift the slip ring from the machine and put it down on the ground carefully. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the slip ring unit, make sure that nobody steps below the weight.

3.16.2 REPLACEMENT OF THE SLIP RING UNIT Special tools:

n/a

Additional equipment:

Crane Slip ring unit: 355 kg

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Carry out installation in reverse order to removal.

NOTE: When lifting the slip ring unit onto the carriers, make sure that the cam (Fig. 3-231, Pos. 3) fits accurately in the counterpart of the bottom plate of the slip ring unit.

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Slip ring unit

Superstructure

This page was left blank intentionally.

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Undercarriage

4 UNDERCARRIAGE

Version 2010/1

PC5500-6E

4 -1

Undercarriage overview

Undercarriage

4.1

UNDERCARRIAGE OVERVIEW

Fig. 4-1

PC5500-6E, undercarriage

4 -2

PC5500-6E

Version 2010/1

Undercarriage

Undercarriage overview

Legend for Fig. 4-1: (1)

Car body

(2)

Track tensioning valve block

(3)

Rotary joint

(4)

Guide wheel (idler)

(5)

Track tensioning cylinder

(6)

Low pressure accumulator

(7)

Carrier roller

(8)

Crawler carrier

(9)

Drive Sprocket

(10)

Travel gear

(11)

Cable drum assembly

(12)

High voltage power supply cable

(13)

Travel brake valve block

(14)

High pressure accumulator

(15)

Track group

(16)

Track roller

(17)

Travel motor

Version 2010/1

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4 -3

Travel system

Undercarriage

4.2

TRAVEL SYSTEM

4.2.1

TRACK GROUP

4.2.1.1 CHANGING OF THE TRACK GROUP Special tools:

n/a

Additional equipment:

Personal Protective Equipment (PPE) Dozer Chain hoist Slide hammer Welding equipment Brass drift Track group 1350 mm: 32,192 kg Pin track group 1350 mm: 19 kg Track group 1800mm: 39,066 kg Pin track group 1800 mm: 20.2 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: Make sure that the wear of the track group was measured according to the PARTS & SERVICE NEWS No. "AH02521". z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, and the dozer.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

Remove the cover (Fig. 4-2, Pos. 1).

z

Relieve pressure in the track tensioning system, refer to the PARTS & SERVICE NEWS No. "AH06530". Make sure that the slack in the track group is at the lower part of the guide wheel.

NOTE: The procedure in the PARTS & SERVICE NEWS "AH06530" prevent the track tensioning cylinders to get pressurized when moving the excavator.

Fig. 4-2 4 -4

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Version 2010/1

Undercarriage

z

Travel system

Flame-cut the nuts (Fig. 4-3, Pos. 3) from the locking bolts (Fig. 4-3, Pos. 1). Remove the locking bolts (Fig. 4-3, Pos. 1), washers (Fig. 4-3, Pos. 2), and nuts (Fig. 4-3, Pos. 3) from one track shoe (Fig. 4-3, Pos. 5). WARNING

Ensure nothing flammable is in the working area when flamecutting the nuts.

z

Pull out two pins (Fig. 4-3, Pos. 4) to open the track group using a sliding hammer.

Fig. 4-3

NOTE: Open the track group at the guide wheel. z

Sling the upper end of the track group using a chain and link it to a dozer in front of the excavator.

z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin.

NOTE: Use only motor no. 2 at Qmin. DANGER Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier.

z

Fig. 4-4

Drive the excavator and the dozer backwards slowly and unroll the track group from the excavator (Fig. 4-4).

NOTE: Assure that excavator and dozer have the same speed. z

When the upper end of the track group runs off the sprocket, stop the excavator while driving the dozer backwards slowly to prevent the track from knocking over.

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4 -5

Travel system

z

Undercarriage

Align the new track group on the ground behind the old track group.

NOTE: Observe the running direction of the new track group. Make sure that the new track group has the correct running direction as shown in Fig. 4-5. z

Remove the chain from the old track group.

z

Continue to drive the excavator backwards slowly on the new track group until the end of the of the track group is nearly reached.

z

Sling the end of the new track group at the sprocket using a chain and link it to a dozer in front of the excavator. DANGER

Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier.

Fig. 4-5 z

Drive the excavator and the dozer forward slowly and pick up the track group with the sprocket.

z

Continue to drive the excavator and the dozer forward slowly to pull up the track group (Fig. 4-6).

NOTE: Assure that excavator and dozer have the same speed.

Fig. 4-6 z

Stop the excavator and the dozer, when the guide wheel reaches the end of the track group (approximately 3 track shoes away from the end of the track group).

z

Place the track group over the guide wheel as shown in Fig. 4-7.

z

Unchain the dozer.

Fig. 4-7 4 -6

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Version 2010/1

Undercarriage

Travel system

z

Align the holes (Fig. 4-8, Pos. 3) in the two open track shoes (Fig. 4-8, Pos. 2) in front of the guide wheel (Fig. 4-8, Pos. 1) using a hoist.

z

Insert the pins (Fig. 4-9, Pos. 4) into the holes (Fig. 4-8, Pos. 3).

Fig. 4-8 z

Instal the locking bolts (Fig. 4-9, Pos. 1), washers (Fig. 4-9, Pos. 2), and nuts (Fig. 4-9, Pos. 3) to the track shoes (Fig. 4-9, Pos. 5).

z

Weld the nuts (Fig. 4-9, Pos. 3) to the bolts (Fig. 4-9, Pos. 1). WARNING

z

Ensure nothing flammable is in the working area during welding work.

z

For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS". Fig. 4-9

CAUTION The bolts (Fig. 4-10, Pos. 1) lock the pins (Fig. 4-10, Pos. 2). Therefore one side of the bolt’s head is hardened in order to prevent wear. This hardened side must face the pin. The hardened side (Fig. 4-10, arrow) of the bolt heads are marked.

Fig. 4-10

Version 2010/1

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4 -7

Travel system

Undercarriage

z

Switch S155 to back normal condition.

z

Perform the procedure given in the PARTS & SERVICE NEWS "AH06530" in reverse order.

z

Install the cover (Fig. 4-2, Pos. 1).

Fig. 4-11

4 -8

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Version 2010/1

Undercarriage

4.2.2

Travel system

SPROCKET

4.2.2.1 REMOVAL OF THE SPROCKET Special tools:

n/a

Additional equipment:

Personal Protective Equipment (PPE) Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate, PN 793 375 73 46 mm hexagon impact socket wrench (1"), PN 232 265 40 2 x Crane Dozer Pulling bolts M30 Sprocket assembly: 4382 kg Hollow shaft: 612 kg Drive shaft: 1007 kg

Dogman/rigger

NOTE: Only for removal of the sprocket it is not necessary to remove the travel gear. If changing the sprocket (Fig. 4-12, Pos. 2) it is recommended to change the flange bearings (Fig. 4-12, Pos. 1 + Pos. 3) too. Therefore the travel gear (Fig. 4-12, Pos. 4) has to be removed, refer to section 4.2.11.1 on page 4-55.

Fig. 4-12 WARNING Ensure appropriate (PPE) Personal Protective Equipment is used during the task. There maybe sharp edges on the worn sprocket that is being removed.

Version 2010/1

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4 -9

Travel system

Undercarriage

z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, and two cranes.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of the machine, counterweight above guide wheels.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

Relieve pressure in the track tensioning system, refer to PARTS & SERVICE NEWS No. "AH06530".

Drain oil of the final drive housing, approx. 165 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES". z

Check the wear of the sprocket hub, refer to PARTS & SERVICE NEWS No. "AH00515".

NOTE: Make sure that the sprocket runs free after opening the track group and it has no contact to the ground or the track group. For example drive the excavator with the track rollers at the respective crawler frame side onto a knoll. NOTE: Before beginning the work, block the track group to prevent the track shoes against falling down (refer to Fig. 4-13). z

Open the track group at the sprocket end (Fig. 4-13, Pos. 1), refer to section 4.2.1.1 on page 4-4.

Fig. 4-13

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Version 2010/1

Undercarriage

Travel system

z

Sling the upper end of the track group using a chain and link it to a dozer behind the excavator.

z

De-isolate the machine according to local regulations. DANGER

Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier. Fig. 4-14 z

Drive the excavator and the dozer forwards slowly and unroll the track group from the excavator (refer to Fig. 4-14).

NOTE: Assure that excavator and dozer have the same speed. z

When the upper end of the track group is over the carrier roll next to the sprocket, stop the excavator and the dozer.

z

Isolate the machine according to local regulations.

z

Fasten the track group to the carrier roll to hold it in position.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling sprocket (refer to Fig. 4-15).

NOTE: The travel parking brake may need to be released to allow sprocket to turn slightly to find centre of gravity.

Fig. 4-15

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PC5500-6E

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Travel system

Undercarriage

Fig. 4-16 Removal of the sprocket z

Remove the bolts (Fig. 4-16, Pos. 1) and the cover (Fig. 4-16, Pos. 10).

NOTE: When the cover is removed, oil may flow out. Catch it in an oil pan. z

Discard the O-ring (Fig. 4-16, Pos. 9).

z

Pull the drive shaft (Fig. 4-16, Pos. 6) out of the hollow shaft (Fig. 4-16, Pos. 5). WARNING

Sling the drive shaft as soon as possible and support it using a crane to prevent the shaft from falling.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the drive shaft, make sure that nobody steps below the weight.

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Version 2010/1

Undercarriage

Travel system

CAUTION Make sure that the hollow shaft (Fig. 4-16, Pos. 5) is not weight loaded before removing the flange bearing (Fig. 4-16, Pos. 8).

z

Remove mounting bolts (Fig. 4-16, Pos. 1) and extract the flange bearing (Fig. 4-16, Pos. 8) including the bush (Fig. 4-16, Pos. 7) from the crawler carrier using pulling bolts.

z

Extract the hollow shaft (Fig. 4-16, Pos. 5) from the sprocket (Fig. 4-16, Pos. 3) and remove it using a crane. WARNING

Sling the drive shaft as soon as possible and support it using a crane to prevent the shaft from falling.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the hollow shaft, make sure that nobody steps below the weight.

z

Lift the sprocket out of the crawler carrier. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the sprocket, make sure that nobody steps below the weight.

z

Discard the dual-cone seals (Fig. 4-16, Pos. 2 and Pos. 4).

NOTE: Dual-cone seals are mounted in the sprocket hub as well as in the inner and outer flange bearing. For further information refer to PARTS & SERVICE NEWS No. "AH05511". z

If required, remove the sprocket from the hub, refer to PARTS & SERVICE NEWS No. "AH00514".

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4 - 13

Travel system

Undercarriage

4.2.2.2 REPLACEMENT OF THE SPROCKET Special tools:

Assembly tool for dual-cone seals (locally made)

Additional equipment:

Personal Protective Equipment (PPE) Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate, PN 793 375 73 46 mm hexagon impact socket wrench (1"), PN 232 265 40 2 x Crane Dozer Compound "KP2K", PN 324 969 40 Paste "Optimol White", PN 999 039 Sprocket assembly: 4382 kg Hollow shaft: 612 kg Drive shaft: 1007 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

Fig. 4-17 Replacement of the sprocket

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Version 2010/1

Undercarriage

Travel system

NOTE: Before reassembly of the sprocket, the axial play has to be determined, refer to PARTS & SERVICE NEWS No. "AH06529". If necessary adjust the axial play, refer to PARTS & SERVICE NEWS No. "AH06529". For mounting the dual-cone seals (Fig. 4-17, Pos. 2 and Pos. 4), an assembly tool has to be manufactured, refer to PARTS & SERVICE NEWS No. "AH05511". z

Mount new dual-cone seals (Fig. 4-17, Pos. 2 and Pos. 4) into the flange bearing, on the gear side and into the flange bearing (Fig. 4-17, Pos. 8) on the opposite side. Refer to PARTS & SERVICE NEWS No. "AH05511".

z

Mount new dual-cone seals (Fig. 4-17, Pos. 2 and Pos. 4) into the sprocket hub, refer to PARTS & SERVICE NEWS No. "AH05511".

NOTE: Observe the mounting position of the drive shaft when installing it. The splines at the drive shaft have different lengths. The longer splines must point to the gearbox. z

Apply "Optimol White" on the splines of the drive shaft (Fig. 4-17, Pos. 6), the hollow shaft (Fig. 4-17, Pos. 5), and the splines of the planet carrier inside the travel gearbox.

z

Carry out further installation in reverse order to removal.

NOTE: Apply compound "KP2K", PN 324 969 40 on the sleeve of the flange bearing (Fig. 4-17, Pos. 8), and on heads and threads of new mounting bolts (Fig. 4-17, Pos. 1) of grade 10.9. Use the new mounting bolts with washers to attach the flange bearing with bush (Fig. 4-17, Pos. 7) to the track frame. Tighten the bolts to the specified tightening torque. Tightening torque for flange bearing mounting bolts (Fig. 4-17, Pos. 1): 1770 Nm

Refill oil in the final drive housing, approx. 165 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES".

Version 2010/1

PC5500-6E

4 - 15

Travel system

Undercarriage

4.2.2.3 REMOVAL OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) Special tools:

n/a

Additional equipment:

Personal Protective Equipment (PPE) Crane Dozer 4 forcing screws M20 Hydraulic torque wrench PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40 Regular sprocket assembly: Sprocket segment 1 (5 teeth): 794.25 kg Sprocket segment 2 (5 teeth): 794.25 kg Sprocket segment 3 (4 teeth): 661.5 kg Oversize sprocket assembly: Sprocket segment 1 (5 teeth): 968.99 kg Sprocket segment 2 (5 teeth): 968.99 kg Sprocket segment 3 (4 teeth): 807.02 kg

Dogman/rigger

NOTE: Make sure that the wear of the track group and the sprocket was measured according to the PARTS & SERVICE NEWS No. "AH02521". NOTE: Only for removal of the segmented sprocket (Fig. 4-18, Pos. 1, 2 and 3) it is not necessary to remove the travel gear (Fig. 4-18, Pos. 4). WARNING Ensure appropriate (PPE) Personal Protective Equipment is used during the task. There maybe sharp edges on the worn sprocket that is being removed.

z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, the dozer and the crane.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of he machine, counterweight above the guide wheels.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.) make sure that the machine is moved to any location with appropriate ground condition. z

Fig. 4-18

Isolate the machine according to local regulations.

4 - 16

PC5500-6E

Version 2010/1

Undercarriage

z

Travel system

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-19, Pos. 1) at the track tensioning valve block (Fig. 4-19, Pos. 2) inside the car body.

NOTE: Make sure that the sprocket runs free after opening the track group and it has no contact to the ground or the track group. For example drive the excavator with the track rollers at the respective crawler frame side onto a knoll.

Fig. 4-19 NOTE: Before beginning the work, block the track group to prevent the track shoes against falling down (refer to Fig. 4-20). z

Open the track group at the sprocket end (Fig. 4-20, Pos. 1), refer to section 4.2.1.1 on page 4-4.

Fig. 4-20 z

Sling the upper end of the track group using a chain and link it to a dozer behind the excavator.

z

De-isolate the machine according to local regulations. DANGER

Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier. Fig. 4-21 z

Drive the excavator and the dozer forwards slowly and unroll the track group from the excavator (refer to Fig. 4-21).

NOTE: Assure that excavator and dozer have the same speed. z

When the upper end of the track group is over the carrier roll next to the sprocket, stop the excavator and the dozer.

z

Fasten the track group to the carrier roll to hold it in position.

Version 2010/1

PC5500-6E

4 - 17

Travel system

Undercarriage

Fig. 4-22 Removal of the sprocket segments z

Turn the sprocket so that the first segment that has to be removed is in the upper position.

z

Isolate the machine according to local regulations.

z

Loosen all bolts (Fig. 4-22, Pos. 1) from the drive sprocket ring (Fig. 4-22, Pos. 3). Don’t remove them. WARNING

Risk of falling weights! Do not remove all bolts from the drive sprocket ring. Death or serious injury may result.

NOTE: Lightly press off drive sprocket ring by means of 4 forcing screws M20 x 80 mm at the drive sprocket ring (Fig. 4-23, Pos. 1). To prevent blocking around the ring, all 4 screws must be tightened evenly. Fig. 4-23 NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling the upper sprocket segment using a crane.

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PC5500-6E

Version 2010/1

Undercarriage

z

Travel system

Remove the bolts (Fig. 4-22, Pos. 1) from the drive sprocket ring (Fig. 4-22, Pos. 3) at the upper sprocket segment. WARNING

Risk of falling weights! Remove only the bolts from the respective sprocket segment. Death or serious injury may result.

z

Lift the sprocket segment out of the crawler carrier using a crane.

z

De-isolate the machine according to local regulations.

z

Rotate the sprocket slowly by actuating the travel drive so that the next sprocket segment that has to be removed is in upper position.

z

Isolate the machine according to local regulations.

z

To remove the other sprocket segments use the same procedure according to the first segment.

Version 2010/1

PC5500-6E

4 - 19

Travel system

Undercarriage

4.2.2.4 REPLACEMENT OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) Special tools:

n/a

Additional equipment:

Personal Protective Equipment (PPE) Crane Dozer Hydraulic torque wrench PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40 Coating compound "INTERZINC 697", PN 674 997 40 Compound "KP2K", PN 324 969 40 Regular sprocket assembly: Sprocket segment 1 (5 teeth): 794.25 kg Sprocket segment 2 (5 teeth): 794.25 kg Sprocket segment 3 (4 teeth): 661.5 kg Oversize sprocket assembly: Sprocket segment 1 (5 teeth): 968.99 kg Sprocket segment 2 (5 teeth): 968.99 kg Sprocket segment 3 (4 teeth): 807.02 kg

Dogman/rigger

z

Carefully clean all required contact surfaces of the sprocket segments, the sprocket drive ring and the travel gear.

z

The segments of the sprocket have to be erected in the shown arrangement (Fig. 4-24, Pos. 1, 2 and 3). Pos. 1: 5 teeth Pos. 2: 5 teeth Pos. 3: 4 teeth

NOTE: It is not allowed to replace single sprocket segments. Always replace all three segments.

Fig. 4-24 NOTE: If it is necessary to install the oversized sprocket segments, refer to PARTS & SERVICE NEWS No. "AH06529". z

Apply surface coating with coating compound "INTERZINC 697" at the contact surface (Fig. 4-25, Pos. 1) on both sides of the sprocket segments, refer to section 6.3.1 on page 6-4. WARNING

Only reassemble the sprocket segments after the coating compound has fully hardened. Fig. 4-25 4 - 20

PC5500-6E

Version 2010/1

Undercarriage

Travel system

Fig. 4-26 Replacement of the sprocket segments z

Carry out further installation in reverse order to removal.

NOTE: Use new bolts (Fig. 4-26, Pos. 1), nuts (Fig. 4-26, Pos. 2) and washers to attach the new sprocket segments to the travel gear (Fig. 4-26, Pos. 7). Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque. Tightening torque for sprocket segment mounting bolts (Fig. 4-26, Pos. 1): 3000 Nm

Version 2010/1

PC5500-6E

4 - 21

Travel system

4.2.3

Undercarriage

GUIDE WHEELS

4.2.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY Special tools:

n/a

Additional equipment:

Crane Guide wheel assembly: 3323 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-27, Pos. 1) at the track tensioning valve block (Fig. 4-27, Pos. 2) inside the car body.

Fig. 4-27

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PC5500-6E

Version 2010/1

Undercarriage

Travel system

z

Remove the track group from the guide wheel, refer to section 4.2.1.1 on page 4-4.

z

Remove bolts (Fig. 4-28, Pos. 1) and remove the stop plates (Fig. 4-28, Pos. 2) from both sides of the guide wheel assembly (Fig. 4-28, Pos. 3).

z

De-isolate the machine according to local regulations.

z

Isolate the machine according to local regulations.

z

Sling guide wheel assembly (Fig. 4-28, Pos. 3) and pull the guide wheel assembly out of the crawler carrier.

Fig. 4-28 NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling guide wheel assembly (Fig. 4-29) and pull the guide wheel assembly out of the crawler carrier. WARNING

Ensure to keep hands away for the component sliding surfaces during removal.

Fig. 4-29 z

Check condition of the sliding surfaces on the crawler carrier and the sliding blocks.

Version 2010/1

PC5500-6E

4 - 23

Travel system

Undercarriage

4.2.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY Special tools:

n/a

Additional equipment:

Crane Guide wheel assembly: 3323 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out installation in reverse order to removal.

NOTE: Observe the mounting position of the sliding blocks (Fig. 4-30, Pos. 3). Assure that the oil plug (Fig. 4-30, Pos. 2) at the guide wheel (Fig. 4-30, Pos. 1) is facing the inner side of the excavator.

Fig. 4-30

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PC5500-6E

Version 2010/1

Undercarriage

4.2.4

Travel system

TRACK TENSIONING ACCUMULATORS

The hydraulic track tensioning system automatically maintains the correct track tension. The pilot oil pressure of the travel brake release circuit is used to pressurize the four adjusting cylinders. The resulting force moves the guide wheels toward the front, until the correct track tension is obtained. External forces acting upon the guide wheels are absorbed through the pressure accumulators (Fig. 4-31, Pos. 1 and 2). Two different types of pressure accumulators are installed: A high pressure (150 bar) bladder accumulator (Fig. 4-31, Pos. 1) and a low pressure (31 bar) diaphragm type accumulator (Fig. 4-31, Pos. 2). Fig. 4-31

4.2.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS Special tools:

n/a

Additional equipment:

Oil drain pan Low pressure accumulator: 12 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Isolate the machine according to local regulations.

z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-32, Pos. 1) at the track tensioning valve block (Fig. 4-32, Pos. 2) inside the car body.

Fig. 4-32

Version 2010/1

PC5500-6E

4 - 25

Travel system

z

Undercarriage

Remove the cover (Fig. 4-33, Pos. 1). WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Fig. 4-33

Disconnect the pressure hose (Fig. 4-34, Pos. 1).

NOTE: When the pressure hose is removed, hydraulic oil from inside the piping and the pressure accumulator will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove four bolts (Fig. 4-34, Pos. 4) and remove the pressure accumulator (Fig. 4-34, Pos. 3).

z

Remove union (Fig. 4-34, Pos. 2).

Fig. 4-34

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PC5500-6E

Version 2010/1

Undercarriage

Travel system

4.2.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS Special tools:

Testing and refilling device, PN 761 520 73

Additional equipment:

n/a Low pressure accumulator: 12 kg If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

z

Carry out installation in reverse order to removal.

z

Fill the pressure accumulator with nitrogen gas (N2). Refer to PARTS & SERVICE NEWS No. "AH01531". DANGER

Danger of explosion! Blindness, serious injury, permanent disfigurement, scaring, or death may result. Only fill pressure accumulators with nitrogen gas (N2). Do not use any other gases due to explosion hazard!

z

Bleed the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z

Add hydraulic oil up to the specified level.

z

Check the track tension system and adjust if required. Refer to the Service Manual for further information.

Version 2010/1

PC5500-6E

4 - 27

Travel system

Undercarriage

4.2.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS Special tools:

n/a

Additional equipment:

n/a High pressure accumulator: 23 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Isolate the machine according to local regulations.

z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-35, Pos. 1) at the track tensioning valve block (Fig. 4-35, Pos. 2) inside the car body. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

Fig. 4-35

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the pressure hose assembly (Fig. 4-36, Pos. 1).

NOTE: When the pressure hose is removed, hydraulic oil from inside the piping and the pressure accumulator will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Open two clamp clips (Fig. 4-36, Pos. 2) and remove the pressure accumulator (Fig. 4-36, Pos. 3).

z

Remove the socket (Fig. 4-36, Pos. 4) from the pressure accumulator (Fig. 4-36, Pos. 3).

4 - 28

PC5500-6E

Fig. 4-36

Version 2010/1

Undercarriage

Travel system

4.2.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS Special tools:

Testing and refilling device, PN 761 520 73

Additional equipment:

n/a High pressure accumulator: 23 kg If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

z

Carry out installation in reverse order to removal.

z

Fill the pressure accumulator with nitrogen gas (N2). Refer to PARTS & SERVICE NEWS No. "AH01531". DANGER

Danger of explosion! Blindness, serious injury, permanent disfigurement, scaring, or death may result. Only fill pressure accumulators with nitrogen gas (N2). Do not use any other gases due to explosion hazard!

z

Bleed the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z

Add hydraulic oil up to the specified level.

z

Check the track tension system and adjust if required. Refer to the Service Manual for further information.

Version 2010/1

PC5500-6E

4 - 29

Travel system

4.2.5

Undercarriage

TRACK TENSION VALVE BLOCK

4.2.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK Special tools:

n/a

Additional equipment:

Chain host Oil drain pan Track tensioning valve block: 40 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Isolate the machine according to local regulations.

z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-37, Pos. 1) at the track tensioning valve block (Fig. 4-37, Pos. 2) inside the car body. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

Fig. 4-37

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect all piping (Fig. 4-38, Pos. 2) from the track tensioning valve block (Fig. 4-38, Pos. 1).

NOTE: When the piping is removed, hydraulic oil from inside the piping and the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Find an appropriate suspension point for the chain hoist and sling the track tensioning valve block (Fig. 4-38, Pos. 1).

z

Remove four mounting bolts and let down the track tensioning valve block (Fig. 4-38, Pos. 1) using the chain hoist.

4 - 30

PC5500-6E

Fig. 4-38

Version 2010/1

Undercarriage

Travel system

z

Remove the pressure increase valve (Fig. 4-39, Pos. 1) from the track tensioning valve block.

z

Remove the check valves (Fig. 4-39, Pos. 2) from the track tensioning valve block.

z

Remove the unions (Fig. 4-39, Pos. 3) from the track tensioning valve block.

Fig. 4-39

Version 2010/1

PC5500-6E

4 - 31

Travel system

Undercarriage

4.2.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK Special tools:

n/a

Additional equipment:

Chain host Track tensioning valve block: 40 kg If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

z

Carry out installation in reverse order to removal.

z

Bleed the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z

Add hydraulic oil up to the specified level.

z

Check the track tension system and adjust if required. Refer to the Service Manual for further information.

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PC5500-6E

Version 2010/1

Undercarriage

4.2.6

Travel system

HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM

4.2.6.1 SUBSTITUTE THE HYDRAULIC HOSES Special tools:

n/a

Additional equipment:

Oil drain pan Hydraulic hose: 10 kg max. If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. For further information about the needed blind plugs, refer to section 6.6 on page 6-18

z

Prepare an area of flat ground large enough to accommodate the machine.

z

Park the machine on the prepared flat ground area.

z

Isolate the machine according to local regulations.

z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-40, Pos. 1) at the track tensioning valve block (Fig. 4-40, Pos. 2) inside the car body. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

Fig. 4-40 DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

NOTE: In the following descriptions, the hydraulic hoses are replaced one at a time.

Version 2010/1

PC5500-6E

4 - 33

Travel system

Undercarriage

Fig. 4-41 Hydraulic hoses of the track tensioning system

4 - 34

PC5500-6E

Version 2010/1

Undercarriage

Travel system

Substitute the hydraulic hoses (Fig. 4-41, Pos. 1): z

Remove the cover (Fig. 4-42, Pos. 1).

z

If equipped with protection sleeve (Fig. 4-41, Pos. 9), clear the hydraulic hose to be removed by opening the protection sleeve.

z

Disconnect both ends of the hydraulic hose to be removed.

NOTE: When the hose is disconnected, hydraulic oil from inside the piping and/or the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Fig. 4-42 z

Pull out the hydraulic hose completely.

z

Insert a new hydraulic hose.

z

Reinstall the cover (Fig. 4-42, Pos. 1).

Substitute the hydraulic hoses (Fig. 4-41, Pos. 3, 4, and 5): z

Remove the cover (Fig. 4-43, Pos. 1).

z

Remove the cover (Fig. 4-43, Pos. 2) and open the clamp (Fig. 4-41, Type B) only if the hoses (Fig. 4-41, Pos. 4 and 5) for the track tensioning cylinders will be replaced.

z

Disconnect both ends of the hydraulic hose to be removed and replace the hose by a new one.

NOTE: When the hose is disconnected, hydraulic oil from inside the piping and/or the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Fig. 4-43

Reinstall the cover(s) (Fig. 4-43, Pos. 1, 2).

Substitute the hydraulic hoses (Fig. 4-41, Pos. 2, 6, 7, and 8): z

Clear the hydraulic hose (Fig. 4-41, Pos. 6, 7, and 8) to be removed by opening the clamps (Fig. 4-41, Type A or B).

z

Disconnect both ends of the hydraulic hose to be removed and replace the hose by a new one.

NOTE: When the hose is disconnected, hydraulic oil from inside the piping and/or the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Version 2010/1

PC5500-6E

4 - 35

Travel system

Undercarriage

Subsequent work z

Bleed the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z

Add hydraulic oil up to the specified level.

z

Check the track tension system and adjust if required. Refer to the Service Manual for further information.

4 - 36

PC5500-6E

Version 2010/1

Undercarriage

4.2.7

Travel system

TRACK TENSIONING CYLINDERS

4.2.7.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS Special tools:

n/a

Additional equipment:

Crane Oil drain pan Track tension cylinder: 400 kg each

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

Remove the guide wheel assembly, refer to section 4.2.3.1 on page 4-22.

z

Remove the cover (Fig. 4-44, Pos. 1).

Fig. 4-44

Version 2010/1

PC5500-6E

4 - 37

Travel system

Undercarriage

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the pressure hoses from the track tension cylinder, refer to section 4.2.6 on page 4-33.

NOTE: When the pressure hoses are removed, hydraulic oil from inside the piping and the track tension cylinder will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the track tension cylinders (Fig.4-45, Pos. 1) at the retracting device (Fig. 4-45, arrow) and pull the cylinders out of their guidance in the crawler carrier (Fig. 4-45, Pos. 2).

Fig. 4-45

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PC5500-6E

Version 2010/1

Undercarriage

Travel system

4.2.7.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS Special tools:

n/a

Additional equipment:

Crane Track tension cylinder: 400 kg each

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out installation in reverse order to removal.

z

Bleed the track tensioning system. Refer to Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z

Add hydraulic oil up to the specified level.

z

Check the track tensioning system and adjust if required. Refer to the Service Manual for further information.

Version 2010/1

PC5500-6E

4 - 39

Travel system

4.2.8

Undercarriage

TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE)

Fig. 4-46 Travel brake valve blocks (1)

Travel brake valve block

(2)

Travel motor

The travel brake valve blocks (Fig. 4-46, Pos. 1) protect the travel motors (Fig. 4-46, Pos. 2) from overspeed during downhill travel. Two travel brake valve blocks are installed, one valve block for the two travel motors of each crawler track.

4 - 40

PC5500-6E

Version 2010/1

Undercarriage

Travel system

4.2.8.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK Special tools:

n/a

Additional equipment:

Chain hoist Oil drain pan Travel brake valve block: 75 kg each For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

Version 2010/1

PC5500-6E

4 - 41

Travel system

Undercarriage

z

Disconnect the pressure hoses (Fig. 4-47, Pos. 2) to the rotary joint from the travel brake valve block (Fig. 4-47, Pos. 4).

z

Disconnect the hydraulic lines (Fig. 4-47, Pos. 1) to the travel motors from the travel brake valve block (Fig. 4-47, Pos. 4).

z

Disconnect the leakage oil line from the travel brake valve block (Fig. 4-47, Pos. 4).

NOTE: When the hydraulic lines are disconnected, hydraulic oil from inside the piping and the travel brake valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Discard the O-rings (Fig. 4-47, Pos. 5).

z

Sling the travel brake valve block (Fig. 4-47, Pos. 4) at the installed hoist rings.

z

Remove the mounting bolts (Fig. 4-47, Pos. 3) and lift off the travel brake valve block (Fig. 4-47, Pos. 4) using a chain hoist.

z

Remove the relief valve (Fig. 4-48, Pos. 1) from the travel brake valve block (Fig. 4-48, Pos. 2).

Fig. 4-47

Fig. 4-48

4 - 42

PC5500-6E

Version 2010/1

Undercarriage

Travel system

4.2.8.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK Special tools:

n/a

Additional equipment:

Chain hoist Travel brake valve block: 75 kg If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

z

Carry out installation in reverse order to removal.

NOTE: Tighten the relief valve (Fig. 4-48, Pos. 1) to the specified torque. Tightening torque for relief valve (Fig. 4-48, Pos. 1): 300 Nm z

Bleed the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z

Add hydraulic oil up to the specified level.

z

Check the travel system and adjust if required. Refer to the Service Manual for further information.

Version 2010/1

PC5500-6E

4 - 43

Travel system

4.2.9

Undercarriage

TRAVEL MOTORS

The travel motor is an axial piston unit with fixed displacement. The drive speed is proportional to the consumption capacity. The output torque increases with the pressure drop between high and low pressure side.

4.2.9.1 REMOVAL OF THE TRAVEL MOTORS Special tools:

n/a

Additional equipment:

Crane Oil drain pan Travel motor: 110 kg each

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of the machine, counterweight above guide wheels.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

If equipped, remove the motor protection, refer to the PARTS & SERVICE NEWS No. "AH08503". Drain oil of the motor adapter housing, approx. 2 liters (L&S) each, 0.5 liters (Zollern) each. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".

4 - 44

PC5500-6E

Version 2010/1

Undercarriage

Travel system

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50°C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Remove the pressure hoses (Fig. 4-49, Pos. 2) and the leak oil hoses (Fig. 4-49, Pos. 1 / Fig. 4-50, Pos. 4) from the travel motor (Fig. 4-49, Pos. 3).

NOTE: When the hoses are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Discard the O-rings.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling travel motor (Fig. 4-49, Pos. 3) and remove the mounting bolts (Fig. 4-49, Pos. 4). Discard the bolts.

z

Remove the travel motor (Fig. 4-49, Pos. 3) by pulling it out of the motor adapter housing (Fig. 4-49, Pos. 5) of the travel parking brake using a crane.

Fig. 4-49

DANGER Risk of falling weights! Death or serious injury may result. When lifting the travel motor, make sure that nobody steps below the weight. Fig. 4-50

Version 2010/1

PC5500-6E

4 - 45

Travel system

Undercarriage

4.2.9.2 REPLACEMENT OF THE TRAVEL MOTORS Special tools:

n/a

Additional equipment:

Crane Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Travel motor: 110 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Clean all drain hoses before assembly.

z

Apply "Optimol White" at the spline shaft of the travel motor (Fig. 4-51, Pos. 1) before attaching the travel motor to the motor adapter housing (Fig. 4-51, Pos. 3).

Fig. 4-51 z

Carry out installation in reverse order to removal.

NOTE: Use new mounting bolts (Fig. 4-51, Pos. 2) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque. Tightening torque for travel motor mounting bolts: 265 Nm z

Add hydraulic oil up to the specified level. Refill oil of the motor adapter housing, approx. 2 liters (L&S) each, 0.5 liters (Zollern) each. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".

z

If equipped, install the motor protection, refer to the PARTS & SERVICE NEWS No. "AH08503".

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4.2.10 TRAVEL PARKING BRAKE

Fig. 4-52 Travel parking brake assembly (dry-type) NOTE: Up to SN 025, the travel gearboxes have been equipped with wet-type brakes. For information about the fluid, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

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Legend for Fig. 4-52: (1)

Disc carrier

(2)

Snap ring

(3)

Retainer

(4)

O-ring

(5)

Seal ring

(6)

Plug screw

(7)

Control pressure port to release the brake

(8)

Spring

(9)

Spring

(10)

O-ring

(11)

Snap ring

(12)

Retainer

(13)

Disk housing

(14)

O-ring

(15)

Radial seal rings

(16)

Piston

(17)

Quad-ring

(18)

Back-up rings

(19)

Back-up rings

(20)

Quad-ring

(21)

Outer discs

(22)

Inner discs

Brake applied: The outer discs (Fig. 4-52, Pos. 21) engaged to the housing by serration and the inner discs (Fig. 4-52, Pos. 1) in serration connection with the disc carrier are pressed together by the springs (Fig. 4-52, Pos. 8 and 9). This results in a fixed connection between housing and disc carrier (Fig. 4-52, Pos. 23). Brake released: Oil pressure via the control pressure port (Fig. 4-52, Pos. 7) forces the piston (Fig. 4-52, Pos. 16) against the springs (Fig. 4-52, Pos. 8 and 9) toward the retainer (Fig. 4-52, Pos. 12). This function eliminates the spring force onto the discs, thus the brake is released. The minimum release pressure is 18 bar, the maximum permissible pressure is 60 bar.

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4.2.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE Special tools:

n/a

Additional equipment:

Crane Oil drain pan Travel parking brake: 75 kg each

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18 z

Prepare an area of flat ground large enough to accommodate the machine and boom.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of the machine, counterweight above guide wheels.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to a location with appropriate ground condition. z

Place wedges at front and rear side of both crawlers and lower the bucket onto the ground.

z

Relieve the pressure in the hydraulic system. Refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

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DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Remove the relevant travel motor (Fig. 4-53, Pos. 6 and 7 respectively), refer to section 4.2.9.1 on page 4-44.

z

Remove the pressure hose (Fig. 4-53, Pos. 3) and the breather hose (Fig. 4-53, Pos. 4) from the travel parking brake (Fig. 4-53, Pos. 1 and 5 respectively).

NOTE: When the pressure hose is removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Fig. 4-53

If equipped with wet-type travel parking brakes (up to SN 025): Drain oil of the travel parking brake housing, approx. 0.1 liters.

z

Sling the travel parking brake (Fig. 4-53, Pos. 1 and 5 respectively).

z

Remove the mounting bolts (Fig. 4-53, Pos. 2) of the travel parking brake (Fig. 4-53, Pos. 1 and 5 respectively).

z

Remove the travel parking brake (Fig. 4-53, Pos. 1 and 5 respectively) by pulling it out of the travel gearbox using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the parking brake, make sure that nobody steps below the weight.

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4.2.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE Special tools:

n/a

Additional equipment:

Crane Paste "Optimol White" PN 999 039 Portable pressure source (hydraulic or air) Travel parking brake: 75 kg each

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Apply "Optimol White" at the input spline shaft (Fig. 4-54, Pos. 4) of the travel gearbox. DANGER

Risk of retainer (Fig. 4-54, Pos. 3) blasting off! Death or serious injury may result. Do not exceed the maximum pressure of 60 bar at the pressure port.

NOTE: Travel brake may need to be released to allow the splines to line up or the mounting bolts (Fig. 4-54, Pos. 1) to be installed. Therefore first install a portable pressure source to the pressure port (Fig. 4-54, Pos. 2) (M18 x 1.5) at the travel parking brake and apply 20 bar.

Fig. 4-54 z

Carry out installation in reverse order to removal.

z

If equipped with wet-type travel parking brakes (machines up to SN 025): Refill oil of the travel parking brake housing, approx. 0.1 liters.

CAUTION Since SN 026, the travel parking brakes are dry multiple disk brakes. DO NOT fill the housings with oil.

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z

Add hydraulic oil up to the specified level.

z

Perform a function check of the travel parking brake. Refer to the Service Manual for further information.

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4.2.11 TRAVEL GEARBOX

Fig. 4-55 Travel gearbox removal (1)

Drive shaft

(2)

O-ring

(3)

Travel gearbox

(4)

Travel motor

(5, 6)

Mounting bolts and washers for travel motor

(7, 8)

Mounting bolts and washers for travel gear to crawler carrier

(9)

Crawler carrier

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4.2.11.1 REMOVAL OF THE TRAVEL GEARBOX Special tools:

n/a

Additional equipment:

Hydraulic torque wrench PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40 Crane Oil drain pan Travel gearbox: 4020 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of the machine, counterweight above guide wheels.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Place wedges at front and rear side of both crawlers and lower the bucket onto the ground.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

If equipped, remove the travel gearbox protection, refer to the PARTS & SERVICE NEWS No. "AH08503". WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

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Drain oil of the final drive housing, approx. 165 liters. Drain oil of the travel gear housing, approx. 155 liters (L&S), 180 liters (Zollern). Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES".

WARNING Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed..

z

Remove the two travel parking brakes, (Fig. 4-56, Pos. 1), refer to section 4.2.10.1 on page 4-50.

z

Remove breather hose (Fig. 4-56, Pos. 2) from the travel gearbox.

NOTE: Cap the openings with blind plugs to avoid contamination. z

Remove the driving performance meter (Fig. 4-57, Pos. 4) and cap the opening to avoid contamination.

Fig. 4-56 NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling the travel gearbox (Fig. 4-57, Pos. 3) at the installed hoist ring (Fig. 4-57, Pos. 2).

z

Remove the mounting bolts (Fig. 4-57, Pos. 5) with washers (Fig. 4-57, Pos. 6). Discard the bolts and washers.

z

Extract the travel gearbox (Fig. 4-57, Pos. 3) from the crawler carrier (Fig. 4-57, Pos. 7) using a crane.

z

Remove the O-ring (Fig. 4-57, Pos. 1) and discard it. Fig. 4-57 DANGER

Risk of falling weights! Death or serious injury may result. When lifting the travel gearbox, make sure that nobody steps below the weight.

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4.2.11.2 REPLACEMENT OF THE TRAVEL GEARBOX Special tools:

n/a

Additional equipment:

Hydraulic torque wrench PN 232 615 40 Electro-hydraulic pump aggregate, PN 793 375 73 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40 Crane Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Travel gearbox: 4020 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

NOTE: Ensure that the mating surfaces on the crawler carrier and travel gearbox (Fig. 4-58, Pos. 2) are clean and free of paint before assembly. z

Replace the driving performance meter (Fig. 4-58, Pos. 4).

z

Insert a new O-ring (Fig. 4-58, Pos. 2).

z

Apply "Optimol White" at the drive shaft (Fig. 4-58, Pos. 1) and the splines of the planet carrier inside the travel gearbox.

z

Sling the travel gearbox at the installed hoist ring (Fig. 4-58, Pos. 3). Fig. 4-58 DANGER

Risk of falling weights! Death or serious injury may result. When lifting the travel gearbox, make sure that nobody steps below the weight.

z

Align the travel gearbox to the drive shaft (Fig. 4-58, Pos. 1) and flange it to the crawler carrier.

z

Use new mounting bolts (Fig. 4-58, Pos. 5) of grade 10.9 and apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts. Insert the new mounting bolts and washers (Fig. 4-58, Pos. 6) and tighten the bolts to the specified tightening torque. Tightening torque for travel gearbox mounting bolts (Fig. 4-58, Pos. 6): 3100 Nm

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z

Undercarriage

Carry out further installation in reverse order to removal. Refill oil of the final drive housing, approx. 165 liters. Refill oil of the travel gear housing, approx. 155 liters (L&S), 180 liters (Zollern). Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES".

NOTE: Be sure to fill in the correct oil as specified, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS". Refill oil of the motor adapter housing, approx. 2 liters (L&S) each, 0.5 liters (Zollern) each. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES". z

If equipped with wet-type travel parking brakes (machines up to SN 025): Refill oil of the travel parking brake housing, approx. 0.1 liters.

CAUTION Since SN 026, the travel parking brakes are dry multiple disk brakes. DO NOT fill the housings with oil.

z

Add hydraulic oil up to the specified level.

z

Perform a function check of the travel parking brake. Refer to the Service Manual for further information.

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4.2.11.3 REMOVAL OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) Special tools:

n/a

Additional equipment:

Personal Protective Equipment (PPE) Crane Oil drain pan Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate, PN 793 375 73 46 mm hexagon impact socket wrench (1"), PN 232 265 40 Travel motor: 110 kg each Spur gear housing with mounted brake housing: 580 kg Support bearing cover: 400 kg Spindle with installed support bearing: 278 kg Planetary gear housing with mounted sprocket: 7250 kg (7750 kg with oversize sprocket assembly) Drive sprocket ring: 244 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, the dozer and the crane.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of the machine, counterweight above the guide wheels.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.) make sure that the machine is moved to any location with appropriate ground condition. NOTE: Before beginning the work, block the track group to prevent the track shoes against falling down (refer to Fig. 4-59). z

Relieve the pressure in the track tensioning system according to the PARTS & SERVICE NEWS "AH06530".

NOTE: The procedure in the PARTS & SERVICE NEWS "AH06530" prevent the track tensioning cylinders to get pressurized when moving the excavator. z

Open the track group at the sprocket end (Fig. 4-59, Pos. 1), refer to section 4.2.1.1 on page 4-4. Fig. 4-59

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z

Sling the upper end of the track group using a chain and link it to a dozer behind the excavator.

z

De-isolate the machine according to local regulations. DANGER

Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier. Fig. 4-60 z

Drive the excavator and the dozer forwards slowly and unroll the track group from the sprocket (refer to Fig. 4-60).

NOTE: Assure that excavator and dozer have the same speed. z

When the upper end of the track group is over the carrier roll next to the sprocket, stop the excavator and the dozer.

NOTE: Fasten the track group to the carrier roll to hold it in position.

Fig. 4-61 Removal / Replacement of the travel gearbox

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WARNING Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system my be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Isolate the machine according to local regulations.

NOTE: For removal of the travel gearbox (Fig. 4-61, Pos. 1) from the crawler frame it is not necessary to remove the sprocket (Fig. 4-61, Pos. 3). z

Remove the travel motors from the travel gearbox, refer to section 4.2.9.1 on page 4-44. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

Drain oil of the spur gear housing, approx. 10 liters. Drain oil of the planetary gear housing, approx. 105 liters. Drain oil of the support bearing, approx. 3.5 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES".

z

Exchange one mounting bolt (Fig. 4-62, Pos. 1) between the travel motor flanges (Fig. 4-62, Pos. 2) with an adequate swivel hoist ring.

Fig. 4-62

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z

If equipped, remove the driving performance meter (Fig. 4-63, Pos. 1) and cap the opening to avoid contamination.

z

Sling the spur gear housing (Fig. 4-63, Pos. 2) together with the brake housing (Fig. 4-63, Pos. 3) at the installed swivel hoist ring and at both brake housings in a way the components are kept in upright position.

z

Remove the remaining mounting bolts (Fig. 4-63, Pos. 4) and install 3 threaded pins (M16×130, thread length: 30 mm) evenly distributed at the circumference as guidance elements.

z

Remove the spur gear housing by pulling it off the spindle (Fig. 4-63, Pos. 5) of the planetary gear housing. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the travel gearbox, make sure that nobody steps below the weight.

Fig. 4-63

NOTE: To loosen a seized connection, jack bolts (M16) can be installed at two threaded bores (Fig. 4-62, Pos. 3). z

Exchange the upmost mounting bolt (M30) with an adequate swivel hoist ring (Fig. 4-64, Pos. 1).

z

Sling the planetary gear housing at the swivel hoist ring (Fig. 4-64, Pos. 1) and at the sprocket (Fig. 4-64, Pos. 3).

z

Tense the sling gear to ease the load of the travel gear mounting bolts.

Fig. 4-64

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z

Remove 3 mounting bolts (Fig. 4-65, Pos. 1) evenly distributed at the support bearing cover and install 3 threaded pins (M30×300, thread length: 80 mm) instead.

z

Remove the remaining mounting bolts (Fig. 4-65, Pos. 1).

z

Pull out the support bearing cover (Fig. 4-65, Pos. 2) out of the bore in the crawler frame using 3 jack bolts inserted in the threaded bores (Fig. 4-65, Pos. 3). WARNING

Sling the bearing cover as soon as possible and support it using an adequate lifting device to prevent the bearing cover from falling.

z

Remove the support bearing cover and the threaded pins.

z

Remove 3 mounting bolts (Fig. 4-66, Pos. 1) evenly distributed at the circumference of the spindle and install 3 threaded pins (M27×300, thread length: 40 mm) instead.

z

Remove the remaining mounting bolts (Fig. 4-66, Pos. 1) and pull the spindle (Fig. 4-66, Pos. 2) from the planetary gear cover (Fig. 4-66, Pos. 3).

Fig. 4-65

WARNING Sling the spindle (Fig. 4-66, Pos. 2) as soon as possible and support it using an adequate lifting device to prevent the spindle from falling.

z

Discard the dual cone seal halves attached to the bearing cover and the spindle (Fig. 4-66, Pos. 4).

NOTE: For further information about the dual cone seals, refer to PARTS & SERVICE NEWS No. "AH05511".

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Fig. 4-66

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z

Remove the mounting bolts (Fig. 4-67, Pos. 1) attaching the spindle (Fig. 4-67, Pos. 2) to the crawler frame (travel motor side) (Fig. 4-67, Pos. 3).

z

Pull the planetary gear housing out of the bore in the crawler frame and lift it out of the crawler frame using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the planetary gear housing, make sure that nobody steps below the weight.

Fig. 4-67 z

Lower the planetary gear housing (Fig. 4-68, Pos. 1) to the ground and rest it on appropriate supports (Fig. 4-68, Pos. 2).

NOTE: For the removal of the segmented sprocket (Fig. 4-68, Pos. 3) and the mounting ring (Fig. 4-68, Pos. 4), refer to section 4.2.2.3 on page 4-16.

Fig. 4-68

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4.2.11.4 REPLACEMENT OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) Special tools:

n/a

Additional equipment:

Personal Protective Equipment (PPE) Crane Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate, PN 793 375 73 46 mm hexagon impact socket wrench (1"), PN 232 265 40 3 x Threaded pin M16x130 (thread length: 30 mm) 3 x Threaded pin M27x300 (thread length: 40 mm) 3 x Threaded pin M30x300 (thread length: 80 mm) Paste "Optimol White", PN 999 039 Fluid "Loctite 245", PN 170 470 40 Sealant "Loctite 574", PN 255 239 40 Compound "KP2K", PN 324 969 40 Support bearing cover: 400 kg Spindle with installed support bearing: 278 kg Spur gear housing with mounted brake housing: 580 kg Planetary gear housing with mounted sprocket: 7250 kg (7750 kg with oversize sprocket assembly) Drive sprocket ring: 244 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. NOTE: It is assumed that all parts to be installed are checked and approved, and parts are replaced if required. For the following description it is also assumed that the components to be installed are in the same state of assembly as after removal. Ensure that the mating surfaces are cleaned thoroughly, and that sealants are removed completely.

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z

Undercarriage

Instal the segmented sprocket (Fig. 4-69, Pos. 3) to the planetary gear housing (Fig. 4-69, Pos. 1), refer to section 4.2.2.4 on page 4-20.

NOTE: Align the sprocket segments to the mounting bores in the travel gearbox by means of two pipes (dia. 38 mm×1000 mm). Instal three swivel hoist rings to the drive sprocket ring (Fig. 4-69, Pos. 4), and put the drive sprocket ring on the sprocket segments using a crane. Remove the swivel hoist rings. Use new bolts, nuts, and washers to attach the sprocket segments and the sprocket ring to the travel gear (Fig. 4-69, Pos. 1). Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque.

Fig. 4-69

Tightening torque for drive sprocket ring mounting bolts (Fig. 4-26, Pos. 1): 3000 Nm z

Install a swivel hoist ring (Fig. 4-70, Pos. 1) to the planetary gear housing (Fig. 4-70, Pos. 9) in exchange for a mounting bolt at the rear cover of the planetary gear housing.

NOTE: Pay attention to the position of the oil plugs. z

Hook up the planetary gear housing at the installed swivel hoist ring (Fig. 4-70, Pos. 1) and the sprocket (Fig. 4-70, Pos. 3).

NOTE: Use a chain hoist (Fig. 4-70, Pos. 2) to align the planetary gear housing vertically. z

Apply "Optimol White" to the bore (Fig. 4-70, Pos. 8) in the crawler frame (travel motor side) (Fig. 4-70, Pos. 7).

z

Lift the planetary gear housing to the inside of the crawler carrier.

z

Align the spindle (Fig. 4-70, Pos. 4) of the planetary gear housing to the bores in the crawler frame and move it into the bore.

z

Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts (Fig. 4-70, Pos. 6) and insert the mounting bolts with washers (Fig. 4-70, Pos. 5).

z

Tighten all mounting bolts to the specified tightening torque using the hydraulic torque wrench PN 232 614 40.

Fig. 4-70

Tightening torque for travel gearbox mounting bolts (Fig. 4-70, Pos. 6): 3000 Nm

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NOTE: Leave the planetary gear housing hooked up to the crane. z

Install one half of the dual cone seal (Fig. 4-71, Pos. 1) to the support bearing spindle (Fig. 4-70, Pos. 2).

NOTE: Before installation, moist rubber seal ring with a mixture of water and spirit. For further information about mounting dual cone seals and the assembly tool that has to be used, refer to PARTS & SERVICE NEWS No. "AH05511". z

If required, install a new bearing (Fig. 4-70, Pos. 3) to the spindle.

Fig. 4-71 z

Install 3 threaded pins (M27×300 mm, thread length: 40 mm) equally distributed at the planetary gear housing (Fig. 4-72, Pos. 3) into the bores for the spindle mounting bolts (Fig. 4-72, Pos. 1).

z

Lift the spindle (Fig. 4-72, Pos. 2) by means of an adequate lifting device and move it onto the threaded pins. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the support bearing spindle, make sure that nobody steps below the weight.

z

Apply compound "Loctite 245" on the threads of new mounting bolts (Fig. 4-72, Pos. 1) of grade 10.9, insert the mounting bolts with new HV-washers, and tighten the mounting bolts to the specified tightening torque.

Fig. 4-72

Tightening torque for spindle mounting bolts: 1520 Nm z

Remove the threaded pins.

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z

Apply oil onto the support bearing (Fig. 4-73, Pos. 4).

z

Apply paste "Optimol White" onto the bore in the crawler frame (Fig. 4-73, Pos. 6).

z

Install the other half of the dual cone seal (Fig. 4-73, Pos. 5) to the bearing cover (Fig. 4-73, Pos. 7).

NOTE: Before installation, moist rubber seal ring with a mixture of water and spirit. For further information about mounting dual cone seals and the assembly tool that has to be used, refer to PARTS & SERVICE NEWS No. "AH05511". z

Align the support bearing (Fig. 4-73, Pos. 4) to the bore in the crawler frame concentrically.

NOTE: Max. allowable eccentricity: 0.05 mm. If required, lift gear housing by means of hydraulic jacks and keep it in position using appropriate supports. z

Install 3 threaded pins (M30×300 mm, thread length: 80 mm) equally distributed to the bores in the crawler frame (Fig. 4-73, Pos. 6).

z

Sling the support bearing cover (Fig. 4-73, Pos. 7) and slip it onto the threaded pins.

Fig. 4-73

DANGER Risk of falling weights! Death or serious injury may result. When lifting the bearing cover, make sure that nobody steps below the weight.

NOTE: Pay attention to the position of the oil plugs in the bearing cover. z

Shift bearing cover over the support bearing into the bore in the crawler frame by means of 5 bolts (M30×160 mm) and washers, both delivered with the travel gear.

z

Remove the bolts.

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z

Travel system

Install new mounting bolts (Fig. 4-73, Pos. 1) of grade 10.9 with washers (Fig. 4-73, Pos. 2).

NOTE: Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specified tightening torque. Tightening torque for bearing cover mounting bolts: 710 Nm z

Remove the lifting gear and the supporting tools from the gear housing.

z

Sling the spur gear housing (Fig. 4-74, Pos. 3) with the installed brake housing.

z

Install new O-ring (Fig. 4-74, Pos. 5) to the spur gear housing.

NOTE: Apply paste "Loctite 574" onto the sealing / mating surfaces (Fig. 4-74, Pos. 2). z

Install 3 threaded pins (M16×130, thread length: 30 mm) into 3 bores for the spur gear mounting bolts (Fig. 4-74, Pos. 6) evenly distributed at the spindle (Fig. 4-74, Pos. 1) of the planetary gear housing.

z

Lift spur gear housing (Fig. 4-74, Pos. 3) and slip it onto the threaded pins. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the spur gear housing, make sure that nobody steps below the weight.

z

Fig. 4-74

Insert new mounting bolts (Fig. 4-74, Pos. 4) of grade 10.9.

NOTE: Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specified tightening torque. Tightening torque for spur gear housing mounting bolts: 255 Nm z

Remove the sling gear.

z

Replace the swivel hoist ring with a mounting bolt.

z

Carry out further installation in reverse order to removal.

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Undercarriage

4.2.12 CARRIER ROLLER 4.2.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY Special tools:

n/a

Additional equipment:

Hydraulic jack 40 tonnes Forklift (as the most economical device) Chain hoist Carrier roller assembly (pinned undercarriage): 175 kg Carrier roller assembly (bolted undercarriage): 205 kg

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and forklift.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-75, Pos. 1) at the track tensioning valve block (Fig. 4-75, Pos. 2) inside the car body.

Fig. 4-75 z

Push up track shoe assembly (Fig. 4-76, Pos. 3) at the carrier roller assembly (Fig. 4-76, Pos. 2) to be removed using hydraulic jack (Fig. 4-76, Pos. 1). In addition to the hydraulic jack, secure the track shoe assembly using appropriate blocks.

NOTE: Fig. 4-76 shows the crawler carrier of the bolted undercarriage, this step is accordingly identical for the crawler carrier of the pinned undercarriage.

Fig. 4-76

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z

Travel system

Carry out the following steps at the crawler carrier of the bolted undercarriage only: z

Shove the forks (Fig. 4-77, Pos. 1) together that far, that the carrier roller (Fig. 4-77, Pos. 2) can rest on the forks. WARNING

z

If the forks can not be locked in that position, use a chain hoist at the forks to prevent them from sliding apart.

z

Make sure that nobody is in the danger zone while lifting the carrier roller assembly from the pedestal. Fig. 4-77

z

Carry out the following step at the crawler carrier of the pinned undercarriage only: z

Sling the carrier roller assembly (Fig. 4-78, Pos. 1) at both sides and connect the slings to the forks (Fig. 4-78, Pos. 2) of a forklift.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges.

Fig. 4-78 z

Remove the carrier roller assembly mounting bolts and lift off the carrier roller assembly using a forklift. DANGER

Risk of falling weights! May result in death or serious injury When lifting the carrier roller, make sure that nobody steps below the weight.

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4.2.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY Special tools:

n/a

Additional equipment:

Hydraulic jack 40 tonnes Forklift (as the most economical device) Chain hoist Carrier roller assembly (pinned undercarriage): 175 kg Carrier roller assembly (bolted undercarriage): 205 kg If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

z

Carry out installation in reverse order to removal.

NOTE: Observe the mounting position of the carrier rollers. The oil plug must face the outside of the excavator. Check the oil level in the carrier roller. The following positions of the oil level and filler plug have been defined for checking the oil level in the carrier rollers: z

9.00 o'clock or 3.00 o'clock position, equal to 90° angle from TOP position of the plug to left or to the right = MINIMUM oil level.

z

9.30 o'clock or 2.30 o'clock position, equal to 75° angle from TOP position of the plug to left or to the right = MAXIMUM oil level (factory filling).

z

For information about the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS". DANGER

Danger of crush or pinch injuries to hands and fingers! Exercise extreme care when aligning the carrier roller assembly to the crawler carrier.

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4.2.13 TRACK ROLLER 4.2.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY Special tools:

Safety unit for changing track rollers, PN 921 149 40 Tool for changing track rollers (P&S-news in development)

Additional equipment:

Crane Track roller assembly: 654 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-79, Pos. 1) at the track tensioning valve block (Fig. 4-79, Pos. 2) inside the car body.

Fig. 4-79 z

Jack up the machine with the work equipment.

z

Support two track rollers with the safety unit for changing track rollers, PN 921 149 40 (Fig. 4-80, Pos. 1).

z

Lower the machine and place the work equipment on the ground.

z

Isolate the machine according to local regulations.

z

Support the track roller assembly (Fig. 4-80, Pos. 2) from the bottom side with the changing tool for track rollers (Fig. 4-82).

z

Remove the track roller mounting bolts (Fig. 4-80, Pos. 3) and lower the tool. Fig. 4-80

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NOTE: The track roller mounting bolts (Fig. 4-81, Pos. 1) are secured with lever-nuts (Fig. 4-81, Pos. 2) inside the crawler frame. When the bolts are removed, the nuts may slip away from their mounting position.

Fig. 4-81 NOTE: Make sure that both sides of the tool are balanced (e.g. with the new track roller assembly). z

Remove the track roller assembly. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the track roller, make sure that nobody steps below the weight.

NOTE: A PARTS & SERVICE NEWS for this tool is under development.

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Fig. 4-82

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Travel system

4.2.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY Special tools:

Safety unit for changing track rollers, PN 921 149 40 Tool for changing track rollers (P&S-news in development)

Additional equipment:

Crane Track roller assembly: 654 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: Observe the mounting position of the track rollers. The oil plug must face the outside of the excavator. Check the oil level in the track roller. The following positions of the oil level and filler plug have been defined for checking the oil level in the track rollers:

z

z

9.00 o'clock or 3.00 o'clock position, equal to 90° angle from TOP position of the plug to left or to the right = MINIMUM oil level.

z

9.30 o'clock or 2.30 o'clock position, equal to 75° angle from TOP position of the plug to left or to the right = MAXIMUM oil level (factory filling).

z

For information about the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

Carry out installation in reverse order to removal. z

When inserting the track roller mounting bolts (Fig. 4-83, Pos. 1), hold the lever-nuts (Fig. 4-83, Pos. 2) inside the crawler frame by hand for the first convolutions.

NOTE: Use new track roller mounting bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 to the bolts.

Fig. 4-83

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4.3

CAR BODY

4.3.1

REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE)

Special tools:

n/a

Additional equipment:

2 x Crane Dozer Oil drain pan Car body: 42,000 kg Crawler carrier assembly: 40,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

NOTE: At first the wear of the bushes in the car body should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508". z

Remove the track groups from both crawler carriers, refer to section 4.2.1.1 on page 4-4.

NOTE: Remove both track groups simultaneously. This can be done using the same dozer. WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Remove the travel gearboxes from both crawler carriers, refer to section 4.2.11.1 on page 4-55.

z

Lift the superstructure, refer to section 3.14.1 on page 3-256.

z

Attach a dozer to the car body by means of a chain.

z

Move the car body below the lifted superstructure using the dozer.

NOTE: Move the car body over the unrolled track group.

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z

Car body

Remove the pressure hoses (Fig. 4-84, Pos. 1) of the track tensioning system leading to the shut-off cocks (Fig. 4-84, Pos. 2) and pull them out of the crawler carriers, refer to section 4.2.6.1 on page 4-33.

NOTE: When the pressure hoses are removed, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 4-84 z

Attach one crawler to two cranes and lift it up (Fig. 4-85).

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. WARNING Before lifting, make sure that the crane operators are trained in dual crane lift.

Fig. 4-85 z

Rest the car body on appropriate supports (see Fig. 4-86). CAUTION

Supports need to be substantial enough to carry the total weight of both crawler carrier (40,000 kg) and car body (42,000 kg).

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Fig. 4-86 Crawler carrier mounting z

Remove all bolts (Fig. 4-86, Pos. 6) and the retainer plates (Fig. 4-86, Pos. 7).

z

Remove the nuts (Fig. 4-86, Pos. 2), the cover plates (Fig. 4-86, Pos. 3), and the thread pins (Fig. 4-86, Pos. 4) only if required (changing to a replacement car body).

z

Pull out the four mounting pins (Fig. 4-86, Pos. 5) just enough to clear the crawler carrier assembly (Fig. 4-86, Pos. 1) from the car body as shown in (Fig. 4-86).

z

Remove the crawler carrier (Fig. 4-86, Pos. 1) using two cranes. WARNING

Before lifting, make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the crawler carrier, make sure that nobody steps below the weight.

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Car body

z

Attach the car body to two cranes (Fig. 4-87).

z

Clear the other crawler carrier from the car body using the same procedure as before.

z

Remove the car body using two cranes.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. WARNING Before lifting, make sure that the crane operators are trained in dual crane lift.

Fig. 4-87

DANGER Risk of falling weights! Death or serious injury may result. When lifting the crawler carrier, make sure that nobody steps below the weight.

z

Carry out the following steps only if required: z

Remove the rotary joint from the car body, refer to section 4.3.5.1 on page 4-98.

z

Remove the high pressure accumulators from the car body, refer to section 4.2.4.3 on page 4-28.

z

Remove the track tensioning valve from the car body, refer to section 4.2.5.1 on page 4-30.

z

Remove the travel brake valve blocks from the car body, refer to section 4.2.8.1 on page 4-41.

z

Remove all hydraulic hoses from the car body, refer to section 4.2.6.1 on page 4-33.

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4.3.2

Undercarriage

REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE)

Special tools:

Water level gauge

Additional equipment:

AL-Compound, PN 509 623 98 2 x Crane Dozer Car body: 42,000 kg Crawler carrier assembly: 40,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. z

Carry out the following steps only if required: z

Instal all hydraulic hoses into the new car body, refer to section 4.2.6.1 on page 4-33.

z

Instal the rotary joint in the new car body, refer to section 4.3.5.2 on page 4-101.

z

Instal the high pressure accumulators in the new car body, refer to section 4.2.4.4 on page 4-29.

z

Instal the track tensioning valve in the new car body, refer to section 4.2.5.2 on page 4-32.

z

Instal the travel brake valve blocks in the new car body, refer to section 4.2.8.2 on page 4-43.

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z

If required, install new inner bushings (Fig. 4-88, Pos. 5) and new outer bushings (Fig. 4-88, Pos. 7) in the new car body.

z

Instal the thread pins (Fig. 4-88, Pos. 4) and the cover plates (Fig. 4-88, Pos. 3) with nuts (Fig. 4-88, Pos. 2) and washers at the four borings for the pins on the car body.

z

Attach the car body (Fig. 4-88, Pos. 1) to two cranes and lift it up. WARNING

Before lifting, make sure that the crane operators are trained in dual crane lift.

DANGER

Fig. 4-88

Risk of falling weights! Death or serious injury may result. When lifting the car body, make sure that nobody steps below the weight.

NOTE: The oil supply lines to the travel motors must be aligned in the direction of the travel motors. z

Align the car body (Fig. 4-88, Pos. 1) to the crawler carrier (Fig. 4-88, Pos. 10) and let it down.

NOTE: The oil supply lines to the travel motors must be aligned in the direction of the travel motors. Insert the hydraulic lines for track tensioning into the crawler carrier before installing it. If applicable, re-assemble the protection sleeve on the hydraulic hose at the joint between the crawler carrier and the car body. z

Align the upper borings first and insert the mounting pins (Fig. 4-88, Pos. 6).

NOTE: Lubricate pins (Fig. 4-88, Pos. 6) with AL-Compound, PN 509 623 98. z

Align the lower borings and insert the mounting pins.

z

Instal the retainer plates (Fig. 4-88, Pos. 9) at the mounting pins and secure the retainer plates with the mounting bolts (Fig. 4-88, Pos. 8) and washers.

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z

Undercarriage

For easier mounting of the second crawler carrier, support left side of the car body with appropriate stands of approx. 1500 mm hight and lower the car body on the stands (see Fig. 4-89). CAUTION

Supports need to be substantial enough to carry the total weight of both crawler carrier (40,000 kg) and car body (42,000 kg).

NOTE: Assure that the track groups are parallel and the distance "A" between track groups is: 4840 mm for track width 1350 4390 mm for track width 1800 Fig. 4-89

Fig. 4-90 Assembly of the car body z

Instal the thread pins (Fig. 4-90, Pos. 4) and the inner retainer plates (Fig. 4-90, Pos. 3) with nuts (Fig. 4-90, Pos. 2) and washers at the four borings for the pins on the car body.

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z

Car body

Attach the second crawler carrier (Fig. 4-90, Pos. 1) to two cranes, lift it up and align it to the car body.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. WARNING Before lifting, make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the car body, make sure that nobody steps below the weight.

z

Align the upper borings first and insert the mounting pins (Fig. 4-90, Pos. 5).

NOTE: Lubricate pins (Fig. 4-90, Pos. 5) with AL-Compound, PN 509 623 98. z

Align the lower borings and insert the mounting pins.

z

Instal the retainer plates (Fig. 4-90, Pos. 7) at the mounting pins and secure the retainer plates with the mounting bolts (Fig. 4-90, Pos. 6) and washers.

z

Lift the undercarriage as far as it is necessary to remove the stands.

z

Rest the undercarriage to the ground.

z

Carry out further installation in reverse order to removal.

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Car body

4.3.3

Undercarriage

REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE)

Special tools:

Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73 Electro-hydraulic pump aggregate, PN 793 375 73

Additional equipment:

2 x Crane Dozer Car body: 46,000 kg Crawler carrier assembly: 44,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Remove the track groups from both crawler carriers, refer to section 4.2.1.1 on page 4-4.

NOTE: Remove both track groups simultaneously. This can be done using the same dozer. z

Remove the travel gearboxes from both crawler carriers, refer to section 4.2.11.1 on page 4-55.

z

Lift the superstructure, refer to section 3.14.1 on page 3-256.

z

Attach a dozer to the car body by means of a chain.

z

Move the car body below the lifted superstructure using the dozer.

NOTE: Move the car body over the unrolled track group.

z

Disconnect the pressure hoses (Fig. 4-91, Pos. 1) for the track tensioning from the shut-off cocks (Fig. 4-91, Pos. 2).

NOTE: When the pressure hoses are removed, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hoses from both crawler carriers.

Fig. 4-91

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z

Car body

Attach one crawler carrier (Fig. 4-92, Pos. 1) to two cranes at the installed lifting eyes (Fig. 4-92, Pos. 2) and lift it up. WARNING

Before lifting, make sure that the crane operators are trained in dual crane lift.

z

Support the car body with appropriate stands so that all of the track rollers are clear of the track roller path. CAUTION

Supports need to be substantial enough to carry total weight of one crawler carrier assembly (44,000 kg) and the car body (46,000 kg).

Fig. 4-92

NOTE: Place supports between the cross-ties (Fig. 4-93, Pos. 1) in a manner that the mounting bolts can be removed.

Fig. 4-93

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Fig. 4-94 Crawler carrier mounting bolts 4 - 86

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z

Car body

Remove all mounting bolts (Fig. 4-94, Pos. M48) and the two measuring bolts (Fig. 4-94, Pos. 7) attaching the crawler carrier assembly to the car body using the hydraulic torque wrench PN 793 374 73 + PN 793 376 73. Discard the bolts.

NOTE: For hints using the hydraulic torque wrench refer to section 6.3.2 on page 6-6, and also refer to chapter 9 "Supplier’s documentation", "AVANTI HYTORQUE". z

Remove the crawler carrier using two cranes. WARNING

Before lifting, make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the crawler carriage, make sure that nobody steps below the weight.

z

Carry out the same procedure described above to remove the second crawler carrier.

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Undercarriage

This page was left blank intentionally.

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4.3.4

Car body

REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE)

Special tools:

Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73 Electro-hydraulic pump aggregate, PN 793 375 73 Measuring device, PN 928 476 40

Additional equipment:

2 x Crane Dozer Compound "KP2K", PN 324 969 40 Coating compound "INTERZINC 697", PN 674 997 40 Car body: 46,000 kg Crawler carrier assembly: 40,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. z

Check the coated flange plates of the new car body for intactness, refer to PARTS & SERVICE NEWS "AH07526".

NOTE: If the coating of flange plates with "INTERZINC 697" has to be renewed, carry out the surface coating according to section 6.3.1 on page 6-4. To ensure an accurate coating, work has to be carried out in an industrial environment. z

Carry out further installation in reverse order to removal and according to section 4.3.2 on page 4-80. When mounting the crawler carrier to the car body, tighten the mounting bolts according to the following procedures.

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Undercarriage

Fig. 4-95 Crawler carrier mounting bolts 4 - 90

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z

Car body

Insert new bolts (Fig. 4-95, Pos. M48) and two measuring bolts (Fig. 4-95, Pos. 7) with resilient sleeves.

NOTE: Lubricate all bolts (Fig. 4-95, Pos. M48) with compound "KP2K", PN 324 969 40. Clean bottom and top surface of the resilient sleeves and contact areas completely free of paint. Insert the two measuring bolts (Fig. 4-95, Pos. 7) into the upper corners. The measuring bolts are part of the measuring device, PN 928 476 40. z

Pre-tighten the mounting bolts using the hydraulic torque wrench PN 793 374 73 + PN 793 376 73, refer to section 6.3.2 on page 6-6. Pre-tightening torque for crawler carrier mounting bolts: 2100 Nm

z

Determine the torque and tighten the crawler carrier mounting bolts to the determined torque, refer to section 4.3.4.1 on page 4-92.

NOTE: Check the torque of the crawler carrier mounting bolts after 1000 operating hours, refer to section 4.3.4.1 on page 4-92.

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Undercarriage

4.3.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS Special tools:

Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73 Electro-hydraulic pump aggregate, PN 793 375 73 Measuring device, PN 928 476 40

Fig. 4-96 Crawler carrier mounting bolts 4 - 92

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Car body

The required tightening torque for all fastening bolts has to be determined with the 4 measuring bolts (Fig. 4-96, Pos. 7), whose dimension resembles the fastening bolts (Fig. 4-96, Pos. M48). The required axial tension force of the bolts depends on the elongation of the fastening bolts. NOTE: The tightening torque must be determined at the first assembly of the excavator at the operation site, for the first inspection, and after 1000 operation hours, or after replacing either crawler carrier or car body. The required measuring device, PN 928 476 40 is delivered with the excavator. To determine the tightening torque, 4 specially prepared measuring bolts are supplied besides the normal fastening bolts. The measuring bolts can be recognized by the machined area at the end of the bolt. The measuring device (Fig. 4-96, Pos. 1 - 6) is composed of the following items and will be delivered with each new machine. Refer to Fig. 4-96: Pos.

Part name

Part number

Qty.

(1)

Angle bar

928 475 40

1

(2)

Dial gauge

092 706 40

1

(3)

Screw M5x16

502 515 98

1

(4)

Feeler

477 172 40

1

(5)

Bolt M10x25

307 777 99

2

(6)

Washer

517 122 98

2

(7)

Measuring bolt (installed)

933 613 40

4

WARNING Pre-condition: Crawler carrier is assembled and bolts tightened to 2100 Nm

z

Loosen all 4 measuring bolts (Fig. 4-96, Pos. 7). Do not lubricate the measuring bolts again.

z

Tighten the 4 measuring bolts (Fig. 4-96, Pos. 7) to 150 Nm.

z

Instal the measuring device (Fig. 4-96, Pos. 1 - 6).

z

Set the dial gauge (Fig. 4-96, Pos. 2) to zero.

z

Instal the special hydraulic torque wrench, PN 793 374 73 + PN 793 376 73, refer to section 6.3.2 on page 6-6.

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Fig. 4-97 Crawler carrier mounting bolts

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Car body

z

Adjust the pressure at the hydraulic torque wrench to 2100 Nm and tighten the measuring bolt (Fig. 4-97, Pos. 7).

z

List the pressure and the changed bolt length in a table.

z

Increase the pressure in steps of 10 bar until the measuring bolts have the required elongation of 0.93 mm.

z

List the corresponding hydraulic pressure in a table.

z

Repeat this procedure for all 4 measuring bolts.

z

Add all 4 determined hydraulic pressures and then divide by 4 to obtain an average value.

z

Loosen one mounting bolt (Fig. 4-97, Pos. M48) and tighten the bolt with the calculated average pressure. CAUTION

Do not lubricate the bolts again. Do not loosen more than one bolt at a time.

z

Repeat this procedure step by step for all the other bolts.

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Car body

4.3.5

Undercarriage

ROTARY JOINT

Fig. 4-98 Rotary joint

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Legend for illustration Fig. 4-98: (1)

Rotary joint

(2)

Through bore (center of rotary joint)

(3)

Cam, attached to the superstructure

(4)

Torque support lever

(5)

Mounting bolt

(6)

Resilient sleeve

(7)

Cross beam

(8)

Car body

(9)

Cover plate

(10)

Ring groove

(11)

Stator connecting port

(12)

Stator, housing of rotary joint

(13)

Rotor

(14)

Leak oil connection port

(15)

Rotor connecting ports

(16)

Sealing element with O-ring

(17)

Leak (case drain) oil

The rotary distributor (rotary joint) serves as a hydraulic connection between the superstructure and the undercarriage. This means that there is an unrestricted hydraulic connection installed between the rotating and stationary part which allows free rotation in both slew directions. During operation the superstructure and the undercarriage rotate against each other. The travel motors must be supplied with hydraulic oil in each position in which the superstructure is slewed against the undercarriage. The rotary joint is provided with a through bore in its center. The high voltage power supply cable runs though the bore in the rotary joint to the slip ring unit attached ot the superstructure.

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4.3.5.1 REMOVAL OF THE ROTARY JOINT Special tools:

n/a

Additional equipment:

Crane Rotary joint: 261 kg

Dogman/rigger Electrician with permission to work on high voltage systems For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and a crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-99, Pos. 1) at the track tensioning valve block (Fig. 4-99, Pos. 2) inside the car body.

Fig. 4-99

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Car body

z

Close the hand wheel (Fig. 4-100, Pos. 1) of main gate valve between suction oil reservoir and main oil reservoir.

z

Transfuse oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 4-100 DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

z

Remove the slip ring unit, refer to section 3.16.1 on page 3-275.

z

Pull the high voltage power supply cable out of the rotary joint and the cross beam of the car body. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Mark and disconnect all hydraulic hoses and pipes from the rotary joint. Discard the O-rings of the SAE flange connections.

NOTE: When the hydraulic lines are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the grease feeding lines of the central lubrication system from the rotary joint.

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PC5500-6E

4 - 99

Car body

z

Undercarriage

Sling rotary joint.

NOTE: The rotary joint is accessible from above, from between the pipe work at the manifold at the center of the machine (Fig. 4-101, arrow). CAUTION Move the sling carefully between the pipe work/hoses at the manifold to prevent the pipe work from being damaged or ripped off.

Fig. 4-101 z

Remove the mounting bolts (Fig. 4-102, Pos. 1), and remove the torque support lever (Fig. 4-102, Pos. 6) from the rotary joint (Fig. 4-102, Pos. 2).

z

Remove the mounting bolts (Fig. 4-102, Pos. 4) and resilient sleeves (Fig. 4-102, Pos. 5).

z

Lift the rotary joint (Fig. 4-102, Pos. 3) off the cross beam (Fig. 4-102, Pos. 3) using a crane and rest the rotary joint on the ground. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the rotary joint, make sure that nobody steps below the weight. Fig. 4-102

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PC5500-6E

Version 2010/1

Undercarriage

Car body

4.3.5.2 REPLACEMENT OF THE ROTARY JOINT Special tools:

n/a

Additional equipment:

Crane Compound "KP2K", PN 324 969 40 Rotary joint: 261 kg

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

z

Lift the new rotary joint (Fig. 4-103, Pos. 2) onto the cross beam (Fig. 4-103, Pos. 3) at the car body. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the rotary joint, make sure that nobody steps below the weight.

z

Install the mounting bolts (Fig. 4-103, Pos. 4) with resilient sleeves (Fig. 4-103, Pos. 5).

NOTE: Apply compound "KP2K", PN 324 969 40 to the mounting bolts. z

Install the torque support lever (Fig. 4-103, Pos. 6) to the rotary joint. Make sure that the torque support lever fits into the cam at the superstructure.

Fig. 4-103

NOTE: Apply compound "KP2K", PN 324 969 40 to the mounting bolts. z

Push up the high voltage power supply cable through the rotary joint from the bottom of the cross beam.

z

Carry out further installation in reverse order to removal.

z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

Version 2010/1

PC5500-6E

4 - 101

Car body

4.3.6

Undercarriage

CABLE DRUM

Fig. 4-104 Cable drum, overview (1)

Mounting flange

(2)

Connection box

(3)

Cable drum brake motor

(4)

Power cable guiding tube

(5)

Carrier

(6)

Cable guide mechanism

(7)

Cable drum

(8)

Brake motor resistor

(9)

Maintenance access ladder

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Undercarriage

Car body

4.3.6.1 PREPARATORY WORK FOR THE REMOVAL AND REPLACEMENT OF THE CABLE DRUM ASSEMBLY Special tools:

n/a

Additional equipment:

n/at

Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and forklift.

z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 4-105).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 4-105 z

Unroll the power supply cable from the cable drum til the end using the manual switch of the unit.

NOTE: If the electric supply has been switched off from the power plant, loosen the brake of the drum motor, refer to the Operation & Maintenance Manual of the cable drum assembly. z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

z

Disconnect the power supply cable at the power station.

Version 2010/1

PC5500-6E

4 - 103

Car body

Undercarriage

4.3.6.2 REMOVAL OF THE CABLE DRUM ASSEMBLY Special tools:

n/a

Additional equipment:

Crane 2 x Chain hoist (carrying capacity: 5000 kg, each) Cable drum: 7500 kg

Dogman/rigger

z

Carry out the preparatory work for the removal and replacement of the cable drum, refer to section 4.3.6.1 on page 4-103.

z

Open the man hole of the cable drum.

z

Disconnect the high voltage power supply cable coming from the power station inside the drum, and pull the cable out of the drum.

z

Disconnect all cables and wires leading from the car body (Fig. 4-106, Pos. 1) to the cable drum assembly, and put them down on the machine.

z

Sling the cable drum assembly at the carrier (Fig. 4-106, Pos. 2) using a crane and two chain hoists.

z

Remove the mounting bolts (Fig. 4-106, Pos. 3) and resilient sleeves (Fig. 4-106, Pos. 4) at the flanges (Fig. 4-106, Pos. 5). DANGER

Risk of falling weights! Death or serious injury may result. When removing the mounting bolts, make sure that nobody steps below the weight.

z

Move the cable drum assembly away from the machine carefully, and put it down on the ground. Fig. 4-106 DANGER

Risk of falling weights! Death or serious injury may result. When lifting the cable drum assembly, make sure that nobody steps below the weight.

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Version 2010/1

Undercarriage

Car body

4.3.6.3 REPLACEMENT OF THE CABLE DRUM ASSEMBLY Special tools:

n/a

Additional equipment:

Crane 2 x Chain hoist Cable drum: 7500 kg

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. z

Carry out the preparatory work for the removal and replacement of the cable drum, refer to section 4.3.6.1 on page 4-103.

z

Clean the mating surfaces of the cable drum assembly and the car body.

NOTE: Ensure that the mating surfaces are free of grease and rust, and that the surfaces are plane.

z

Sling the cable drum assembly (Fig. 4-107, Pos. 2) using a crane and two chain hoists.

z

Bring the cable drum assembly into mounting position at the car body (Fig. 4-106, Pos. 1). DANGER

Risk of falling weights! Death or serious injury may result. When lifting the cable drum assembly, make sure that nobody steps below the weight.

z

Install the mounting bolts (Fig. 4-106, Pos. 3) with resilient sleeves (Fig. 4-106, Pos. 4) at the mounting flanges (Fig. 4-106, Pos. 5).

NOTE: Always use new mounting bolts of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified tightening torque: Fig. 4-107 Tightening torques for the cable drum assembly mounting bolts: 880 Nm

z

Reconnect all cables and wires leading from the machine to the cable drum and the connection box of the cable drum assembly.

Version 2010/1

PC5500-6E

4 - 105

Car body

Undercarriage

z

Open the manhole of the cable drum.

z

Reconnect the power supply cable from the power station inside the cable drum.

z

Change the dryer pack according to the Operation & Maintenance Manual of the cable drum assembly.

z

Clean the inside of the cable drum.

NOTE: Dirt, water, oil or other contamination is not permissible inside the cable drum. z

Close the manhole of the cable drum.

NOTE: Ensure that all bolts are fitted. z

De-isolate the machine according to local regulations and according to the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

NOTE: For the initial operation of the cable drum assembly, refer to the Operation & Maintenance Manual of the cable drum assembly, delivered with the machine.

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Undercarriage

Car body

This page was left blank intentionally.

Version 2010/1

PC5500-6E

4 - 107

Car body

4.3.7

Undercarriage

CABLE SUPPLY (OPTIONAL)

Fig. 4-108 Cable supply, overview (1)

Connection box

(2)

Cable supply assembly main beam

(3)

Cable lifting rack

(4)

Power supply cable

(5)

Mounting flange to car body

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PC5500-6E

Version 2010/1

Undercarriage

Car body

4.3.7.1 PREPARATORY WORK FOR THE REMOVAL AND REPLACEMENT OF THE CABLE SUPPLY Special tools:

n/a

Additional equipment:

n/at

Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and forklift.

z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 4-109).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 4-109 z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

z

Disconnect the high voltage power supply cable from the power station.

Version 2010/1

PC5500-6E

4 - 109

Car body

Undercarriage

4.3.7.2 REMOVAL OF THE CABLE SUPPLY Special tools:

n/a

Additional equipment:

Crane Cable supply assembly: 640 kg

Dogman/rigger Electrician with permission to work on high voltage systems

Fig. 4-110 Cable supply assembly, installation z

Carry out the preparatory work for the removal and replacement of the cable supply, refer to section 4.3.7.1 on page 4-109.

z

Open the connection box (Fig. 4-110, Pos. 1).

z

Disconnect the power supply cables coming from the slip ring of the machine (Fig. 4-110, Pos. 9) and the power supply cable coming from the power station (Fig. 4-110, Pos. 3) inside the connection box.

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PC5500-6E

Version 2010/1

Undercarriage

Car body

z

Pull the power supply cables out of the connection box.

z

Sling the cable supply assembly (Fig. 4-110, Pos. 2).

z

Remove the cable from the cable clamps (Fig. 4-110, Pos. 4).

z

Detach the cable pull sock (Fig. 4-110, Pos. 5) from the shackles (Fig. 4-110, Pos. 6) at the cable supply assembly.

z

Lift the cable supply assembly away from the machine and put it on the ground. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the cable supply assembly, make sure that nobody steps below the weight.

Version 2010/1

PC5500-6E

4 - 111

Car body

Undercarriage

4.3.7.3 REPLACEMENT OF THE CABLE SUPPLY ASSEMBLY Special tools:

n/a

Additional equipment:

Crane Cable supply assembly: 640 kg

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

Fig. 4-111 Cable supply assembly, installation z

Carry out the preparatory work for the removal and replacement of the cable supply, refer to section 4.3.7.1 on page 4-109.

z

Sling the new cable supply assembly (Fig. 4-111, Pos. 2) to a crane.

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Version 2010/1

Undercarriage

z

Car body

Lift the cable supply assembly to the mounting position at the car body. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the cable supply assembly, make sure that nobody steps below the weight.

z

Install the mounting bolts (Fig. 4-111, Pos. 7) with resilient sleeves (Fig. 4-111, Pos. 8).

NOTE: Always use new mounting bolts of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified tightening torque: Tightening torques for the cable supply assembly mounting bolts: 880 Nm

z

Open the cover of the connection box (Fig. 4-111, Pos. 1).

z

Connect the high voltage power cable (Fig. 4-111, Pos. 9) coming from the slip ring of the machine to the connection box of the cable supply assembly.

z

Pull the power supply cable (Fig. 4-111, Pos. 3) from the power station to the cable supply assembly using a cable pull sock (Fig. 4-111, Pos. 5).

z

Connect the power supply cable (Fig. 4-111, Pos. 3) to the connection box.

z

Mount the power supply cable (Fig. 4-111, Pos. 3) to the cable supply assembly with the clamp set (Fig. 4-111, Pos. 4).

z

Hook the cable pull sock (Fig. 4-111, Pos. 5) into the shackles (Fig. 4-111, Pos. 6) of the cable supply assembly.

z

Reconnect the power supply cable (Fig. 4-111, Pos. 3) to the power station.

z

De-isolate the machine according to local regulations and according to the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

Version 2010/1

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4 - 113

Car body

Undercarriage

This page was left blank intentionally.

4 - 114

PC5500-6E

Version 2010/1

Attachment

5 ATTACHMENT

Version 2010/1

PC5500-6E

5 -1

Backhoe

Attachment

5.1

BACKHOE

Fig. 5-1

Backhoe attachment overview

(1)

Bucket (backhoe)

(2)

Bucket link rod

(3)

Bucket cylinder

(4)

Stick cylinder

(5)

Boom

(6)

Boom cylinder

(7)

Stick

(8)

Steering rod

5 -2

PC5500-6E

Version 2010/1

Attachment

Backhoe

This page was left blank intentionally.

Version 2010/1

PC5500-6E

5 -3

Backhoe

5.1.1

Attachment

BOOM

5.1.1.1 REMOVAL OF THE BOOM

Fig. 5-2

5 -4

Boom, removal and installation

PC5500-6E

Version 2010/1

Attachment

Backhoe

Legend for Fig. 5-2: (1)

Stick cylinder

(2)

Boom cylinder

(3)

Boom

(4)

Bolt

(5)

Shackle

(6)

Pin

(7)

Bush

(8)

Seal

(9)

Bush

(10)

Seal

(11)

Bush

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Boom: 45,100 kg Pin boom/superstructure: 365 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area and position the bucket with its flat side (underside) on the ground.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Use blocks and support the bucket from behind to secure the bucket.

z

Isolate the machine according to local regulations.

Version 2010/1

PC5500-6E

5 -5

Backhoe

Attachment

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Remove the stick, refer to section 5.1.2 on page 5-20.

z

Support the boom with appropriate stands (Fig. 5-3, Pos. 1) of approx. 1 m height.

z

Remove the boom cylinders, refer to section 5.1.1.3 on page 5-10.

z

Disconnect the hydraulic hoses from the boom which are leading to the manifold, refer to section 5.1.6 on page 5-58.

NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect all electric wires from the boom.

z

Disconnect the grease feed lines leading to the boom.

z

Sling the boom (Fig. 5-4).

Fig. 5-3

Fig. 5-4 z

Remove the two bolts (Fig. 5-5, Pos. 1), and the shackle (Fig. 5-5, Pos. 2) securing the pin (Fig. 5-5, Pos. 3).

z

Remove the pin (Fig. 5-5, Pos. 3) connecting the boom to the superstructure. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

Fig. 5-5 5 -6

PC5500-6E

Version 2010/1

Attachment

Backhoe

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the superstructure, make sure that the boom is fixed in its position and secured with a crane.

z

Remove the boom using a crane and place it on the ground and in an appropriate position. DANGER

Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted boom.

z

If required, remove all provided parts and the hydraulic piping from the boom.

Version 2010/1

PC5500-6E

5 -7

Backhoe

Attachment

5.1.1.2 REPLACEMENT OF THE BOOM Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Boom: 45,100 kg Pin boom/superstructure: 365 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-6, Pos. 2) and install new seals! Apply the appropriate grease on every bush (Fig. 5-6, Pos. 1) and pin on assembly!

Fig. 5-6 z

Install new bushes (Fig. 5-7, Pos. 2) into the boom (Fig. 5-7, Pos. 1) if required, and insert new seals (Fig. 5-7, Pos. 3) into the bushes. CAUTION

There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

Fig. 5-7

5 -8

PC5500-6E

Version 2010/1

Attachment

z

Backhoe

Carry out further installation in reverse order to removal. DANGER

Never put hands into the holes when aligning the boom to the superstructure.

z

De-isolate the machine according to local regulations.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

Version 2010/1

PC5500-6E

5 -9

Backhoe

Attachment

5.1.1.3 REMOVAL OF BOOM CYLINDERS

Fig. 5-8

5 - 10

Boom cylinder, removal and installation

PC5500-6E

Version 2010/1

Attachment

Backhoe

Legend for Fig. 5-8: (1)

O-ring

(2)

Pipe

(3)

Boom cylinder

(4)

Superstructure

(5)

Pin

(6)

Shackle

(7)

Bolt

(8)

Pin

(9)

Catch

(10)

Shackle

(11)

Bolt

(12)

Bush

(13)

Bush

(14)

Seal

(15)

Bush

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Oil drain pans Boom cylinder: 6500 kg each Pin boom cylinder/boom: 177 kg Pin boom cylinder/superstructure: 224 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. NOTE: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508". WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

Version 2010/1

PC5500-6E

5 - 11

Backhoe

Attachment

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended position (Fig. 5-9).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition.

Fig. 5-9 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Remove grease feed lines and fittings from the boom cylinder(s) to be removed.

z

Sling boom cylinder (piston rod side) (Fig. 5-10).

z

Remove the bolts (Fig. 5-10, Pos. 3) and the shackle (Fig. 5-10, Pos. 4) securing the pin (Fig. 5-10, Pos. 2).

z

Remove the pin (Fig. 5-10, Pos. 2) connecting the boom cylinder to the superstructure. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling.

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the superstructure, make sure that the cylinder is fixed in its position and secured with a crane.

Fig. 5-10

NOTE: Check bushes (Fig. 5-10, Pos. 1) for wear and damage. Replace if required. z

De-isolate the machine according to local regulations.

5 - 12

PC5500-6E

Version 2010/1

Attachment

z

Backhoe

Switch S155 to Qmin and retract the boom cylinder to be removed fully.

NOTE: Use only motor no. 2 at Qmin. z

Retract the piston rod of the boom cylinder fully.

z

Tie the piston rod to the cylinder body with a wire rope.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations. Fig. 5-11 WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the main hydraulic hoses from the cylinder, refer to section 5.1.6.2 on page 5-62.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Lift the boom cylinder into a horizontal position (Fig. 5-11).

Version 2010/1

PC5500-6E

5 - 13

Backhoe

Attachment

z

Sling the other side of the cylinder additionally.

z

Ease the load of the pin (Fig. 5-12, Pos. 4) in the boom (Fig. 5-12, Pos. 5) by lifting the cylinder lightly.

z

Remove the bolts (Fig. 5-12, Pos. 1) and the shackle (Fig. 5-12, Pos. 2) securing the pin (Fig. 5-12, Pos. 4).

NOTE: The catches (Fig. 5-12, Pos. 3) are welded to the boom. z

Remove the pin (Fig. 5-12, Pos. 4) connecting the boom cylinder to the boom. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

Fig. 5-12

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the boom, make sure that the cylinder is fixed in its position and secured with a crane.

NOTE: Pull the pin (Fig. 5-12, Pos. 4) using two puller bolts at the threaded holes (Fig. 5-13, Pos. 1). (Fig. 5-13 is an example)

Fig. 5-13 Example z

Lower the boom cylinder to the ground and place it in an appropriate position using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the cylinder, make sure that nobody steps below the lifted cylinder.

5 - 14

PC5500-6E

Version 2010/1

Attachment

Backhoe

z

Check bushes for wear and damage. Replace if required.

z

If required, disconnect the other boom cylinder from the boom and remove it using the same procedure as above.

z

If required, remove the pipe work from the removed cylinder(s). Discard the O-rings and fit caps to the cylinder(s) openings to avoid environmental contamination.

Version 2010/1

PC5500-6E

5 - 15

Backhoe

Attachment

5.1.1.4 REPLACEMENT OF BOOM CYLINDERS Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Boom cylinder: 6500 kg each Pin boom cylinder/boom: 177 kg Pin boom cylinder/superstructure: 224 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-14, Pos. 2) and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Check the bushes (Fig. 5-14, Pos. 1) and, if required, insert new bushes into the boom cylinder. Refer to the PARTS & SERVICE NEWS No. "AH06545".

z

Insert new seals (Fig. 5-14, Pos. 2) into the bushes (Fig. 5-14, Pos. 1) of the boom cylinder. CAUTION

Fig. 5-14

There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

z

Flush out and clean all the pipes.

z

Install the hydraulic pipe at the boom cylinder, if required.

5 - 16

PC5500-6E

Version 2010/1

Attachment

z

Backhoe

Position the replacement cylinder (Fig. 5-15, Pos. 6) at the boom (Fig. 5-15, Pos. 5) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the cylinder, make sure that nobody steps below the lifted cylinder.

z

Install the pin (Fig. 5-15, Pos. 4) connecting the boom cylinder to the boom. DANGER

Never put hands into the holes when aligning the cylinder to the boom. Fig. 5-15 NOTE: Align the pin’s head to the catches (Fig. 5-15, Pos. 3). z

Install the shackle (Fig. 5-15, Pos. 2) and the bolts (Fig. 5-15, Pos. 1) to secure the pin (Fig. 5-15, Pos. 4).

z

Connect the main hydraulic hoses to the boom cylinder, refer to section 5.1.6.2 on page 5-62.

NOTE: Always use new O-rings at the SAE flange connections. z

Remove the wire rope from the cylinder at the side installed to the boom.

z

Lower the cylinder until the piston rod points in the direction of the mounting location at the superstructure (Fig. 5-16).

Fig. 5-16 z

De-isolate the machine according to local regulations.

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PC5500-6E

5 - 17

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z

Attachment

Switch S155 to Qmin and retract the boom cylinder fully.

NOTE: Use only motor no. 2 at Qmin. z

Remove the wire rope securing the piston rod to the boom cylinder body.

z

Extend and retract the boom cylinder slowly at Qmin 2…3 times as far as possible to partly bleed the cylinder.

z

Extend the piston rod to the required position to insert the pin (Fig. 5-17, Pos. 2) connecting the boom cylinder to the superstructure. DANGER

Never put hands into the holes when aligning the cylinder to the superstructure.

z

Fig. 5-17

Install the pin (Fig. 5-17, Pos. 2).

NOTE: Put the suitable grease into the bushes (Fig. 5-15, Pos. 1). z

Isolate the machine according to local regulations.

z

Install the bolts (Fig. 5-15, Pos. 3) and the shackle (Fig. 5-15, Pos. 4) to secure the pin (Fig. 5-15, Pos. 2).

z

Carry out further installation in reverse order to removal.

z

De-isolate the machine according to local regulations.

z

Perform the bleeding procedure for the stick cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

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Attachment

Backhoe

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5.1.2

Attachment

STICK

5.1.2.1 REMOVAL OF THE STICK

Fig. 5-18 Stick assembly

5 - 20

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Version 2010/1

Attachment

Backhoe

Legend for Fig. 5-18: (1)

Bucket

(2)

Bucket link rod

(3)

Bucket cylinder

(4)

Stick cylinder

(5)

Steering rod

(6)

Bushes

(7)

Bushes

(8)

Seal

(9)

Bushes

(10)

Stick

Special tools:

Thread protector PN 409 329 40

Additional equipment:

Safety harness in conformity with DIN EN 361 Swivel hoist ring Crane Mobile elevator working platform Stick: 19,160 kg Pin stick/boom: 1440 kg Nut-Cap: 48 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area and position the bucket with its flat side (underside) on the ground.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition.

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5 - 21

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Attachment

z

Use blocks and support the bucket from behind to secure it.

z

Remove the bucket, refer to section 5.1.3.1 on page 5-36.

NOTE: Fully retract the bucket cylinders. z

Disconnect all electric wires attached to the stick.

z

Disconnect the grease feeding lines leading to the stick.

z

Remove the pins connecting the stick cylinders to the stick, refer to section 5.1.2.3 on page 5-26.

NOTE: Support the stick cylinders (Fig. 5-19, Pos. 1) with blocks (Fig. 5-19, Pos. 2) between stick cylinders and boom (Fig. 5-19, Pos. 3).

Fig. 5-19 z

Remove the pins connecting the stick cylinders to the stick, refer to section 5.1.2.3 on page 5-26.

z

Sling the stick (Fig. 5-20).

Fig. 5-20 z

Undo the lock of the nut-cap (Fig. 5-21, Pos. 1) at the pin connecting the stick with the boom by removing the cotter pin (Fig. 5-21, Pos. 2) from the bore (Fig. 5-21, Pos. 3), and then removing the bolt (Fig. 5-21, Pos. 2).

z

Insert a swivel hoist ring into the nut-cap (Fig. 5-21, Pos. 1) and attach it to a crane.

Fig. 5-21

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Attachment

Backhoe

z

Remove the nut-cap (Fig. 5-22, Pos. 2) from the pin (Fig. 5-22, Pos. 1), then fit the "Thread Protector" PN 409 329 40.

z

Pull the pin (Fig. 5-21, Pos. 4) out completely to clear boom (Fig. 5-22, Pos. 3) and stick. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling.

Fig. 5-22 NOTE: Pull the pin (Fig. 5-22, Pos. 1) using two puller bolts at the threaded holes (Fig. 5-23, Pos.1). (Fig. 5-23 is an example.) DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the boom, make sure that the stick is fixed in its position and secured with a crane.

Fig. 5-23 Example z

Remove the stick using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick, make sure that nobody steps below the lifted stick.

z

Lower the stick to the ground and rest it in an appropriate position.

z

Remove the bucket link rod and the steering rod(s), refer to section 5.1.4 on page 5-49.

z

Remove the bucket cylinders from the stick, refer to section 5.1.3.3 on page 5-40.

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Attachment

5.1.2.2 REPLACEMENT OF THE STICK Special tools:

Thread protector PN 409 329 40

Additional equipment:

Safety harness in conformity with DIN EN 361 Swivel hoist ring Crane Mobile elevator working platform Stick: 19,160 kg Pin stick/boom: 1440 kg Nut-Cap: 48 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-24, Pos. 2) and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Insert new seals (Fig. 5-14, Pos. 2) into the bushes (Fig. 5-14, Pos. 1) of the stick. CAUTION

Fig. 5-24

There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

z

Carry out installation in reverse order to removal. DANGER

Never put hands into the holes when aligning the stick to the boom.

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Version 2010/1

Attachment

Backhoe

z

De-isolate the machine according to local regulations.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

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5 - 25

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Attachment

5.1.2.3 REMOVAL OF STICK CYLINDERS

Fig. 5-25 Stick cylinder, removal and installation

5 - 26

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Version 2010/1

Attachment

Backhoe

Legend for Fig. 5-25: (1)

Stick cylinder

(2)

Stick

(3)

Boom

(4)

Bolt

(5)

Shackle

(6)

Pin

(7)

Seal

(8)

Bolt

(9)

Shackle

(10)

Catch

(11)

Pin

(12)

Pipe

(13)

O-ring

(14)

Seal

(15)

Bush

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Oil drain pan Stick cylinder: 4600 kg each Pin stick cylinder/stick: 127 kg Pin stick cylinder/boom: 179 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

At first the wear of the bushes in the hydraulic cylinders should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508".

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Attachment

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area and position the bucket on the ground with the cylinders in partially extended position (Fig. 5-26).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Remove grease feed lines and fittings from the stick cylinder(s) to be removed.

z

Sling the cylinder (Fig. 5-27, Pos. 1) to be removed.

Fig. 5-26

Fig. 5-27

z

Remove the bolts (Fig. 5-28, Pos. 1), washers, and the shackle (Fig. 5-28, Pos. 2) securing the pin (Fig. 5-28, Pos. 3).

z

Remove the pin (Fig. 5-28, Pos. 3) connecting the stick cylinder to the stick. Remove the two seals (Fig. 5-28, Pos. 4). WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

Fig. 5-28 DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the cylinder, make sure that the cylinder is fixed in its position and secured with a crane.

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Attachment

Backhoe

z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and retract the cylinder(s) to be removed fully.

NOTE: Use only motor no. 2 at Qmin. z

Tie the piston rod to the cylinder body with a wire rope (refer to Fig. 5-47).

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

NOTE: If the stick is to be removed, put the stick cylinders (Fig. 5-29, Pos. 1) down on blocks (Fig. 5-29, Pos. 2) between the stick cylinders and the boom (Fig. 5-29, Pos. 3).

Fig. 5-29

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z

Attachment

If the stick cylinder (Fig. 5-30, Pos. 6) is to be removed, slightly lift up the cylinder to ease to load on the pin (Fig. 5-30, Pos. 4). WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the main hydraulic hoses from the stick cylinder, refer to section 5.1.6.3 on page 5-66.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan.

Fig. 5-30

Cap the openings with blind plugs to avoid contamination. z

Remove the bolts (Fig. 5-30, Pos. 1), the washers, and the shackle (Fig. 5-30, Pos. 2) securing the pin (Fig. 5-30, Pos. 4).

NOTE: The catches (Fig. 5-30, Pos. 3) are welded to the boom. z

Remove the pin (Fig. 5-30, Pos. 4) connecting the stick cylinder to the boom (Fig. 5-30, Pos. 5).

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Attachment

Backhoe

NOTE: Pull the pin (Fig. 5-30, Pos. 4) using two puller bolts at the threaded holes (Fig. 5-31, Pos. 1). (Fig. 5-31 is an example) WARNING Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the cylinder, make sure that the cylinder is fixed in its position and secured with a crane.

z

Remove the stick cylinder using a crane.

z

Lower the stick cylinder to the ground and place it in an appropriate position.

Fig. 5-31 Example

DANGER Risk of falling weights! Death or serious injury may result. When moving the cylinder, make sure that nobody steps below the lifted cylinder.

z

If required, remove the other stick cylinder from the boom using the same procedure as above.

z

If required, remove the hydraulic pipe from the removed cylinder(s). Discard the O-rings and fit caps to the cylinder(s) openings to avoid environmental contamination.

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Attachment

5.1.2.4 REPLACEMENT OF STICK CYLINDERS Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Stick cylinder: 4600 kg each Pin stick cylinder/stick: 127 kg Pin stick cylinder/boom: 179 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Install new bushes (Fig. 5-32, Pos. 1) into the stick cylinder(s), if required, refer to the PARTS & SERVICE NEWS No. "AH06545"!

z

Insert two seals (Fig. 5-32, Pos. 2) into the bushes (Fig. 5-32, Pos. 1) of the stick cylinder(s).

Fig. 5-32

CAUTION There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

z

Flush out and clean all pipes.

z

Clean the mating surfaces at the cylinder mounting hole on the boom.

z

Install the hydraulic pipe(s) to the stick cylinders, if required.

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Attachment

z

Backhoe

Using a crane, align the replacement cylinder (Fig. 5-33, Pos. 6). DANGER

Risk of falling weights! Death or serious injury may result. When moving the cylinder, make sure that nobody steps below the lifted cylinder.

z

Install the pin (Fig. 5-33, Pos. 4). CAUTION

Never put hands into the holes when aligning the cylinder to the boom.

NOTE: Align the pin’s head to the catches (Fig. 5-33, Pos. 3). z

Install the shackle (Fig. 5-33, Pos. 2) and the bolts (Fig. 5-33, Pos. 1) with washers to secure the pin (Fig. 5-33, Pos. 4). Fig. 5-33

z

Connect the main hydraulic hoses to the cylinder, refer to section 5.1.6.3 on page 5-66.

NOTE: Always use new O-rings at the SAE flange connections. z

Remove the wire rope from the piston rod.

z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin.

NOTE: Use only motor no. 2 at Qmin. z

To partly bleed the new cylinders, perform the following procedure: z

Extend the cylinders as far as possible.

z

Fully retract the cylinders. WARNING

The air in the cylinder will result in slightly jerky movements of the cylinder.

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z

Attachment

Lower the cylinder and extend the piston rod to the required position to install the pin into the stick. WARNING

Never put hands into the holes when aligning the cylinder to the stick.

z

Isolate the machine according to local regulations.

z

Install new seals (Fig. 5-34, Pos. 4). CAUTION

There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

z

Install the pin (Fig. 5-34, Pos. 3) connecting the stick cylinder to the stick.

z

Install the two bolts (Fig. 5-34, Pos. 1), washers, and the shackle (Fig. 5-34, Pos. 2) to secure the pin (Fig. 5-34, Pos. 3).

z

Carry out further installation in reverse order to removal.

z

Perform the bleeding procedure for the stick cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

5 - 34

PC5500-6E

Fig. 5-34

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5.1.3

Attachment

BUCKET

5.1.3.1 REMOVAL OF THE BUCKET

Fig. 5-35 Bucket assembly (1)

Bucket

(2)

Bucket link rod

(3)

Seal fixing ring

(4)

Seal

(5)

Seal fixing ring

(6)

Seal

5 - 36

PC5500-6E

Version 2010/1

Attachment

Backhoe

Special tools:

Thread protector PN 409 329 40

Additional equipment:

Crane Pin bucket/stick: 574 kg Pin bucket/bucket link rod: 822 kg Bucket (if lifted): 30,600 kg Nut-cap: 35 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area and position the bucket with its flat side (underside) on the ground.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Use blocks and support the bucket from behind to secure it.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Remove grease feeding line from the bucket mounting pin and from the link rod.

z

Undo the locks of both the nut-caps at the bucket by removing the cotter pin (Fig. 5-36, Pos. 2) from the bore (Fig. 5-36, Pos. 3), and removing the bolt (Fig. 5-36, Pos. 4) afterwards.

z

Insert swivel hoist rings into the nut-caps (Fig. 5-36, Pos. 1) and attach them to a crane.

Fig. 5-36

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Attachment

z

Remove the seal fixing rings (Fig. 5-37, Pos. 1) located on both sides of the stick and the bucket link rod.

z

Remove the nut-caps (Fig. 5-37, Pos. 7) from the pins (Fig. 5-37, Pos. 3 and 4), then fit the "Thread Protector" PN 409 329 40.

z

Remove the rings (Fig. 5-37, Pos. 6). CAUTION

Tie the link rod to the stick with a wire rope to prevent it from swinging when the pin is pulled out. Fig. 5-37 z

Pull the pin (Fig. 5-37, Pos. 3) out completely to clear the bucket (Fig. 5-37, Pos. 8) from the bucket link rod. Also remove the seals (Fig. 5-37, Pos. 2) when pulling out the pin. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

z

Pull the pin (Fig. 5-37, Pos. 4) out completely to clear the bucket (Fig. 5-37, Pos. 8) from the stick. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

NOTE: Pull the pins using two puller bolts at the threaded holes (Fig. 5-38, Pos. 1), (Fig. 5-38 is only an example). z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and lift the boom to clear the bucket.

NOTE: Use only motor no. 2 at Qmin. z

Isolate the machine according to local regulations.

Fig. 5-38 Example z

Remove and discard the seals (Fig. 5-37, Pos. 2).

z

Check bushes (Fig. 5-37, Pos. 5) for wear and damage. Replace if required.

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Version 2010/1

Attachment

Backhoe

5.1.3.2 REPLACEMENT OF THE BUCKET Special tools:

Thread protector PN 409 329 40

Additional equipment:

Crane Pin bucket/stick: 574 kg Pin bucket/bucket link rod: 822 kg Bucket (if lifted): 30,600 kg Nut-cap: 35 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals (Fig. 5-39, Pos. 2)! Apply the appropriate grease on every bush and pin on assembly! z

Slip the seals (Fig. 5-39, Pos. 2) onto the flanges of the bushes (Fig. 5-39, Pos. 5 and 6) attached to the bucket.

NOTE: During installation, there is not enough space to insert these seals. z

Fig. 5-39

Carry out further installation in reverse order to removal.

NOTE: Before installing the new bucket, check the grease filling in the chamber of the bucket link rod (bucket side), refer to PARTS & SERVICE NEWS No. "AH09522".

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Attachment

5.1.3.3 REMOVAL OF BUCKET CYLINDERS

Fig. 5-40 Bucket cylinder, removal and installation

5 - 40

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Version 2010/1

Attachment

Backhoe

Legend for Fig. 5-40: (1)

Bucket cylinder

(2)

Cylinder piston rod

(3)

Bucket link rod

(4)

Steering rod

(5)

Bolt

(6)

Shackle

(7)

Pin cylinder/stick

(8)

Nut-cap

(9)

Pin cylinder/steering rods

(10)

Seal fixing ring

(11)

Seal

(12)

Seal

(13)

Bush

(14)

Rod protection cover

(15)

Pipe

Special tools:

Thread protector PN 409 329 40

Additional equipment:

Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Oil drain pan Bucket cylinder: 3210 kg each Pin bucket cylinder/stick: 86 kg Pin bucket cylinder/steering rods: 865 kg Nut-Cap: 35 kg Rod protection cover: 360 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

Version 2010/1

PC5500-6E

5 - 41

Backhoe

Attachment

NOTE: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS & SERVICE NEWS No."AH08508". z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

z

Park the machine on the prepared flat ground area and position the bucket on the ground as shown in Fig. 5-41, with the bucket cylinders not fully retracted.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Base the stick on an appropriate stand (Fig. 5-41, Pos. 1).

z

Base the bucket cylinders with appropriate blocks (Fig. 5-41, Pos. 2).

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Remove grease feed lines and fittings from the cylinder(s) to be removed.

z

Carry out the following two steps only if the bucket cylinder is equipped with a rod protection cover. z

Connect the rod protection cover (Fig. 5-42, Pos. 1) to a crane using the shackle (Fig. 5-42, arrow).

z

Remove the protection cover (Fig. 5-42, Pos. 1) from the bucket cylinder (Fig. 5-42, Pos. 2).

Fig. 5-41

Fig. 5-42 z

Undo the lock of the nut-cap at the piston rod side of the bucket cylinder by removing the cotter pin (Fig. 5-43, Pos. 2) from the bore (Fig. 5-43, Pos. 3), and then removing the bolt (Fig. 5-43, Pos. 4).

z

Insert a swivel hoist ring into the nut-cap (Fig. 5-43, Pos. 1) and attach it to a crane.

Fig. 5-43 5 - 42

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Version 2010/1

Attachment

Backhoe

z

Remove the seal fixing rings (Fig. 5-44, Pos. 1) located on both sides of the cylinder piston rods (Fig. 5-44, Pos. 2).

z

Remove the nut-cap (Fig. 5-44, Pos. 3) from the pin (Fig. 5-44, Pos. 4), then fit the "Thread Protector" PN 409 329 40.

Fig. 5-44 z

Sling the steering rods (Fig. 5-45, Pos. 2).

z

Using a crane, support the bucket link rod (Fig. 5-45, Pos. 1) if both or the left cylinder needs to be removed.

z

Pull the pin (Fig. 5-45, Pos. 4) at the bucket cylinders, refer to section 5.1.3.1 on page 5-36. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling. Fig. 5-45 NOTE: If removing the right-hand cylinder only, pull the pin (Fig. 5-45, Pos. 4) out just enough to clear the cylinder piston rod. NOTE: Pull the pin (Fig. 5-44, Pos. 4) out using two puller bolts at the threaded holes (Fig. 5-46, Pos. 1).

Fig. 5-46 z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and retract the bucket cylinder(s) to be removed.

NOTE: Use only motor no. 2 at Qmin.

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5 - 43

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z

Attachment

Tie the piston rod to the cylinder body with a wire rope (Fig. 5-47).

Fig. 5-47 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM". WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Isolate the machine according to local regulations.

z

Disconnect the main hydraulic hoses from the cylinder(s), refer to section 5.1.6.4 on page 5-70.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

5 - 44

PC5500-6E

Version 2010/1

Attachment

z

Backhoe

Using a crane, sling the cylinder (Fig. 5-48, Pos. 1) to be removed. Ease the load of the pin (Fig. 5-48, Pos. 2) by lifting the cylinder lightly.

Fig. 5-48 z

Remove the two bolts (Fig. 5-49, Pos. 2), washers, and the shackle (Fig. 5-49, Pos. 3) securing the pin (Fig. 5-49, Pos. 4).

z

Remove the pin (Fig. 5-49, Pos. 4) connecting the cylinder (Fig. 5-49, Pos. 1) to the stick. Remove the two seals (Fig. 5-49, Pos. 5). WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling. Fig. 5-49 z

Remove the cylinder using a crane. Lower the cylinder to the ground and place it in an appropriate position. DANGER

Risk of falling weights! Death or serious injury may result. When moving the cylinder, make sure that nobody steps below the lifted cylinder.

NOTE: If required, disconnect the other bucket cylinder from the stick and remove it using the same procedure as above. z

If required, remove the pipe work, the connecting blocks, and the seals from the removed cylinder(s). Discard the seals and fit caps to the cylinder(s) openings to avoid environmental contamination.

Version 2010/1

PC5500-6E

5 - 45

Backhoe

Attachment

5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS Special tools:

Thread protector PN 409 329 40

Additional equipment:

Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket cylinder: 3210 kg each Pin bucket cylinder/stick: 86 kg Pin bucket cylinder/steering rods: 865 kg Nut-Cap: 35 kg Rod protection cover: 360 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Check all bushes in the bucket cylinder. Replace as required, refer to the PARTS & SERVICE NEWS No. "AH06545"!

z

Flush out and clean all the pipes and connecting blocks.

z

If required, install the pipe work, the connecting blocks, and the seals at the cylinder(s).

5 - 46

PC5500-6E

Version 2010/1

Attachment

z

Backhoe

Insert new seals (Fig. 5-50, Pos. 5) into the bushes at the bucket cylinder mounting hole in the stick. CAUTION

There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

z

Using a crane, support and position the replacement bucket cylinder (Fig. 5-50, Pos. 1) at the stick.

Fig. 5-50

DANGER Risk of falling weights! Death or serious injury may result. When lifting the cylinder, make sure that nobody steps below the weight.

z

Install the pin (Fig. 5-50, Pos. 4). CAUTION

Never put hands into the holes when aligning the cylinder to the stick.

z

Install the shackle (Fig. 5-50, Pos. 3), the two washers, and the bolts (Fig. 5-50, Pos. 2) to secure the pin (Fig. 5-50, Pos. 4).

z

Connect the main hydraulic hoses to the bucket cylinder(s), refer to section 5.1.6.4 on page 5-70.

NOTE: Always use new O-rings at the SAE flange connections. z

De-isolate the machine according to local regulations.

z

Remove the wire rope from the piston rod.

z

Switch S155 to Qmin.

NOTE: Use only motor no. 2 at Qmin.

Version 2010/1

PC5500-6E

5 - 47

Backhoe

z

Attachment

To partly bleed the new cylinder, perform the following procedure 2…3 times: z

Extend the cylinder as far as possible.

z

Fully retract the cylinder. WARNING

The air in the cylinder will result in slightly jerky movements of the cylinder.

z

Carry out further installation in reverse order to removal.

z

Perform the bleeding procedure for the stick cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

5 - 48

PC5500-6E

Version 2010/1

Attachment

5.1.4

Backhoe

BUCKET LINK ROD AND STEERING RODS

5.1.4.1 REMOVAL OF THE BUCKET LINK ROD Special tools:

Thread protector PN 409 329 40

Additional equipment:

Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 2280 kg Steering rod: 1300 kg Pin bucket cylinder/steering rod: 865 kg Pin bucket/bucket link rod: 822 kg Nut-cap: 35 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

z

Park the machine on the prepared flat ground area and position the bucket on the ground as shown in Fig. 5-51, with the bucket cylinders not fully retracted.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Base the stick on an appropriate stand (Fig. 5-51, Pos. 1).

z

Base the bucket cylinders with appropriate blocks (Fig. 5-51, Pos. 2).

z

Relieve the pressure in the bucket cylinders only. Refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Disconnect the grease feed lines from the bucket link rod.

Version 2010/1

PC5500-6E

Fig. 5-51

5 - 49

Backhoe

Attachment

z

Sling the bucket link rod (Fig. 5-52, Pos. 1) and both steering rods (Fig. 5-52, Pos. 2).

z

Remove the pin (Fig. 5-52, Pos. 4) at the bucket cylinders, refer to section 5.1.3.3 on page 5-40. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

z

De-isolate the machine according to local regulations.

z

At Qmin fully retract the bucket cylinder to clear the link rod.

z

Remove the pin (Fig. 5-52, Pos. 3) at the bucket, refer to section 5.1.3.1 on page 5-36.

Fig. 5-52

WARNING Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

z

Remove the bucket link rod (Fig. 5-52, Pos. 1) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the bucket link rod, make sure that nobody steps below the lifted weight.

5 - 50

PC5500-6E

Version 2010/1

Attachment

Backhoe

5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD Special tools:

Thread protector PN 409 329 40

Additional equipment:

Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 2280 kg Steering rod: 1300 kg Pin bucket cylinder/steering rod: 865 kg Pin bucket/bucket link rod: 822 kg Nut-cap: 35 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: Always discard used seals and install new seals! Prior to assembly all bushes must be inspected and replaced as required! Before installing the new bucket, fill the chamber of the bucket link rod (bucket side) with grease, refer to PARTS & SERVICE NEWS No. "AH09522". Apply the appropriate grease on every bush and pin on assembly! z

Carry out installation in reverse order to removal.

Version 2010/1

PC5500-6E

5 - 51

Backhoe

Attachment

5.1.4.3 REMOVAL OF THE STEERING RODS Special tools:

Thread protector PN 409 329 40

Additional equipment:

Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 2280 kg Steering rod: 1300 kg Pin bucket cylinder/steering rod: 865 kg Pin steering rod/stick: 479 kg Nut-cap: 35 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

z

Park the machine on the prepared flat ground area and position the bucket on the ground as shown in Fig. 5-53, with the bucket cylinders not fully retracted.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Base the stick on an appropriate stand (Fig. 5-53, Pos. 1).

z

Base the bucket cylinder with appropriate blocks (Fig. 5-53, Pos. 2).

z

Relieve the pressure in the bucket cylinders only. Refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Disconnect the grease feed line from the left-hand steering rod.

5 - 52

PC5500-6E

Fig. 5-53

Version 2010/1

Attachment

z

Backhoe

Sling the bucket link rod (Fig. 5-54, Pos. 1) and the steering rod(s) (Fig. 5-54, Pos. 2) to be removed.

NOTE: If removing the left-hand steering rod only or both steering rods, sling both steering rods. If removing the right-hand steering rod only, sling the right-hand steering rod only. z

Remove the pin (Fig. 5-54, Pos. 3) at the bucket cylinders, refer to section 5.1.3.3 on page 5-40. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

Fig. 5-54

NOTE: If removing the right-hand steering rod only, pull the pin out just enough to clear the steering rod. If removing the left-hand steering rod or both steering rods, pull out the pin completely to clear both steering rods. z

Undo the lock of the nut-cap at the pin (Fig. 5-54, Pos. 4) by removing the cotter pin (Fig. 5-55, Pos. 2) from the bore (Fig. 5-55, Pos. 3), then removing the bolt (Fig. 5-55, Pos. 4).

z

Insert a swivel hoist ring into the nut-cap (Fig. 5-55, Pos. 1) and attach it to a crane.

Fig. 5-55 z

Remove the seal fixing rings (Fig. 5-56, Pos. 1) located on both sides between the steering rod (Fig. 5-56, Pos. 3) and the stick (Fig. 5-56, Pos. 5).

z

Remove the nut-cap (Fig. 5-56, Pos. 2) from the pin (Fig. 5-56, Pos. 4), then fit the "Thread Protector" PN 409 329 40.

z

Pull the pin (Fig. 5-56, Pos. 4 / Fig. 5-54, Pos. 4) out completely to clear both steering rods. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

Version 2010/1

PC5500-6E

Fig. 5-56

5 - 53

Backhoe

Attachment

NOTE: Pull the pin (Fig. 5-56, Pos. 4) out using two puller bolts at the threaded holes (Fig. 5-57, Pos. 1). If removing the right-hand steering rod only, pull the pin out just enough to clear the steering rod (Fig. 5-56, Pos. 3). If removing the left-hand steering rod or both steering rods, pull out the pin completely to clear both steering rods

Fig. 5-57 z

Remove the steering rod(s) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the steering rod, make sure that nobody steps below the lifted weight.

5 - 54

PC5500-6E

Version 2010/1

Attachment

Backhoe

5.1.4.4 REPLACEMENT OF THE STEERING RODS Special tools:

Thread protector PN 409 329 40

Additional equipment:

Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 2280 kg Steering rod: 1300 kg Pin bucket cylinder/steering rod: 865 kg Pin steering rod/stick: 479 kg Nut-cap: 35 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: Always discard used seals and install new seals! Prior to assembly all bushes must be inspected and replaced as required! Apply the appropriate grease on every bush and pin on assembly! z

Carry out installation in reverse order to removal.

NOTE: Before installing the pin connecting the steering rods to the bucket link rod, check the grease filling in the chamber of the bucket link rod, and fill it up with grease, if required. Refer to PARTS & SERVICE NEWS No. "AH09522".

Version 2010/1

PC5500-6E

5 - 55

Backhoe

5.1.5

Attachment

GROUND ENGAGING TOOLS (GET)

As ground engaging tools, the ESCO POSILOK Tooth System is used. (Other feasible systems have a similar build-up.)

Fig. 5-58 POSILOK System (1)

Shroud

(2)

Wedge

(3)

Toplok boss

(4)

Base plate

(5)

Wear plate

(6)

Wear cap (option)

(7)

Tooth adapter (center/corner)

(8)

Point (tooth)

(9)

Locking pin

(10)

Pin

5 - 56

PC5500-6E

Version 2010/1

Attachment

Backhoe

5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET Special tools:

POSILOK Pin removal tool PN 793 502 73 Hensley Pin removal tool (ask local dealer)

Additional equipment:

ESCO POSILOK Tooth System S130 Hensley Tooth System (ask local dealer) Forklift Point (tooth): 55 kg (ESCO) Shroud: 337 kg (ESCO) Tooth adapter: 182 kg (ESCO)

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

CAUTION Hazard of injuries from splinters! When working on the locking pins, always wear hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep people not directly involved well out of the way.

z

Prepare an area of flat ground large enough to accommodate the machine, bucket, and a forklift.

z

Park the machine on the prepared flat ground area and position the bucket in an appropriate height for work.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

For removing and installing the ESCO Tooth System, refer to PARTS & SERVICE NEWS No. "AH03510".

z

Remove and install the Hensley Tooth System accordingly to PARTS & SERVICE NEWS No. "AH03510". (Hensley uses a basically similar system to that from ESCO.)

NOTE: Use a forklift to remove and install the GET.

Version 2010/1

PC5500-6E

5 - 57

Backhoe

5.1.6

Attachment

HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT

5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES

Fig. 5-59 Arc hoses, removal and installation

5 - 58

PC5500-6E

Version 2010/1

Attachment

Backhoe

Legend for Fig. 5-59: (1)

Hose clamp

(2)

Clamp line

(3)

Nut

(4)

Manifold

(5)

Hydraulic pipe

(6)

Hydraulic hose

(7)

Bolt

(8)

O-ring

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Oil drain pan Boom arc hose: 39 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING Always wear a safety harness when working at the attachment.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended and the stick cylinders in fully retracted position (Fig. 5-60).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-60

Version 2010/1

PC5500-6E

5 - 59

Backhoe

Attachment

Fig. 5-61 Arc hoses, removal and installation z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

5 - 60

PC5500-6E

Version 2010/1

Attachment

z

Backhoe

Open the hose clamps (Fig. 5-61, Pos. 1) and clear the hydraulic hose (Fig. 5-61, Pos. 6) to be removed from the clamp lines (Fig. 5-61, Pos. 2). WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scarring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Sling the hydraulic hose (Fig. 5-61, Pos. 6) to be removed.

z

Remove the bolts (Fig. 5-61, Pos. 7) as well as the nuts (Fig. 5-61, Pos. 3) and disconnect the SAE flanges from the manifold (Fig. 5-61, Pos. 4) and from the hydraulic pipe (Fig. 5-61, Pos. 5) at the boom.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a crane.

z

Replace the boom arc hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-61, Pos. 8) at the SAE flange connections. z

Substitute the other boom arc hoses if required, using the same procedure.

z

Perform the bleeding procedure for all cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again and add oil if required.

Version 2010/1

PC5500-6E

5 - 61

Backhoe

Attachment

5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES

Fig. 5-62 Hoses of the boom cylinders, removal and installation (1, 2)

Hydraulic hose

(3)

Hydraulic piping at the boom cylinder

(4)

Hydraulic pipe

(5)

Guard plate

(6)

Bolt

(7)

Boom cylinder

(8)

O-ring

5 - 62

PC5500-6E

Version 2010/1

Attachment

Backhoe

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Oil drain pan Boom cylinder hose (depending on length): 29.5 kg 39 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended and the stick cylinders in fully retracted position (Fig. 5-63).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-63 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

Version 2010/1

PC5500-6E

5 - 63

Backhoe

Attachment

Fig. 5-64 Hoses of the boom cylinders, removal and installation z

Sling the hydraulic hose (Fig. 5-64, Pos. 1 or 2) to be removed.

z

Remove the guard plate (Fig. 5-64, Pos. 5).

5 - 64

PC5500-6E

Version 2010/1

Attachment

Backhoe

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Remove the bolts (Fig. 5-64, Pos. 6) and disconnect the SAE flanges from the boom cylinder (Fig. 5-64, Pos. 7) respective the hydraulic piping (Fig. 5-64, Pos. 3) at the boom cylinder and from the pipe (Fig. 5-64, Pos. 4) at the boom.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a crane.

z

Replace the boom cylinder hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-64, Pos. 8) at the SAE flange connections. z

Substitute all other boom cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the boom cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again and add oil if required.

Version 2010/1

PC5500-6E

5 - 65

Backhoe

Attachment

5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES

Fig. 5-65 Hoses of the stick cylinders, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Hydraulic pipe

(4)

O-Ring

(5)

Bolt

5 - 66

PC5500-6E

Version 2010/1

Attachment

Backhoe

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Oil drain pan Stick cylinder hose (depending on length): 23 kg 27.5 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended and the stick cylinders in fully retracted position (Fig. 5-66).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-66 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

Version 2010/1

PC5500-6E

5 - 67

Backhoe

Attachment

Fig. 5-67 Hoses of the stick cylinders, removal and installation z

Sling the hydraulic hose (Fig. 5-67, Pos. 1 or 2) to be removed. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

5 - 68

PC5500-6E

Version 2010/1

Attachment

z

Backhoe

Remove the bolts (Fig. 5-67, Pos. 5) and disconnect the SAE flanges at the stick cylinder and the hydraulic pipe (Fig. 5-67, Pos. 3) at the boom.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a crane.

z

Replace the stick cylinder hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-67, Pos. 4) at the SAE flange connections. z

Substitute all other stick cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the stick cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again and add oil if required.

Version 2010/1

PC5500-6E

5 - 69

Backhoe

Attachment

5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES

Fig. 5-68 Hoses of the bucket cylinders, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Hydraulic pipe

(4)

O-ring

(5)

Bolt

5 - 70

PC5500-6E

Version 2010/1

Attachment

Backhoe

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Oil drain pan Bucket cylinder hose: 33 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended and the stick cylinders in fully retracted position (Fig. 5-69).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-69 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

Version 2010/1

PC5500-6E

5 - 71

Backhoe

Attachment

Fig. 5-70 Hoses of the bucket cylinders, removal and installation z

Sling the hydraulic hose (Fig. 5-70, Pos. 1 or 2) to be removed. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

5 - 72

PC5500-6E

Version 2010/1

Attachment

z

Backhoe

Remove the bolts (Fig. 5-70, Pos. 5) and disconnect the SAE flanges from the bucket cylinder and the hydraulic pipe (Fig. 5-70, Pos. 3) at the boom.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a crane.

z

Replace the bucket cylinder hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-70, Pos. 4) at the SAE flange connections. z

Substitute all other bucket cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the bucket cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again and add oil if required.

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5 - 73

Face shovel (FSA)

5.2

Attachment

FACE SHOVEL (FSA)

Fig. 5-71 Face shovel attachment overview (1)

Bull clam bucket (clam)

(2)

Bull clam bucket (wall)

(3)

Stick

(4)

Boom

(5)

Bucket cylinder

(6)

Boom cylinder

(7)

Stick cylinder

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Attachment

5.2.1

Face shovel (FSA)

USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS

Designated use: Each hydraulic cylinder has a groove (Fig. 5-72, arrow) at each end of the cylinder body (Fig. 5-72, Pos. 1). Clamp the installation tool (Fig. 5-72, Pos. 2) on the hydraulic cylinder using the groove.

Fig. 5-72

The tools are designed to handle the attachment’s hydraulic cylinders vertically in combination with a forklift. Thereby, the forks of the forklift are inserted between the cylinder body and the scorpers (Fig. 5-73, Pos. 2). The tools’ extensions (Fig. 5-73, Pos. 1) rest on the forks of the forklift. This is the tools’ main direction of stress, indicated by "F". DANGER Use the installation tools in the proper way shown only! Cylinders may only be handled vertically when using these tools. Misuse may result in death, serious injury, or damage to the tools.

Version 2010/1

PC5500-6E

Fig. 5-73

5 - 75

Face shovel (FSA)

5.2.2

Attachment

BOOM

5.2.2.1 REMOVAL OF THE BOOM

Fig. 5-74 Boom removal (1)

Boom

(2)

Pin

(3)

Shackle

(4)

Bolt

(5)

Shackle

(6)

Bolt

(7)

Pin

(8)

Chain hoist

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Version 2010/1

Attachment

Face shovel (FSA)

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Mobile elevator working platform 2 x Crane 4 x Chain hoist Oil drain pan Boom with attached stick and boom cylinders: 52,900 kg Pin boom/superstructure: 365 kg Pin boom cylinder/superstructure: 224 kg Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: Before the disassembly of the attachment, the wear of the bushes of the attachment and at the superstructure should be checked. Refer to the PARTS & SERVICE NEWS No. "AH08508". z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

z

Park the machine on the prepared flat area and position the bucket on the ground with the stick and the bucket cylinders in vertical position (Fig. 5-75).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-75 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Remove the stick, refer to section 5.2.3 on page 5-96.

NOTE: Leave the stick cylinders retracted and fixed to the boom. Secure them under the boom using chain hoists.

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PC5500-6E

5 - 77

Face shovel (FSA)

Attachment

Fig. 5-76 Boom removal z

Tie the piston rods to the stick cylinder bodies with a wire rope (refer to Fig. 5-47).

z

Disconnect the grease feeding lines leading to the boom and the bearing of the boom cylinder rod.

z

Disconnect all electric wires from the boom.

z

Fix the boom cylinders to the boom using chain hoists (Fig. 5-76, Pos. 8).

z

Attach the front part of the boom to a crane.

z

Remove the bolts (Fig. 5-76, Pos. 6) and the shackles (Fig. 5-76, Pos. 5) securing the pins (Fig. 5-76, Pos. 7).

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Attachment

z

Face shovel (FSA)

Remove the pins (Fig. 5-76, Pos. 7) attaching the boom cylinders to the superstructure. Note the seals. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and retract the boom cylinders fully.

NOTE: Use only motor no. 2 at Qmin. z

Tie the piston rods to the boom cylinder body with a wire rope (refer to Fig. 5-47).

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations. DANGER

Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect all hydraulic hoses from the boom leading to the manifold, refer to section 5.2.6.1 on page 5-142.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Attach the rear part of the boom to another crane.

z

Remove the bolts (Fig. 5-76, Pos. 4) and the shackles (Fig. 5-76, Pos. 3) securing the pins (Fig. 5-76, Pos. 2).

z

Remove the pins (Fig. 5-76, Pos. 2) attaching the boom to the superstructure. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

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5 - 79

Face shovel (FSA)

z

Attachment

Remove the boom with attached stick cylinders and boom cylinders using two cranes. Place it on appropriate stands. WARNING

Make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted boom.

z

Carry out the next steps with the boom placed on appropriate stands: z

Remove the pins of the boom cylinders, refer to section 5.2.2.3 on page 5-88, and remove the boom cylinders from the boom.

z

Remove the pins of the stick cylinders, refer to section 5.2.3.3 on page 5-104, and remove the stick cylinders from the boom.

z

Remove all provided parts and the hydraulic piping from the boom.

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Attachment

Face shovel (FSA)

This page was left blank intentionally.

Version 2010/1

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5 - 81

Face shovel (FSA)

Attachment

5.2.2.2 REPLACEMENT OF THE BOOM Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 2 x Crane 4 x Chain hoist Mobile elevator working platform Boom with attached stick and boom cylinders: 52,900 kg Pin boom/superstructure: 365 kg Pin boom cylinder/superstructure: 224 kg Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease in every bush and pin on assembly! z

Install new bushes (Fig. 5-77, Pos. 3 and 5) into the boom (Fig. 5-77, Pos. 1), if required, and insert new seals (Fig. 5-77, Pos. 2 and 4) into the bushes.

Fig. 5-77

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Version 2010/1

Attachment

Face shovel (FSA)

CAUTION There is a tolerance gap between the bush (Fig. 5-78, Pos. 2) in the boom (Fig. 5-78, Pos. 1) and the seal (Fig. 5-78, Pos. 3), so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

Fig. 5-78 z

Install all provided parts and the hydraulic piping to the boom.

NOTE: Tie the piston rods to the cylinder bodies with wire ropes (refer to Fig. 5-47). z

Install the boom cylinders to the boom in reverse order to removal, refer to section 5.1.1.4 on page 5-16.

z

Install the stick cylinders to the boom in reverse order to removal, refer to section 5.1.2.4 on page 5-32.

NOTE: Make sure the hydraulic hoses are already connected to the cylinders at this state.

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5 - 83

Face shovel (FSA)

Attachment

Fig. 5-79 FSA boom installation z

Fix the cylinders at the boom using chain hoists (Fig. 5-79, Pos. 8).

z

Attach the boom to two cranes. WARNING

Before lifting the boom, make sure that the crane operators are trained in dual crane lift.

z

Lift the boom (Fig. 5-79, Pos. 1) with the boom and stick cylinders attached using two cranes.

NOTE: Lift the front part of the boom higher than the back part.

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Attachment

Face shovel (FSA)

DANGER Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted weight.

z

Align the boom (Fig. 5-79, Pos. 1) to the superstructure. DANGER

Never put hands into the holes when aligning the boom to the superstructure.

z

Insert the two pins (Fig. 5-79, Pos. 2).

z

Detach the rear part of the boom from the crane.

z

Install the shackles (Fig. 5-79, Pos. 3), and bolts (Fig. 5-79, Pos. 4) to secure the pins (Fig. 5-79, Pos. 2).

z

Connect the hydraulic lines leading from the manifold to the boom, refer to section 5.2.6.1 on page 5-142.

WARNING Do not open the plugged hydraulic ports for the cylinders when the wire ropes are removed, because the cylinder rods may start sliding by their own mass. First connect the hydraulic line, then remove the wire ropes.

z

De-isolate the machine according to local regulations.

z

Align the boom cylinder to the superstructure by lifting or lowering the boom using the crane.

NOTE: Use the chain hoist (Fig. 5-79, Pos. 8) to lift or lower the boom cylinders until they point to the mounting location at the superstructure. z

Switch S155 to Qmin.

z

Retract the boom cylinder fully.

NOTE: Use only motor no. 2 at Qmin. WARNING The air in the cylinder will result in slightly jerky movements of the cylinder.

z

Remove the wire ropes from the boom cylinders.

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5 - 85

Face shovel (FSA)

z

Attachment

Align the boom cylinders to the superstructure. Move the boom up and down using the crane, and use the chain hoists to align the cylinders to the mounting location at the superstructure. DANGER

Never put hands into the holes when aligning the boom cylinders to the superstructure.

z

Insert the pins (Fig. 5-79, Pos. 7).

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Install the shackle (Fig. 5-79, Pos. 5) and the bolt (Fig. 5-79, Pos. 6) to secure the pin (Fig. 5-79, Pos. 7).

z

Lower the boom completely and detach the crane.

z

De-isolate the machine according to local regulations.

z

Perform the bleeding procedure for the boom cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Carry out further installation in reverse order to removal.

z

De-isolate the machine according to local regulations.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

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Attachment

Face shovel (FSA)

This page was left blank intentionally.

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5 - 87

Face shovel (FSA)

Attachment

5.2.2.3 REMOVAL OF THE BOOM CYLINDERS

Fig. 5-80 Boom cylinder, removal and installation

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Version 2010/1

Attachment

Face shovel (FSA)

Legend for Fig. 5-80: (1)

Boom cylinder

(2)

Boom

(3)

Catch

(4)

Pin

(5)

Cover

(6)

Bolt

(7)

Seal

(8)

Bush

(9)

Seal

(10)

Bush

(11)

O-ring

(12)

Hydraulic hose

(13)

Bolt

(14)

Bush

(15)

Bush

(16)

Pin

(17)

Superstructure

(18)

Shackle

(19)

Bolt

Special tools:

Installation tool, PN 934 611 40

Additional equipment:

Safety harness in conformity with DIN EN 361 Forklift Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Boom cylinder: 5680kg Pin boom cylinder/superstructure: 224 kg Pin boom cylinder/boom: 234 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

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PC5500-6E

5 - 89

Face shovel (FSA)

Attachment

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: At first, the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508". z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 5-81).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Fig. 5-81 Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Disconnect the grease feeding lines from the boom cylinder(s) to be removed.

z

Sling the lower end of the boom cylinder (Fig. 5-82, Pos. 1) and fix it to the boom (Fig. 5-82, Pos. 2) using a chain hoist.

z

Remove the bolt (Fig. 5-82, Pos. 3) and the shackle (Fig. 5-82, Pos. 4) securing the pin (Fig. 5-82, Pos. 5).

z

Remove the pin (Fig. 5-82, Pos. 5) attaching the boom cylinder to the superstructure. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling. Fig. 5-82 z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and retract the boom cylinder fully.

NOTE: Use only motor no. 2 at Qmin. z

Tie the piston rod to the boom cylinder body with a wire rope.

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Version 2010/1

Attachment

Face shovel (FSA)

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50°C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the hydraulic hoses from the boom cylinder, refer to section 5.2.6.2 on page 5-146.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping and the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Lower the boom cylinder with the chain hoist until the cylinder is in vertical position.

z

Install the installation tool PN 934 611 40 at the boom cylinder’s upper side.

z

Support the boom cylinder by means of the installation tool using the forks of a forklift.

z

Remove the bolts (Fig. 5-83, Pos. 1), the cover (Fig. 5-83, Pos. 2), and the ring (Fig. 5-83, Pos. 3).

z

Remove the pin (Fig. 5-83, Pos. 4) with the catches (Fig. 5-83, Pos. 5). WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

Fig. 5-83

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5 - 91

Face shovel (FSA)

z

Attachment

Remove the boom cylinder using the forklift.

NOTE: Use a crane to lift the cylinder from the forklift. DANGER Risk of falling weights! Death or serious injury may result. When moving the boom cylinder, make sure that nobody steps below the lifted cylinder.

z

If required, remove the pipe work, the connecting blocks, and the seals from the removed cylinder(s). Discard the seals and fit caps to the cylinder(s) openings to avoid environmental contamination.

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Version 2010/1

Attachment

Face shovel (FSA)

5.2.2.4 REPLACEMENT OF THE BOOM CYLINDERS Special tools:

Installation tool, PN 934 611 40

Additional equipment:

Safety harness in conformity with DIN EN 361 Chain hoist Forklift Mobile elevator working platform (telescopic or articulated boom lift) Boom cylinder: 5680 kg Pin boom cylinder/superstructure: 224 kg Pin boom cylinder/boom: 234 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Insert a new bushes (Fig. 5-84, Pos. 3) into the boom cylinder (Fig. 5-84, Pos. 1), if required. Refer to the PARTS & SERVICE NEWS No. "AH06545".

z

Insert new seals (Fig. 5-84, Pos. 2) into the bushes (Fig. 5-84, Pos. 3) of the boom cylinder (Fig. 5-84, Pos. 1).

Fig. 5-84 z

Install the installation tool PN 934 611 40 at the upper end of the new boom cylinder.

z

Tie the moving rod to the cylinder body with a wire rope.

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5 - 93

Face shovel (FSA)

z

Attachment

Sling the boom cylinder and place it on the forklift in a vertical position, so that the upper end of the cylinder is at the top, and that the cylinder is supported by means of the installation tool. DANGER

Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted boom.

z

Align the upper end of the boom cylinder with the boom using the forklift. DANGER

Never put hands into the holes when aligning the boom cylinder to the boom.

z

Insert the pin (Fig. 5-85, Pos. 4) with the catches (Fig. 5-85, Pos. 5).

z

Install the ring (Fig. 5-85, Pos. 3), the cover (Fig. 5-85, Pos. 2), and the bolts (Fig. 5-85, Pos. 1) with lock washers.

Fig. 5-85 z

Sling the boom cylinder body at the piston rod side using a chain hoist. Fix the chain hoist to the boom.

z

Hoist the boom cylinder as far as needed to point in the direction of its mounting position at the superstructure.

z

Connect the hydraulic lines to the boom cylinder, refer to section 5.2.6.2 on page 5-146. WARNING

Do not open the plugged hydraulic ports at the cylinder when the wire ropes are removed, because the cylinder rod starts sliding by its own mass. First connect the hydraulic line, then remove the wire ropes.

Fig. 5-86

NOTE: Always use new O-rings at the SAE flange connections. z

De-isolate the machine according to local regulations.

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Version 2010/1

Attachment

z

Face shovel (FSA)

Switch S155 to Qmin and retract the boom cylinder fully.

NOTE: Use only motor no. 2 at Qmin. z

Remove the wire rope securing the piston rod of the boom cylinder.

z

Extend and retract the boom cylinder slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder. WARNING

The air in the cylinder will result in slightly jerky movements of the cylinder.

z

Extend the boom cylinder as needed to align the cylinder with the superstructure. DANGER

Never put hands into the holes when aligning the boom cylinder to the superstructure.

z

Insert the pin (Fig. 5-86, Pos. 5).

z

Isolate the machine according to local regulations.

z

Install the shackle (Fig. 5-86, Pos. 4), and the bolt (Fig. 5-86, Pos. 3) to secure the pin (Fig. 5-86, Pos. 5).

z

Detach the chain hoist from the boom cylinder body.

z

Carry out further installation in reverse order to removal.

z

De-isolate the machine according to local regulations.

z

Perform the bleeding procedure for the boom cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

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Face shovel (FSA)

5.2.3

Attachment

STICK

5.2.3.1 REMOVAL OF THE STICK

Fig. 5-87 Stick, removal and installation

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Version 2010/1

Attachment

Face shovel (FSA)

Legend for Fig. 5-87: (1)

Boom

(2)

Stick

(3)

Bush

(4)

Seal ring

(5)

Catch

(6)

Pin

(7)

Ring

(8)

Cover

(9)

Bolt

(10)

Seal

(11)

Ring (welded to the stick)

(12)

Flange bush

(13)

Bush

(14)

Pin

(15)

Shackle

(16)

Bolt

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Stick: 21,000 kg Stick cylinder: 3340 kg Pin stick/boom: 168 kg Pin stick cylinder/stick: 90 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

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PC5500-6E

5 - 97

Face shovel (FSA)

Attachment

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area and position the bucket on the ground with the stick and the bucket cylinders in vertical position (Fig. 5-88).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Fig. 5-88 Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Remove all grease feeding lines and electric wires from the stick.

z

Remove the bull clam bucket, refer to section 5.2.4.1 on page 5-114.

z

Hang up both stick cylinders (Fig. 5-89, Pos. 1) at the boom using chain hoists (Fig. 5-89, Pos. 2).

z

Carry out the following steps for each stick cylinder: z

Remove the bolts (Fig. 5-89, Pos. 7) and the shackle (Fig. 5-89, Pos. 4) securing the pin (Fig. 5-89, Pos. 3).

z

Remove the pin (Fig. 5-89, Pos. 3). WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

NOTE: Note the seals (Fig. 5-89, Pos. 5) when removing the pin. Fig. 5-89 z

Check the bushes (Fig. 5-89, Pos. 6) and replace if required.

z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and retract the stick cylinders (Fig. 5-89, Pos. 1) fully.

NOTE: Use only motor no. 2 at Qmin. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

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Version 2010/1

Attachment

Face shovel (FSA)

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect all grease feeding lines and hydraulic hoses from the stick leading to the boom, refer to section 5.2.6.3 on page 5-150.

z

Sling the stick (Fig. 5-90, Pos. 1) to a crane, and lift the stick slightly to ease the load of the pins (Fig. 5-90, Pos. 6).

z

Remove the bolts (Fig. 5-90, Pos. 2) and the covers (Fig. 5-90, Pos. 3).

z

Remove the pins (Fig. 5-90, Pos. 6) with the catches (Fig. 5-90, Pos. 5). WARNING

Sling the pins as soon as possible and support them using a crane to prevent the pins from falling.

z

Remove the stick and rest it on the ground using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick, make sure that nobody steps below the lifted weight. Fig. 5-90 z

Remove all pieces of equipment and the hydraulic piping from the stick (Fig. 5-90, Pos. 1).

Version 2010/1

PC5500-6E

5 - 99

Face shovel (FSA)

Attachment

5.2.3.2 REPLACEMENT OF THE STICK Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Stick: 21,000 kg Pin stick/boom: 168 kg Pin stick cylinder/stick: 90 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: If the flange connections (Fig. 5-91, Pos. 1) of the hydraulic lines to the bucket cylinder mounted at the stick (Fig. 5-91, Pos. 2) are arranged horizontally (as shown in Fig. 5-91), the hydraulic lines at the stick, the hydraulic hoses between boom and stick, and the hose clamps should be replaced. For further information, refer to the PARTS & SERVICE NEWS No. "AH09505".

Fig. 5-91 NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Put the appropriate grease in every bush on assembly!

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PC5500-6E

Version 2010/1

Attachment

Face shovel (FSA)

z

Check the bushes at the stick (Fig. 5-92, Pos. 1), and the bushes for the stick at the boom. Replace, if required.

z

Insert new seals into the grooves (Fig. 5-92, Pos. 3) of the bushes (Fig. 5-92, Pos. 2). CAUTION

There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position. Fig. 5-92

z

Install all provided parts and the hydraulic piping to the stick (Fig. 5-93, Pos. 1).

z

Sling the stick (Fig. 5-93, Pos. 1) and align it to the boom using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick, make sure that nobody steps below the lifted stick.

DANGER Never put hands into the holes when aligning the stick to the boom.

z

Install the pins (Fig. 5-93, Pos. 6) attaching the stick (Fig. 5-93, Pos. 1) to the boom.

z

Install the catches (Fig. 5-93, Pos. 5), the rings (Fig. 5-93, Pos. 4), the covers (Fig. 5-93, Pos. 3), and the bolts (Fig. 5-93, Pos. 2) to secure the pins (Fig. 5-93, Pos. 6).

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Fig. 5-93

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Face shovel (FSA)

Attachment

z

Bring the stick to the position shown in Fig. 5-94 using the crane.

z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and extend the stick cylinders (Fig. 5-94, Pos. 1) to align the stick cylinders with the stick horizontally. Use the chain hoists (Fig. 5-94, Pos. 2) to align the stick cylinders with the stick vertically.

NOTE: Use only motor no. 2 at Qmin. DANGER Never put hands into the holes when aligning the stick cylinders to the stick. Fig. 5-94 z

Put the appropriate grease in the bushes (Fig. 5-94, Pos. 6) and install the pins (Fig. 5-94, Pos. 3) with new seals (Fig. 5-94, Pos. 5).

z

Install the shackle (Fig. 5-94, Pos. 4) and the bolts (Fig. 5-94, Pos. 7) to secure the pins (Fig. 5-94, Pos. 3).

z

Carry out further installation in reverse order to removal.

z

De-isolate the machine according to local regulations.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil, if required.

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Attachment

Face shovel (FSA)

This page was left blank intentionally.

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Face shovel (FSA)

Attachment

5.2.3.3 REMOVAL OF THE STICK CYLINDERS

Fig. 5-95 Stick cylinder, removal and installation

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Version 2010/1

Attachment

Face shovel (FSA)

Legend for Fig. 5-95: (1)

Stick cylinder

(2)

Boom

(3)

Stick

(4)

Seal

(5)

O-ring

(6)

Connecting block

(7)

Pipe

(8)

Pin

(9)

Seal

(10)

Bush

(11)

Bolt

(12)

Catch

(13)

Pin

(14)

Catch

(15)

Bolt

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 2 x Chain hoist Forklift Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Stick cylinder: 3340 kg each Pin stick cylinder/boom: 90 kg Pin stick cylinder/stick: 90 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

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Face shovel (FSA)

Attachment

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 5-96).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-96 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Secure the stick cylinder (Fig. 5-97, Pos. 1) to be removed under the boom using one chain hoist at each side of the cylinder.

z

Pull out the pin connecting the stick cylinder piston rod to the stick, refer to section 5.2.3.1 on page 5-96. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling when it is pulled out completely. Fig. 5-97 z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and retract the stick cylinder (Fig. 5-97, Pos. 1) fully.

NOTE: Use only motor no. 2 at Qmin. z

Tie the piston rod to the cylinder body with a wire rope (refer to Fig. 5-47).

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

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Attachment

Face shovel (FSA)

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the hydraulic hoses from the stick cylinder, refer to section 5.2.6.4 on page 5-154.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping and the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the bolts (Fig. 5-98, Pos. 1) and the shackle (Fig. 5-98, Pos. 2), securing the pin (Fig. 5-98, Pos. 3). WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling when it is pulled out completely.

NOTE: Note the seals (Fig. 5-98, Pos. 4) when removing the pin. z

Check the bush (Fig. 5-98, Pos. 5), and replace it if required.

Fig. 5-98

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Face shovel (FSA)

z

Attachment

Lower the stick cylinder into a horizontal position using the chain hoists simultaneously. Use the forklift to take over the stick cylinder. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick cylinder, make sure that nobody steps below the lifted cylinder.

z

If both stick cylinders are to be removed, repeat the dismounting procedure for the second stick cylinder.

z

If required, remove the pipe work, the connecting blocks, and the seals from the removed cylinder(s). Discard the seals and fit caps to the cylinder(s) openings to avoid environmental contamination.

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Version 2010/1

Attachment

Face shovel (FSA)

5.2.3.4 REPLACEMENT OF THE STICK CYLINDERS Special tools:

Installation tool, PN 923 828 40

Additional equipment:

Safety harness in conformity with DIN EN 361 Forklift 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Stick cylinder: 3340 kg each Pin stick cylinder/boom: 90 kg Pin stick cylinder/stick: 90 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals, and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

If required, install the pipe work and the connecting blocks to the stick cylinder(s).

z

Attach two chain hoists to the underside of the boom.

z

Tie the piston rod of the stick cylinder to be installed to the cylinder body with a wire rope (refer to Fig. 5-47).

z

Place the stick cylinder on a forklift horizontally, and position the stick cylinder right underneath the chain hoists.

z

Connect a chain hoist to each side ot the stick cylinder. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick cylinder, make sure that nobody steps below the lifted cylinder.

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5 - 109

Face shovel (FSA)

z

Attachment

Insert new seals (Fig. 5-99, Pos. 4) into the bushes (Fig. 5-99, Pos. 5) for the stick cylinder at the boom and at the stick. CAUTION

There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

z

Pull up the stick cylinder using the chain hoists, and align the stick cylinder to the boom. DANGER

Never put hands into the holes when aligning the stick cylinders to the boom.

z

Insert the pin (Fig. 5-99, Pos. 3).

z

Install the shackle (Fig. 5-99, Pos. 2) and the bolts (Fig. 5-99, Pos. 1) to secure the pin (Fig. 5-99, Pos. 3).

z

Connect the hydraulic hoses to the stick cylinder (Fig. 5-100, Pos. 1), refer to section 5.2.6.4 on page 5-154.

z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and retract the stick cylinder (Fig. 5-100, Pos. 1) fully.

Fig. 5-99

NOTE: Use only motor no. at Qmin. z

Remove the wire rope from the stick cylinder (Fig. 5-100, Pos. 1).

z

Extend and retract the stick cylinder (Fig. 5-100, Pos. 1) slowly at Qmin 2…3 times as far as possible to partly bleed the cylinder.

Fig. 5-100

WARNING The air in the cylinder will result in slightly jerky movements of the cylinder.

z

Extend the stick cylinder slowly at Qmin and use the chain hoist to align the stick cylinder to the stick.

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Attachment

Face shovel (FSA)

DANGER Never put hands into the holes when aligning the stick cylinder to the stick.

z

Install the pin connecting the stick cylinder with the stick, refer to section 5.2.3.4 on page 5-109.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Carry out further installation in reverse order to removal.

z

De-isolate the machine according to local regulations.

z

Perform the bleeding procedure for the stick cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

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Face shovel (FSA)

5.2.4

Attachment

BULL CLAM BUCKET

Fig. 5-101 Bull clam bucket, removal and installation

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Version 2010/1

Attachment

Face shovel (FSA)

Legend for Fig. 5-101: (1)

Bull clam bucket

(2)

Bush

(3)

Ring (welded to the bucket)

(4)

Pin

(5)

Axle stirrup

(6)

Catch (welded to the bucket)

(7)

Shackle

(8)

Bolt

(9)

Bush

(10)

Pin

(11)

Axle stirrup

(12)

Catch (welded to the bucket)

(13)

Shackle

(14)

Bolt

(15)

Bucket cylinder

(16)

Seal

(17)

Stick

(18)

Seal fixing ring

(19)

Seal

Version 2010/1

PC5500-6E

5 - 113

Face shovel (FSA)

Attachment

5.2.4.1 REMOVAL OF THE BULL CLAM BUCKET Special tools:

n/a

Additional equipment:

Crane Oil drain pan Bucket: 35,060 kg Pin bucket cylinder/bucket: 190 kg Pin bucket/stick: 318 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area and position the bucket on the ground with the stick and the bucket cylinders in vertical position (Fig. 5-102).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Fig. 5-102 Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Disconnect the grease feeding lines leading to the bucket.

z

Remove the plate (Fig. 5-103, Pos. 2) from inside the bucket (Fig. 5-103, Pos. 1) to gain access to the assembly opening.

Fig. 5-103

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Attachment

Face shovel (FSA)

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the hydraulic hoses from the clam cylinder distributor blocks, refer to section 5.2.6.6 on page 5-162.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the seal fixing rings (Fig. 5-104, Pos. 1) from the pin (Fig. 5-104, Pos. 4) located on both sides of the cylinder and the stick (Fig. 5-104, Pos. 3) respectively.

Fig. 5-104

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Face shovel (FSA)

Attachment

Fig. 5-105 Bull clam bucket removal z

Sling the bucket cylinders (Fig. 5-105, Pos. 15) to prevent them from swinging when the pins (Fig. 5-105, Pos. 10) are removed.

z

Remove the bolts (Fig. 5-105, Pos. 14) with washers and the shackle (Fig. 5-105, Pos. 13).

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Version 2010/1

Attachment

z

Face shovel (FSA)

Push the pin (Fig. 5-105, Pos. 10) to the inside just enough to remove the axle stirrups (Fig. 5-105, Pos. 11) from the catches (Fig. 5-105, Pos. 12).

NOTE: The catches (Fig. 5-105, Pos. 12) are welded to the bucket (Fig. 5-105, Pos. 1). z

Remove the pin (Fig. 5-105, Pos. 10) to clear the bucket cylinder (Fig. 5-105, Pos. 15). Remove the seals (Fig. 5-104, Pos. 2) when removing the pin. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

z

Remove the bolts (Fig. 5-105, Pos. 8) with washers and the shackle (Fig. 5-105, Pos. 7).

z

Push the pins (Fig. 5-105, Pos. 4) to the inside just enough to remove the axle stirrups (Fig. 5-105, Pos. 5) from the catches (Fig. 5-105, Pos. 6).

NOTE: The catches (Fig. 5-105, Pos. 6) are welded to the bucket. Use the assembly opening (refer to Fig. 5-103) to push the pins. z

Push the pins (Fig. 5-106, Pos. 1) out of the inner pin bearing (Fig. 5-106, Pos. 2) to the outside until the stick is cleared from the bucket. Remove the seals (Fig. 5-104, Pos. 2) and the rings (Fig. 5-105, Pos. 3) when removing the pin.

NOTE: When the stick is cleared, the pins can remain in the outer pin bearings (Fig. 5-106, Pos. 3).

Fig. 5-106 z

Check the bushes (Fig. 5-105, Pos. 2 and 9) for wear or damage, and replace them if required.

z

De-isolate the machine according to local regulations.

z

Lift the boom and move the excavator away.

z

Isolate the machine according to local regulations.

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5 - 117

Face shovel (FSA)

Attachment

5.2.4.2 REPLACEMENT OF THE BULL CLAM BUCKET

Fig. 5-107 Bull clam bucket replacement

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Version 2010/1

Attachment

Face shovel (FSA)

Special tools:

n/a

Additional equipment:

n/a Bucket: 35,060 kg Pin bucket cylinder/bucket: 190 kg Pin bucket/stick: 318 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: When performing the installation procedures, comply to the following: Always discard used seals, and install new seals! Insert new bushes into the stick (Fig. 5-107, Pos. 17) if required! Apply the appropriate grease on every bush and pin on assembly! z

Slip the seals (Fig. 5-107, Pos. 16 and 19) onto the flanges of the bushes attached to the bull clam bucket (Fig. 5-107, Pos. 1).

NOTE: During installation, there is not enough space to insert these seals. z

Carry out further installation in reverse order to removal.

NOTE: Perform the bleeding procedure for the clam cylinder. Refer to PARTS & SERVICE NEWS No. "AH06524". z

De-isolate the machine according to local regulations.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again, and add oil if required.

Version 2010/1

PC5500-6E

5 - 119

Face shovel (FSA)

Attachment

5.2.4.3 REMOVAL OF THE BUCKET CYLINDERS

Fig. 5-108 Bucket cylinders, removal and installation

5 - 120

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Version 2010/1

Attachment

Face shovel (FSA)

Legend for Fig. 5-108: (1)

Bucket cylinder

(2)

Stick

(3)

Boom

(4)

Axle stirrup

(5)

Pin

(6)

Ring

(7)

Cover

(8)

Bolt

(9)

Bull clam bucket

(10)

Bush

(11)

Seal fixing ring

(12)

Seal

(13)

Catch

(14)

Shackle

(15)

O-ring

(16)

SAE flange

(17)

Flange

(18)

Connecting plate

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5 - 121

Face shovel (FSA)

Attachment

Special tools:

Installation tool, PN 909 374 40

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Forklift Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Bucket cylinder: 4005 kg Pin bucket cylinder/boom: 168 kg Pin bucket cylinder/bucket: 190 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 5-109), bucket cylinders in vertical position.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Fig. 5-109 Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Disconnect the grease feeding lines from the bucket cylinder(s) to be removed.

z

Install the installation tool, PN 909 374 40 at the piston rod side of the bucket cylinder, refer to section 5.2.1 on page 5-75.

z

Support the bucket cylinder by means of the installation tool using the forks of a forklift.

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Version 2010/1

Attachment

Face shovel (FSA)

z

Remove the bolts (Fig. 5-110, Pos. 1), the cover (Fig. 5-110, Pos. 2), and the ring (Fig. 5-110, Pos. 3).

z

Remove the pin (Fig. 5-110, Pos. 4) with the catches (Fig. 5-110, Pos. 5) as well as the seals at the bucket cylinder. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

Fig. 5-110 z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and retract the bucket cylinder fully.

NOTE: Use only motor no. 2 at Qmin. z

Tie the piston rods to the bucket cylinder body with a wire rope.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM". WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Isolate the machine according to local regulations.

z

Disconnect the hydraulic hoses from the bucket cylinder, refer to section 5.2.6.5 on page 5-158.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping and the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Version 2010/1

PC5500-6E

5 - 123

Face shovel (FSA)

z

Attachment

Remove the seal fixing rings (Fig. 5-111, Pos. 1) from the pin (Fig. 5-111, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-111, Pos. 3).

NOTE: Always discard used seals (Fig. 5-111, Pos. 2).

Fig. 5-111 z

Remove the bolts (Fig. 5-112, Pos. 5) and the shackle (Fig. 5-112, Pos. 4) securing the pin (Fig. 5-112, Pos. 1).

z

Pull out the pin (Fig. 5-112, Pos.1). Thereby remove the axle stirrups (Fig. 5-112, Pos.2) from the catches (Fig. 5-112, Pos. 3).

NOTE: The catches are welded to the bucket.

Fig. 5-112 z

Remove the bucket cylinder using the forklift.

NOTE: Use a crane to lift the bucket cylinder from the forklift and to put it down on the ground. WARNING Do not sling the bucket cylinder at the installation tool, refer to section 5.2.1 on page 5-75.

DANGER Risk of falling weights! Death or serious injury may result. When moving the bucket cylinder, make sure that nobody steps below the lifted cylinder.

5 - 124

PC5500-6E

Version 2010/1

Attachment

Face shovel (FSA)

5.2.4.4 REPLACEMENT OF THE BUCKET CYLINDERS Special tools:

Installation tool, PN 909 374 40

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Forklift Mobile elevator working platform (telescopic or articulated boom lift) Bucket cylinder: 4005 kg Pin bucket cylinder/boom: 168 kg Pin bucket cylinder/bucket: 190 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Check the bushes (Fig. 5-113, Pos. 1) of the bucket cylinder and of the corresponding pin bearings at the boom and at the bucket. Replace the bushes if required. Refer to the PARTS & SERVICE NEWS No. "AH06545".

z

Install new seals (Fig. 5-113, Pos. 2) into the bushes in the piston rod. CAUTION

There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

z

Fig. 5-113

Slip new seals (Fig. 5-113, Pos. 3) onto the flange of the bushes installed in the bucket.

NOTE: During installation of the cylinder at the bucket, there is not enough space to insert the seals. Version 2010/1

PC5500-6E

5 - 125

Face shovel (FSA)

Attachment

z

Install the installation tool, PN 909 374 40 at the piston rod side of the new bucket cylinder.

z

Sling the bucket cylinder to a crane at the piston rod side, using the installation tool as a stop for the wire rope. WARNING

Do not sling the wire rope to the installation tool.

z

Lift the bucket cylinder until it is in upright position.

z

Take over the bucket cylinder with a forklift, supporting the cylinder at the installation tool with the forks of the forklift. DANGER

Risk of falling weights! Death or serious injury may result. When moving the bucket cylinder, make sure that nobody steps below the lifted cylinder.

z

Align the bucket cylinder with the bucket. DANGER

Never put hands into the holes when aligning the bucket cylinder to the bucket.

NOTE: Pay attention not to damage the seals on the bushes in the bucket z

Insert the pin (Fig. 5-114, Pos. 1) and the seals (Fig. 5-115, Pos. 2). Secure the pin with the axle stirrups (Fig. 5-114, Pos. 2) in the catches (Fig. 5-114, Pos. 3).

z

Install the shackle (Fig. 5-114, Pos. 4) and insert the bolts (Fig. 5-114, Pos. 5) with washers.

Fig. 5-114

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Attachment

z

Face shovel (FSA)

Install the seal fixing rings (Fig. 5-115, Pos. 1) at the pin (Fig. 5-115, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-115, Pos. 3) to fix the seals (Fig. 5-115, Pos. 2).

Fig. 5-115 z

Remove the installation tool.

NOTE: Continue to hold the bucket cylinder in an upright position with the forks of the forklift. z

Connect the hydraulic lines to the bucket cylinder, refer to section 5.2.6.5 on page 5-158.

NOTE: Always use new O-rings at the SAE flange connections. z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin.

NOTE: Use only motor no. 2 at Qmin. z

Extend and retract the bucket cylinder slowly at Qmin 2…3 times as far as possible to partly bleed the cylinder. WARNING

The air in the cylinder will result in slightly jerky movements of the cylinder.

z

Extend the bucket cylinder slowly at Qmin and align the piston rod with the boom vertically. Use the forklift to align the stick cylinder to the boom horizontally. DANGER

Never put hands into the holes when aligning the bucket cylinder to the boom.

Version 2010/1

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Face shovel (FSA)

Attachment

z

Insert the pin (Fig. 5-116, Pos. 4) with the catches (Fig. 5-116, Pos. 5) and fix the bucket cylinder.

z

Install the ring (Fig. 5-116, Pos. 3), the cover (Fig. 5-116, Pos. 2), and the bolts (Fig. 5-116, Pos. 1).

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

Fig. 5-116 z

Carry out further installation in reverse order to removal.

z

De-isolate the machine according to local regulations.

z

Perform the bleeding procedure for the stick cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

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Attachment

5.2.4.5 REMOVAL OF THE CLAM CYLINDERS

Fig. 5-117 Clam cylinders, removal and installation

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Attachment

Face shovel (FSA)

Legend for Fig. 5-117: (1)

Clam cylinder

(2)

Hydraulic hose

(3)

Bucket clam

(4)

Pin

(5)

Catch

(6)

Shackle

(7)

Lock washer

(8)

Bolt

(9)

Seal

(10)

Bush

(11)

Seal

(12)

Bush

(13)

Catch

(14)

Bolt

(15)

Plate

(16)

Pin

(17)

Protective frame

Special tools:

n/a

Additional equipment:

Crane Oil drain pan Clam cylinder: 885 kg Clam cylinder’s upper pin: 48 kg Clam cylinder’s lower pin: 66 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18.

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Attachment

z

Prepare an area of flat ground large enough to accommodate the machine boom and crane.

z

Park the machine on the prepared flat area and position the bucket horizontally on the ground (Fig. 5-118).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM". Fig. 5-118

z

Isolate the machine according to local regulations.

z

Support the clam cylinder with appropriate blocks (Fig. 5-119, arrows) to fix it in its position.

z

Disconnect the grease feeding lines from the clam cylinder.

Fig. 5-119 z

Remove the bolts (Fig. 5-120, Pos. 1) and the cover (Fig. 5-120, Pos. 2) to access the pin connecting the clam cylinder to the bucket clam.

Fig. 5-120

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Face shovel (FSA)

z

Remove the bolts (Fig. 5-121, Pos. 6) with lock washers (Fig. 5-121, Pos. 7), the shackle (Fig. 5-121, Pos. 5), and the catches (Fig. 5-121, Pos. 4).

z

Pull out the pin (Fig. 5-121, Pos. 3) to clear the clam cylinder (Fig. 5-121, Pos. 2) from the bucket clam (Fig. 5-121, Pos. 1).

Fig. 5-121 z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin and retract the clam cylinder to be removed fully.

NOTE: Use only motor no. 2 at Qmin. WARNING Both clam cylinders are connected to the same hydraulic line, so when the cleared cylinder is fully retracted, the other cylinder will be retracted, and the clam will open. Do not open the clam.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

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Face shovel (FSA)

z

Attachment

Disconnect the hydraulic hoses from the clam cylinder, refer to section 5.2.6.6 on page 5-162.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Discard the O-rings. z

Sling the clam cylinder at both ends.

z

Remove the bolt (Fig. 5-122, Pos. 2) and the plate (Fig. 5-122, Pos. 3).

NOTE: The catch (Fig. 5-122, Pos. 4) is welded to the bucket. z

Pull out the pin (Fig. 5-122, Pos. 1) using pulling bolts.

Fig. 5-122 z

Remove the clam cylinder from the bucket using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the clam cylinder, make sure that nobody steps below the lifted cylinder.

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Face shovel (FSA)

5.2.4.6 REPLACEMENT OF THE CLAM CYLINDERS Special tools:

n/a

Additional equipment:

Crane Clam cylinder: 885 kg Clam cylinder’s upper pin: 48 kg Clam cylinder’s lower pin: 66 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14. NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Insert new bushes (Fig. 5-123, Pos. 1) into the clam cylinder, if required. Refer to the PARTS & SERVICE NEWS No. "AH06545".

z

Install new seals (Fig. 5-123, Pos. 2) into the bushes (Fig. 5-123, Pos. 1). CAUTION

There is a tolerance gap between bush and seal, so that the seal can move freely within the groove. In order to avoid damage to the seals, stick the seals into the grooves of the bushes with grease, and center the seals in their mounting position.

Fig. 5-123 z

Insert the clam cylinder into the bucket using a crane and align the cylinder with the bucket to insert the lower pin. DANGER

Never put hands into the holes when aligning the clam cylinder to the bucket.

NOTE: For easier alignment, it is recommended to support the clam cylinder at the front side and from below with appropriate blocks (Fig. 5-124, arrows) to fix it in its position. Fig. 5-124

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Attachment

z

Insert the pin (Fig. 5-125, Pos. 1) and position it in the catch (Fig. 5-125, Pos. 4).

z

Fix the pin with the plate (Fig. 5-125, Pos. 3).

z

Secure the plate with the bolt (Fig. 5-125, Pos. 2).

Fig. 5-125 z

Connect the hydraulic hoses to the clam cylinder, refer to section 5.2.6.6 on page 5-162.

NOTE: Use new O-rings at the SAE flange connections. z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin.

NOTE: Use only motor no. 2 at Qmin. z

Extend and retract the clam cylinder slowly at Qmin 2…3 times as far as possible to partly bleed the cylinder. WARNING

The air in the cylinder will result in slightly jerky movements of the cylinder.

WARNING Both clam cylinders are connected to the same hydraulic line, so when the cleared cylinder is fully retracted, the other cylinder will be retracted, and the clam will open. Do not open the clam.

z

Extend the clam cylinder slowly at Qmin and align the cylinder piston rod with the clam. WARNING

Never put hands into the holes when aligning the clam cylinder to the clam.

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Face shovel (FSA)

z

Insert the pin (Fig. 5-126, Pos. 3) connecting the clam cylinder (Fig. 5-126, Pos. 2) to the bucket clam (Fig. 5-126, Pos. 1).

z

Isolate the machine according to local regulations.

z

Install the shackle (Fig. 5-126, Pos. 5) with the bolts (Fig. 5-126, Pos. 6) and lock washers (Fig. 5-126, Pos. 7).

Fig. 5-126 z

Carry out further installation in reverse order to removal.

z

De-isolate the machine according to local regulations.

z

Perform the bleeding procedure for the clam cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

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Face shovel (FSA)

5.2.5

Attachment

GROUND ENGAGING TOOLS (GET)

As ground engaging tools, the ESCO POSILOK Tooth System is used.

Fig. 5-127 GET

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Face shovel (FSA)

Legend for Fig. 5-127: (1)

Shroud

(2)

Toplok boss

(3)

Wedge

(4)

Point (tooth)

(5)

Wedge

(6)

Tooth adapter (center/corner)

(7)

Pin

(8)

Wear plate

(9)

Base plate

(10)

Bucket clam (shroud mounting position)

(11)

Integral rubber lock

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Attachment

5.2.5.1 REMOVAL AND REPLACEMENT OF THE GET Special tools:

POSILOK Pin removal tool PN 793 502 73

Additional equipment:

ESCO POSILOK Tooth System S130 Forklift Point (tooth): 55 kg (ESCO) Shroud: 270 kg (ESCO) Tooth adapter: 182 kg (ESCO)

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

CAUTION Hazard of injuries from splinters! When working on the locking pins, always wear hard hat, safety glasses steel-toed shoes, and gloves. To avoid injury to others, keep people not directly involved well out of the way.

z

Prepare an area of flat ground large enough to accommodate the machine, bucket and a forklift.

z

Park the machine on the prepared flat ground area and position the bucket in an appropriate height for work.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

z

For removing and installing the ESCO Tooth System, refer to PARTS & SERVICE NEWS No. "AH03510".

NOTE: Use a forklift to remove and install the GET.

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5.2.6

Attachment

HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT

5.2.6.1 SUBSTITUTE THE BOOM ARC HOSES

Fig. 5-128 Boom arc hoses, removal and installation 5 - 142

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Attachment

Face shovel (FSA)

Legend for Fig. 5-128: (1)

Hydraulic hose

(2)

Bolt

(3)

O-ring

(4)

Manifold

(5)

Hose clamp

(6)

Clamp line

(7)

Hydraulic pipe

(8)

Nut

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Oil drain pan Boom arc hose: 39 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING Always wear a safety harness when working at the attachment.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area with the stick cylinder fully retracted and position the bucket horizontally on the ground (Fig. 5-129).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-129

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Attachment

Fig. 5-130 Boom arc hoses, removal and installation

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Face shovel (FSA)

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Open the hose clamps (Fig. 5-130, Pos. 5) and clear the hydraulic hose (Fig. 5-130, Pos. 1) to be removed from the clamp lines (Fig. 5-130, Pos. 6). WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Sling the hydraulic hose (Fig. 5-130, Pos. 1) to be removed.

z

Remove the bolts (Fig. 5-130, Pos. 2) and disconnect the SAE flanges from the manifold (Fig. 5-130, Pos. 4) and from the hydraulic pipes (Fig. 5-130, Pos. 7) at the boom.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a crane.

z

Replace the boom arc hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-130, Pos. 3) at the SAE flange connections. z

Substitute the other boom arc hoses if required, using the same procedure.

z

Perform the bleeding procedure for all cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again, and add oil if required.

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Face shovel (FSA)

Attachment

5.2.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES

Fig. 5-131 Boom cylinder hoses, removal and installation

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Attachment

Face shovel (FSA)

Legend for Fig. 5-131: (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Boom cylinder

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Boom cylinder hose: 30.5 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area with the stick cylinder fully retracted and position the bucket horizontally on the ground (Fig. 5-132).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-132

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Face shovel (FSA)

Attachment

Fig. 5-133 Boom cylinder hoses, removal and installation

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Attachment

Face shovel (FSA)

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Sling the hydraulic hose (Fig. 5-133, Pos. 1 or 2) to be removed.

z

Remove the bolts (Fig. 5-133, Pos. 3) and disconnect the SAE flanges from the boom cylinder (Fig. 5-133, Pos. 6) and from the hydraulic pipe at the boom.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a crane.

z

Replace the boom cylinder hoses with new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-133, Pos. 4) and the rings (Fig. 5-133, Pos. 5) at the SAE flange connections. z

Substitute the other boom cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the boom cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again and add oil if required.

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Attachment

5.2.6.3 SUBSTITUTE THE STICK ARC HOSES

Fig. 5-134 Stick arc hoses, removal and installation NOTE: Fig. 5-134 shows the hydraulic hose routing of the machines up to SN 077 with two hoses leading to the stick equipped with a 90 degree tube bend. For machines equipped in this way, the hydraulic hoses with the 90 degree tube bend, the hydraulic lines at the stick, and the hose clamps should be replaced. For further information, refer to PARTS & SERVICE NEWS No. "AH09505".

5 - 150

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Attachment

Face shovel (FSA)

Legend for Fig. 5-134: (1)

Hydraulic hose

(2)

Hose clamp line

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Hydraulic pipe

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Stick arc hose: 29.5 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area with the stick cylinder fully retracted and position the bucket horizontally on the ground (Fig. 5-135).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-135

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Attachment

Fig. 5-136 Stick arc hoses, removal and installation z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

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Attachment

Face shovel (FSA)

z

Remove the hose clamp line(s) (Fig. 5-136, Pos. 2).

z

Sling the hydraulic hose (Fig. 5-136, Pos. 1) to be removed. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Remove the bolts (Fig. 5-136, Pos. 3) and disconnect the SAE flanges from the hydraulic pipes (Fig. 5-136, Pos. 6).

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a crane.

z

Replace the stick arc hoses by new ones, and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-136, Pos. 4) and the rings (Fig. 5-136, Pos. 5) at the SAE flange connections. z

Substitute the other stick arc hoses, if required, using the same procedure.

z

Perform the bleeding procedure for the bucket and clam cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again and add oil if required.

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Face shovel (FSA)

Attachment

5.2.6.4 SUBSTITUTE THE STICK CYLINDER HOSES

Fig. 5-137 Stick cylinder hoses, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

5 - 154

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Version 2010/1

Attachment

Face shovel (FSA)

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Forklift Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Stick cylinder hose (depending on length): 25 kg 27.4 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and forklift.

z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 5-138).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-138 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

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5 - 155

Face shovel (FSA)

Attachment

Fig. 5-139 Stick cylinder hoses, removal and installation

5 - 156

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Attachment

z

Face shovel (FSA)

Sling the hydraulic hose (Fig. 5-139, Pos. 1 or 2) to be removed using a forklift. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Remove the bolts (Fig. 5-139, Pos. 3) and disconnect the SAE-flanges.

NOTE: When the hydraulic hose is disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a forklift.

z

Replace the stick cylinder hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-139, Pos. 4) and the rings (Fig. 5-139, Pos. 5) at the SAE flange connections. z

Substitute the other stick cylinder hoses, if required, using the same procedure.

z

Perform the bleeding procedure for the stick cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again and add oil if required.

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5 - 157

Face shovel (FSA)

Attachment

5.2.6.5 SUBSTITUTE THE BUCKET CYLINDER HOSES

Fig. 5-140 Bucket cylinder hoses, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Intermediate flange

(7)

Bucket cylinder

(8)

Stick

5 - 158

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Version 2010/1

Attachment

Face shovel (FSA)

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Bucket cylinder hose: 28 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: If the flange connections of the hydraulic pipes coming from the bucket cylinder hoses (Fig. 5-91, Pos. 1) leading to the boom are arranged horizontally, the hydraulic lines at the stick, the hydraulic hoses between boom and stick, and the hose clamps should be replaced. For further information, refer to the PARTS & SERVICE NEWS No. "AH09505". z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat area with the stick cylinder fully retracted and position the bucket horizontally on the ground (Fig. 5-141).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-141 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

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Face shovel (FSA)

Attachment

Fig. 5-142 Bucket cylinder hoses, removal and installation z

Sling the hydraulic hose (Fig. 5-142, Pos. 1 or 2) to be removed. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

5 - 160

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Attachment

Face shovel (FSA)

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Remove the bolts (Fig. 5-142, Pos. 3) and disconnect the SAE flanges. z

Remove the intermediate flange (Fig. 5-142, Pos. 6) from the cylinder when removing the bucket cylinder hose (Fig. 5-142, Pos. 1) on the piston rod side of the bucket cylinder (Fig. 5-142, Pos. 7).

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a crane.

z

Replace the bucket cylinder hoses by new ones, and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-142, Pos. 4) and the rings (Fig. 5-142, Pos. 5) at the SAE flange connections. z

Substitute the other bucket cylinder hoses, if required, using the same procedure.

z

Perform the bleeding procedure for the bucket cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again and add oil if required.

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5 - 161

Face shovel (FSA)

Attachment

5.2.6.6 SUBSTITUTE THE CLAM CYLINDER HOSES The clam cylinder hose set contains two hydraulic hoses at the stick and four (two for each cylinder) hydraulic hoses at the clam cylinders. Substitute the clam cylinder hoses at the stick

Fig. 5-143 Clam cylinder hoses at stick, removal and installation (1)

Hydraulic hose

(2)

Bolt

(3)

O-Ring

(4)

Ring

5 - 162

PC5500-6E

Version 2010/1

Attachment

Face shovel (FSA)

Special tools:

n/a

Additional equipment:

Forklift Oil drain pan Clam cylinder hose: 28 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and forklift.

z

Park the machine on the prepared flat area with the superstructure turned by 90°, and position the bucket on the ground as shown (Fig. 5-144).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-144 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

z

Sling the hydraulic hose (Fig. 5-143, Pos. 1) to be removed.

Version 2010/1

PC5500-6E

5 - 163

Face shovel (FSA)

Attachment

Fig. 5-145 Clam cylinder hoses at stick, removal and installation WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

5 - 164

PC5500-6E

Version 2010/1

Attachment

z

Face shovel (FSA)

Remove the bolts (Fig. 5-145, Pos. 2) and disconnect the SAE flanges.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a forklift.

z

Replace the clam cylinder hose by a new one, and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-142, Pos. 3) and the rings (Fig. 5-142, Pos. 4) at the SAE flange connections. z

Substitute the other clam cylinder hose, if required, using the same procedure.

z

If required, substitute the clam cylinder hoses at the clam cylinders as described in the next section on page 166.

z

Perform the bleeding procedure for the clam cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again, and add oil if required.

Version 2010/1

PC5500-6E

5 - 165

Face shovel (FSA)

Attachment

Substitute the clam cylinder hoses at the cylinders

Fig. 5-146 Clam cylinder hoses, removal and installation 5 - 166

PC5500-6E

Version 2010/1

Attachment

Face shovel (FSA)

Legend for Fig. 5-146: (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Hydraulic hose

(4)

Hydraulic hose

(5)

Bolt

(6)

O-ring

(7)

Distributor block

(8)

Clam cylinder

(9)

Flange half

Special tools:

n/a

Additional equipment:

Oil drain pan Clam cylinder hose (depending on length): 8.8…11.2 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-18. If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

z

Prepare an area of flat ground large enough to accommodate the machine.

z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 5-147).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-147 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z

Isolate the machine according to local regulations.

Version 2010/1

PC5500-6E

5 - 167

Face shovel (FSA)

Attachment

Fig. 5-148 Clam cylinder hoses, removal and installation

5 - 168

PC5500-6E

Version 2010/1

Attachment

Face shovel (FSA)

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Remove the bolts (Fig. 5-148, Pos. 5) from the flange halves (Fig. 5-148, Pos. 9) to disconnect the SAE flanges from the distributor block (Fig. 5-148, Pos. 7) and from the clam cylinder (Fig. 5-148, Pos. 8).

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Replace the hydraulic hoses (Fig. 5-148, Pos. 1 to 4).

z

Replace the clam cylinder hoses by a new ones, and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-148, Pos. 6) at the SAE flange connections. z

Perform the bleeding procedure for the clam cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z

Add hydraulic oil up to the specified level.

z

Check for leaks and the cylinders operation.

z

Check hydraulic oil level again, and add oil if required.

Version 2010/1

PC5500-6E

5 - 169

Metering valves (grease injectors) at the attachment

5.3

Attachment

METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT

Fig. 5-149 Location of the grease injectors at the FSA attachment

5 - 170

PC5500-6E

Version 2010/1

Attachment

Metering valves (grease injectors) at the attachment

Legend for Fig. 5-149: (1)

Indicator stem

(2)

Output adjusting screw

(3)

Boom

(4)

Stick

(5)

Bull clam bucket

(6)

Metering valve group at the boom

(7)

Metering valves at the bull clam bucket

(8)

Metering valve group at the stick

5.3.1

OPERATION TEST OF THE METERING VALVES (GREASE INJECTORS)

The operation of the metering valves (Fig. 5-149, Pos. 6 up to 8) at the attachment can be carried out visually by watching the cycle indicator stem (Fig. 5-149, Pos. 1) while operating the central lubrication system manually. The stem must move in and out once every lubrication cycle. NOTE: Remember the timing setting which may cause a delay of up to 11 minutes, before a manual lubrication loop may start after its release. If in doubt, refer to the relating timing diagram in your flowchart. If any indicator stem does not move during a lubrication cycle, the grease supply to the lubrication point of the respective valve is interrupted or clogged. NOTE: There are two types of metering valves installed: type "SL1” and type “SL11”.

Version 2010/1

PC5500-6E

5 - 171

Metering valves (grease injectors) at the attachment

5.3.2

Attachment

REMOVAL OF THE METERING VALVES (GREASE INJECTORS)

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Mobile elevator working platform

WARNING z

Always wear a safety harness when working at the attachment.

z

The work requires the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and mobile elevator working platform.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

For machines with face shovel attachment (FSA) only: Park the machine on the prepared flat area and position the attachment in the "defined position" (see Fig. 5-150).

Fig. 5-150 z

For machines with backhoe attachment (BHA) only: Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended and the stick cylinders in fully retracted position (Fig. 5-151).

Fig. 5-151 z

Isolate the machine according to local regulations.

NOTE: In the following, it is described how to remove the metering valves at the FSA boom exemplarily. 5 - 172

PC5500-6E

Version 2010/1

Attachment

Metering valves (grease injectors) at the attachment

All other metering valves at the attachment (BHA included) are removed analogously. z

Disconnect all grease lines (Fig. 5-152, Pos. 2) from the metering valve assemblies (Fig. 5-152, Pos. 5).

z

Disconnect the grease feeding line at the union (Fig. 5-152, Pos. 3).

z

Remove the bolts (Fig. 5-152, Pos. 4), and remove the metering valve assemblies (Fig. 5-152, Pos. 5) from the boom (Fig. 5-152, Pos. 1).

Fig. 5-152 z

Remove the adapter bolt (Fig. 5-153, Pos. 2), and remove the valve housing (Fig. 5-153, Pos. 1) from the metering valve assembly (Fig. 5-153, Pos. 4).

Fig. 5-153

Version 2010/1

PC5500-6E

5 - 173

Metering valves (grease injectors) at the attachment

5.3.3

Attachment

REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS)

Special tools:

n/a

Additional equipment:

Safety harness in conformity with DIN EN 361 Mobile elevator working platform If there is nothing mentioned explicitly, tighten all bolts according to KOMATSU company standard, refer to section 6.5 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z

The work requires the use of men safety cages on elevator working platforms.

z

Carry out installation in reverse order to removal.

z

Use new seals (Fig. 5-154, Pos. 3) at the valve housing (Fig. 5-154, Pos. 1).

Fig. 5-154 z

Check metering valves at the attachment for proper operation, refer to section 5.3.1 on page 5-171.

NOTE: Remember the timing setting which may cause a delay of up to 11 minutes, before a manual lubrication loop may start after its release. If in doubt, refer to the relating timing diagram in your flowchart.

5 - 174

PC5500-6E

Version 2010/1

Attachment

5.4

Cylinder bypass test

CYLINDER BYPASS TEST

Special tools:

n/a Safety harness in conformity with DIN EN 361 Mobile elevator working platform Infrared thermometer Oil drain pan

Additional equipment: Hydraulic hose with 1 1/2" or 2" 6000 PSI SAE flange The SAE flange size depends on the cylinder flange size, the hose should be long enough to lead from the respective cylinder to an oil pan. For further information about the needed blind plugs, refer to section 6.6 on page 6-18. The cylinder bypass test can be performed to check if a hydraulic cylinder has an internal leakage. NOTE: A cylinder with an internal leakage also has a higher temperature (at working temperature of the machine) than a hydraulic cylinder which has no internal leakage. WARNING Always wear a Safety harness when working at the attachment.

NOTE: First check hydraulic cylinder temperature using an infrared thermometer if an internal leakage is assumed. If the temperature is not higher than the temperature of the other cylinders, another reason e.g. leakage of a valve may be the reason for loosing pressure. If the temperature is higher than the temperature of the other cylinders, perform the following steps: z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, section 3.15.1.

z

Isolate the machine according to local regulations. WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

Version 2010/1

PC5500-6E

5 - 175

Cylinder bypass test

Attachment

DANGER Danger of hydraulic pressure. May result in blindness, serious injury, permanent disfigurement, or scaring. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic lines will be removed.

z

Disconnect the hydraulic hose from the piston rod side of the respective cylinder.

NOTE: When the hydraulic hose is disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the hydraulic hose with a blind plug to avoid contamination. z

Connect a hydraulic hose to the piston rod side of the cylinder. Put the open end of the hose into an oil pan.

z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin.

Fig. 5-155

NOTE: Use only motor no. 2 at Qmin. WARNING Make sure that nobody is at close range of the hydraulic hose’s open end when extending the cylinder.

z

Fully extend the hydraulic cylinder at Qmin.

NOTE: The oil inside the cylinder will flow out of the hydraulic hose connected to the piston rod side of the cylinder. Catch it in the oil pan. z

When the piston of the cylinder reaches its mechanical stop, continue to extend the cylinder.

If the cylinder has an internal leakage, some oil will continuously flow out of the hydraulic hose connected to the piston rod side of the cylinder. If the cylinder has no internal leakage, oil will stop flowing out of the hydraulic hose.

5 - 176

PC5500-6E

Version 2010/1

Service Information

6 SERVICE INFORMATION

Version 2010/1

PC5500-6E

6 -1

Fluids and lubricants

6.1

Service Information

FLUIDS AND LUBRICANTS

Due to extremely different environmental and working conditions for the excavator as well as special customized approvals for lubricants, it is not possible to get a general conclusion about the used fluids and lubricants. Therefore, no lubrication or other fluids are listed at this point in this R&R-Manual. NOTE: For proper fluids and lubricants refer to the Service Manual of your machine.

6.2

FILLING CAPACITIES

NOTE: Capacities listed below are approximated values. For proper checking use level plugs, dipsticks, and inspection openings provided for this purpose, and refer to the Service Manual of the excavator. Units or system

Liters (approximate)

Main hydraulic oil reservoir

3600*1

Complete hydraulic system

6600

Pump distributor gear (PTO), each

95

Oil collector reservoir, auxiliary hydraulic pumps

1

Main hydraulic pumps, drive shaft housing

1.5

Slew gear (L&S), each

42

Motor adapter housing

0.6

Slew gear (Siebenhaar), each

60

Motor adapter housing

*2

Brake housing

0.2

Travel gear (L&S, type GFA 1300 K 1003), each Motor adapter housing

2.5 *2

Brake housing

0.1 *2

Spur gear housing

10 *2

Planetary gear housing

105 *2

Support bearing

3.5 *2

NOTE: *1) Oil change quantity, including suction oil tank and return oil collector pipes, is approx. 4450 liters (when attachment is in oil level checking position), see oil level gauge on the main hydraulic oil reservoir. *2) Fill up to level gauge marking.

6 -2

PC5500-6E

Version 2010/1

Service Information

Filling capacities

Units or system

Liters (approximate)

Travel gear (L&S, type GFA 305 K 1017), each

155

Motor adapter housing

2

Travel gear (Zollern), each

180

Motor adapter housing

0.5

Final drive housing

165

Guide wheel

3.2

Carrier rollers

*3

Track rollers

*4

Water tank in operator’s cabin

50

Water reservoir for windshield washer

7

NOTE: *3) Fill up to the specified level, refer to section 4.2.12.2 on page 4-72. *4) Fill up to the specified level, refer to section 4.2.13.2 on page 4-75.

Version 2010/1

PC5500-6E

6 -3

Work instructions

Service Information

6.3

WORK INSTRUCTIONS

6.3.1

SURFACE COATING WITH INTERZINC 697 Coating compound "INTERZINC 697", PN 674 997 40 Thinner, PN 907 886 40 Dust bonding cloths, PN 932 911 40

Additional equipment:

WARNING z

All working procedures in coherency with the coating compound "INTERZINC 697" must be carried out according to local regulations and standards concerning occupational health and safety.

z

All working procedures in coherency with the coating compound "INTERZINC 697" must be carried out by authorized specialists only.

CAUTION Welding or cutting on parts which have been coated with the coating compound "INTERZINC 697" results in harmful dusting and gassing. Carry out welding or cutting work with personal protective equipment only. Dust and gases must be lead away from the workplace.

z

Clean the surface to be coated according to ISO 8504, purity level 3 with thinner, PN 907 886 40. The surface to be coated must be completely free of dirt, grease, or oil.

NOTE: Do not use compressed air because it contains oil. z

Plug all threads.

z

Set up the surface to be coated with sand paper (grain 60) or a grinder, according to ISO 8504-1:1998.

z

Cover the area around the surface to be coated (e.g. with plastic film).

z

Use dust bonding cloths PN 932 911 40 to clean the surface to be coated from grinding swarf.

NOTE: Do not use compressed air because it contains oil. If a rust film has formed at the surface to be coated before INTERZINC can be applied, repeat the cleaning procedure.

6 -4

PC5500-6E

Version 2010/1

Service Information

Work instructions

NOTE: INTERZINC contains of two parts, a liquid binder and powder. z

Pour the powder into the liquid binder while agitating. Mixing ratio: 1 part liquid binder: 0.7 parts powder (volume) 1 part liquid binder: 4 parts powder (weight) WARNING

z

Don not add liquid to the powder.

z

Do not water down the powder or the final coating compound.

z

Apply the INTERZINC compound with a clean spraygun equipped with a 2.5 mm flat spray nozzle. WARNING

Only use a compressed air supply without air line lubricator.

NOTE: Apply interzinc in one pass only to obtain the permissible film thickness. z

The specified dry paint film thickness (DFT) must be 75 µm (3.0 Mil) or 125 µm (5.0 Mil) wet paint film thickness (WFT). WARNING

Do not use brushes or paint rollers.

WARNING z

The temperature of the surface to be coated must be at least 10 °C (50 °F). The humidity should be 50% to 60%, otherwise the hardening time will increase considerably.

z

The coated parts must be ventilated well while drying. The air speed must be at least 0.1 m/s (4 in/sec). Otherwise the coating will be cracked. If the coating is cracked, the coating must be removed, and the coating procedure has to be repeated.

z

Pay attention to the hardening time. The hardening time depends on ambient temperature, humidity and dry paint film thickness (DFT). At an ambient temperature of 20 °C (68 °F), the hardening takes about five days.

Version 2010/1

PC5500-6E

6 -5

Work instructions

6.3.2

Service Information

REMOVE / INSTALL THE CRAWLER CARRIER

Special tools:

Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73 Electro-hydraulic pump aggregate, PN 793 375 73

NOTE: Fig. 6-1 shows the following: (Fig. 6-1, Pos. 1) Hydraulic wrench PN 793 374 73. (Fig. 6-1, Pos. 2) Special wrench socket PN 793 376 73. (Fig. 6-1, Pos. 3) Electro-hydraulic pump aggregate PN 795 922 73 (picture as example). For information about the Electro-hydraulic pump aggregate, refer to chapter 9 "Supplier’s documentation", "AVANTI HYTORQUE".

Fig. 6-1

6 -6

PC5500-6E

Hydraulic torque wrench

Version 2010/1

Service Information

Weight tables

6.4

WEIGHT TABLES

6.4.1

SUPERSTRUCTURE Part or assembly

Weight

Remark

Service crane (MKG) with beam

1900 kg

Electric motor

see rating plate on motor

Roof plate, PTO side

355 kg

Roof plate, cooling air outlet

483 kg

Roof plate, capacitor side

186 kg

Beam (Bridge)

285 kg

Capacitor assembly

125 kg

each

Battery

62 kg

each

Flexible coupling (Vulkan), housing ring

94 kg

each

Flexible coupling (Vulkan), coupling element

47 kg

each

362.4 kg

each

Main pump assembly with flanged gear pump Oil circulation pump (auxiliary pump)

25 kg

PTO (pump distributor gearbox)

1900 kg

each

Control and filter plate assembly

260 kg

each

Hydraulic cooler fan drive pump

40 kg

Hydraulic cooler fan assembly

117.4 kg

Hydraulic cooler fan

19 kg

Hydraulic cooler fan mounting assembly

72 kg

Hydraulic cooler fan motor assembly

26.4 kg

Hydraulic oil cooler

275 kg

Hydraulic oil cooler frame incl. hydraulic oil coolers

3950 kg

Pilot oil pump

27.4 kg

Main gate valve

12.3 kg

Hydraulic oil reservoir incl. back pressure valve

3465 kg

Main control valve block 1, incl. ACVs & SRVs

717 kg

Main control valve block 2, incl. ACVs & SRVs

726 kg

High pressure filter (main control block 2)

44.6 kg

Main control valve block 3, incl. ACVs & SRVs

713 kg

Main control valve block 4

143 kg

High pressure filter (main control block 4)

15 kg

Anti cavitation valve on main control block (ACV)

3 kg

Version 2010/1

PC5500-6E

each element

6 -7

Weight tables

Service Information

Part or assembly

Weight

Throttle check valve on main control block (SRV)

4 kg

Single anti cavitation valve on manifold

15 kg

Double anti cavitation valve on manifold

44.6 kg

Throttle check valve on manifold (long version)

31 kg

Throttle check valve on manifold (short version)

28 kg

Manifold incl. ACVs & SRVs (BHA)

921.2 kg

Manifold incl. ACVs & SRVs (FSA)

893.2 kg

Swing motor with attached slew service brake valve

292.5 kg

Slew brake valve

97 kg

Slew gear (Siebenhaar)

1700 kg

Slew gear (L&S)

1880 kg

Bearing ring of the slew parking brake (L&S)

32 kg

Slew parking brake assembly

115 kg

Swing circle

10,000 kg

Pinion cover

11.6 kg

Lubrication pinion assembly

18.2 kg

Double lubrication pump station

412 kg

Triple lubrication pump station

618 kg

Lubrication pump

28 kg

Operator's cab

3785 kg

Viscous mount

4 kg

Absorber plate incl. 2 viscous mounts

11.9 kg

Absorber plate incl. 3 viscous mounts

17.4 kg

Front window

112 kg

Operator's seat

62 kg

Cab base (medium voltage switch cabinet)

4000 kg

Support frame

987 kg

Emergency exit ladder

55.5 kg

Access ladder

167 kg

Access ladder cylinder

23 kg

Slip ring unit

355 kg 42,000 kg 46,000 kg

Counterweight

6 -8

Remark

PC5500-6E

(BHA) (FSA)

Version 2010/1

Service Information

Weight tables

Part or assembly

Weight

Superstructure incl. electric motors, without counterweight, attachment, and fluids

150,000 kg

High voltage switch cabinet

6200 kg

Platform on the side of the high voltage cabinet

150 kg

Version 2010/1

PC5500-6E

Remark

6 -9

Weight tables

6.4.2

Service Information

UNDERCARRIAGE Part or assembly

Weight

Track group 1350 mm

Remark

32.192 kg

Pin between track shoes (Track group 1350 mm)

19 kg

Track group 1800 mm

39.066 kg

Pin between track shoes (Track group 1800 mm)

20.2 kg

Sprocket

4382 kg

Hollow shaft

612 kg

Drive shaft

1007 kg

Segmented sprocket assembly (3 segments)

2250 kg

Sprocket segment 1 (5 teeth)

794.25 kg

Sprocket segment 2 (5 teeth)

794.25 kg

Sprocket segment 3 (4 teeth)

661.5 kg

Segmented sprocket assembly (3 segments, oversize)

2745 kg

Sprocket segment 1 (5 teeth, oversize)

968.99 kg

Sprocket segment 2 (5 teeth, oversize)

968.99 kg

Sprocket segment 3 (4 teeth, oversize)

807.02 kg

Guide wheel assembly

3323 kg

Low pressure accumulator

12 kg

High pressure accumulator

23 kg

Track tensioning valve block

40 kg

Hydraulic hoses of the track tensioning system

10 kg max

depending on type

Travel brake valve block

75 kg

each

Track tensioning cylinder

400 kg

each

Travel motor

110 kg

each

Travel parking brake

75 kg

each

Travel gearbox

4020 kg

Spur gear housing with mounted brake housing

580 kg

Support bearing cover

400 kg

Spindle with installed support bearing

278 kg

Planetary gear housing with mounted sprocket (oversize sprocket)

7250 kg (7750 kg)

Drive sprocket ring

244 kg

Carrier roller assembly (bolted connection)

205 kg

Carrier roller assembly (with mounting pins)

175 kg

6 - 10

PC5500-6E

Version 2010/1

Service Information

Weight tables

Part or assembly

Weight

Track roller assembly

Remark

654 kg

Car body without crawler carrier (with mounting pins)

42,000 kg

Crawler carrier assembly with mounting pins (without track group)

40,000 kg

Crawler carrier assembly (track width 1350 mm, with mounting pins)

70,000 kg

each

Crawler carrier assembly (track width 1800 mm, with mounting pins)

80,000 kg

each

Car body without crawler carrier (bolted connection)

46,000 kg

Crawler carrier assembly, bolted connection (without track group)

44,000 kg

Crawler carrier assembly (track width 1350 mm, bolted connection)

76,722 kg

each

Crawler carrier assembly (track width 1800 mm, with mounting pins)

83,646 kg

each

Rotary joint

261 kg

Cable drum assembly (without high voltage supply cable)

7500 kg

Cable supply assembly

640 kg

Version 2010/1

PC5500-6E

6 - 11

Weight tables

6.4.3

Service Information

BACKHOE ATTACHMENT (BHA) Part or assembly

Weight

Boom

Remark

45,100 kg

Pin boom/superstructure

365 kg

Pin boom cylinder/boom

177 kg

Pin boom cylinder/superstructure

224 kg

Boom cylinder

6500 kg

Stick

each

19,160 kg

Pin stick/boom

1440 kg

Nut-cap for pin stick/boom

48 kg

Stick cylinder

4600 kg

Pin stick cylinder/stick

127 kg

Pin stick cylinder/boom

179 kg

Bucket

each

30,600 kg

Pin bucket/stick

574 kg

Pin bucket/bucket link rod

822 kg

Nut-caps for pin bucket/stick and for pin bucket/bucket link rod

35 kg

each

3210 kg

each

Bucket cylinder Pin bucket cylinder/stick

86 kg

Pin bucket cylinder/steering rod

865 kg

Nut-caps for pin bucket cylinder/stick and for pin bucket cylinder/steering rod

35 kg

Rod protection cover

360 kg

Bucket link rod

2280 kg

Steering rod

1300 kg

Pin steering rod/stick

479 kg

Point (ESCO)

55 kg

Shroud (ESCO)

337 kg

Tooth adapter (ESCO)

182 kg

Boom arc hose

39 kg

each

Boom cylinder hoses

29.5 kg 39 kg

depending on length

Stick cylinder hoses

23 kg 27.5 kg

depending on length

Bucket cylinder hoses

33 kg

Metering valve

6 - 12

<25 kg

PC5500-6E

Version 2010/1

Service Information

6.4.4

Weight tables

FACE SHOVEL ATTACHMENT (FSA) Part or assembly

Boom with attached stick and boom cylinders

Weight

Remark

52,900 kg

boom without cylinders: 34,800 kg

Pin boom/superstructure

365 kg

Pin boom cylinder/boom

234 kg

Pin boom cylinder/superstructure

224 kg

Boom cylinder

5680 kg

Stick

21,000

Pin stick/boom

168 kg

Stick cylinder

3340 kg

Pin stick cylinder/stick

90 kg

Pin stick cylinder/boom

90 kg

Bucket

35,060 kg

Pin bucket cylinder/bucket

190 kg

Pin bucket/stick

318 kg

Bucket cylinder

4005 kg

Pin bucket cylinder/boom

168 kg

Clam cylinder

885 kg

Upper pin at clam cylinder

48 kg

Lower pin at clam cylinder

66 kg

Point (tooth) (ESCO)

55 kg

Shroud (ESCO)

270 kg

Tooth adapter (ESCO)

182 kg

Boom arc hose

39 kg

Boom cylinder hose

30.5 kg

Stick arc hose

29.5 kg

Stick cylinder hose

25 kg 27.4 kg

Bucket cylinder hose

28 kg

Clam cylinder hose at stick

28 kg

Clam cylinder hose at clam cylinder

8.8 kg 9.8 kg 10 kg 11.2 kg

Metering valve

<25 kg

Version 2010/1

PC5500-6E

depending on length

depending on length and type

6 - 13

Torque charts according to KOMATSU company standard

Service Information

6.5

TORQUE CHARTS ACCORDING TO KOMATSU COMPANY STANDARD

6.5.1

METRIC STANDARD THREAD

Bolt diameter

Wrench size [mm]

Tightening torque [Nm] Bolt quality grades

Metric regular 8.8

10.9

12.9

M 8

13

6

21

31

36

M 10

17

8

43

63

73

M 12

19

10

74

108

127

M 14

22

12

118

173

202

M 16

24

14

179

265

310

M 18

27

14

255

360

425

M 20

30

17

360

510

600

M 22

32

17

485

690

810

M 24

36

19

620

880

1030

M 27

41

19

920

1310

1530

M 30

46

22

1250

1770

2080

M 33

50

24

1690

2400

2800

M 36

55

27

2170

3100

3600

M 39

60

2800

4000

4700

M 42

65

3500

4950

5800

M 45

70

4350

6200

7200

M 48

75

5200

7500

8700

M 52

80

6700

9600

11200

M 56

85

8400

12000

14000

M 60

90

10400

14800

17400

M 64

95

12600

17900

20900

M 68

100

15200

21600

25500

32

35

41

46

NOTE: Threads and bolts must be greased carefully with grease KP2K. Contact surfaces which should be screwed together must be free of grease.

6 - 14

PC5500-6E

Version 2010/1

Service Information

6.5.2

Torque charts according to KOMATSU company standard

METRIC FINE THREAD

Bolt diameter

Wrench size [mm]

Tightening torque [Nm] Bolt quality grades

Metric fine

8.8

10.9

12.9

M 8 x 1.0

13

6

23

33

39

M 10 x 1.0

17

8

48

70

82

M 12 x 1.25

19

10

81

119

139

M 14x1.5

22

12

127

187

219

M 16 x 1.5

24

14

191

280

330

M 18 x 2.0

27

14

270

385

450

M 20 x 2.0

30

17

380

540

630

M 22 x 2.0

32

17

510

720

850

M 24 x 2.0

36

19

680

960

1130

M 27 x 2.0

41

19

990

1410

1650

M 30 x 2.0

46

22

1380

1960

2300

M 33 x 2.0

50

24

1850

2650

3100

M 36 x 3.0

55

27

2300

3250

3850

M 39 x 3.0

60

3000

4200

4950

M 42 x 3.0

65

3750

5300

6200

M 45 x 3.0

70

4600

6600

7700

M 48 x 3.0

75

5700

8100

9500

M 52 x 3.0

80

7300

10400

12100

M 56 x 4.0

85

8900

12600

14800

M 60 x 4.0

90

11000

15600

18300

M 64 x 4.0

95

13300

19000

22200

M 68 x 4.0

100

16100

22900

27000

32

35

41

46

NOTE: Threads and bolts must be greased carefully with grease KP2K. Contact surfaces which should be screwed together must be free of grease. CAUTION Bolts at the slew rings have different torques, refer to Service NEWS No. "AH00511" last edition!

Version 2010/1

PC5500-6E

6 - 15

Torque charts according to KOMATSU company standard

6.5.3

SAE FLANGE CONNECTIONS

Fig. 6-2

Torques for SAE flange connections

6 - 16

PC5500-6E

Service Information

Version 2010/1

Service Information

Torque charts according to KOMATSU company standard

This page was left blank intentionally.

Version 2010/1

PC5500-6E

6 - 17

Blind plugs

Service Information

6.6

BLIND PLUGS

6.6.1

DUMMY PLATES FOR SAE FLANGES

Fig. 6-3

Forms / types of dummy plates for SAE flanges Up to 3000 PSI

6 - 18

SAE size

Form / type according to Fig. 6-36-3

PN

DN (hose / pipe)

1/2"

A

506 521 98

12

3/4"

A

506 583 98

20

1 1/4"

A

506 584 98

32

1 1/2"

A

506 522 98

40

2"

A

506 523 98

50

2 1/2"

A

506 585 98

65

3"

A

512 570 98

80

3/4"

B

516 826 98

20

1 1/4

B

517 479 98

32

1 1/2"

B

506 528 98

40

2"

B

506 529 98

50

2 1/2"

B

506 530 98

65

3"

B

512 571 98

80

PC5500-6E

Version 2010/1

Service Information

Blind plugs

Up to 6000 PSI

SAE size

Form / type according to Fig. 6-36-3

PN

DN (hose / pipe)

3/4"

A

506 580 98

20

1"

A

506 519 98

25

1 1/4"

A

506 520 98

32

1 1/2"

A

506 581 98

40

2"

A

506 582 98

50

1"

B

506 524 98

25

1 1/4"

B

506 525 98

32

1 1/2"

B

506 526 98

40

2"

B

506 527 98

50

1 1/4"

C

516 499 98

32

1 1/2"

C

509 375 98

40

2"

C

509 376 98

50

Version 2010/1

PC5500-6E

6 - 19

Blind plugs

6.6.2

Service Information

CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH Heavy class (up to 6000 PSI)

Light class (up to 3000 PSI)

Size

Ra

DN

Ra

DN

M 12 x 1.5

-

-

6

5

M 14 x 1.5

-

-

8

6

M 16 x 1.5

8

5

10

8

M 18 x 1.5

10

6

12

10

M 20 x 1.5

12

8

-

-

M 22 x 1.5

14

10

15

12

M 24 x 1.5

16

12

-

-

M 26 x 1.5

-

-

18

16

M 30 x 1.5

-

-

-

-

M 30 x 2

20

16

22

20

M 36 x 2

25

20

28

25

M 38 x 1.5

-

-

-

-

M 42 x 2

30

25

-

-

M 45 x 1.5

-

-

-

-

M 45 x 2

-

-

35

32

M 52 x 1.5

-

-

-

-

M 52 x 2

38

32

42

40

M 65 x 2

-

-

-

-

Method of using the above table to find an appropriate plugs and fittings according to Table 6.6.3 on page 21: EXAMPLE: To cover up a hose / tube with a diameter of 25 mm, for a pressure up to 3000 PSI perform the following steps: z

Locate the 25 in the column "DN" in the category "up to 3000 PSI".

z

Check the digit in the column "Ra" next to DN 25 in the same row and category. For this example the proper plug and fitting is BUZ 28-L and ROV 28-L, refer to Table 6.6.3 on page 21.

NOTE: The column "Size" indicates the thread-size for the ROV-fittings.

6 - 20

PC5500-6E

Version 2010/1

Service Information

6.6.3

Blind plugs

PLUGS AND FITTINGS ACCORDING TO DIN 2353 / ISO 8434-1 Up to 3000 PSI BUZ (plugs)

PN

ROV (fittings)

PN

8-L

501 692 98

8-L

518 113 98

10-L

371 852 99

10-PL

513 789 98

12-L

371 854 99

12-PL

513 547 98

15-L

371 855 99

15-PL

507 051 98

18-L

371 856 99

18-PL

513 787 98

22-L

371 857 99

22-PL

513 788 98

28-L

371 858 99

28-PL

509 377 98

35-L

371 859 99

35-PL

516 770 98

42-L

371 860 99

42-PL

513 790 98

Up to 6000 PSI BUZ (plugs)

PN

ROV (fittings)

PN

-

-

8-PS

515 921 98

-

-

10-PS

507 023 98

-

-

12-PS

507 022 98

16-S

371 866 99

-

-

20-S

371 853 99

20-PS

512 005 98

25-S

371 867 99

25-PS

508 033 98

30-S

371 868 99

30-PS

507 021 98

38-S

371 869 99

38-PS

507 020 98

Version 2010/1

PC5500-6E

6 - 21

Conversion table

Service Information

6.7

CONVERSION TABLE

6.7.1

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE: Method of using the Conversion Table to convert from millimeters to inches. Convert 55 mm into inches: z

Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A).

z

Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).

z

Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches.

Convert 550 mm into inches: z

The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm.

z

Carry out the same procedure as above to convert 55 mm to 2.165 inches.

z

The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

6 - 22

PC5500-6E

Version 2010/1

Service Information

6.7.2

Conversion table

MILLIMETER - INCH & KILOGRAM - POUND

Version 2010/1

PC5500-6E

6 - 23

Conversion table

6.7.3

6 - 24

Service Information

LITER - U.S. GALLON & LITER - U.K. GALLON

PC5500-6E

Version 2010/1

Service Information

6.7.4 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

Conversion table

NM - FT.LB 0 0 7.37 14.74 22.11 29.48 36.85 44.22 51.59 58.96 66.33 73.70 81.07 88.44 95.81 103.18 110.55 117.92 125.29 132.66 140.03 147.40

1 0.74 8.11 15.48 22.85 30.22 37.59 44.96 52.33 59.07 67.07 74.44 81.81 89.18 96.55 103.92 111.29 118.66 126.03 133.40 140.77 148.14

2 1.47 8.84 16.21 23.58 30.95 38.32 45.69 53.06 60.43 67.80 75.17 82.54 89.91 97.28 104.65 112.02 119.39 126.76 134.13 141.50 148.87

3 2.21 9.58 16.95 24.32 31.69 39.06 46.43 53.08 61.17 68.54 75.91 83.28 90.65 98.02 105.39 112.76 120.13 127.50 134.87 142.24 149.61

4 2.95 10.32 17.69 25.06 32.43 39.80 47.17 54.54 61.91 69.28 76.65 84.02 91.39 98.76 106.13 113.50 120.87 128.24 135.61 142.98 150.35

5 3.69 11.06 18.43 25.80 33.17 40.54 47.91 55.28 62.65 70.02 77.39 84.76 92.13 99.50 106.87 114.24 121.61 128.98 136.35 143.72 151.09

6 4.42 11.79 19.16 26.53 33.90 41.27 48.64 56.01 63.38 70.75 78.12 85.49 92.86 100.23 107.60 114.97 122.34 129.71 137.08 144.45 151.82

7 5.16 12.53 19.90 27.27 34.64 42.01 49.38 56.75 64.12 71.49 78.86 86.23 93.60 100.97 108.34 115.71 123.08 130.45 137.82 145.19 152.56

8 5.90 13.27 20.64 28.01 35.38 42.75 50.12 57.49 64.86 72.23 79.60 86.97 94.34 101.71 109.08 116.45 123.82 131.19 138.56 145.93 153.30

9 6.63 14.00 21.37 28.74 36.11 43.48 50.85 58.22 65.59 72.96 80.33 87.70 95.07 102.44 109.81 117.18 124.55 131.92 139.29 146.66 154.03

1 Nm = 0,737 FT.LB

Version 2010/1

PC5500-6E

6 - 25

Conversion table

6.7.5

Service Information

BAR - PSI - KPA - MPA 1...200 Bar

205...400 Bar

Bar

PSI

kPa

MPa

Bar

PSI

kPa

MPa

1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200

14.5037 72.52 145.03 217.55 290.07 362.58 435.1 507.62 580.13 652.65 725.17 797.68 870.2 942.71 1015.23 1087.75 1160.26 1232.78 1305.3 1377.81 1450.33 1522.85 1595.36 1667.88 1740.4 1812.91 1885.43 1957.95 2030.46 2102.98 2175.5 2248.01 2320.53 2393.04 2465.56 2538.08 2610.59 2683.11 2755.63 2828.14 2900.66

100 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000 12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 18000 18500 19000 19500 20000

0.1 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13 13.5 14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19 19.5 20

205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350 355 360 365 370 375 380 385 390 395 400

2973.18 3045.69 3118.21 3190.73 3263.24 3335.76 3408.28 3480.79 3553.31 3625.83 3698.34 3770.86 3843.37 3915.89 3988.41 4060.92 4133.44 4205.96 4278.47 4350.99 4423.51 4496.02 4568.54 4641.06 4713.57 4786.09 4858.61 4931.12 5003.64 5076.16 5148.67 5221.19 5293.7 5366.22 5438.74 5511.25 5583.77 5656.29 5728.8 5801.32

20500 21000 21500 22000 22500 23000 23500 24000 24500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000 30500 31000 31500 32000 32500 33000 33500 34000 34500 35000 35500 36000 36500 37000 37500 38000 38500 39000 39500 40000

20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26 26.5 27 27.5 28 28.5 29 29.5 30 30.5 31 31.5 32 32.5 33 33.5 34 34.5 35 35.5 36 36.5 37 37.5 38 38.5 39 39.5 40

1 Bar = 14.5037 PSI

6 - 26

PC5500-6E

Version 2010/1

Service Information

6.7.6

Conversion table

BASIC VALUES IN OHM ACCORDING TO DIN 4376 / IEC 751

Conversion Table - Ohm to Centigrade of PT100 sensors °C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80.31

79.91

79.51

79.11

78.72

78.32

77.92

77.52

77.13

76.73

-40

84.27

83.88

83.48

83.08

82.69

82.29

81.89

81.50

81.10

80.70

-30

88.22

87.83

87.43

87.04

86.64

86.25

85.85

85.46

85.06

84.67

-20

92.16

91.77

91.37

90.98

90.59

90.19

89.80

89.40

89.01

88.62

-10

96.09

95.69

95.30

94.91

94.52

94.12

93.73

93.34

92.95

92.55

0

100.00

99.61

99.22

98.83

98.44

98.04

97.65

97.26

96.87

96.48

°C

0

1

2

3

4

5

6

7

8

9

0

100.00

100.39

100.78

101.17

101.56

101.95

102.34

102.73

103.12

103.51

10

103.90

104.29

104.68

105.07

105.46

105.85

106.24

106.63

107.02

107.40

20

107.79

108.18

108.57

108.96

109.35

109.73

110.12

110.51

110.90

111.28

30

111.67

112.06

112.45

112.83

113.22

113.61

113.99

114.38

114.77

115.15

40

115.54

115.93

116.31

116.70

117.08

117.47

117.85

118.24

118.62

119.01

50

119.40

119.78

120.16

120.55

120.93

121.32

121.70

122.09

122.47

122.86

60

123.24

123.62

124.01.

124.39

124.77

125.16

125.54

125.92

126.31

126.69

70

127.07

127.45

127.84

128.22

128.60

128.98

129.37

129.75

130.13

130.51

80

130.89

131.27

131.66

132.04

132.42

132.80

133.18

133.56

133.94

134.32

90

134.70

135.08

135.46

135.84

136.22

136.60

136.98

137.36

137.47

138.12

100

138.50

138.88

139.26

139.64

140.02

140.39

140.77

141.15

141.53

141.91

110

142.29

142.66

143.04

143.42

143.80

144.17

144.55

144.93

145.31

145.68

120

146.06

146.44

146.81

147.19

147.57

147.94

148.32

148.70

149.07

149.45

130

149.82

150.20

150.57

150.95

151.33

151.70

152.08

152.45

152.83

153.20

140

153.58

153.95

154.32

154.70

155.07

155.45

155.82

156.19

156.57

156.94

150

157.31

157.69

158.06

158.43

158.81

159.18

159.55

159.93

160.30

160.67

Version 2010/1

PC5500-6E

6 - 27

Conversion table

6.7.7

Service Information

TEMPERATURE

The figures in the table below refer to the temperature in either degree Fahrenheit or degree Celsius. If it is desired to convert from degree Fahrenheit to degree Celsius, consider the center column as a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left. If it is desired to convert from degree Celsius to degree Fahrenheit, consider the center column as a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.

6 - 28

PC5500-6E

Version 2010/1

Service Information

Tools

6.8

TOOLS

6.8.1

STANDARD TOOL CASE

Komatsu provides a standard tool case, PN 232 709 40. Q‘ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 2 1 1 1 1 1 2 2 1 1 1

Part name Measuring tape 3 m long Hammer 500 g Sliding caliper, 200 mm long Reamer (countersink, stem diameter 10 mm; reamer diameter 20 mm Socket wrench ½“ - set (WS 10 - 32) Internal hexagon socket, 1/2“ - set, (WS 5 - 17) Double ended open wrench - set (WS 6 - 32) Combination wrenches - set (WS 10 - 32) Twist drill - set (1 - 13 mm) Needle files - set Tool bag Toolbox L= 460; B= 170; L= 310 Socket wrench ¼“ - set (WS 3 - 13) Drift punch 3 - 8 mm Socket wrench with ball head - set (1.5 - 10 mm) Side cutter insulated up to 1000 Volt, 190 mm Combination pliers insulated up to 1000 Volt, 185 mm Bent nose pliers, Knipex Water pump pliers 250 mm long Cable stripping knife 4 - 16 mm Screwdriver for slotted screws 11 x 300 mm Screwdriver for slotted screws 13 x 390 mm Crosstip screwdriver size 0 Crosstip screwdriver size 1 Crosstip screwdriver size 2 Infrared thermometer IR 1 LCD-Digital Multimeter VC 444 VDE Screwdriver, WERA Hydraulic mini testing kit Pressure gauge 400 bar Measuring hose 2.5 m Pressure gauge fitting G¼ Set – Screwdriver Side cutting pliers, Knipex Stripping- and cutting tool Stripax for PVC-isolation up to 6 mm², 20 mm Crimp pliers, rimp capacity 0.5 - 4 mm² Crimp pliers HTN 21 Testing wire 4mm Type 410 (red) Testing wire 4mm Type 410 (black) Testing tip "Hirschmann Prüf 2" (red) Testing tip "Hirschmann Prüf 2" (black) Clip terminal "Hirschmann Ak 2 S" (red)

Version 2010/1

PC5500-6E

Part number 470 615 40 232 130 40 232 107 40 232 690 40 232 691 40 232 570 40 232 692 40 232 693 40 232 207 40 232 199 40 232 694 40 232 695 40 232 696 40 232 697 40 232 698 40 232 401 40 232 400 40 232 403 40 232 139 40 232 699 40 232 120 40 232 121 40 232 111 40 232 112 40 232 113 40 232 665 40 232 688 40 232 689 40 232 591 40 793 363 73 896 483 40 232 501 40 907 696 40 232 700 40 232 663 40 232 661 40 232 701 40 232 702 40 232 703 40 232 704 40 232 705 40 232 706 40

6 - 29

Tools

Service Information

Q‘ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Part name Clip terminal "Hirschmann Ak 2 S" (black) Fluke 179 Digital-Multimeter Rollbox K 412 (740 x 365 x 375) Tachometer Moviport Magnet-stick Electric set with pliers Software (Bodem 24) Bodem connection cable Crimp-pliers for revolved contacts Cable set Prostat Cable VL 3 (X27 -PC) Prosyd Cable VL 12 (PLC-PC) TazETM Cable VL 10 (ETM-PC) Cable VL 9a Cable VL 9b PC4000-6 VHMS download-cable (new for 08156 and up) Converter, cable, and software as set Converter USB extension wire UMG diagnostic software (CD)

6 - 30

PC5500-6E

Part number 232 707 40 232 708 40 232 711 40 232 551 40 232 712 40 793 265 73 796 726 73 896 791 40 793 729 73 796 443 73 659 820 40 926 503 40 891 175 40 891 176 40 891 177 40 894 580 40 796 442 73 796 439 73 796 440 73 796 441 73

Version 2010/1

Service Information

6.8.2

Tools

USED SPECIAL TOOLS (OVERVIEW)

Component

Part number

Part name

Q‘ty

PN 232 386 40

Universal grounding short-circuting device

1

PN 232 390 40

Measuring rod 3...6 kV

PN 232 389 40

Measuring rod 5...10 kV

PN 232 519 40

55 mm hexagon impact socket wrench (1 1/2")

1

PN 232 615 40

Hydraulic torque wrench

1

PN 793 375 73

Electro-hydraulic pump aggregate

1

PN 376 792 40

Measuring jaw

1

PN 409 437 40

Measuring bolt

8

PN 409 484 40

Measuring bolt (cold weather)

8

PN 379 077 40

Test block

1

PN 477 577 40

Mounting cross

1

PN 232 519 40

55 mm hexagon impact socket wrench (1 1/2")

1

PN 232 615 40

Hydraulic torque wrench

1

PN 793 375 73

Electro-hydraulic pump aggregate

1

PN 921 149 40

Safety unit for changing track rollers

1

Removal and installation of the track rollers and guide wheel assembly

PN ??? (P&S-news under development)

Tool for changing track rollers

1

Removal and installation of the track rollers

PN 761 520 73

Testing- and refilling device

1

Refilling pressure accumulators

High voltage switch cabinet

Swing circle mounting

Nature of work, remarks

Grounding procedure

Removal and installation of the high voltage switch cabinet

Installation of the swing circle. Assembly of superstructure onto undercarriage

Track rollers

Pressure accumulators of the track tensioning system

Version 2010/1

PC5500-6E

6 - 31

Tools

Service Information

Component

Part number

Part name

Q‘ty

Nature of work, remarks

PN 409 329 40

Thread protector

1

Removal and installation of the bucket BHA Removal and installation of the bucket cylinders BHA Removal and installation of the steering rods BHA Removal and installation of the stick BHA

PN 909 374 40

Installation tool

1

Removal and installation of the bucket cylinders FSA

PN 923 828 40

Installation tool

1

Removal and installation of the stick cylinders FSA

PN 934 611 40

Installation tool

1

Removal and installation of the boom cylinders FSA

GET

PN 793 502 73

POSILOK pin removal tool

1

Removal and installation of the GET

Hydraulic system (general)

PN 232 591 40

Hydraulic testing kit

1

Measurement of hydraulic pressures

PN 793 788 73

Rotational speed infrared probe DS03

1

Measurement of fan speed

PN 232 805 40

75 mm hexagon impact socket wrench (1 1/2")

1

PN 793 374 73

Hydraulic torque wrench

1

PN 793 375 73

Electro-hydraulic pump aggregate

1

PN 232 519 40

55 mm hexagon impact socket wrench (1 1/2")

1

PN 232 615 40

Hydraulic torque wrench

1

PN 793 375 73

Electro-hydraulic pump aggregate

1

PN 232 519 40

55 mm hexagon impact socket wrench (1 1/2")

1

PN 232 615 40

Hydraulic torque wrench

1

PN 793 375 73

Electro-hydraulic pump aggregate

1

Attachment

Hydraulic cooler fan drive pump Hydraulic cooler fan assembly

Counterweight

Superstructure

Medium voltage cabinet (cab base)

6 - 32

PC5500-6E

Removal and installation of the counterweight

Removal and installation of the superstructure

Removal and installation of the medium voltage cabinet (cab base)

Version 2010/1

Service Information

Component

Tools

Part number

Part name

Q‘ty

PN 793 374 73

Hydraulic torque wrench

1

PN 793 376 73

Wrench socket with supporting bar

1

PN 793 375 73

Electro-hydraulic pump aggregate

1

PN 928 476 40

Measuring device (kit)

1

Installation of the crawler carriers

Locally made (refer to PARTS & SERVICE NEWS No. "AH05511")

Assembly tool for dual-cone seals

1

Installation of new dual-cone seals

PN 232 519 40

55 mm hexagon impact socket wrench (1 1/2")

1

PN 232 615 40

Hydraulic torque wrench

1

PN 793 375 73

Electro-hydraulic pump aggregate

1

PN 232 614 40

Hydraulic torque wrench

1

PN 232 265 40

46 mm hexagon impact socket wrench (1")

1

PN 232 615 40

Hydraulic torque wrench

1

PN 793 375 73

Electro-hydraulic pump aggregate

1

PN 232 519 40

55 mm hexagon impact socket wrench (1 1/2")

1

PN 232 614 40

Hydraulic torque wrench

1

PN 232 265 40

46 mm hexagon impact socket wrench (1")

Car body/crawler carrier

Sprocket

Travel gearbox

Version 2010/1

PC5500-6E

Nature of work, remarks

Removal and installation of the car body/crawler carrier

Installation and removal of the segmented sprocket (up to Sn 025)

Installation and removal of the sprocket

Installation and removal of travel gearbox and sprocket

Installation and removal of the travel gearbox (up to Sn 025) 1

6 - 33

Tools

Service Information

This page was left blank intentionally.

6 - 34

PC5500-6E

Version 2010/1

Tools catalogue

7 TOOLS CATALOGUE

Version 2010/1

PC5500-6E

7 -1

Tools catalogue

7 -2

PC5500-6E

Version 2010/1

Tools and Accessories

th

Release: May 19 , 2010

Contents

Page No.

Section 1

Assembly Tools for Screws and Nuts

3

Section 2

Power Tools

11

Section 3

Pliers

15

Section 4

Metal Working Tools

18

Section 5

Measuring Tools

21

Section 6

Data Transfer and IT Tools

28

Section 7

Repair Sets for Wiring & Connectors

30

Section 8

Repair Sets for Hydraulic Cylinders & Line Fittings

32

Section 9

Others

33

Section 10

Paint and Accessories

37

Section 11

Auxiliaries, Cleaner, Adhesive & Sealant

38

Part-No.

Description

Release:

th

May 19 , 2010

Combination wrenches, single [mm] 232 001 40 232 002 40 232 003 40 232 004 40 232 005 40 232 006 40 232 007 40 232 008 40 232 009 40 232 010 40 232 011 40 232 012 40 323 013 40 232 014 40 232 015 40 232 016 40 232 017 40 232 018 40 232 019 40 232 557 40

A/F 6 A/F 7 A/F 8 A/F 9 A/F 10 A/F 11 A/F 12 A/F 13 A/F 14 A/F 15 A/F 17 A/F 19 A/F 22 A/F 24 A/F 27 A/F 30 A/F 32 A/F 36 A/F 41 A/F 46

232 693 40

Combination wrenches, set A/F 10 - 32 [mm] Combination wrenches, single [inch]

232 432 40 232 433 40 232 434 40 232 435 40 232 436 40 232 437 40 232 438 40 232 439 40 232 440 40 232 441 40 232 442 40 232 443 40 232 444 40 232 445 40 232 446 40 232 447 40

A/F 1/4" A/F 5/16" A/F 3/8" A/F 7/16" A/F 1/2" A/F 9/16" A/F 5/8" A/F 11/16" A/F 3/4" A/F 13/16" A/F 7/8" A/F 15/16" A/F 1" A/F 11/16" A/F 11/8" A/F 11/4"

Special ring wrench - open [mm] 232 305 40 232 306 40 232 307 40 232 308 40

A/F 41 A/F 46 A/F 50 A/F 60

A/F = width Across Flats/wrench size

991-1010 Section 1

Tools Assembly Tools for Screws and Nuts

Page

3

Part-No.

Description

Release:

th

May 19 , 2010

Double ended open wrenches, single [mm] 232 020 40 232 021 40 232 022 40 232 023 40 232 024 40 232 025 40 232 026 40 232 027 40 232 028 40 232 029 40 232 030 40 232 031 40 232 032 40 232 033 40

A/F 6 x 7 A/F 8 x 9 A/F 10 x 11 A/F 12 x 13 A/F 14 x 15 A/F 16 x 17 A/F 18 x 19 A/F 20 x 22 A/F 21 x 23 A/F 24 x 27 A/F 25 x 28 A/F 30 x 32 A/F 36 x 41 A/F 50 x 55 Single ended open wrenches, single [mm]

232 361 40 232 211 40 232 212 40 232 213 40 232 214 40 232 215 40 232 362 40 232 216 40 232 363 40 232 217 40

A/F 41 A/F 46 A/F 50 A/F 55 A/F 60 A/F 65 A/F 70 A/F 75 A/F 80 A/F 85 Hook wrenches, single

232 275 40 232 276 40 232 277 40 232 278 40 232 279 40 232 280 40

120 - 130 mm Ø 155 - 165 mm Ø 180 - 195 mm Ø 205 - 220 mm Ø 260 - 270 mm Ø 280 - 300 mm Ø Push-pull ratchet

232 337 40 232 047 40 232 562 40 232 563 40

1/4" 1/2" 3/4" 1" Reversible ratchet

232 380 40 232 218 40

3/4" x 620 mm (24") 1" x 660 mm (26") Sliding & tommy bar

232 339 40 232 050 40 232 303 40 232 219 40

1/4" 1/2" x 290 mm (11") 3/4" x 500 mm (20") 1" x 640 mm (25")

A/F = width Across Flats/wrench size

991-1010 Section 1

Tools Assembly Tools for Screws and Nuts

Page

4

Part-No.

Description

Release:

th

May 19 , 2010

Torque wrench 232 262 40 232 285 40 232 477 40 232 478 40

70 - 320 Nm 300 - 750 Nm 500 - 1300 Nm 800 - 2000 Nm

232 379 40 232 304 40 232 220 40 232 221 40

3/4" x 200 mm (8") 3/4" x 430 mm (17") 1" x 250 mm (10") 1" x 405 mm (16")

232 285 40

Torque wrench with scale DSG-5S, measuring range: 300 - 750 Nm

232 681 40

Elbow socket, 28/5 - 3/4" x 70 mm

232 477 40

Torque wrench with scale DSG-6S, measuring range: 500 - 1300 Nm

232 682 40

Elbow socket, 28/6 - 7; 1" x 70 mm

232 478 40

Torque wrench with scale DSG-7S measuring range: 800 - 2000 Nm

232 682 40

Elbow socket, 28/6 - 7; 1" x 70 mm Socket wrench 1/4", single [mm]

232 326 40 232 327 40 232 328 40 232 329 40 232 330 40 232 331 40 232 332 40 232 333 40 232 334 40 232 335 40 232 336 40

A/F 4 A/F 4,5 A/F 5 A/F 5,5 A/F 6 A/F 7 A/F 8 A/F 9 A/F 10 A/F 11 A/F 13 Socket wrench, 1/2", single [mm]

232 034 40 232 035 40 232 036 40 232 037 40 232 038 40 232 039 40 232 040 40 232 041 40 232 042 40 232 340 40 232 043 40 232 044 40 232 045 40 232 046 40

A/F 9 A/F 10 A/F 11 A/F 12 A/F 13 A/F 14 A/F 15 A/F 17 A/F 19 A/F 21 A/F 24 A/F 27 A/F 30 A/F 32

A/F = width Across Flats/wrench size

991-1010 Section 1

Tools Assembly Tools for Screws and Nuts

Page

5

Part-No.

Description

Release:

th

May 19 , 2010

Socket wrench, 1/2", single [inch] 232 448 40 232 449 40 232 450 40 232 451 40 232 452 40 232 453 40 232 454 40 232 455 40 232 456 40 232 457 40 232 458 40 232 459 40 232 460 40 232 461 40 232 462 40 232 463 40 232 464 40 232 465 40

A/F 3/8" A/F 13/32" A/F 7/16" A/F 1/2" A/F 9/16" A/F 19/32" A/F 5/8" A/F 11/16" A/F 3/4" A/F 25/32" A/F 13/16" A/F 7/8" A/F 15/16" A/F 1" A/F 1 1/16" A/F 1 1/8" A/F 1 3/16" A/F 1 1/4" Socket wrench, 3/4", single [mm]

232 369 40 232 370 40 232 371 40 232 372 40 232 373 40 232 374 40 232 375 40 232 376 40 232 377 40 232 378 40

A/F 22 A/F 24 A/F 27 A/F 30 A/F 32 A/F 36 A/F 38 A/F 41 A/F 46 A/F 50 Socket wrench, 1", single [mm]

232 223 40 232 224 40 232 225 40 232 226 40 232 227 40 232 228 40 232 229 40 232 230 40 232 231 40 232 232 40

A/F 36 A/F 41 A/F 46 A/F 50 A/F 55 A/F 60 A/F 65 A/F 70 A/F 75 A/F 80 Impact socket wrench, 1", single [mm]

232 264 40 232 515 40 232 516 40 232 265 40 232 266 40 232 267 40 232 494 40 232 268 40

A/F 36 A/F 38 A/F 41 A/F 46 A/F 50 A/F 55 A/F 60 A/F 65

A/F = width Across Flats/wrench size

991-1010 Section 1

Tools Assembly Tools for Screws and Nuts

Page

6

Part-No.

Description

Release:

th

May 19 , 2010

Impact socket wrench, 1 ½" [mm] 232 517 40 232 518 40 232 519 40 232 520 40 232 521 40

A/F 46 A/F 50 A/F 55 A/F 60 A/F 65 Impact internal hexagon socket, 1", single [mm]

232 765 40 232 766 40 232 767 40 232 768 40 232 769 40 232 770 40

A/F 19 A/F 22 A/F 24 A/F 27 A/F 32 A/F 36

232 569 40

Extra deep socket wrench for grease nipple of grease cylinder 1/2", long, A/F 27 mm Internal hexagon socket, 1/2", single [mm]

232 052 40 232 053 40 232 054 40 232 055 40 232 056 40 232 057 40 232 058 40 232 059 40 232 060 40

A/F 5 A/F 6 A/F 7 A/F 8 A/F 9 A/F 10 A/F 12 A/F 14 A/F 17 Internal hexagon socket, 1/2", single [inch]

232 423 40 232 424 40 232 425 40 232 426 40 232 427 40 232 428 40 232 429 40 232 430 40 232 431 40

A/F 3/16" A/F 7/32" A/F 1/4" A/F 9/32" A/F 5/16" A/F 3/8" A/F 1/2" A/F 9/16" A/F 5/8" Internal hexagon socket, 1/2", single

232 341 40 232 342 40 232 343 40 232 344 40 232 345 40 232 346 40

A/F 5 x 180 mm A/F 6 x 90 mm A/F 8 x 120 mm A/F 10 x 140 mm A/F 12 x 140 mm A/F 14 x 140 mm Internal hexagon socket, 3/4" [mm]

232 347 40 232 348 40 232 349 40 232 350 40

A/F 14 A/F 17 A/F 19 A/F 22

A/F = width Across Flats/wrench size

991-1010 Section 1

Tools Assembly Tools for Screws and Nuts

Page

7

Part-No.

Description

Release:

th

May 19 , 2010

Internal hexagon socket, 1" [mm] 232 351 40 232 352 40 232 353 40

A/F 19 A/F 22 A/F 24 Internal Torx socket [mm]

232 597 40 232 598 40 232 599 40 232 600 40 232 601 40 232 602 40 232 603 40

A/F 4 - 5 A/F 4.5 - 5 A/F 4.5 - 5 - 6 A/F 6 - 7 A/F 7 - 8 A/F 8 - 10 A/F 10 External Torx socket [mm]

232 604 40 232 605 40 232 606 40 232 607 40 232 608 40 232 609 40 232 610 40

A/F 4 A/F 5 A/F 6 A/F 6 - 7 A/F 8 A/F 10 A/F 12 Universal joint

232 051 40

1/2" Reducing socket

232 573 40 232 096 40 232 574 40

1" - 3/4" 3/4" - 1/2" 1 1/2" - 1" Expansion socket

232 575 40 232 576 40 232 577 40

1/2" - 3/4" 3/4" - 1" 1" - 1 1/2"

232 511 40

Torque multiplier max. 2700 Nm (2000 lbf-ft) 3/4" drive Reduction 1 : 5

232 208 40

Screw extractor kit with spiral drills to remove damaged or broken screws

A/F = width Across Flats/wrench size

991-1010 Section 1

Tools Assembly Tools for Screws and Nuts

Page

8

Part-No.

Description

Release:

th

May 19 , 2010

Screwdriver for slotted screws 232 120 40 232 121 40

11 x 300 mm 13 x 390 mm Screwdriver, insulated up to 1000 Volt

232 391 40 232 764 40 232 392 40 232 393 40 232 394 40 232 395 40

2.5 x 75 mm 3.0 x 100 mm 3.5 x 100 mm 4.0 x 100 mm 5.5 x 125 mm 6.5 x 150 mm Crosstip screwdriver, insulated up to 1000 Volt

232 397 40 232 398 40 232 399 40

size 0 size 1 size 2 Allen head wrench "L" type, single [mm]

232 066 40 232 067 40 232 068 40 232 069 40 232 070 40 232 071 40 232 072 40 232 073 40 232 074 40 232 075 40 232 076 40 232 077 40 232 078 40 232 079 40 232 080 40 232 081 40 232 082 40 232 354 40 232 355 40 232 356 40

A/F 2 A/F 2.5 A/F 3 A/F 4 A/F 5 A/F 6 A/F 7 A/F 8 A/F 9 A/F 10 A/F 12 A/F 14 A/F 17 A/F 19 A/F 22 A/F 24 A/F 27 A/F 30 A/F 32 A/F 36 Allen head wrench "L" type [inch]

232 414 40 232 415 40 232 416 40 232 417 40 232 418 40 232 419 40 232 420 40 232 421 40 232 422 40

A/F 3/16" A/F 7/32" A/F 1/4" A/F 5/16" A/F 3/8" A/F 1/2" A/F 9/16" A/F 5/8" A/F 3/4"

A/F = width Across Flats/wrench size

991-1010 Section 1

Tools Assembly Tools for Screws and Nuts

Page

9

Part-No.

Description

Release:

th

May 19 , 2010

Allen head wrench "L" type, with spherical head [mm] 232 582 40 232 583 40 232 584 40 232 585 40 232 586 40 232 587 40 232 588 40 232 589 40

A/F 2 A/F 3 A/F 4 A/F 5 A/F 6 A/F 8 A/F 10 A/F 12

232 698 40

Allen head wrenches "L" type, with spherical head, set 1.5 - 10 mm

A/F = width Across Flats/wrench size

991-1010 Section 1

Tools Assembly Tools for Screws and Nuts

Page

10

Part-No.

Description

Release: 232 611 40

th

May 17 , 2010

High-power pneumatic drive wrench, 900 - 4,200 Nm 1'' drive including reaction arm (long type), torque adjustment and service unit, pneumatic hose 6 m, torque certificate, and silencer

232 612 40

High-power pneumatic drive wrench, 1,500 - 7,100 Nm 1 ½'' drive including reaction arm (long type), torque adjustment and service unit, pneumatic hose 6 m, torque certificate, and silencer

232 614 40

High-power hydraulic drive wrench, 390 - 3,934 Nm 1'' drive incl. reaction arm

232 615 40

High-power hydraulic drive wrench, 741 - 7,402 Nm 1 ½'' drive incl. reaction arm

793 374 73

High-power hydraulic drive wrench, 1,049 - 10,671 Nm, required for track frame assembly* 1 ½'' drive incl. reaction arm * For mounting of track frames the supplemental extended reaction arm 793 376 73 is required

232 759 40

High-power hydraulic drive wrench & aggregate, set Torque range 390 - 3,934 Nm The set contains: • High-power hydraulic drive wrench (232 614 40) 1'' drive incl. reaction arm • High pressure hydraulic aggregate (793 375 73) Supply voltage 230 V 3-stages-delivery Setting range up to 700 bar incl. digital manometer, oil, and 5 m remote control incl. safety couplings • High pressure twin-hose NS 6 x 5 m (795 923 73) Welded Burst pressure 2,800 bar • Transportation box (232 719 40)

991-1010 Tools

Power Tools

Section 2 Page

11

Part-No.

Description

Release: 232 758 40

th

May 17 , 2010

High-power hydraulic drive wrench & aggregate, set Torque range 741 - 7,402 Nm The set contains: • High-power hydraulic drive wrench (232 615 40) 1 ½'' drive incl. reaction arm • High pressure hydraulic aggregate (793 375 73) Supply voltage 230 V 3-stages-delivery Setting range up to 700 bar incl. digital manometer, oil, and 5 m remote control incl. safety couplings • High pressure twin-hose NS 6 x 5 m (795 923 73) Welded Burst pressure 2,800 bar • Transportation box (232 719 40)

232 757 40

High-power hydraulic drive wrench & aggregate, set Torque range 1,049 - 10,671 Nm For mounting crawler carriers The set contains: • High-power hydraulic drive wrench (793 374 73) 1 ½'' drive incl. reaction arm • High pressure hydraulic aggregate (793 375 73) Supply voltage 230 V 3-stages-delivery Setting range up to 700 bar incl. digital manometer, oil, and 5 m remote control incl. safety couplings • High pressure twin-hose NS 6 x 5 m (795 923 73) Welded Burst pressure 2,800 bar • Torque wrench accessory Extended reaction arm with tool drive unit M48 suitable for torque wrench 793 374 73, for bolts with resilient sleeve • Transportation box (232 719 40)

991-1010 Tools

Power Tools

Section 2 Page

12

Part-No.

Description

Release: 232 718 40

Electro-hydraulic pump set, assy

793 375 73

Electro-hydraulic pump

232 719 40

Transportation box

793 376 73

Extended reaction arm for crawler carrier mounting

th

May 17 , 2010

(in combination with high-power hydraulic torque wrench 793 374 73)

795 923 73

High pressure hose DN6 x 5000 Adapted for high-power hydraulic torque wrenches: 232 614 40 • 232 615 40 • 793 374 73

232 749 40

Reaction arm, for high-power hydraulic drive wrenches Spare part - adapted for high-power hydraulic torque wrenches: 232 614 40 • 232 615 40 • 793 374 73

232 750 40

Fixing screw for the reaction arm Spare part - adapted for the reaction arm 232 749 40

991-1010 Tools

Power Tools

Section 2 Page

13

Part-No.

Description

Release: 232 666 40

th

May 17 , 2010

Pneumatic impact wrench 7000 1/min ½'' drive Torque max. 350 Nm Bolt ø max. M 18

232 667 40

Pneumatic impact wrench 4500 1/min ¾'' drive Torque max. 900 Nm Bolt ø max. M 27

793 828 73

Cordless impact wrench Torque up to 150 Nm ½" drive including exchange accumulator 14.4 V 3.3 Ah in a tool case

Pin-driving press, complete set for crawler chassis 232 313 40

100 t - for all excavators up to H 121

232 381 40

150 t - for all excavators up to H 185

232 717 40

Stud welding unit for threaded pins, with welding gun

991-1010 Tools

Power Tools

Section 2 Page

14

Part-No.

Description

Release: 232 139 40

Water pump pliers, 250 mm long

232 140 40

Grip pliers, 250 mm long

232 141 40

Stork beak pliers, 200 mm long, straight

232 142 40

Telephone pliers, 200 mm long, bent jaws

232 143 40

Wire strippers, 160 mm long

232 401 40

Side cutter, insulated up to 1000 Volt, 190 mm

232 400 40

Combination pliers, insulated up to 1000 Volt, 185 mm

232 147 40

Pipe wrenches, angled jaws, with adjusting nut, 350 mm long

232 404 40

Flat nose pliers, insulated up to 1000 Volt, 185 mm

232 405 40

Round nose pliers, insulated up to 1000 Volt, 185 mm

th

May 17 , 2010

991-1010 Tools

Pliers

Section 3 Page

15

Part-No.

Description

Release:

th

May 17 , 2010

Circlip pliers, straight, for external circlips 232 150 40 232 151 40 232 152 40

19 - 60 mm Ø 40 - 100 mm Ø 85 - 140 mm Ø Circlip pliers, 90°, for external circlips

232 156 40 232 157 40 232 158 40

19 - 60 mm Ø 40 - 100 mm Ø 85 - 140 mm Ø Circlip pliers, straight, for internal circlips

232 159 40 232 160 40 232 161 40

19 - 60 mm Ø 30 - 100 mm Ø 85 - 130 mm Ø Circlip pliers, angled, for internal circlips

232 153 40 232 154 40 232 155 40

19 - 60 mm Ø 31 - 100 mm Ø 85 - 140 mm Ø

232 281 40

Circlip pliers, straight, for external circlips 122 - 300 mm Ø

232 282 40

Circlip pliers, angled, for external circlips 122 - 300 mm Ø

232 283 40

Circlip pliers, straight, for internal circlips 122 - 300 mm Ø

232 284 40

Circlip pliers, angled, for internal circlips 122 - 300 mm Ø

991-1010 Tools

Pliers

Section 3 Page

16

Part-No.

Description

Release: 232 663 40

th

May 17 , 2010

Stripping and cutting tool Stripax for PVC-isolation up to 6 mm², 20 mm

793 729 73

Crimp pliers for Deutsch connectors Crimp range: 0.35 - 3.0 mm² 12 - 22 AWG

232 662 40

Crimp pliers set for wire end sleeves Crimp range 0.5 - 4.0 mm²

232 661 40

Crimp pliers Crimp range 0.5 - 4.0 mm²

232 209 40

Crimp pliers, elbow-lever action with quick-release lever - Self-grip crimping pliers for crimping and clamping connectors conforming to DIN and VG standards in a single operation 2

For crimping cable lugs 0.5 - 1.0 / 1.5 - 2.5 / 4 - 6 [mm ]

991-1010 Tools

Pliers

Section 3 Page

17

Part-No.

Description

Release:

th

May 17 , 2010

Hammer 232 129 40 232 130 40 232 131 40

300 g 500 g 1000 g

232 310 40

Sledge hammer, 5 kg

232 579 40

Plastic hammer, 450 g

Flat chisel 232 135 40 232 136 40

16 x 165 mm 19 x 180 mm

232 137 40

Cape chisel, 6 x 165 mm

232 138 40

Center punch, 4 x 130 mm Drift punch

232 132 40 232 133 40 232 134 40

5 x 150 mm 6 x 160 mm 8 x 180 mm Cotter pin drive

232 099 40 232 100 40 232 101 40 232 102 40 232 103 40 232 104 40

3 mm Ø 4 mm Ø 5 mm Ø 6 mm Ø 8 mm Ø 10 mm Ø

232 122 40

Hack saw with blade

232 123 40

Three square scraper (hollow), 250 mm long

232 124 40

Flat scraper, 250 mm long

991-1010 Tools

Metal Working Tools

Section 4 Page

18

Part-No.

Description

Release:

th

May 17 , 2010

Adjustable tap wrench for taps 232 164 40 232 165 40 232 235 40

M 1 - 10 M 10 - 27 M 20 - 42 Tap

232 166 40 232 167 40 232 168 40 232 169 40 232 170 40 232 171 40 232 172 40 232 173 40 232 174 40 232 357 40 232 175 40 232 240 40 232 241 40 232 242 40 232 243 40

M 3 M 4 M 5 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 24 M 30 M 36 M 42 Tap

232 244 40 232 245 40 232 246 40 232 247 40 232 248 40

M 8x1 M 10 x 1 M 14 x 1.5 M 20 x 1.5 M 24 x 1.5

232 236 40 232 237 40 232 238 40 232 239 40

R 1/8" R 3/8" R 1/4" R 1/2" Thread restorer

232 162 40 232 163 40

Whitworth Metric

991-1010 Tools

Metal Working Tools

Section 4 Page

19

Part-No.

Description

Release:

th

May 17 , 2010

Holder for threading dies 232 176 40 232 177 40 232 178 40 232 179 40 232 180 40 232 359 40 232 249 40 232 250 40 232 364 40 232 365 40 232 358 40

M 3/M4 M 5/M6 M 8/M8x1 M 10 / M 10 x 1 M 12 / M 14 M 16 / M 18 / M 20 M 24 M 30 / M 36 M 14 x 1.5 / R 1/8" / R 1/4" M 24 x M 1.5 R 3/8" / R 1/2"

20 x 5 mm 20 x 7 mm 25 x 9 mm 30 x 11 mm 38 x 14 mm 45 x 18 mm 55 x 22 mm 65 x 25 mm 38 x 10 mm 55 x 16 mm 45 x 14 mm

Threading die 232 181 40 232 182 40 232 183 40 232 184 40 232 185 40 232 186 40 232 187 40 232 188 40 232 189 40 232 360 40 232 190 40 232 261 40 232 260 40 232 259 40 232 255 40 232 256 40 232 257 40 232 258 40

M 3 M 4 M 5 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 24 M 30 M 36 M 8x1 M 10 x 1 M 14 x 1.5 M 24 x 1.5

232 251 40 232 252 40 232 253 40 232 254 40

R 1/8" R 1/4" R 3/8" R 1/2"

991-1010 Tools

Metal Working Tools

Section 4 Page

20

Part-No.

Description

Release: 232 194 40

Inside caliper, 200 mm long

232 195 40

Outside caliper, 200 mm long

232 107 40

Sliding caliper, 200 mm long

232 108 40

Measuring tape, 2000 mm long

232 590 40

Metal rule, 1000 mm long

232 109 40

Feeler gauge set

232 110 40

Thread gauge, metric & whitworth

232 668 40

Micrometer gauge, measuring range: 0 - 150 mm

232 669 40

Micrometer gauge, measuring range: 150 - 300 mm

232 591 40

Hydraulic testing kit, consisting of:

th

May 17 , 2010

1 pressure gauge 0 - 25 bar 1 pressure gauge 0 - 60 bar 2 pressure gauges 0 - 400 bar 2 instrument hoses 3 m each 1 hose 5 m and diverse adapters

79453773

Digital dial gauge, 0 - 12.5 mm

232 673 40

Magnetic articulated stand, 390 mm, 60 x 50 x 55 mm

991-1010 Tools

Measuring tools

Section 5 Page

21

Part-No.

Description

Release: 232 720 40

th

May 17 , 2010

Digital pressure manometer SPG-DIGI Measuring units: mbar, bar, PSI, kPa, MPa MIN/MAX or 'End of Range Value' display Display with backlight Zero correction Batteries: 2x 1.5 V DC AA (LR6-AA) Alkaline Mignon Battery condition displayed

232 708 40

Digital Multimeter Fluke 179 True-RMS-DMM Features: • True-RMS for precise measurement of non linear signals • 0,09% basic accuracy • 6000 count resolution • Large, easy-to-read display with analog bargraph and backlight for work in dimly lit areas • Manual and automatic ranging • Display Hold and Auto Hold • Smoothing mode allows filtering of rapidly changing inputs • Easy battery exchange without opening the case • Closed case calibration through front panel • Measuring frequency and capacity • Resistance, continuity and diode check • Measuring temperature • Min/Max/Avg recording • EN 61010-1 CAT III 1000 V/CAT iV 600 V

232 753 40

Fuse 440 mA

232 754 40

Fuse 11 A

232 619 40

Autorange digital multimeter incl. fuse set and temperature sensor Specification: V = : 100 µV - 1 KV, accuracy ± 0,3% + 2 dig. V ~ : 100 µV - 1 KV, accuracy ± 0,5% + 3 dig. A = : 100 nA - 20 A, accuracy ± 1% + 5 dig. A ~ : 100 nA - 20 A, accuracy ± 1% + 5 dig. Resistance: 100 mOhm - 40 Mohm, accuracy ± 0,5% + 3 dig. Frequenz (Hz): 1 Hz - 200 kHz, accuracy ± 0,2% + 2 dig. Diode test: Test voltage (open) below 3 V Acust. continuity tester: sounds below 100 Ohm Voltage supply: 1 x 9 V block battery

232 756 40

Clamp-on ammeter AC/DC, Fluke 336 incl. carrying case, test lead, 2 batteries (AAA), user manual Technical data: Measurement range A/AC & A/DC: 0 - 600 A Measurement range V/AC & V/DC: 0 - 600 V Frequency range: 10 - 400 Hz Measurement range resistance: 0 - 6000 Ω

991-1010 Tools

Measuring tools

Section 5 Page

22

Part-No.

Description

Release: 232 670 40

th

May 17 , 2010

SUBITO Internal gauge, 280 - 510 mm in a case without dial

232 671 40

SUBITO Measuring depth extension pipe Ø 18 mm, 2000 mm long

232 384 40

Flow meter gauge incl. accessories

793 787 73

Measuring turbine RE4 measuring range: 16 up to 600 l/min

232 593 40

Shock pulse measuring instrument For monitoring the bearing condition of electric motors

232 594 40

Cable for shock pulse transducer (1.5 m)

232 595 40

Shock pulse transducer

232 596 40

Head receiver for the shock pulse measuring instrument

991-1010 Tools

Measuring tools

Section 5 Page

23

Part-No.

Description

Release: 232 684 40

Vibrotip-Set "Trend" Engine analyzer and data collector

232 686 40

Drill for Vibrotip

232 685 40

Sensor with quick coupling for Vibrotip

232 665 40

Infrared thermometer

694 944

Electric thermometer with temp. probe tip

793 788 73

Infrared revolution counter DS03 Measuring range: 1 to 9999 min

th

May 17 , 2010

-1

793 789 73

Magnetic holder for DS03

232 551 40

Manual non-contact revolution counter (digital)

Test manometer, incl. accessories 770 466 73 769 150 73 770 464 73 770 465 75

0 - 60 bar 0 - 400 bar 0 - 16 bar 0 - 25 bar

991-1010 Tools

Measuring tools

Section 5 Page

24

Part-No.

Description

Release:

th

May 17 , 2010

Pressure gauge 793 361 73 793 362 73 793 363 73

0 - 25 bar (1 pc) 0 - 60 bar (1 pc) 0 - 400 bar (2 pcs)

232 501 40

Pressure gauge fitting (4 pcs) 1/4" to the hydraulic test port of the 'Mini-Mess' test equipment

Measuring hose 792 283 73 792 284 73

3200 mm 5000 mm

761 520 73

Filling and testing device for piston, diaphragm and bladder accumulators 0 - 100 bar (with pressure reducer)

232 752 40

Tool case (without tools)

232 382 40

Filling and testing device for piston and diaphragm and accumulators 0 - 25 bar

Thread reducing fitting (manometer) 232 506 40 232 507 40 232 508 40

R 1/4" R 3/8" R 1/2"

232 385 40

Voltage tester 25 kV

232 386 40

Universal grounding short-circuiting device (high voltage) Ø 95/35 mm

232 387 40

2

Insulation tester . . . 500 V

991-1010 Tools

Measuring tools

Section 5 Page

25

Part-No.

Description

Release: 232 713 40

th

May 17 , 2010

ALIGNEO laser set for the alignment of horizontal mounted machines

232 714 40

ALIGNEO bracket set

232 712 40

Magnet-Stick

232 388 40

Phase-sequence indicator 100 . . . 600 V

Electronical unipolar voltage meter 232 389 40 232 390 40

5 - 10 kV 3 - 6 kV

232 762 40

Test box (breakout box) for electrical components with Deutsch connectors

942 136 40

CAN bus test box Under construction

991-1010 Tools

Measuring tools

Section 5 Page

26

Part-No.

Description

Release: 766 138 73

Diagnostic device for BEKA-MAX lubrication systems

966 225

Crack detection testing kit, consisting of:

966 229

Permanent magnet

966 226

Magnetic powder

996 228

Cleaner, spray can, 500 ml

966 227

Contrasting agent

232 723 40

Universal box

793 780 73

Hand-held measuring unit MH 3020

th

May 17 , 2010

3 channels, USB interface, ISDS Memory: max. 1 million readings incl. power supply unit, USB cable and software

793 781 73

Pressure sensor (2 pcs) - 0 - 400 bar, ISDS

793 783 73

Direct connector for pressure sensor no. 1620 (2 pcs)

793 784 73

Screw-in temperature sensor no. 1620 (2 pcs) -50°C up to 200°C, ISDS

793 785 73

Rev counter sensor DS 03 - incl. 25 reflection foils

793 787 73

Measuring cable (2 pcs) - 5.0 m

793 786 73

Measuring extension cable - 5.0 m

793 782 73

Carrier box

991-1010 Tools

Measuring tools

Section 5 Page

27

Part-No.

Description

Release: 796 440 73

USB extension wire

793 796 73

Data communication cable USB

796 441 73

KMG diagnostic software (CD)

796 439 73

Converter

796 443 73

Cable set, for data transfer between PC and PLC & text display Cable VL3 Cable VL12

th

May 17 , 2010

Download of fault messages (protocol) from the text display to the PC Download and upload of the PLC software

Upload of text display setup from the PC to the text display: Cable VL10 Cable VL9a Cable VL9b

796 726 73

Data bus Power supply Board net power supply

Bodem PC software CD-ROM and dongle For pump controller (MC7/RC4) monitoring and settings

896 791 40

Bodem connection cable

232 747 40

LAN card, USB 2.0, 10/100 Mbit/s This USB-RJ45-adapter is a high-performance network converter for the USB 2.0 port

232 748 40

CAT-5 Crossover adapter For fast direct PC connection via LAN (RJ45)

991-1010 Tools

Data Transfer and IT Tools

Section 6 Page

28

Part-No.

Description

Release:

797 390 73

th

May 17 , 2010

Electric kit for DEUTSCH connectors Contains: Part-No. 932 518 40 055 104 40 055 100 40 907 511 40 600 259 99 055 107 40 055 108 40 055 110 40 055 105 40 055 109 40 055 112 40 055 114 40 440 109 40 055 131 40 323 961 40 440 109 40 055 115 40 907 577 40 500 090 98 056 070 40 635 042 40 056 071 40 056 072 40 324 484 40 269 078 40 907 641 40 907 501 40 057 296 40 795 132 73 795 134 73 795 495 73 795 131 73 795 461 73 795 501 73 651 461 40 898 680 40 898 681 40 966 661 464 814 792 104 73 792 105 40 792 106 40

Qty. 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 50 50 50 50 10 10 10 50 10 1 2 2 2 2 2 2 2 2 2 1 1 100 100 100

Description Cable lug 2 Cable lug 0.5-1mm /ø4mm Cable lug Cable lug Cable lug 2 Cable lug 1mm /ø5mm 2 Cable lug 4.9mm /ø5mm 2 Cable lug 3mm /ø6.5mm Cable lug Cable lug 2 Cable lug 4.9mm /ø2mm Plug-in sleeve Plug-in sleeve ø4mm 2 Plug-in sleeve 4-6mm Sleeve 6.3x0.8mm Plug-in sleeve Plug-in sleeve Distributor Cable sleeve 0.75mm Cable sleeve 1.0-2.5mm Cable sleeve 1.5mm Cable sleeve 2.5-6mm Cable sleeve 4mm 2 Cable sleeve 6mm Cable sleeve ø6mm Cable sleeve Cable sleeve Connection Plug Plug Plug Plug housing Plug housing Plug housing Housing assy Relay assy Relay assy Squeezing pliers Insulating tape Cable strap 200x4.8 Cable strap Cable strap

991-1010 Tools

Repair Sets for Wiring & Connectors

Section 7 Page

29

Part-No.

Description

Release:

793 265 73

th

May 17 , 2010

Electric kit for YAZAKI connectors Contains: Part-No. 055 100 40 055 102 40 055 103 40 055 104 40 055 105 40 055 107 40 055 108 40 055 109 40 055 110 40 055 111 40 055 112 40 055 114 40 055 115 40 055 120 40 055 125 40 055 131 40 055 141 40 055 142 40 056 070 40 056 071 40 056 072 40 202 973 40 256 084 40 269 078 40 323 725 40 323 961 40 324 484 40 440 109 40 440 151 99 500 090 98 635 042 40 907 577 40 891 031 40 891 030 40 891 039 40 891 040 40 891 038 40 891 032 40 464 814 057 296 40 898 680 40 898 681 40 792 104 73 792 105 40 792 106 40 966 661

Qty. 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 50 50 10 10 10 10 10 10 10 10 10 50 50 10 2 2 2 2 2 2 1 1 2 2 100 100 100 1

Description 2 Cable lug 2.5mm /ø5mm 2 Cable lug 1.5-2.5mm 2 Cable lug 0.5-1mm 2 Cable lug 0.5-1mm /ø4mm 2 Cable lug 4-6mm /ø6mm 2 Cable lug 1mm /ø5mm 2 Cable lug 4.9mm /ø5mm 2 Cable lug 12.5mm /ø8.5mm 2 Cable lug 3mm /ø6.5mm 2 Cable lug 12.5mm /ø4mm 2 Cable lug 4.9mm /ø2mm 2 Cable lug 2.5mm /ø6.3mm 2 Plug-in sleeve 3mm 2 Cable lug 1mm 2 Pin 7mm Plug-in sleeve 4-6mm 2 Connection 1.5-2.5mm 2 Connection 4-6mm Cable sleeve 1.0-2.5mm Cable sleeve 2.5-6mm Cable sleeve 4mm Distributor 2 Cable lug 1.75mm /ø6.5mm Cable sleeve ø6mm Cable lug ø4mm/ø3mm Sleeve 6.3x0.8mm 2 Cable sleeve 6mm Plug-in sleeve ø4mm Plug-in sleeve 6.3mm Cable sleeve 0.75mm Cable sleeve 1.5mm Distributor Plug Plug Plug Plug Plug Plug Insulating tape Connection Relay assy Relay assy Cable strap 200x4.8 Cable strap Cable strap Squeezing pliers

991-1010 Tools

Repair Sets for Wiring & Connectors

Section 7 Page

30

Part-No.

Description

Release:

797 391 73

th

May 17 , 2010

Fitting set for hydraulic line connections Contains: Part-No. 371 271 99 371 261 99 371 273 99 371 258 99 371 274 99 371 275 99 371 259 99 374 427 99 907 080 40 906 347 40 516 156 98 516 183 98 374 420 99 374 430 99 906 346 40 906 348 40 906 349 40 517 242 98 374 416 99 907 152 40 516 158 98 515 711 40 516 184 98 551 379 40 371 459 99 516 182 98 515 701 40 371 276 99 517 225 98 374 407 99 370 312 99 516 157 98 516 741 98 374 436 99 516 224 98 371 949 99 517 073 98 655 426 40 516 962 98 516 174 98 517 226 98 796 043 73 796 045 73 796 047 73

Qty. 2 2 2 2 2 2 2 2 5 5 2 2 2 2 5 5 5 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 20 21

Description Nut N-L 6 Union nut Nut N-L 10 Union nut N-S 10 Nut N-L 12 Nut N-L 15 Nut N-L 12 Union SDS-S10XG 3/8A Type E Cutting ring ES-4 S 6 Cutting ring ES-4 S12 Socket L10 Socket L10-G Union SDS-L10xM14X1.5 Type E Union SDS-L12xM16X1.5 Type E Cutting ring ES-4 S10 Cutting ring ES-4 L15 Cutting ring ES-4 L18 Union L08-M Union SDS-L10XG 1/4A-Type E Union SDS-L12XG 1/4A-Type E/OM Union SWE-L 15 Union L10 Union L12-G Union 12/10-PL/OMD Union SDS-L12XG 3/8A-Type E Union L10-M Union L12 Nut N-L 18 Union L08 Union SDS-L15XM18X1.5-Type E Union D L10E Union L12 Union SWE-S 12 Union SDS-L15XG 1/2A-Type E Union L10 Union MAV-EV 12-ER Union 10 LRD/OMD Union GV 12-LR Union BH-L 12 Union L12 Union L08 Case Box in the case Box in the case

991-1010 Tools

Repair Sets for Hydraulic Cylinders & Line Fittings

Section 8 Page

31

Part-No.

Description

Release: 232 621 40

Cordless headphone intercom

232 623 40

Vacuum pump + adaptor

232 626 40

Mounting bushing set for cylinder repair

th

May 17 , 2010

When ordering tools, please always state the identification number of the cylinder.

947 173 40

Auxiliary tool 1 for threaded pins M12

947 178 40

Auxiliary tool 2 for threaded pins M16 Used for the repair of hydraulic cylinders

For detailed information refer to the PARTS & SERVICE NEWS AH08501 (latest edition)

232 299 40

Pinch bar with pointed and claw ends, 1000 mm long

232 146 40

Strap wrench

Puller, grip width/depth 232 300 40 232 301 40 232 302 40

120 mm/100 mm 200 mm/150 mm 350 mm/200 mm

232 287 40

Grease gun, hand-lever type, with couplings, 400 bar

232 288 40

Fitters tub

232 000 40

Tool box, 5 trays 420 x 200 x 210 mm

991-1010 Tools

Others

Section 9 Page

32

Part-No.

Description

Release: 232 761 40

th

May 17 , 2010

Tool chest With 3 wide & 3 small drawers and 1 removable element. Width 663 mm, height 364 mm, depth 308 mm, weight 25.5 kg. Delivery without tools.

232 763 40

Universal tool box Outside: Width 600 mm, height 330 mm, depth 400 mm, weight 4.5 kg Inside: Width 550 mm, height 310 mm, depth 350 mm, capacity 60 ℓ

793 639 73

Removal tool for double-level terminals

232 542 40

Oil analysis

232 622 40

Suction pump, extracting oil for testing

Flat-link chain hoist 232 368 40 232 289 40 ???

Lifting capacity 0.75 t Lifting capacity 1.5 t Lifting capacity 3.0 t

324460 40

Cable suspension, 5 t

991-1010 Tools

Others

Section 9 Page

33

Part-No.

Description

Release: 792 005 73

Edge protector

792 006 73

Edge protector

232 616 40

4-hook chain, WMH S6

th

May 17 , 2010

A = 1500 mm

232 617 40

Nylon lifting belt, AL 4 Width 75 mm, length 3500 mm 1500 kg

232 618 40

Nylon lifting belt Width 25 mm, length 1500 mm 1000 kg Lifting bolt

941 650 40 941 651 40 906 519 40 906 780 40 906 782 40 906 783 40 906 421 40 906 233 40

M 8 M10 M12 M16 M20 M24 M30 M36

999 860 73

5 finger gloves, with textile extension, with lining

999 861 73

Rubber gloves, size F3 and F4

999 925 73

Working gloves, pork leather, with lining

991-1010 Tools

Others

Section 9 Page

34

Part-No.

Description

Release: 950 642

Canister 10 l (plastics)

950 643

Canister 25 l (plastics)

232 683 40

Combination angle set

232 715 40

Hydro-pump, type IPV 3-8 101

232 716 40

Coupling

766 307 73 766 308 73 766 309 73 766 310 73 766 311 73 766 312 73 766 313 73 766 314 73 766 315 73 766 316 73 766 317 73 766 318 73 766 319 73 766 320 73 766 321 73 766 322 73 766 323 73 768 881 73 797 549 73

Mounting tools for dual cone seal rings at the undercarriage

th

May 17 , 2010

For detailed information refer to the PARTS & SERVICE NEWS AH05511 (latest edition)

991-1010 Tools

Others

Section 9 Page

35

Part-No.

Description

Release:

th

May 17 , 2010

Thinner 767 566 73

10 kg Primer, lemon yellow

767 567 73

1kg Paint yellow, RAL 1007

083 026

spray can, 400 ml Paint sky-blue, RAL 5015

501 415 98

can, 2,5 kg Paint black, RAL 9005

767 568 73

can, 1 kg Paint yellow = DEMAG KOMATSU colour

767 569 73

can, 1 kg Paint grey = KOMATSU colour

767 570 73

can, 1 kg

999 019

Nickel spray can, Metaflux 70-81

991-1010 Tools

Paint and accessories

Section 10 Page

36

Part-No.

Description

Release: 592 199 40

Liquid sealing compound (Epple blue, No. 28), 250 ml

461 798 40

Adhesive Sicomet 85, in tubes

th

May 17 , 2010

for sealing the rotary joint (with rollers or balls) 390 905

Teflon tape

464 814

Insulating tape, 33-19 Tesa PVCd

691 959

Filler bottle Startpilot

989 967

Oil binding agent paper sacks, 8 kg each

993 528 73

Cleaning agent Bio Pent E, for steam blasting cleaners

993 529 73

Cleaning agent Bio Versal, for steam blasting cleaners

999 926 73

Cleaning rags (fleece rags) 35 x 35 cm, bale of 30 kg

991-1010 Tools

Auxiliaries, cleaners, adhesive & sealant

Section 11 Page

37

Part-No.

Description

Release:

th

May 17 , 2010

Loctite products 414 299 40

Loctite No. 222 E, bolt lock fluid, 50 ml low stability, up to M36

973 125

Loctite No. 241, bolt lock fluid, 50 ml medium stability, up to M12

973 130

Loctite No. 24333, bolt lock fluid, 50 ml medium stability, up to M36

255 242 40

Loctite No. 243, bolt lock fluid, 250 ml medium stability, up to M36

170 470 40

Loctite No. 245, bolt lock fluid, 250 ml medium stability, up to M80

158 856 40

Loctite No. 27041, bolt lock fluid, 250 ml high stability, up to M20

167 644 40

Loctite No. 307, 50 ml metal adhesive (only in conjunction with 7471)

288 906 40

Loctite No. 330, bonding set bonds nearly all materials (except Gi)

461 798 40

Loctite No. 401, 20 g, Cyanacrylat bonds Kn, rubber, paperboard, leather, wood, and many more

255 238 40

Loctite No. 511, fluid sealing, 50 ml low stability, sealing threaded connections up to R2"

232 554 40

Loctite No. 511, fluid sealing, 250 ml low stability

083 399 40

Loctite Nr. 586, fluid sealing, 50 ml high stability, up to R2"

255 239 40

Loctite 574, sealant for surfaces, 50ml gap size up to 0,5 mm

255 237 40

Loctite No. 603, for join connections, 50 ml high stability

991-1010 Tools

Auxiliaries, cleaners, adhesive & sealant

Section 11 Page

38

Part-No.

Description

Release: 288 907 40

Loctite No. 706, fast cleaner, 400 ml

321 32240

Loctite, removal of adhesives and sealants

th

May 17 , 2010

spray can, 300 ml 083 376 40

Loctite Nr. 7471, activator, 500 ml for hardening of 307 and for the acceleration of the hardening process

991-1010 Tools

Auxiliaries, cleaners, adhesive & sealant

Section 11 Page

39

Parts & Service News

8 PARTS & SERVICE NEWS

Version 2010/1

PC5500-6E

8 -1

Parts & Service News

Contents of this chapter: SB-No.

Subject

AH00511

Installation procedure for the swing circle (SC)

AH00514

Track group – Hints for sprocket exchange

AH00515

Final drive: Wear and tear measurements / Mounting procedures

AH00519

Adhesive lubricants for the slew ring gear

AH01513

Bleeding of hydraulic pumps

AH01523

Replacement of the elastic coupling (electro drive shovels)

AH01531

Hydraulic accumulators - testing and refilling

AH02513

Testing wear and tear of swing circle bearing

AH02521

Track group – wear measurement

AH03506

Hydraulic oil cooler and water cooler fan bearings

AH03509

Slew gear GFB 174 E 9017 (Part No. 917 915 40)

AH03510

ESCO bucket tooth system

AH03511

Pilot Pressure Pump (Part No. 907 209 40)

AH03512

Gear Pumps (Part Nos. 907 209 40; 906 442 40; 896 730 40 and 654 930 40

AH03528

Pilot control safety line

AH04518

Welding procedure for welded counterweight

AH05501

Abnormal vibration on hydraulic pipes

AH05510

Bearing flushing of the A4VS variable displacement axial piston pump

AH05511

Dual cone seal ring mounting

AH05518

Swing circle pinion

AH05520

Installation hints for a new type of pilot pump

AH05525

Suction elbows of the main pumps

AH05535

Hints for replacing by the slewing gear of an other manufacturer

AH05546

Automatic lubrication system - vent valve (PN 769 879 73)

AH06524

Hydraulic cylinder

AH06529

Track group - hints for sprocket exchange

AH06530

Relieving of the track chain tension

AH06542

Swash plate pump H-A4VSO500

AH06543

Gear pumps PN 907 622 40 and PN 940 048 40 (supplied from the company “Kracht”) (Pilot pressure pump; gear oil pump; circulation pump)

AH06545

Hydraulic cylinder bushings

AH07509

Swing brake manufactured by "Siebenhaar" (Swing gear PN 902 550 40 and PN 925 864 40)

AH07526

Bolted undercarriage: Protective coating on the flange plates

AH08503

Track drive

8 -2

PC5500-6E

Version 2010/1

Parts & Service News

SB-No.

Subject

AH08504

Windscreen

AH08507

Steel structure

AH08508

Bushings of the attachment and at the undercarriage

AH09505

Hoses between boom and stick

AH09522

Wishbone and rod

The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest edition is always filed to the binder of this manual.

Version 2010/1

PC5500-6E

8 -3

Parts & Service News

This page was left blank intentionally.

8 -4

PC5500-6E

Version 2010/1

COMPONENT CODE:

2500

REF NO.

AH00511e

PARTS & SERVICE NEWS

DATE

October 6, 2006 Page 1 of 20

This PARTS & SERVICE NEWS supersedes the previous issue No. AH00511d which should be discarded. SUBJECT:

Installation procedure for the swing circle / Slew Ring (SR)

PURPOSE:

Revision

APPLICATION:

From H185S (06078) up to PC8000

FAILURE CODE:

2500Z9

DESCRIPTION: Content

Page

1. 2. 3. 4. 5. 6.

List of swing circle types Safety instructions General Measurements Determination of tightening torques Mounting of a swing circle Adjustment: Unhardened spot “s” Tooth back lash Hints for rotating the slew ring 7. Checking of fastening bolts 8. Lubrication and maintenance 8.1 Races of roller bearings 8.2 Outer toothing 8.3 General

1.

Type

H 185S H 255S / PC3000 H 285S PC4000 H 455S / PC5500 H 485S H 655S / PC8000 ( - 12036) PC8000 (12037 - ) H 685SP H 685SX (12030)

Slew ring Weight [t] 3,5 3,5 6,0 6,7 9,0 / 10,0 14,0 14,0 16,3 14,0 16,3

01 02 03 04 06 08 11 12 14 16 16 16 18 20 Mounting cross P/N

Tooth back lash [mm]

379 383 40 379 383 40 379 128 40 379 128 40 477 577 40 379 129 40 379 129 40 on request 379 129 40 on request

0.4 – 0.8 0.4 – 0.8 0.6 –1.0 0.6 – 1.0 0,6 – 1,0 0.5 – 0.9 0.5 – 0.9 0.5 – 2.5 0.5 – 0.9 0.5 – 2.5

AH00511e

Page 2 of 20

2. Safety Instructions •

Assign trained or well-instructed personnel only, and clearly define the respective spheres of responsibility for the repair work.

•

Inform the operating personnel prior to the commencing special and regular maintenance work.

•

Secure the maintenance area amply enough, as far as required.

•

Carry out repair and maintenance work only with the machine standing on firm and level ground and secured against rolling away and sinking in.

•

During exchange action, fix and secure individual parts and assemblies carefully to the lifting devices so that they cannot become dangerous in any way. Use exclusively suitable lifting devices consistent with sound engineering and load-lifting elements with sufficient load-bearing capacity! Never stay or work beneath suspended loads!

•

Entrust experienced personnel only with fastening and securing of loads and guiding crane operators! The guide has to be within the operator's visual range or have voice contact with him.

•

In case of assembly work exceeding body height, use suitable and otherwise secure means of access and working platforms. Never step on machine parts as an access! For maintenance work at higher levels, use the appropriate safety devices! Keep all handles, steps, handrails, landings, working platforms, ladders, etc. free from dirt, snow and ice!

•

Retighten immediately all bolted connections loosened during repair and maintenance work!

•

If disassembly of safety devices is required for rigging, maintenance, and repair, reassembly and checking of such safety devices has to be carried out immediately after having finished the respective work.

•

Strictly observe all safety instructions and warnings in the country of destination.

AH00511e

Page 3 of 20

3. General •

Before removing swing circle mark location of both slew rings to superstructure and the carbody as well for further investigations.

•

Shocks to the swing circle, especially radial ones, must be avoided.

•

Transport and store exclusively with transport star fitted. It is strictly forbidden to hook up the SR (Slew Ring) at the transport star.

•

Hang up and/or transport and store swing circle only horizontally. If a special attachment is available, the transportation and storage in oblique position may be carried out.

•

Only hang SR at four/three eyebolts evenly distributed in screw circle of the upper ring.

•

Prior to mounting the SR clean all supporting surfaces and the toothing, if necessary clean those areas with fat solvents, methylene chloride, cold cleaners. The cleaning agents must not enter the races. Hence, the swing circle has to be thoroughly lubricated before and after cleaning.

•

With each replacement swing circle and each new machine, fastening bolts, measuring bolts, a measuring device and mounting compound P/N. 324 969 40 will be delivered. If this parts delivery is not complete, please get immediately in contact with KOMATSU MINING GERMANY, because a proper mounting may not be possible in case of missing items.

AH00511e

Page 4 of 20

4. Measurements • •

Check the level of bearing area (only center section undercarriage) with a laser device before installing a new slew ring. To prevent incorrect measuring results caused by partial sun radiation onto the pedestal /carbody it is recommended that the whole area be protected from the direct sunlight.

Legend ID = Inner diameter slewring OD = Outer diameter slewring Π = 3.14 P = Maximum Deviation (deflection)

P=

OD – ID 2

: 100 x 0.2 *

* 0.2 = Constant Example: OD = 4000 mm ID = 3600 mm

W

P = 4000 – 3600 : 100 x 0.2

2 P = 200 : 100 x 0.2 P = 0.4 mm

• If the measured value exceeds the calculated value P, the surface has to be remachined.

AH00511e

Page 5 of 20 • •

Check the outer diameter of the new slewring top surface and compare with the outer diameter of the factory machined surface of the superstructure. Remove the shoulder by machining if necessary.

)

• A shoulder exists only at some excavators.

AH00511e

Page 6 of 20

5. Determination of tightening torque The required tightening torque for all fastening bolts (inner and outer) has to be determined with the measuring bolts, which dimension is analogous to the outer fastening bolts mounted to carbody / swing circle. • The required axial tension force of the bolts is determined by means of the elongation of the fastening bolts, carbody and swing circle. • The tightening torque must be determined each time the SR (Slew Ring) is replaced as well as at the first assembling of the excavator at the operation site and for the first and final inspection after 1000 operation hours. • The required measuring device is delivered with the excavator or with the SR (Slew Ring) (see ill.). • To determine the tightening torque, eight specially prepared test bolts are supplied besides the normal fastening bolts. The test bolts can be recognized at the centering (Z) in the bolt head and in the end of the threads. The measuring device is composed of the following items and will be delivered with each replacement swing circle and each new machine:

(1) Measuring jaw (2) Test block

1pce. 1pce.

(3) Measuring bolt (4) Washer

8pcs. 1pce.

For the determination of the tightening torque, the eight measuring bolts have to be mounted one by one to the measuring device as illustrated. Then the bolt has to be tightened in steps to the prescribed elongation (see table page 05). The needed tightening torque will be determined as a result of average of eight tightening torque's. For the exactly procedure refer to the following pages.

AH00511e

Page 7 of 20

For the determination of the torque / or pressure (hydr. torque multiplier) for the elongation of the test bolts proceed according to illustration on page 03 and the following description. Before the mounting of the measuring bolts (3) to the jaw, the bearing surface of head, threads and washers have to be applied with compound P/N. 324 969 40. • Screw test bolt (3) with washer (4) in test block (2) and tighten manually. • Fit jaw (1) and micrometer gauge into the centering "Z" of the bolt and set gauge to zero. • Increase tightening torque of test bolts by steps of app. 200 Nm until the required elongation of the bolt according to the table is reached. Measuring bolts Type

Analogous to the dimension of the outer fastening bolts (8)

Quality grade

Wrench size

Elongation [mm]

H 185S

M 30 x 230

10.9

46 mm

0.55 ±0.015

H 255S / PC3000/1

M 30 x 230

10.9

46 mm

PC3000/6

M 30 x 230

10.9

46 mm

0.55 ±0.015 0.550±0.015

PC3000/6

M 30 x 190

10.9

46 mm

0.442±0.013

H 285S

M 36 x 220

10.9

55 mm

0.61 ±0.020

PC4000

M 36 x 220

10.9

55 mm

0.61 ±0.020

H 455S / PC5500

M 36 x 230

10.9

55 mm

0.58 ±0.020

H 485S (to 12010) H 485S (12011 up)

M 36 x 230 M 36 x 270

10.9 10.9

55 mm 55 mm

0.58 ±0.020 0.65 ±0.020

M 36 x 270

10.9

55 mm

0.65 ±0.020

M 36 x 295

10.9

55 mm

0.71 ±0.020

H 685SP

M 36 x 270

10.9

55 mm

0.65 ±0.020

H 685SX (12030)

M 36 x 295

10.9

55 mm

0.71 ±0.020

H 655S PC8000 (to 12036) PC8000 (12037 up)

• Note down the tightening values in Nm, ft. lbf. resp. bar. • Repeat this procedure with all eight test bolts. • Add all 8 tightening values and than divide by 8. • Tighten bolts (7) and (8) to the calculated value (refer to the drawing at the next page).

AH00511e

Page 8 of 20

6. Mounting of a Swing circle (refer to ill. pages 06/08)

Depending on the model, bushes (11) or washers (10) have to be mounted.

AH00511e

Page 9 of 20

)

• When replacing the swing circle, all fastening bolts must also be replaced.

The eight measuring bolts have to be mounted equally distributed on the outer ring of the swing circle. If scratches are found at supporting surfaces of washers or bushes, they must be reworked or replaced. Replacement swing circles has to be mounted without dowel pins. If the mounted SR (Slew Ring) was fixed to the platform with dowel pins, remove these ones. •

Clean fat-free supporting surfaces (A) carbody and platform.

•

Supporting surfaces (A) must be absolutely fat-free. Even the solvent must be rinsed away before assembling.

•

Check surface evenness (A).

•

The swing circles (5/6) must have good contact to the carbody and superstructure platform.

•

Check mating surfaces with feeler gauge.

•

Check lube lines for correct condition and grease passage.

•

Check accordance of tapped and through holes in SR (Slew Ring) with those in carbody and platform. Discordance's may easily cause distortions of SR.

AH00511e

Page 10 of 20

• For removal and assembly always use a mounting cross (M). Fabricate mounting cross (M) according to the drawing or order it under giving the corresponding P/N. The construction drawing of the mounting cross has to be ordered from the Parts Department if necessary. Swing circle weight

Mounting cross

[t]

P/N

H 185S

3.5

379 383 40

H 255S / PC3000

3.5

379 383 40

H 285S

6.0

379 128 40

PC4000

6.7

379 128 40

9.0 / 10.0

477 577 40

14.0

379 129 40

14.0

379 129 40

16.3

864 187 40

H685SX (12030)

16.3

864 187 40

H 685SP

14.0

379 129 40

Type

H 455S / PC5500 H 485S H 655S PC8000 ( - 12036) PC8000 (12037 - )

AH00511e

Page 11 of 20 • • •

Deposit and center SR with transport star (T, see page 07) on mounting cross (M). Check length of threads in platform and SR, if necessary retap. Place SR at its fastening position under the jacked-up platform.

Adjustment: Unhardened spot „S“ For the adjustment of the Unhardened spot "S", see illustration. The Unhardened spot of race surfaces (changeover area between beginning and ending of hardening process) is punch marked with a "S" at the inner resp. outer side of each race ring (5 and 6), see illustration. These spots "S" must not be placed within the main load area of the swing circle. Hence, the unhardened spot "S" has to be turned in an angle of 90° to the main load area as illustrated.

AH00511e

Page 12 of 20 • Lift SR until approx. 10 mm below the platform (observe unhardened spot "S"). • Screw fastening bolts (7) with washers (10) through swing circle into the platform. Slightly treat bolt heads, threads and washers with Compound, P/N 324 969 40. • Lift SR to the supporting surface by screwing in the bolts crosswise. • Lower mounting cross. • Remove transport cross.

Tooth back lash

The tooth back lash is the play measured by a feeler gauge in point D if tooth A press on the reference circle (B) against tooth C. On swing circle where you find a green color marking on 3 teeth, rotate the lower ring (6) until the 3 green marked teeth are mating with the teeth of a slew pinion.

Type

Tooth back lash [mm]

H 185S H 255S/PC3000 H 285S PC4000 H 455S/PC5500 H 485S H 655S/PC8000 ( -12036) PC8000 (12037 - ) H685SX (12030) H 685SP

0.4 – 0.8 0.4 – 0.8 0.6 – 1.0 0.6 – 1.0 0.6 – 1.0 0.5 – 0.9 0.5 – 0.9 0.5 – 2.5 0.5 – 2.5 0.5 – 0.9

Note: The green teeth indicate the point of the SR having the greatest circularity deviation of the reference circle (positive deviation). At this narrowest spot, a tooth backlash clearance according to the chart should be measured. On machines without green color marking at the teeth, adjust backlash at 4 points evenly distributed according to the following dimensions.

AH00511e

Page 13 of 20 Before lowering the platform with SR on center section of the undercarriage: 1. Mark 4 teeth(1; 2; 3; 4 - refer to illustration) displaced by 90 °. The slew gears are marked gear 1, gear 2 and gear 3 (if so present). 2. Rotate the slew ring so far that tooth 1 is engaged at pinion of slew gear 1. 3. Measure play between A and D. Note value in the table below. C means tooth 1 and must have contact at point B. 4. Rotate superstructure further until tooth 1 is engaged at pinion of slew gear 2. Measure play as described under step 3. 5. Rotate superstructure further until tooth 1 is engaged at pinion of slew gear 3. Measure play as described under step 3. 6. Rotate superstructure further that tooth two is engaged at pinion of slew gear 1. Measure play and note value in table. 7. Carry out same measuring procedure as described for the other teeth. At the end for every slew gear, four dimensions are noted in the table. 8. If necessary, adjust the backlash by displacement of the SR. For the correct backlash, refer to chart above. 9. Hints for the three slew gear version: Adjust an equal play at pinion of slew gear 1 and 3 by shifting the slew ring. For this use the installed adjusting bolts. Afterwards adjust play at slew gear 2 to the same value before adjusted at 1 and 3.

Tooth backlash Slew gear gear 1 gear 2 gear 3

Play – nominal value

Tooth 1 Tooth 2 Tooth 3 Tooth 4

refer to table at page 10

AH00511e

Page 14 of 20 Hints for rotating the slew ring 1. Remove the slew motor. 2. If the excavator is equipped with more than one slew motor: Remove the hoses at the other slew motor(s). 3. Loosen the slew brake(s) by applying external pressure (25 - 60 bar). 4. Use the below shown tool in place of the removed slew motor for rotating the slew ring (drive: 36 mm).

36 mm

)

• The shown tool can be used for Series: PC3000; PC4000; PC5500; PC8000.

Part no.: 864 501 40

AH00511e

Page 15 of 20

Tighten all SR fastening bolts with the torque determined. Use the same torque multiplier you have used for the determination.

) •

•

• Before mounting the bearing surface of bolt head, threads and washers have to be applied with compound P/N 324 969 40.

Fasten crosswise fastening bolts (7) with the previously determined tightening torque (see page 05). This has to be performed twice or three times, to ensure a setting of the bolts. During tightening check permanently toothed outer ring (6) for easy running. For this purpose unscrew hydraulic lines of slew motor and loosen all slew brakes by applying external pressure (25 - 60 bar). Check for easy motion in all ranges by turning the outer ring (6).

•

After tightening of all bolts (7) from SR to the superstructure, the tooth backlash has to be checked once more at 4 points, if necessary adjust again.

•

Lower platform with SR on center section of the undercarriage. Watch position of not hardened spot "S" of the ring (6) according to illustration on page 09. If necessary turn ring (6).

•

Screw in 8 measuring bolts with washers resp. bushings (11) evenly distributed and the other fastening bolts (8) with washers (10), and bushings (11).

•

Tighten crosswise all fastening bolts (7/8) with the previously determined tightening torque. This has to be performed twice or three times, to ensure a setting of the bolts.

AH00511e

Page 16 of 20

7. Checking of bolts To compensate settling between SR and parts connected to it the bolts must be checked after 1000 operation hours. If necessary retighten bolts with the determined torque (refer to page 05). • • • •

Unscrew the eight test bolts (4) of the connection SR / carbody. Determine the required torque with these eight test bolts (4) in the test block (2). For the procedure, refer to the pages 03 - 05. Retighten all bolts (4/7/8) with the same torque multiplier you have used for the determination. On the models H 285 - H 685 for the retightening of the bolts of the connection SR / platform you need an extension, Part-No. 232 511 40.

8. Lubrication and maintenance (RDV) 8.1.

Races of roller bearings

Races must be lubricated regularly using high quality brands of lubricants. This is particularly important before and after longer interruptions of operation (e.g. winter intermission). The grease content in the race system is intended to avoid friction, to seal and to prevent corrosion. Greasing must be done abundantly until a continuous collar of grease pours out of the entire circumference of the upper seal "L" and the lower bearing gap "G". When greasing check visually the upper bearing seal "L" and, if necessary, replace immediately in order to prevent dirt and/or water to penetrate into the race system.

)

• Avoid cleaning agents to enter the race system when cleaning the excavator with high-pressure water or with vapor blast apparatuses. Before and after each cleaning grease thoroughly. The even distribution of grease requires slewing of the superstructure during greasing.

AH00511e

Page 17 of 20

Lubricating by central lube systems use With central lube systems, the lubricating intervals are controlled by the time control unit and the grease quantity is controlled by the adjustable metering valves / distributor valves in order to meet the local requirements. Manual greasing The lubrication intervals can be found in the Lubrication and Maintenance Manual. Before greasing clean grease nipples. Shorter intervals must be selected in tropical climate, in high humidity, under important effects of dust and dirt, considerable changes of temperature and continuous slewing motions e.g. during material transfer. Lubricants For greasing only use high quality grease which meets the requirements of the KOMATSU MINING GERMANY Lubricant Specification 011 597 99 (published in July 1995) section A. When choosing the grease, consider the ambient temperature range. Exchange of the lip type seal "L" (see ill., page 06) If a damage of the seal is determined while greasing operation, it has to be exchanged immediately, to avoid damages, caused by contamination. The exchange has to be performed as follows: • • • •

Remove the complete lip type seal. Clean groove fat-free, remove lip remainder completely Insert new lip type seal (P/N, refer Parts Catalogue). The seal must not be stretched during pushing in. Finally, the seal has to be cut to the needed length and the ends has to be glued together. The gluten is available under P/N 989 965.

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Page 18 of 20

8.2.

Outer toothing

Adhesive lubricants may be applied by means of an automatic swing circle gear lubrication system or manually by a spatula, a brush or a spray tin. Lubrication with automatic lubrication system •

Spray lube system

•

Drop lube system

•

Swing circle gear lubrication system

The most important requirement of a swing circle gear lubricant, besides the extreme pressure resistance, is its optimum adhesion to the tooth flanks, which can only be obtained by using the recommended lubricants in the prescribed temperature ranges. The following table includes several adhesive lubricants providing excellent results on several machines under different working conditions. The use of other lubricants is not recommended before consultation of Dept. 8151.

AH00511e

Page 19 of 20

)

• Use these Greases for Swing Circle open Gear Lubrication only!

Ambient Temperature °C ⇒ °F ⇒ Supplier

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 86

40 104

50 122

60 140

Castrol Molub-Alloy 936 SF Heavy NG Castrol Industrie GmbH

Castrol Molub-Alloy 936 SF Heavy Castrol Molub-Alloy 958 SF Castrol Molub-Alloy 936 SF Arctic BERULIT GA 2500 / BERUGEAR W4000

BECHEM

BERULIT GA 800 BERUGEAR W 3000 Beru Gear FG 34 (Biodegradable) Molub unee lubricant 7059 Molub Gear Tac 6895

BEL RAY Molub Gear Tac 6894 / 6899 ESSO

Dynagear Extra Ceplattyn KG 10 ECO (Biodegradable)

FUCHS LUBRITECH

Ceplattyn KG 10 HMF URETHYN HGO *1)

MOLYBOND

TSG Heavy Malleus GL 500

SHELL

Malleus GL 400 Malleus GL 25

TEXACO *1) *2)

Crater 2X Fluid *2)

The URETHYN HGO Grease should be used only in Arctic climates, where the ambient temperatures fall to –50° C. In regions where the ambient temperatures do not fall below –40° C, a grease of the temperature range to –40° C should be used. Use the Crater 2X Fluid for Spray systems only.

AH00511e

Page 20 of 20 Lubrication: Manual The manually lubrication has to be carried out with the following adhesive lubricants. Those lubricants are suitable for all temperature ranges. Company Product Komatsu Voler Compound 2000 E Mining Germany Spray (0,625kg) Voler Compound 2000 E Special Adhesive lub grease (indicate quantity in kg)

T1 -5°C ⇒ +60°C +23°F ⇒ +140°F

T2 -20°C ⇒ +10°C -4°F ⇒ +10°F

T3 -40°C ⇒ -10°C -40°F ⇒ +14°F

P/N 500 893 98

P/N 006 057 98

8.3 General The adhesive lubricants protect the tooth profile against dust, dirt, and damage resulting from driving or braking actions. However, this protection is effective only when the adhesive greases have been applied to clean surfaces where it can form a continuous coating. When bright spots show up at the tooth profile the toothing must be sprayed or laid on immediately with the special adhesive grease. When visiting customers, the service staff or dealers should also check the machine equipment and stock of lubricant and advise the exchange, if necessary, to prevent premature wear of the toothing. •

The adhesive lubricants provide totally different features compared to the Bearing greases / MPG (e.g. used in the central lubrication system). Hence, those lubricants must not be replaced against each other or mixed. Example: This may happen when grease pressed out of the upper sealing system of the races forms too big collar at the swing circle and penetrates into the toothing. This eventuality must be avoided by removing the excess grease.

• If tooth profiles of the slewing connection have been damaged due to one of the above mentioned reasons they do not fall under our warranty.

AH00511e

PARTS & SERVICE NEWS

COMPONENT CODE:

3000

REF NO.

AH00514

DATE

08162000 Page 1 of 11

This PARTS & SERVICE NEWS supercedes the previous issue No. 21 – 251c dated May 2000 which should be discarded. SUBJECT:

Track group - Hints for sprocket exchange

PURPOSE:

Sprocket exchange in case of normal wear

APPLICATION:

H 185S; H 241; H 285; H 285S; PC4000; H 485; H 485S; H 685S/SX; H 655S; PC8000

FAILURE CODE:

3000CA

DESCRIPTION: 1. Sprocket types 1.1 Standard sprocket 1.2 Oversize sprocket 2. Part no. 2.1 Sprockets with hub 2.2 Sprockets without hub / shaering pins 3. Removal sprocket 4. Conversion of the hub 5. Preparing the shearing pins 6. Determination of the Axial Play 7. Remachining 8. Assembly 9. Torque Data for Standard Application

AH00514

Page 2 of 11

1. Sprocket types 1.1 Standard sprocket The standard sprocket has to be used in case of assembling new machine or regenerating the track group in connection with new track pads. 1.2 Oversize sprocket The oversize sprocket has to be used to compensate chain elongation, wear on sprocket diameter and wear in the roller path on track pads, caused by the wear of the chain, if the X-dimension / circular pitch, comes up to 0.5 mm (see Service Bulletin 21-205 latest edition). This retrofitting assures assembly condition of the X – dimension of a new machine, furthermore the service life of the track group will be increased. The oversize sprocket is available without a sprocket hub, if the old one is reuseable. For the part no. of sprockets and the mounting procedure, refer to the following pages. The conversion of the sprockets is very time- and cost-intensive, so it is recommended to exchange the final-drive bearings at the same time if the dimensions have reached the wear tolerances, to avoid a standstill of the machine for the final-drive bearing exchange only. Before placing the order, pay attention to Service News AH00515 and Parts Catalogue for correct choice of the bush type. Basically, all seals (4; 5; 6; 10, see page 04) according to Parts Catalogue have be replaced.

.

• The difference between the standard version (NT) and the very low temperature version (TT) are only the bolts. The sprocket and the shearing pins are the same.

AH00514

Page 3 of 11 2. Part no. 2.1 Standard sprocket (T) with hub

Oversize sprocket with hub (T)

Type H 185S H 241 H 285 H 285S PC4000 H 485 H 485S H 685S/SX H 655S/ PC8000

Type H 185S * H 241 H 285 H 285S

Part No. 429 206 40 261 678 40 352 433 40 643 940 40 643 936 40 313 343 40 643 930 40 643 930 40 643 930 40

Part No. 448 943 40 425 656 40 425 654 40 643 936 40

PC4000 643 940 40 H 485 426 016 40 H 485S 643 926 40 H 685S/SX 643 926 40 H 655S/ PC8000 643 926 40 * Oversize sprocket for H 185S is available only with hub

AH00514

Page 4 of 11

2.2 Oversize sprocket without hub (R) / Shearing pins (O) Type H 241 H 285 H 285S PC4000 H 485 H 485S H 685S/SX H 655S/ PC8000

Sprocket (R) Part No. 425 655 40 448 961 40 887 105 40 887 105 40 448 969 40 643 923 40 643 923 40 887 115 40

Pin numbers 4 6 6 6 8 8 8 8

Pin (O) Part No. 429 638 40 429 691 40 429 691 40 429 691 40 429 640 40 429 692 40 429 692 40 429 692 40

AH00514

Page 5 of 11 3. Removal sprocket • • • • • • • •

Suspend travel gear (1) to a crane, remove mounting bolts. Remove travel gear by using the pulling bolts, put aside. Remove cover (2). Underpin sprocket (T/R) from below, suspend to a crane. Pull out drive shaft (8). Remove mounting bolts in flange bearing (7), loosen by using the pulling bolts, extract. Extract hollow shaft (9) to cover side (2), lift sprocket (T/R) out. Remove mounting bolts in flange bearing (3), loosen by using the pulling bolts, extract. 14

22

50

34 AH00514

Page 6 of 11 4. Conversion of the hub Loosen bolts and bore into shearing pins.

Pin

Do not drill through !

Model H 241 H 285/ H 285S PC4000 H 485/ H 485S H 685S/SX H 655/ PC8000

Pin dia. (mm) standard 42 50 50 55 55 55

Drill dia. (mm) 36 44 44 49 49 49

Pin dia. (mm) oversize 44 52 52 57 57 57

Drill dia. (mm) 36 44 44 49 49 49

Pull out shearing pins. Separate hub and sprocket, if necessary heat up sprocket to approx. 100°C. Insert hub into the new sprocket and align corresponding to the existing holes. Insert bolts and tighten.

AH00514

Page 7 of 11

Drill holes on a vertical boring machine. The sprocket has to be on top. Use Shell counterbores of high speed steel. Model H 241 H 285/ H 285S PC4000 H 485/ H485S H 685S/SX H 655/ PC8000

Holes for the shearing pins 4 x 43.5 mm 6 x 51.5 mm 6 x 51.5 mm 8 x 56.5 mm 8 x 56.5 mm 8 x 56.5 mm

Ream the holes for the shearing pins. Model H 241 H 285/ H 285S PC4000 H 485/ H485S H 685S/SX H 655/ PC8000

Holes for the shearing pins 4 x 44 H7 6 x 52 H7 6 x 52 H7 8 x 57 H7 8 x 57 H7 8 x 57 H7

After reaming bur the holes carefully. 5. Preparing the shearing pins “A” sprocket

“B”

hub

By means of a 3 point inside micrometer measure the diameter “A” and “B” at the spots as shown in the illustration. Add 0.04 mm to the larger diameter and grind the oversize sharing pin to this dimension. Repeat this procedure separately for all pins. Example: “A” = 57.01 mm “B” = 57.02 mm “B” is bigger.

The diameter of the pin has to be : 57.02 mm + 0.04 mm = 57.06 mm

Shearing pins have to be deep-freezed by using liquid nitrogen (-196°C/-320°F and pushed into the reamed holes. AH00514

Page 8 of 11

4

29

50 29

AH00514

Page 9 of 11 6. Determination of the Axial Play After removal, all seals have to be renewed. • • • • • • • • • • •

Slide O-ring (5) over flange bearing (3). Mount flange bearing (3) without dual-cone seal (29). Pay attention to the lubrication-grooves position, they have to be displaced by 22.5° to the vertical line. Mount all bolts (50) and tighten according to tightening torques on the last page. Suspend sprocket (T/R) to a crane , insert without dual-cone seals(29). Mount hollow shaft (9) and slide against collar “B”. By this, the sprocket (T/R) is moved against the collar of the bushing. Mount flange bearing (7) with 3 bolts (22) without dual-cone seal (29). Measure dimension “X”. Slide sprocket (T/R) to direction “C” until the hollow shaft (9) rests against the collar “D” of the flange bushing. Measure dimension “Y”. The axial play result in X – Y .

7. Remachining If the amount of axial play exceeds 0.9 mm (H 241 > 0.5mm). area E has to be remachined until the original dimension, is reached. If the amount of axial play is less than 0.2 mm, area F has to be remachined until the original dimension, is reached. Type H 185S H 241 H 285/ H 285S PC4000 H 485/ H485S H 685S/SX H 655S/ PC8000 •

Original 0.2 – 0.9 0.2 – 0.5 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9

Wear limit 2.75 2.00 2.75 2.75 2.75 2.75 2,75

Suspend sprocket (T/R) to crane, pull out hollow shaft (9), lift sprocket (T/R) out.

AH00514

Page 10 of 11

5

29

9

29

50

AH00514

Page 11 of 11 8. Assembly • • • • • • • • • • • • •

Mount dual-cone seal (29) according to SB 10-33 into flange bearing (3). Mount dual-cone seals (29) according to SB 10-33 into sprocket (T/R). Place sprocket (T/R) into the side frame by using a crane, align and underpin sprocket in mounting position. Mount hollow shaft (9). Mount dual-cone seal (29) according to SB 21-558 into flange bearing (7). Mount flange bearing (7). The lubrication grooves of the bushing(4) have to be displaced by 22.5° to the vertical line. Tighten bolts (22), according to the tightening torques below. Insert O-ring(6) in cover (2). Mount cover (2) with bolts (14). Tighten bolts (14), according to the tightening torques below. Insert O-ring (10). Suspend travel gear (1) to a crane and mount to side frame. Tighten bolts (34), according to the tightening torques below. Refill oil and check levels.

.

• When selecting tightening torques, observe size and quality grade of the bolts.

9. Torque Data for Standard Application Bolt dia. [mm]

Wrench size [mm]

M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36

17 19 22 24 27 30 32 36 41 46 50 55

8.8 43/32 74/54.6 118/87 179/132 255/188 360/265 485/358 620/457 920/679 1250/922 1690/1246 2170/1600

Tightening torque Nm/lbs.ft. Quality grades 10.9 63/47 108/80 173/128 265/196 360/265 510/376 690/509 880/649 1310/966 1770/1305 2400/1770 3100/2286

12.9 73/54 127/94 202/149 310/229 425/313 600/443 810/597 1030/760 1530/1128 2080/1534 2800/2065 3600/2655

Insert all bolts lubricated with MPG, KP2K type lubricant.

AH00514

PARTS & SERVICE NEWS

COMPONENT CODE:

30

REF NO.

AH00515c

DATE

July 5, 2006 Page 1 of 10

This PARTS & SERVICE NEWS supersedes the previous issue No. AH00515b which should be discarded. SUBJECT:

Final drive:

Wear and tear measurements Mounting procedures

PURPOSE:

Revision

APPLICATION:

H 185S; H 285; H 285S; PC4000; PC5500 (#15026 and up); H 485; H485S; H 685S/SX; H 655S; PC8000

FAILURE CODE:

3000CA

DESCRIPTION: 1. Wear and tear measurements 1.1 Radial wear determination a) Preparation b) Measuring procedure Method A c) Measuring procedure Method B d) Determination of wear depending on the Bushing version Old or New 1.2. Axial play determination of the hollow shaft a) Measuring procedure b) Reducing the axial play by remachining 2. Mounting procedures 2.1 Mounting of drive shaft a) Gap between drive shaft and cover plate b) Measuring procedure c) How to establish the recommended gap 2.2 Exchange bushings a) Freeze shrinking bush b) Flange Assy. with freezed in bush 3. Final works

1. Wear and tear measurements The wear- and tear-measurements on the bearing bushings in mounted condition inform quickly and exactly about the axial and parallel abrasion, without quickly a time and cost-intensive disassembly of the final drive. It is recommended to perform the measurements every 5000 working hours to avoid consequential damages as a result of a too high abrasion amount. The wear- and tear-measurements are described and illustrated on the following pages.

AH00515c

Page 2 of 10

1. Wear and tear measurements 1.1. Radial wear determination a) Preparation For the measurements proceed according to the following sequence: • • • • •

Place suitable oil pan for outflowing oil and remove cover (H). Operate travel gear that the bores (B) in the hollow shaft are placed in vertical position (see illustration). Turn the superstructure to the illustrated position. Hoist the sprocket side by using the attachment, until a wooden plank can be placed under the track (middle of sprocket). Lift attachment until the bucket no longer touches the ground.

AH00515c

Page 3 of 10 b) Measuring procedure Method A • • • •

Place dial gauge bracket with magnet (1), dial gauge (2) and bolt (3) as shown in illustration below. Set dial gauge (2) to “0” when attachment is lifted. Wooden plank must lie under the sprocket. Hoist the sprocket side by using the attachment until the wooden plank is free. Take reading of dial gauge.

c) Measuring procedure Method B •

Check by using a feeler gauge between hollow shaft and bearing bush.

AH00515c

Page 4 of 10 d) Determination of wear depending on the Bushing version Old or New Because of technical development the bushings (P/N 429 649 40 for H 485; H485S; H 685S/SX; H 655S; PC8000) and (P/N 429 652 40 for PC4000) are made of a new material and have spiral grooves instead of radial grooves of the former version.

Type H 485; H485S; H 685S/SX; H 655S; PC8000 H 285; H 285S; PC4000 PC5500 (#15026 and up)

Bearing assy.* (outside) old new

Bearing assy.* (inside) old new

Bushings * old

new

31335540

91159540

31335640

92298040

42964940

92298440

36103640 ----

92253840 93360240

36103740 ---

92253940 93360440

42965240 ---

92253740 93360040

* Refer to the respective Parts Catalogue of the machines. Old bushing version

)

• The radial play after new machine assembly amounts to 0.35 mm to 0.45 mm *. • If the maximum permissible parallel play comes up to 2 mm, the bushings have to be changed *. * – H 485; H485S; H 685S/SX; H 655S; PC8000 only up to S/N 12041. – PC4000 only up to S/N 08155.

New bushing version

)

• For machines with the new bushings (P/N 922 984 40) the radial play after installation amounts to 0.74 mm to 0.85 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed. • For machines with the new bushings (P/N 922 537 40) the radial play after installation amounts to 0.56 mm to 0.66 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed. • For machines with the new bushings (P/N 933 600 40) the radial play after installation amounts to 0.67 mm to 0.77 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed.

AH00515c

Page 5 of 10

1.2. Axial play determination of the hollow shaft a) Measuring procedure • • • • • • • • •

Make bracket (1) as shown in the illustration. The bores dia. have drilled respectively to the thread diameter (see table). Screw threaded rods (4) into the hollow shaft. Mount nuts (3), bracket (1) and bolts (2) as shown in the illustration. Hoist the sprocket side by using the attachment until the sprocket no longer touches the ground. Slide hollow shaft in by using nuts (3) until it comes against the final stop. Place dial gauge with bracket, set dial gauge to “0”. Slide hollow shaft out by nuts (3) until it comes against the final stop. Take reading of dial gauge. When the maximum values (see table) are reached, the play can be reduced to the new machine value by remachining according to page 5.

Type

H 185 / S H 285 / S PC4000 PC5500 H 485 / S H 685S / SX H 655S/PC8000

Mounting bolt (2)

Threaded shaft (mm)

M 12 M 16 M 16 M 12 M 16 M 16 M 16

M 16 M 20 M 20 M 20 M 20 M 20 M 20

Gauge (S) (mm)

316 360 360 435 460 460 460

Axial play new (mm)

0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9

Max. permissible axial play (mm) 2.75 2.75 2.75 2.75 2.75 2.75 2.75

AH00515c

Page 6 of 10 b) Reducing the axial play by remachining When the axial play comes up to the maximum value according to the table on page 4, flange (2) can be remachined in area (E) , to bring the axial play to the new machine condition. • • • •

Underpin sprocket, suspend to a crane. Remove bolts (S) (see page 06), remove flange (2) by means of puller bolts. Remachine flange (2) in area (E), until the axial play (new value) is reached. For the mounting , proceed in inverse sequence of the removal.

AH00515c

Page 7 of 10

2. Mounting procedures 2.1 Mounting of drive shaft a) Gap between drive shaft and cover plate • Install drive shaft (12)

)

• The drive shaft has a multi-spline shaft at both ends. • The correct mounting position is when the longer toothing faces the gear.

b) Measuring procedure • Check if the drive shaft rests completely against the stop in the gear by means of a hit with a mounting bar and a metallic click is audible. • Measure dimension “A” at the cover plate (7). • Measure dimension “B” according to the illustration by mean of measuring device (1). • Calculate the existing play with formula: “B” minus “A” = 2 mm. c) How to establish the recommended gap Play too much, machine cover plate at surface “C”. Play too low, machine cover plate at surface “D”. C

Cover (Drawing enlarged)

7

D

„B“

1

12

5

„A“ AH00515c

Page 8 of 10

2.2 Exchange bushings

)

• The removal of the travel gear is described in Service News AH00514 (latest version), the mounting of the dual-cone seals (4) is described in Service Bulletin AH05511 (latest version).

Exchange bushings are available in the following types: a) Freeze shrinking bush Exchange bush (3) has to be fixed by freeze- shrinking according to Service Bulletin 21 – 62a. Afterwards, it has to be remachined to the final dimension according to table below. Parts (3; 4; 5 and 6) have to be ordered for the conversion. For the part no. refer to the respective Part Catalogue of the machines. Type

Dnew (mm)

H 185 / S

355.35+0.07

H 285 / S

400.56+0.06

PC4000 PC5500

400.56+0.06 480.67+0.06

H 485 / S

520.74+0.07

H 685S / SX

520.74+0.07

H655S/PC8000 520.74+0.07

AH00515c

Page 9 of 10 b) Flange Assy. with freezed in bush If the remachining of the flange under consideration of the tolerances and diameters is not possible, it is recommended to order the flanges with freezed–in and machined bushings , to shorten the standstill of the machine. For conversion, the parts shown below (3; 4; 5; 6 and 7) have to be ordered according to the respective Parts Catalogue of the machines.

AH00515c

Page 10 of 10 3. Final works (For detailed informations refer to the respective Maintenance Manual of the machines.) 1. Fill in new oil up to the ”MAX” marking on oil level gauge (3). 2. After short operating period check oil level and gear for leaks.

AH00515c

PARTS & SERVICE NEWS

COMPONENT CODE:

25

REF NO.

AH00519e

DATE

January 15, 2007 Page 1 of 4

This PARTS & SERVICE NEWS supercedes the previous issue AH00519d which should be discarded. SUBJECT:

Adhesive lubricants for the Slew Ring Gear

PURPOSE:

Revision

APPLICATION:

All types

FAILURE CODE:

2500Z9

DESCRIPTION: The transmission of a torque from the slew pinion to the toothing of the slew ring causes the slewing of the superstructure. The existing extreme force in this section requires the separating of the engaged gears by means of grease film, to ensure a proper damping of shocks and to prevent metallic abrasion. Adhesive lubricants may be applied by means of an automatic slew ring gear lubrication system or manually by a spatula, a brush or a spray tin. Automatically tooth lubrication systems provides the upper most protection because of the continuously uninterrupted lubrication, permanent checks are not required.

AH00519e

Page 2 of 4

)

• Independent of the lubricant and lubrication system, the toothing should be visually checked approx. every 500 working hours. If the check is not possible because of applied lubricant, the toothing has to be cleaned at several points equally distributed on the circumference of the slew ring. In case of wear or damages, Dept. 8151 has to be informed to discuss suitable remedies.

ã

• These adhesive lubricants provide totally different features compared to the Bearing greases / MPG (e.g. used in the central lubrication system). Hence, those lubricants must not replace against each other or mixed. Example: This may happen when grease (1) pressed out of the upper sealing system of the races forms too big collar at the slew ring and penetrates into the toothing (2). This eventuality must be avoided by removing the excess grease.

AH00519e

Page 3 of 4 The following table includes several adhesive lubricants providing excellent results on several machines under different working conditions. The use of other lubricants is not recommended before consultation of Dept. 8151. Note: Use these Greases for Swing Circle open Gear Lubrication only Ambient Temperature °C ⇒ °F ⇒ Supplier

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 86

40 104

50 122

60 140

Castrol Molub-Alloy 936 SF Heavy NG Castrol Industrie GmbH

Castrol Molub-Alloy 936 SF Heavy Castrol Molub-Alloy 958 SF Castrol Molub-Alloy 936 SF Arctic BERULIT GA 2500 / BERUGEAR W4000

BECHEM

BERULIT GA 800 BERUGEAR W 3000 Beru Gear FG 34 (Biodegradable) Molub unee lubricant 7059 Molub Gear Tac 6895

BEL RAY Molub Gear Tac 6894 / 6899 ESSO

Dynagear Extra Ceplattyn KG 10 HMF

FUCHS LUBRITECH

Ceplattyn KG 10 HMF LT URETHYN HG O *1)

MOLYBOND

TSG Heavy Malleus GL 500

SHELL

Malleus GL 400 Malleus GL 25

TEXACO LUBRITENE *1) *2)

Crater 2X Fluid *2) Lubrene Multi ServOGL

The URETHYN HG O Grease should only be used in Arctic climates where the ambient temperatures fall to –50° C. In regions where the ambient temperatures do not fall below –40° C, a grease of the temperature range to –40° C should be used. Use the Crater 2X Fluid for Spray systems only.

AH00519e

Page 4 of 4 The manually lubrication has to be carried out with the following adhesive lubricants. Those lubricants are suitable for all temperature ranges.

Company

Product Voler Compound

KOMATSU

2000 E Spray (0,625kg) Voler Compound

Special grease

)

2000 E Adhesive lub (indicate quantity in kg)

T1 -5°C ⇒ +60°C +23°F ⇒ +140°F

T2 -20°C ⇒ +10°C -4°F ⇒ +10°F

T3 -40°C ⇒ -10°C -40°F ⇒ +14°F

P/N 500 893 98

P/N 006 057 98

• What has to be done in case of grease exchange according to the chart on page 03 ? • The new adhesive grease may directly be changed without a complete cleaning of the toothing. An increased grease supply after the exchange is recommended until the toothing is completely applied.

AH00519e

COMPONENT CODE:

K1; J1

REF NO.

AH01513

DATE

06252001

PARTS & SERVICE NEWS

Page 1 of 4 This PARTS & SERVICE NEWS supercedes the previous issues No.: 21–491 which should be discarded. SUBJECT:

Bleeding of hydraulic pumps

PURPOSE:

Avoiding of cavitation

APPLICATION:

All types

FAILURE CODE:

J100PH; K100PH

DESCRIPTION: The bleeding of the hydraulic pumps (Axial piston and Gear pumps) and the complete filling of the suction oil reservoir and the suction lines has strictly be done, to prevent damages caused by air in the suction system (cavitation). If the oil level decreases in the suction oil reservoir or the pump flows empty in case of commissioning or repairs the bleeding of the system is momentous and has to carried out as follows.

.

The bleeding procedure has to be carried out on all pumps !

Hydraulic pump

PTO

Suction line Hydraulic oil reservoir Cock closed

Suction oil reservoir

AH01513

Page 2 of 4

Hydraulic pumps at the Pump Distributer gear (Example PC4000)

3; 4

Gear pumps

1; 2

Axial piston pump (bent axis design)

I; II; III; IV

Axial piston pump (swashing plate design)

AH01513

Page 3 of 4

1. Gear pump

5 4

1

Cock closed

3

Precondition Þ • Hydraulic oil reservoir (1) filled • Cock (2) closed • Suction oil reservoir (3) totally empty or decreased level • Suction line (4) empty • Hydraulic pump (5) empty

2

5

outflowing oil

4

1

Measure Þ • Place oil pan for out coming oil. • Loosen suction line (4) • Open cock (2), when oil runs out, reconnect suction line (4)

Cock opened

3

2

The a.m. precondition has also be observed for the axial piston pumps.

2.a Axial piston pump (bent axis design)

Precondition (see above) 6

Measure Þ • Remove plug (6) • Open cock (2) • When oil flows out of the bore, insert plug (6) tighten. Cock opened

.

• The bleeding plug (6) may be placed different, it depends on

the design and mounting position.

AH01513

Page 4 of 4

2.a Axial piston pump (swashing plate design) The pump housings has to be filled up with hydraulic oil before installation and after repairs via the special bore (A) or via the leak oil connection (B).

A

B

C

.

• The suction lines of the Axial piston pumps (swashing plate

design) have to be bled via plug “C”. For that open the plug and wait until oil is coming out.

After the bleeding procedure, the hydraulic oil reservoir has to be refilled to the permissible level.

AH01513

COMPONENT CODE:

10

REF NO.

AH01523c

PARTS & SERVICE NEWS

DATE

July 28, 2006 Page 1 of 3

This PARTS & SERVICE NEWS supersedes the previous issue No.AH01523b which should be discarded. SUBJECT:

Replacement of the elastic coupling (Electro drive shovels)

PURPOSE:

Revision (Addition of a new model)

APPLICATION:

H 185SE (06099 and up); H 255SE (06122 and up); H 285SE (78137 and up); H 655SE; PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

1000FA

DESCRIPTION: The above mentioned excavators are equipped with highly flexible couplings. The inspection for the indicated tightening torques and the visual inspection for cracks have to be carried out in the following intervals (refer also to the Maintenance Manual of your excavator): • •

250 working hours after commissioning Every 2000 working hours or every 6 month

When should the elastic elements be changed? • •

In case of cracks in the marked area (arrows in illustration A and B) After 15.000 working hours or after 10 years.

In case of new installation or exchange, the following alignment tolerances have to be checked by using a gauge and, if necessary, corrected. Excavator Type H 185 SE H 255 SE H 285 SE H 655 SE PC3000 E PC4000 E PC5500 E

Clutch Part-No. 551 980 40 655 615 40 896 479 40 902 215 40 655 615 40

Radial (x)* misalignment ± 1,0 mm ± 1,0 mm ± 1,0 mm ± 0,35 mm ± 1,0 mm ± 0,35 mm ± 1,0 mm

Axial (y)* misalignment ± 2,0 mm ± 2,0 mm ± 2,0 mm ± 2,0 mm ± 2,0 mm ± 2,0 mm ± 2,0 mm

907 174 40 655 615 40 902 215 40 ± 0,35 mm ± 2,0 mm PC8000-E 907 174 40 * Explanation refers to illustrations at the next page.

Angular (z)* misalignment ± 0,5 ° ± 0,5 ° ± 0,5 ° ± 0,5 ° ± 0,5 ° ± 0,5 ° ± 0,5 °

Installation Dimension (a) 477 ± 2 mm 527 ± 2 mm 645 ± 2 mm 866 ± 2 mm 527 ± 2 mm 866 ± 2 mm 527 ± 2 mm

± 0,5 °

866 ± 2 mm

AH01523c

Page 2 of 3

axial

radial

z

angular

x

y

Inspection of the coupling elements 1. Move the cover ring(3) to the left (refer to the removing procedure) 2. Inspect the surface of the rubber elements visually (If there are 2 rubber elements – illustration B - use a small mirror) Removing of the coupling element/s 1. Remove nuts (1) and bolts (2). 2. Move the cover ring (3) to the left. 3. Remove the bolts (4). 4. Move the rubber element/s(5) to the right and remove it/them. 5. Remove the screws (6) and the ring (7). Installing of the new coupling element/s 1. Bolt ring (7) and the rubber element (5) together with the screws (6). 2. Further installation reverse order to the removal.

Excavator type H 185SE

Tightening torques Tightening torques Tightening torques A (Nm)* B (Nm)* C (Nm)* 215.0

560.0

H 255SE; PC3000; 480.0 + 50 175.0 +20 PC5500; H 285 SE H 655SE; PC8000; 250.0 +30 960.0 +110 PC4000 * Threads and bolt heads must be greased carefully with engine oil.

86.0 70.0 +

9

960.0 +110

AH01523c

Page 3 of 3 3

Illustration A

1

2 A

5 B

7

4

a

gearbox side C 6

motor side

Illustration B

3 1

2 A

B 4

a

C gearbox side 5b

motor side

5a

AH01523c

COMPONENT CODE:

30; 63

REF NO.

AH01531A

PARTS & SERVICE NEWS

DATE

06122002 Page 1 of 9

This PARTS & SERVICE NEWS supersedes the previous issues No. 21-426; 21-549 and AH01531 which should be discarded. SUBJECT:

Hydraulic accumulators – testing and refilling

PURPOSE:

Regular check

APPLICATION:

All types

FAILURE CODE:

307EPB; 6347PB

DESCRIPTION: The testing and refilling of the hydraulic accumulators have to be performed by testing- and refilling device Part no. 761 520 73. When ordering this particular device, please always indicate country of destination.

1. Testing of existing gas pressure at piston and diaphragm accumulators For testing of existing gas pressure at bladder accumulators, refer to page 7 – 9. •

Stop engine.

•

Allow pressure relief of the system to be checked.

•

Remove protective cap from accumulator.

•

Unscrew a union of the feeding line in order to allow the hydraulic oil to pour out.

AH01531A

Page 2 of 9

The testing- and refilling device includes following pressure gauges: 0 to 25 bar 0 to 100 bar 0 to 250 bar •

Screw the pressure gauge with the correct pressure range into the testing and refilling device.

•

Screw home screw (14) at the filling device.

•

Loosen the socket-head screw of the gas valve by ½ turn with a hex key 6 mm.

•

Screw filling device without hose carefully by hand onto accumulator.

•

Observe correct position of the o-ring.

. •

• Check valve in hose connection is operative only if hose is not connected.

Turn T-handle (12) several times in both directions until it is engaged in socket head of gas filler screw (11).

•

By means of the T-handle unscrew gas filler screw (11) by 4 to 5 turns until pressure gauge indicates the existing gas pressure.

AH01531A

Page 3 of 9

For the specified gas pressure of the piston-diaphragm and bladder type accumulator, refer to the circuitry diagrams in the Operation Manual.

Compare the pressure reading on the gauge with the specified gas pressure.

If the pressure reading is too low, the accumulator has to be refilled. • To fill the accumulator, a pressure – reducing valve must be used. • Only nitrogen must be used to fill the accumulator.

2. Filling of the accumulator •

Close shut-off valve (5) at the bottle pressure – reducing valve. Turn in completely outlet screw (14) of filling device and install the hose.

AH01531A

Page 4 of 9

•

Open valve (8) of nitrogen bottle and check bottle pressure. The bottle pressure must always be higher than the pressure specified for the accumulator.

•

adjust specified accumulator pressure with pressure-reducing valve (6).

•

Turn out the filling screw (11) by means of the T-handle of the filling device.

•

Open slowly shut-off valve at bottle pressure reducing valve and let nitrogen flow into accumulator, until pressure gauge on filling device indicates the specified pressure. Then close shut – off valve.

AH01531A

Page 5 of 9

•

Wait for temperature to be equalized (approx. 5 min.) and open outlet screw (14) to let the pressure drop to the specified value.

•

Close outlet screw (14).

•

Screw in tightly screw (11) by means of T – handle (12).

•

Open outlet screw to let nitrogen escape from filling device.

•

Disconnect hose connection and unscrew filling device.

•

Fasten O - ring (13) to the testing device.

•

Tighten the screw (11) by means of a hex key 6 mm.

AH01531A

Page 6 of 9

•

Reinstall protective card and retighten union in feeding line.

•

Close bottle valve (8).

•

Turn out completely the T – handle at the pressure reducing valve (6).

AH01531A

Page 7 of 9

3. Testing of existing gas pressure bladder accumulators The testing- and refilling device includes pressure gauges: 0 to 25 bar 0 to 100 bar 0 to 250 bar. •

• • • •

Screw the pressure gauge with the correct pressure range in the testing- and refilling device. Shut down the engine. Allow pressure relief of the system to be checked. Unscrew the feeding line in order to allow the hydraulic oil to pour out. Remove cap (1) and nut (2). Do not remove O - ring (3).

. • • • • • • •

• Check valve in hose connection is operative only when hose is not connected.

Turn the socket head screw (4) installed in the adapter (2) a little bit. Mount testing- and refilling device to adapter (2). Install adapter (2) to testing connection (3). Turn in completely outlet screw of the filling device. Turn T – handle (12) several times in both directions until it is engaged in the screw (4) of the adapter (2). By means of the T – handle (12) turn in the screw so far that the existing gas pressure is indicated by the pressure gauge. Do not turn in the screw any further; the gas valve may be destroyed.

AH01531A

Page 8 of 9

If the pressure reading does not correspond with the nominal filling pressure, the accumulator has to be refilled.

4. Filling of the bladder accumulator • To fill the accumulator, a pressure – reducing valve must be used. • Only nitrogen must be used to fill the accumulator. •

Close the shut off valve (5) on the pressure-reducing valve.

•

Turn in completely the outlet screw (14), see illustration on page 5.

•

By means of the T-handle (12), turn out the screw (4) of the adapter (2) until the gas valve in the testing connection (3) of the accumulator is closed. After that, install connecting hose.

•

Open the valve (8) at the nitrogen bottle and check the gas pressure of the bottle. The gas pressure of the nitrogen bottle must always be higher than the specified filling pressure of the accumulator.

•

Adjust the specified filling pressure by means of setting screw (6) of the pressure reducing valve. Open the gas valve in the testing connection (3) of the accumulator ba turning in screw (4).

•

Slowly open the shut off valve (5) at the pressure reducing valve and fill the accumulator until the pressure gauge (7) of the testing and refilling device indicates the specified filling pressure. Then close the shut-off valve (5).

AH01531A

Page 9 of 9

•

Wait for temperature to be equalized (approx. 5 min) and, if necessary, reduce pressure with outlet screw (14) or let the pressure reach the specified value according to page o4.

•

Close outlet screw (14).

By means of T-handle (12) turn out screw (4) from the adapter (2) till the gas valve in the testing connection (3) is closed. • •

•

Open outlet screw (14) that the nitrogen can escape from the filling and testing device. Close the nitrogen bottle and remove the filling- and testing device, filling hose and pressure –reducing valve. Turn out completely screw (6) of the pressure-reducing valve. By doing so, the spring-reducing valve is discharged.

•

Re-install protection cap in the testing connection.

•

Re-tighten the hydraulic line.

AH01531A

COMPONENT CODE:

25

REF NO.

AH02513b

PARTS & SERVICE NEWS

DATE

January 4, 2005 Page 1 of 4

This PARTS & SERVICE NEWS supersedes the previous issue No. AH02513a which should be discarded. SUBJECT:

Testing wear and tear of swing circle bearing

PURPOSE:

In time ordering of a new swing circle in order to prevent unexpected downtime

APPLICATION:

All types

FAILURE CODE:

2500CA

DESCRIPTION: For assessing the condition of the swing circle bearing, we recommend that its normal wear rate is determined. The first measurement must be performed when the excavator is put into operation in order to obtain a base value for subsequent repeat measurements. The following measurements have to be effected: 1. Period of the first 10.000 h: 2. Period more than 10.000 h:

every 5.000 working hours; every 2.500 working hours.

After finishing the measurements, record the values obtained in a tabular form. The diagram shows the principle of bearing wear progression. If the “increased wear” situation is reached, prepare the changing of the swing circle.

)

• We recommend to turn the swing circle (180°) after 20 000 working hours.

normal wear

increased extrem wear wear

Axial movement/wear

mm

Base value

Working hours

h AH02513b

Page 2 of 4 Measurement procedure 1. Park the machine on level ground. 2. Slew the attachment to the normal working position (idler wheel in front). 3. Remove cover as shown in the photos (Illust. 7 and 8). 4. Clean the center slew gear tooth and the contact point on the superstructure. 5. Install the dial gauge* as shown in the photos. 6. Turn the swing brake switch in the on position. 7. Straighten the attachment fully (lmax) and raise the shovel approx. A=3 m over the ground (Illust. 1, 3 or 5). 8. Set measuring instrument (dial gauge*) to zero.

ã

• Make sure the area below and around the excavator is clear of all persons before you start operating.

9. Move the attachment in the shown position (Illust. 2, 4 or 6). Lower the attachment until the track lift off the ground up to the sprocket (B).

)

• Use for all measurements the same distances “A” and “B”.

10. Move the attachment in the normal parking position. 11. Read measurement “M 1” (out of the memory) and record in the table (page 4). 12. Repeat the measuring procedure at the same point for a 2nd value (M 2). 13. Remove the dial gauge, swing the superstructure 180 degrease and repeat the measuring procedure two times. * We recommend to use a digital dial gauge with min. / max. measuring value memory (Part No. 794 537 73).

Photo only as example

AH02513b

Page 3 of 4

AH02513b

Page 4 of 4

Excavator Typ: Planned h 0

Actual h

Date

Serial number: Front M1

Front M2

Mfront = (M1 + M2)/2

Rear M1

Rear M2

Mrear = (M1 + M2)/2

5 000 10 000 12 500 15 000 17.500 20 000 22.500 25 000 27.500 30 000 32.500 35 000 37.500 40.000

AH02513b

COMPONENT CODE:

75

REF NO.

AH02521b

PARTS & SERVICE NEWS

DATE

April 3, 2007 Page 1 of 10

This PARTS & SERVICE NEWS supersedes the previous issue Number AH02521a which should be discarded. SUBJECT:

Track group – wear measurement

PURPOSE:

Revision

APPLICATION:

H 185 to PC8000

FAILURE CODE:

752DCA

DESCRIPTION: 1. 2. 3. 4. 5. 6. 7.

Preconditions for the measurements Adjusting range for guide wheels Chain elongation / measured over three track pads (4 pins) Circular pitch (Sprocket / Track pad) Wear of track pads (Roller contact surface) The X-dimension becomes zero Table

The professional and regular inspection increases the service life of the track group and can avoid early and very expensive repairs, including unforeseen standstill of the machine. It is recommended to perform the inspections every 3 month or 1500 working hours according to the description and to fill in the measured values to the table on page 10. The measurements are described in detail and illustrated on pages 4 to 6. To prevent unnecessary problems and standstills and to assure fast help when wear limits are reached, it is recommended to send the filled-in tables in the mentioned intervals to Komatsu Mining Germany, Service Department 8151.

Illustration 1

AH02521b

Page 2 of 10 1.

Preconditions for the measurements:

1.1.

Cleaning of the track group, according to the Maintenance Manual

Illustration 2 1.2

Track sag (A): On Machines without the hydraulic track - tensioning system up to max. 230 mm • H 185S • H 285 - H 285S up to max. 300 mm • H 485 - H 485S up to max. 420 mm

1.3

Track sag (A): On Machines with hydraulic track - tensioning system • No specification, since self-regulating

Illustration 3

AH02521b

Page 3 of 10 2.

Adjusting range for guide wheels

Illustration 4

Legend (1)Guide wheel (2)Slide block (3)Stop plate “X” Adjusting range for track tension The adjusting range for track tension is the distance “X” between guide wheel slide block (2) and stop plate (3). Depending on the stretching of the track the slide block (2) may come in contact with stop plate (3). In such a case, it must be ensured that the track does not become too loose. Depending on track condition; the removal of one track pad will restore the adjusting range “X”. If necessary contact our Service Department for more information.

AH02521b

Page 4 of 10

3. Chain elongation / measured over three track pads (4 pins) This wear check has to be carried out in 4 equally distributed areas of the track chain (L1 to L4 - l.h. and R1 to R4 - r.h.). • Turn superstructure 90° to the travel direction. • Retract attachment and lower bucket on the ground until the chain has no longer contact with the ground. • Block the machine against inadvertent lowering with suitable devices.

ã

• Turn sprocket until the first measuring area (L1) is located at the deepest point of sag (“T“).

)

• To measure the areas L2-L4 turn the chain always forward until point “T“ is reached.

• To obtain a comparable measuring result, stop the main drive motor/engine of short duration, so that the track tensioning system is released to pilot pressure. • Place the points of the dividers into the centre bores of pins 1 and 4 of the measuring area L1 / R1, determine the distance and record in the table on page 10. • Repeat measuring procedure at measuring areas L2 / R2 to L4 / R4.

Illustration 5

AH02521b

Page 5 of 10 4.

Circular pitch (Sprocket / Track pad)

For this inspection, the excavator has to be placed on an even surface and only one chain has to be moved, like turning. Diesel engine: Electric motor:

Operate at low idle. Operate joy-stick slightly.

• Move l.h. track group forward (Sprocket rotation F = forward), until the contact area of the uppermost sprocket tooth (0) and the track-pad lug (0) is in the illustrated position, (Refer to illustration 6 “A”, page 6). • Measure gaps (X1). A. Measure inside and outside of the sprocket between the sprocket teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain. • Record the values into table -circular pitch A- on page 10. • Repeat the measurements on the r.h. track group. • Move l.h. track group back (Sprocket rotation R = backwards), until the contact area of the lowest sprocket tooth (0) and the track-pad lug (0) is in the illustrated position, (Refer to illustration 6 “B”, page 6). • Measure gaps (X2). Measure inside and outside of the sprocket between the sprocket teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain. • Record the values to the table -circular pitch B- on page 10. • Repeat the measurements at the r.h. track group. 5.

Wear of track pads (Roller contact surface)

• Stop the engine/motor and secure the machine against unintentional movement. • Mark 3 track pads of each track group (l.h. track group and r.h. track group) to make repeated measurements in the future comparable. • Take a ruler to measure the wear of the roller contact surface. The ruler needs an even contact surface, if not exist, prepare the track pad as necessary. (Refer to illustration 6 “C”, page 6). • Record the measuring results in the form sheet on page 10.

)

• For wear limits of individual parts please refer to P&S News “AH06507 Undercarriage – wear limit values”.

AH02521b

Page 6 of 10

Illustration 6 AH02521b

Page 7 of 10 6.

One X-dimension becomes zero

What to do if one X-dimension becomes zero 1.

If the connection point of Roller path depth and Elongation is in the oversize sprocket area*, change to oversize sprocket. 2.1 If the connection point of Roller path depth and Elongation is in the standard sprocket area* run further with this configuration as long as you reach the oversize sprocket area. 2.2 If there becomes a significant interference of sprocket and track pad match; in such case it could become necessary to change to standard sprocket size. * refer to illustrations 7 to 10 For the exchange of the oversize sprockets, refer to Service Bulletin AH00514.

AH02521b

Page 8 of 10

Illustration 7

Illustration 8 AH02521b

Page 9 of 10

Illustration 9

Illustration 10 AH02521b

Page 10 of 10

7.

Table for measurements

Machine-Type : Customer : Oversize sprocket ? : (left hand side)

Oversize sprocket ? : (right hand side)

NO

Serial-No. : Location : Date of installation: ................... at operating hours: ..................... Date of installation: ................... at operating hours: .....................

YES

Ö

NO

YES

Ö

Chain elongation (Illustration 5): Measuring area W-dimension [mm] via 4 pins

Left hand crawler track “L“ L1

Chain elongation (Illustration 5): Measuring area W-dimension [mm] via 4 pins

Operating hours : Date of measurement : Part-No. of track pad :

L2

L3

L4

Right hand crawler track “R“ L1

L2

L3

L4

Circular pitch: Illustration 6 “A“ Sprocket side X1-dimension [mm] L.H X1-dimension [mm] R.H

3

inside

3 points (equally distributed on the chain) 1 2 outside inside outside inside

3

inside

3 points (equally distributed on the chain) 1 2 outside inside outside inside

Illustration 6 “B“ Sprocket side X2-dimension [mm] L.H X2-dimension [mm] R.H

outside

outside

Wear of Track pads (Illustration 6 “C“): Track pad

Side

No.1 No.2 No.3 No.4 No.5 No.6

L.H. L.H. L.H. R.H. R.H. R.H.

Dimension “B“ [mm]

Number of cracked track pads left hand crawler track

right hand crawler track

AH02521b

COMPONENT CODE:

03

REF NO.

AH03506b

PARTS & SERVICE NEWS

DATE

October 25, 2003 Page 1 of 5

This PARTS & SERVICE NEWS supersedes the previous issue AH03506a which should be discarded. SUBJECT:

Hydraulic oil cooler and water cooler fan bearings

PURPOSE:

Replacement of the bearings

APPLICATION:

PC4000; PC5500; PC8000

FAILURE CODE:

0373CA

DESCRIPTION: Two types of bearing units are used for the cooler fans at the above mentioned excavator models: 1. Grease lubricated bearings

)

2. Gear oil lubricated bearings

• We recommend to replace these bearings to avoid consequential damages according to the following table: Bearing unit Replacing time after: Grease lubricated bearings 8 000 working hours Gear oil lubricated bearings 10 000 working hours * * or if damage or a leak has occurred.

)

• The hydraulic motors for the fans should be replaced preventively every 10.000 working hours.

AH03506b

Page 2 of 5

Hints for replacement: 1. Grease lubricated bearings

1 Bearing retainer 2 Shaft 3 Hydraulic motor 4 Fan 5 Bearing 6 Grease nippel 7 Circlip 8 Bolt 9 Bolt 10 Locking plate

1. Remove the hydraulic and the grease lines; the fan; and then the motor. 2. Remove the bearings and the fan shaft. 3. Clean all parts carefully. 4. Install the first bearing (5) and fill the chamber between the bearings to 50% with grease. 5. Install the shaft with the first bearing (5) and the grease into the bearing retainer. 6. Install the second bearing and fix it with the circlip (7). (Install also the sleeve between the bearings if applicable.) 7. Grease the hydraulic motor drive shaft with “Optimol paste white T” and fill the chamber in the fan shaft to 50% with normal grease according to the drawing above. 8. Reinstall the bearing hub, the fan and the motor. 9. Reconnect all lines. • Grease the bearings every 500 working hours with maximal 2 strokes with the hand greasing pump.

AH03506b

Page 3 of 5

2. Gear oil lubricated bearings 2. Gear oil lubricated bearings 1 Bearing retainer 2 Shaft 3 Circlip 4 Bearing 5 Shaft grommet 6 Shaft seal 7 Plug Fill the chamber at the lip type seal with grease.

1. Remove the hydraulic lines; the fan, then the complete unit. 2. Drain off the gear oil and remove the motor, the bearings, the fan shaft, the shaft grommet and the shaft seal. 3. Clean all parts carefully. 4. Check the dia. “d” according to drawing and table at the next page. 5. Install a new shaft grommet with the flanged end at first (press it into depth “a” see next page). 6. Do not remove the seam of the shaft grommet. 7. Install the 1st bearing and the shaft seal into the bearing retainer. 8. Grease the shaft and install it. 9. Mount the 2nd bearing(4) and the circlip. 10. Check the spline and grease the hydraulic motor drive shaft with “Optimol paste white T”. 11. Reinstall the motor by using a new O – ring and mount then the fan. 12. Fill in the bearing retainer gear oil according to the Maintenance Manual. 13. Reconnect the hydraulic lines.

AH03506b

Page 4 of 5

PC4000

PC5500

PC8000

Oil cooler

Water cooler

Oil cooler

Water cooler

Oil cooler

Water cooler*

Part no.

Part no.

Part no.

Part no.

Part no. Part no.**

Part no.

Fan mounting 89590740 90202640 91091140 90479140 90389040 93394140 90968540b (assy.) Repair kit *** Press depht "a" (mm) Shaft dia. "d" (mm)

79296573 79296673 79296573 79296673 79296773 79484873 79296873

4 -0,5

3,7 +0,2

4 -0,5

3,7 +0,2

∅80 ±0,05

∅110 ±0,05

∅80 ±0,05

∅110 ±0,05

4 -0,5

6,4 ±0,8

∅100±0,05 ∅130−0,025

4,3 ±0,8 ∅ 85 ±0,05

* Serial No. 12040 up – see drawing next page ** Serial No. 12048/12049 only *** The Repair kit includes: 2 bearings; 1 shaft seal; 1 shaft grommet; 1 O-ring

Fill the chamber at the lip type seal with grease.

AH03506b

Page 5 of 5

PC8000-6 Water cooler fan bearings

Intermediate ring

AH03506b

COMPONENT CODE:

26

REF NO.

AH03509a

PARTS & SERVICE NEWS

DATE

22nd July 2003 Page 1 of 25

This PARTS & SERVICE NEWS supersedes the previous issue AH03509 which should be discarded. SUBJECT:

Slew gear GFB 174 E 9017 (Part No. 917 915 40)

PURPOSE:

Modification to slew gear GFB 174 E 9020 (Part No. 92432540) including exchanging the sun gear shaft

APPLICATION:

PC8000 (12037 – 39); PC5500 (15012 – 15017); PC4000 (08151); PC3000 (06194)

FAILURE CODE:

2600Z9

DESCRIPTION:

General In order to increase the lifetime of the parking brake discs the swing gear oil filling capacity should be reduced by approximately 20 liters. The new filling capacity is approx. 42 liters. The present oil level gauge on the gear can no longer be used for checking the oil level. There are two possibilities to modify the oil level checking system. For increasing the lifetime of the slew gear the sun gear shaft should be changed during the slew gear modification. Page 1. Modification Kits 2 2.

Variant (A) – Modification by replacing of the swing gear cover with the complete parking brake unit,

6

3.

Variant (B) – Modification by machining the swing gear cover. 3.1 Modification of the swing gear cover a) Dismounting b) Machining of the swing gear cover c) Reassembly

8 11 11 12 13

4.

Completion of the swing gear cover

24

5.

Oil level checking procedure

25

AH03509a

Page 2 of 25 1. 1.0

Modification Kits One new gear shaft is required for one slew gear (Part No. 757 360 73 – differences to the old sun gear shaft: refer to illustration 6) 1.1 Kits for modification of the slew gear(s) according to Variant (A) 1.1.1 PC3000-1 Part No.: 794 016 73 Pos.

Part-No.

1 15 16 17 14 18 1 20 1 2

79227073 37441299 90635240 37126599 92582540 31318499 90756840 92582940 972111 50774898

Qty. Description 1 4 4 4 4 4 1 1 1 1

Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring

Illustration 3 6 6 6 6 6 6 6 2 2

1.1.2 PC4000-6 Part No.: 794 017 73 Pos.

Part-No.

1 15 16 17 14 18 19 20 1 2

79227073 37441299 90635240 37126599 92582540 31318499 90756840 92582940 972111 50774898

Qty. Description 2 12 12 12 12 12 2 2 2 2

Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring

Illustration 3 6 6 6 6 6 6 6 2 2

(Cover plates must be adapted.)

AH03509a

Page 3 of 25 1.1.3 PC5500 Part No.: 794 018 73 Pos.

Part-No.

1 15 16 17 14 18 19 20 1 2

79227073 37441299 90635240 37126599 92582440 31318499 90756940 92582840 972111 50774898

Qty. Description 2 10 10 10 10 10 1 1 2 2

Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring

Illustration 3 6 6 6 6 6 6 6 2 2

1.1.4 PC8000 Part No.: 794 019 73 Pos.

Part-No.

1 15 16 17 14 18 19 20 1 2 1 1

79227073 37441299 90635240 37126599 92582440 31318499 90756940 92582840 972111 50774898 92583240 92583140

Qty. Description 3 14 14 14 14 14 2 2 3 3 1 1

Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring Cover plate Cover plate

Illustration 3 6 6 6 6 6 6 6 2 2 -

AH03509a

Page 4 of 25 1.2 Kits for modification of the slew gear(s) according to Variant (B) 1.2.1 PC3000-1 Part No.: 794 020 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2

37441299 90635240 37126599 92582540 31318499 90756840 92582940 33132299 79224973 972111 50774898

Qty. Description 4 4 4 4 4 1 1 1 1 3 1

Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring

Illustration 6 6 6 6 6 6 6 4 4 2 2

1.2.2 PC4000 Part No.: 794 021 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2

37441299 90635240 37126599 92582540 31318499 90756840 92582940 33132299 79224973 972111 50774898

Qty. Description 12 12 12 12 12 2 2 2 2 6 2

Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring

Illustration 6 6 6 6 6 6 6 4 4 2 2

(Cover plates must be adapted.)

AH03509a

Page 5 of 25 1.2.3 PC5500 Part No.: 794 022 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2

37441299 90635240 37126599 92582440 31318499 90756940 92582840 33132299 79224973 972111 50774898

Qty. Description 10 10 10 10 10 1 1 2 2 6 2

Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring

Illustration 6 6 6 6 6 6 6 4 4 2 2

1.2.4 PC8000 Part No.: 794 023 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2 1 1

37441299 90635240 37126599 92582440 31318499 90756940 92582840 33132299 79224973 972111 50774898 92583240 92583140

Qty. Description 14 14 14 14 14 2 2 3 3 9 3 1 1

Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring Cover plate Cover plate

Illustration 6 6 6 6 6 6 6 4 4 2 2 -

AH03509a

Page 6 of 25 2. Variant (A) – Modification by replacing of the swing gear cover with the complete parking brake unit 1. 2. 3. 4.

Prepare the swing gear cover as described on page 23. Drain the motor adapter housing (about 0.6l oil). Remove the 8 bolts (7) M16 mm at the hydraulic motor (refer to illustration 1). Remove the motor with connected hoses and place it beside or if this is not possible, disconnect the hydraulic lines and close the ports. 5. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16 from the gear box. 6. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit. 7. Replace the sun gear shaft (5) (refer to illustration 2). 8. Install the new Cover-Brake-Unit by using a new O-ring. 9. Modify the Swing gear type on the type plate old: GFB 174 E9017 to new: GFB 174 E9020 with punch marks. 10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring. 11. Fill the motor adapter housing with oil according to the Maintenance Manual. 12. Weld on the oil level gauge brackets (20) on the hydraulic oil reservoir carrier and if so planed a second one onto the machinery house wall. 13. Insert the attached oil level gauges (19)into the brackets. 14. Check the oil level in the swing gear as described on page 25.

AH03509a

Page 7 of 25

Illustration 1 Illustration 1 – before modification 1

Oil level gauge swing machinery

2

Oil filler plug swing machinery

3

Breather filter swing machinery

4

Oil level gauge motor adapter housing

5

Breather filter motor adapter housing

6

Oil drain plug

7

Motor fastening bolts

8

- Gearbox fastening bolts (quantity: 34) - Mounting screws (quantity: 8)

AH03509a

Page 8 of 25 3. Variant (B) – Modification by machining the swing gear cover 1. Drain the motor adapter housing (about 0.6l oil). 2. Remove the 8 bolts (7) M16 at the hydraulic motor (refer to illustration 1). 3. Remove the motor with connected hoses and place it beside or if this is not possible, disconnect the hydraulic lines and close the ports. 4. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16 from the gear box (refer to illustration 1). 5. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit. 6. Replace the sun gear shaft (5) (refer to illustration 2). 7. Remove the old O-ring and clean the groove. 8. Modify the swing gear cover as described on pages 11 - 22. 8. Install the modified Cover-Brake-Unit by using a new O-ring. 9. Modify the Swing gear type on the type plate old: GFB 174 E9017 Part No. 917 915 40 to new: GFB 174 E9020 Part No. 924 325 40 with punch marks. 10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring. 11. Fill the motor adapter housing with oil according to the Maintenance Manual. 12. Weld on an oil level gauge bracket (20) on the hydraulic oil reservoir carrier and if so planed a second one onto the machinery house wall. 13. Insert the attached oil level gauges (19)into the brackets. 14. Check the oil level in the swing gear as described on page 24.

AH03509a

Page 9 of 25 Illustration 2 – Overview before modification 1

3

4 5

2

AH03509a

Page 10 of 25 Illustration 3 – Cover with brake (partly)

1

Pressure connection (M18x1.5) – max 60 bar

AH03509a

Page 11 of 25 3.1 Modification of the swing gear cover a) Dismounting 1. Remove the old oil level gauge assy. (390) and close the opening with a plug (99). 2. Remove the both snap rings (508; 549). 3. Loosen the 8 socket head cap screws (519). 4. Remove the bearing ring (503) by using of 2 eyebolts (M 16). 5. Before reinstallation apply the piston (116) with pressure (max. 60 bar) (see also illustration 4), otherwise the 2 screws (316)are prestressed (springloaded). 6. Remove the 2 socket head cap screws (316). Remove the piston (116). 6. Dismount the 10 Inner discs (505); the 11 outer discs (506) and the 10 sinus rings (551). 7. Remove the drive shaft (130). 501 8. Remove the disc (504). 99 501 390 316 551 505 503 506 504

130 549

508

116

519 Illustration 4

AH03509a

Page 12 of 25 b) Machining of the swing gear cover (501 – disc housing) 1. Mill at the swing gear cover six areas as shown. 2. Drill 6 holes in the milled areas and tap 1 ¼ inch. Illustration 5

45°

45°

R31.5 30

30°

+0.5

30°

Ø524 Ø660 R 1.6 30

G 5/4 AH03509a

Page 13 of 25

AH03509a

Page 14 of 25 c) Reassembly 3. Install the new disc (504) as shown.

4. Reinstall the drive shaft (130) with the ball bearing (51353298).

AH03509a

Page 15 of 25

5. Install the new discs. At first an outer disc (grease it with oil), then an inner disc and then a sinus ring ... and so on.

AH03509a

Page 16 of 25

AH03509a

Page 17 of 25

AH03509a

Page 18 of 25 Before installation supply the piston (116) with pressure (max. 60 bar). Do not forget to exchange the O-ring.

AH03509a

Page 19 of 25

AH03509a

Page 20 of 25

AH03509a

Page 21 of 25

AH03509a

Page 22 of 25

AH03509a

Page 23 of 25

AH03509a

Page 24 of 25 4. Completion of the swing gear cover 1. Remove plugs* (A3) from the swing gear cover. * numbers depends on type of the excavator 2. Install the oil level gauge tubes (14; 15; 16; 17) as shown in the illustration 6. 3. Close the tubes with plugs M24 (18).

20

19

Illustration 6

A3 – Plug 14 – Oil level gauge tube 15 – Socket 16 – Cutting ring 17 – Union nut 18 – Plug 19 – Oil level gauge 20 – Oil level gauge bracket AH03509a

Page 25 of 25 5. Oil level checking procedure (engine at standstill) The design of the swing gear requires four or five locations for oil level checking. The correct oil level is below the upper planetary stage. To reach this level between the planetary gears it is necessary to find out at which of the four, five or six tubes the oil level gauge can be insert to the stop.

Proceed as follow: 1. Take out oil level gauge (19) from bracket (20). 2. Remove plug (18) from one tube (14) and insert gauge (19). If the gauge can not be moved in to the stop use the next tube (14). Repeat this procedure until the gauge can be inserted to the stop. 3. The oil level should be between the MIN and MAX marking on the gauge. Add oil if necessary. 4. Remove oil level gauge from the tube and insert into bracket (20). 5. Close the tubes with the plugs (18).

• Do not leave the gauge (19) in the tube (14). If the gauge is left in the tube the swing gear and the gauge will be damaged when the swing gear operates.

AH03509a

COMPONENT CODE:

71

REF NO.

AH03510

PARTS & SERVICE NEWS

DATE

2nd June 2003 Page 1 of 18

SUBJECT:

ESCO bucket tooth system

PURPOSE:

Hints for handling

APPLICATION:

PC4000; PC5500 (15012 - ); PC8000

FAILURE CODE:

7168Z9

DESCRIPTION: At our excavators PC4000; PC5500 (15012-) and PC8000 the new bucket tooth system “POSILOK” is used. In the following is showed how to handle the parts of this system. Page 2

1.

Overview

1.1 1.2

Komatsu standard version Optional version

2.

The Points

3

2.1 2.2

Removing the points Installing the points

4 5

2 2

3.

The Adapters

3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.4

Adapter removal Nose rebuild Nose end and sides rebuild Nose flats rebuild Rear corner rebuild Adapter installation Retighten Sidewinder Pin

6 8 8 9 9 10 11

6

4.

Wear Caps

11

4.1 4.1.1 4.1.2 4.2

11 11 12 13

4.2.1 4.2.2

Lock style wear caps (PC4000) Removal Installation Non lock style wear caps (Option PC4000; PC5500; PC8000) Removal Installation

5.

The Shrouds

14

5.1 5.2 5.2.1 5.2.2 5.2.3 5.3 5.4

Removal the shrouds Installing the shrouds Prepare the surface Position the bosses Welding the bosses Inspecting Worn Shrouds Installing (Shrouds and Pins)

14 15 15 16 17 17 18

13 13

AH03510

Page 2 of 18 1. 1.1

Overview Komatsu standard version

Additional wearcap for plate lips version (PC4000) Wearcap

1.2

Optional version

!

• For changing to optional version new points, new adapters and the wearcaps are required.

AH03510

Page 3 of 18 Classification of the Tooth Systems to the Excavator Types Type of Excavator PC4000 PC5500 PC8000 - ( 12030) - ( 12034)

Shovel Version S 110 S 130 S 145 S 130 S 130

Backhoe Version S 95 S 130 S 145 -

Component Preparation Prior to installing the new tooth system components: • Thoroughly clean all bearing surfaces on the tooth base, adapter and pin. • Visually inspect top and bottom of tooth base for wear, refer to following sections. • Replace all damaged components.

2.

The points

4 2

3

6

5 1 1

Point

2

Posilok Locking Pin

3

Integral rubber lock

4

Adapter

5

Mating rails between point and adapter

6

Stabilizing flats

AH03510

Page 4 of 18 2.1

Removing the points

!

• All persons performing maintenance work should wear a approved hard hat, safety glasses, steel-toed shoes and gloves. • To avoid injury to others, keep people not directly involved well out of the way.

1. Removal tool between the (PART NO. 79350273) Posilok Pin and the lock

2. Drive the Posilok Pin out using a removal tool

(Part No. 793 502 73)

Use this end to start the Posilok Pin out.

• • •

Use this end to drive it through.

Remove the vertical drive-through pin using a hammer and a pin removal tool (Part No. 79350273). Make sure to insert the tip of the removal tool between the Posilok Pin and the rubber lock. In order to loosen the point for removal from the adapter, it may be necessary to tap the sides of the point to loosen fines.

AH03510

Page 5 of 18 2.2

Installing the points

Preparation Prior to point replacement, make sure adapters are clean and free of damage. Carefully inspect adapters for excessive wear. If the nose is worn or if insufficient wear metal remains to see adapters through their work cycle, they should be replaced with new ones. Vertical locking pins: Locking pins may be reused provided they do not show signs of significant wear, damage or distortion. Points: If you are going to install new points, make sure the rubber lock is installed so the arrows embossed on the surface of the lock are pointing forward (toward the tip of the point).

Position the locking pin and drive it in.

Vertical locking pin

Point • •

Install the points onto the adapters. After positioning a point onto its adapter, drive in the vertical locking pin using an 4 kg (8lb) hammer. The rubber lock keeps the Posilok Pin securely in place.

Posilok Pin engages the lock.

Topside and forward •

Drive in the Posilok Pin until it engages the lock. When the Posilok Pin is correctly in place, the rubber lock fits into the slot of the Posilok Pin to secure it.

AH03510

Page 6 of 18 3.

The adapters

3.1

Adapter removal Prior to using an adapter tool be sure that the following safety precautions are followed at all times: • Always wear proper safety equipment including hardhat, gloves, safety glasses and steel-toed shoes. • Never exceed the lifting capacity of the tool. Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb) - for the S145 tooth system. Lifting tool 112K (Part No. 793 504 73) rated capacity 230kg (500lb) - for the S130 tooth system. • Tool is intended for vertical lift only. • Always stand clear of the raised adapter. • Never allow anyone to work under the adapter until it is secured to the lip by the appropriate locking mechanism. • Always use the safety features (lock and safety pin) as indicated. Never use hand tools or other fastener to secure the sleeve. Never use anything other than the sleeve provided to support the adapter. • Replace the tool when it becomes visibly damaged or distorted. Do not attempt to repair a damaged tool.

• •

Position the bucket with the nose tilted slightly upward. Clean debris from adapter Sidewinder Pin head slot and remove cap from Sidewinder Pin head. (The fastening Sidewinder Pin may become frozen in the nose hole by cemented fines. In this event, use either a hammer and drift or a porta-power, applied directly against the end of the Sidewinder Pin sleeve, to force the Sidewinder Pin out. Use a striking plate, as needed, to avoid hammering the end of the Sidewinder Pin base. With body completely retracted, insert drift that fits inside hex recess and hammer Sidewinder Pin through nose hole. Alternately, drift can be placed against outer sleeve. Avoid hammering over hex recess and thereby peening over the edges of this recess.)

AH03510

Page 7 of 18

•

Insert Allen hex bit (14; 17 or 19 mm) into the head of Sidewinder Pin and turn counterclockwise (only for S 95 clockwise) until the Sidewinder Pin body is fully retracted. Do not continue to turn after “stop” is felt. The Sidewinder Pin is designed for operation with a ratchet wrench and should not normally require use of an air-impact wrench.

! •

• For removing the adapter the Sidewinder Pin need not to remove out off the adapter base if it is in good condition. • If the Sidewinder Pin have to be removed the end opposite the hex socket must be removed at first.

Lifting tools (refer to drawing next page): 122K (793 503 73): (for S145)

- Remove the safety pin of the adapter tool and slide the sleeve off the arm. - Guide the arm through the square hole in the nose of the adapter. - Arm must be pointed towards rear of the adapter. - Slide the sleeve onto the arm, align the holes in the arm and sleeve and install safety pin.

112K (793 504 73): (for S130)

- Guide the lug on the end of the arm through the D-shaped hole in the nose of the adapter. - Rotate the arm towards the rear of the adapter until the tool is aligned with the adapter 90° and slide the lock down through the D-shaped hole and insert the safety pin.

AH03510

Page 8 of 18

Part No. 793 503 73 (for S145) Part No. 793 504 73 (for S130) Rotate the arm 90° for fixing

Safety pin of the adapter tool Sleeve •

Using a boom rated at 270 kg (600 lb) or greater (PC5500 and PC8000) or a boom rated at 230 kg (500 lb) or greater (PC4000), hook into the shackle at the top of the arm and remove the adapter.

3.2 Nose rebuild Nose fit: This tooth system is designed to operate with movement of the adapter on the nose. However, movement may become excessive over long term service because of nose wear. In this event, the nose can be rebuilt in the indicated areas with welding and grinding.

3.2.1 Nose end and sides rebuild

AH03510

Page 9 of 18

•

Place the nose side template on the centerline of nose. Nose side template Size S 95 S 110 S 130 S 145

• •

Nose Side Template 79350573 79350773 79350973 79400373

Nose Flats Template 79350673 79350873 79351073 79400473

Weld–rebuild nose end surface and grind flat until gage ends align with front edge of pin hole. Weld stringer beads should run parallel to the nose width. Rebuild nose end radii as necessary.

3.2.2 Nose flats rebuild • •

Place the nose flats template over the nose as shown. Weld buildup nose flats and radii and grind flat until template contacts nose end. Nose flat template

3.2.3 Rear corner rebuild • • • •

Weld rebuild rear corners of nose. Chalk or paint weld buildup areas, place adapter as far as possible on nose and then remove. High spots will be indicated by missing chalk or paint. Grind weld buildup areas until a new adapter has a little or no movement up and down. Grind blend smoothly into rear shoulders.

AH03510

Page 10 of 18 3.3

Adapter installation Prior to using an adapter tool be sure that the following safety precautions are followed at all times: • Always wear proper safety equipment including hardhat, gloves, safety glasses and steel-toed shoes. • Never exceed the lifting capacity of the tool. Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb) - for the S145 tooth system. Lifting tool 112K (Part No. 793 504 73) rated capacity 230kg (500lb) - for the S130 tooth system. • Tool is intended for vertical lift only. • Always stand clear of the raised adapter. • Never allow anyone to work under the adapter until it is secured to the lip by the appropriate locking mechanism. • Always use the safety features (lock and safety pin) as indicated. Never use hand tools or other fastener to secure the sleeve. Never use anything other than the sleeve provided to support the adapter. • Replace the tool when it becomes visibly damaged or distorted. Do not attempt to repair a damaged tool.

•

The Sidewinder Pin must be fully retracted in the adapter base. Sidewinder Pin can be inserted from either side of base. Recommend corner positions be installed from inside.

•

Position the bucket with the nose tilted slightly upward.

•

Use a lifting tool and a lifting boom for the movement of the adapter as described in section 3.1. Test lift the adapter to check for satisfactory adapter tilt angle.

!

• The adapter should tilt downwards at the rear for easy installation onto the nose.

•

Lower the adapter and reposition the shackle as needed to achieve appropriate tilt angle.

•

Lift the adapter and slide it onto the nose. With the lifting boom still holding the adapter, install the adapter locking pin:

!

• For applications where soil fines pack and harden, it is recommended that the outer sleeve of the pin be covered in grease.

AH03510

Page 11 of 18

•

Using hex bit and socket drive, turn hex socket end of Sidewinder Pin clockwise to extend the pin into the pin hole in the opposite side of the adapter. Tighten to the specified torque value shown below. Size S 95 S 110 S 130 S 145

•

3.4

Allen type wrench size 14 mm 17 mm 19 mm 19 mm

Recommended pin torque 160-200 Nm (120-150ft-lb) 200-260 Nm (150-190ft-lb) 260-390 Nm (190-290 ft-lb) 260-390 Nm (190-290 ft-lb)

Insert the Sidewinder Pin cap to prevent the pin hex socket from filling with soil fines. Cap should snap into place. Retighten Sidewinder Pin

Retighten the Sidewinder Pin every 600 to 1200 hours of operating service depending on the severity of application.

!

• Some loosening of pin ½ - ¾ turns is normal. It is not necessary to keep it tightened to the recommended torque.

4. Wear Caps 4.1 Lock style wear caps (PC4000) 4.1.1 Removal • •

•

Clean debris from the gaps around the wearcap lock. Do not strike corners or edges with hammer! Rotate Lock : Use a drift and a 2-4 kg/4-8 lb hammer to rotate the lock to the unlocked position.

It may be necessary to partially rotate the lock in both directions to break loose soil fines, before fully rotating it.

!

• Lock must be rotated completely (180 degrees) to release the wearcap. • Lock can rotate either way.

AH03510

Page 12 of 18

Remove Wearcap: Slide wearcap out of adapter slots. Use appropriate lifting devices to support and remove wearcap. It may be necessary to place a pry bar between the adapter and the rear inside face of the wearcap to lift and free it from soil fines.

4.1.2 Installation

!

• Wearcap tabs, adapter tab slots, and lock recesses must be thoroughly cleaned. Inspect all components for damage. Replace any damaged parts.

•

Position Wearcap Lock First place the lock flat side down against the inside of the wearcap, adjacent to the lock opening. Slide it toward the wearcap lug. One of the lock shafts will enter the hole in the lug. Push the lock up tight against the lug. Then, using a drift placed in one of the lock pockets, tap the drift with a hammer to cause the lock to rotate halfway around, until the flat side of the lock is facing you and is lined up with the inside face of the wearcap.

•

Wearcap Installation Place the wearcap on the adapter. The tabs on the inside of the wearcap fit into the tab slots in the adapter.

•

Lock Wearcap Use an suitable tool and hammer to rotate the lock to the locked position. If lock resists rotation, this indicates more cleaning of the adapter slots is required. When flat is facing out, the lock is in a locked position.

AH03510

Page 13 of 18

4.2

Non lock style wear caps (Option PC4000; PC5500; PC8000)

!

• For using of these kind of wear caps special points and special adapters are required.

4.2.1 Removal • •

Drive out the point pin and remove the point. Slide the worn wearcap off the adapter.

!

• If soil packs tightly between the wearcap and the adapter, it may be necessary to strike the flat sides of the wearcap several times with a hammer, to loosen it for removal. • Do not strike corners or edges with hammer!

4.2.2 Installation • • •

Inspect all components for damage. Replace any damaged parts. Slide wearcaps onto the adapter top and bottom surfaces, so that the wearcap rear central and two forward side tabs insert fully into the respective slots of the adapter. Install and pin the point.

AH03510

Page 14 of 18 5. 5.1

The Shrouds Removal the shrouds

The Toplok shroud system is engineered to make change-out easy. Before following these simple steps shown to the Figures, it’s important to clean fines from pin area by tapping the shroud to loosen them, then scraping them using a chisel or needle gun (if fines are heavily packed). • •

Use a small bar with flat end (19 mm wide maximum) to retract the latch and lift the pin out. Pins can be reused if not worn below the locator flange and the insert latch rubber is fully bonded to the steel tip and fully seated in the pin body.

Place a pry bar or pinch bar behind the latch as shown, as a lever to compress it.

!

Lift out and remove the lock. Slide the shroud off the lip base.

• In severe applications assist removal by inserting a pry bar under the lock from the rear of the shroud and lifting up the latch end of the pin while prying as shown.

AH03510

Page 15 of 18

5.2 Installing the shroud 5.2.1 Prepare the surface In order to provide sufficient support for the boss as well as its pin, the mounting surface must: • Be relatively smooth and free of debris, weld spatter, and other irregularities. • Have a profile that produces a gap no greater than 3 mm or 1/16" at the boss weld. Any gap greater than 3 mm or 1/16" must be shimmed. Checking the Fit Pad Areas • • • •

The fit pad surface (1) & (2) should be perpendicular to each other. Make sure 70% of the fit pad surfaces (1) & (2) are in contact with the gauge. After achieving this, the fit pad surface (3) should be checked. Use a straight edge to help check the surface consistency.

Plate lips (PC4000)

Cast lips (PC5500 and PC8000)

Templates Part numbers for checking and preparation the lips Type of Excavator PC4000 PC5500 PC8000

Shovel Version Lip Shroud Template 654 547 40 654 548 40 794 005 73 655 867 40 or 907 281 40 907 006 40

794 007 73

Backhoe Lip Shroud 654 627 40 654 628 40 654 629 40 655 867 40

Version Template

794 008 73

907 448 40 On request

794 006 73 794 007 73

AH03510

Page 16 of 18

5.2.2 Position the bosses Checking the Boss Position To insure the boss is located correctly, the gap between the gauge and the boss rails should not exceed 1mm/.04in. If the gap exceeds 1mm/.04in.,the boss has to be removed and a new boss installed (see below). The back of the boss should line up with the back of the gauge rail. If the boss does not line up with the back of the gauge rail, then two repair options are possible: • (A) If the gap does not exceed 1.5mm/.06in., build up the back of the boss; or • (B) Weld build the leading edge fit pad (2). This may result in the ramp fit pad (3) also requiring weld build up.

Weld Rebuilding Fit Pads When weld rebuilding fit pads ensure the weld surface is clean and free of any contamination that might prevent a good weld. Follow the preheat, interpass and post heat guidelines below. Summary of Welding Specifications • Electrodes: E7016 or E7018 low hydrogen (keep dry!) • Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas. • Preheat: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.) • Interpass: Maintain interpass temperature less than 500°F/260°C. • Postheat: If air temperature is 40°F or lower, postheat 350-400°F, then let air cool. • Remove slag after each pass and peen each bead. New Boss installation • Set the boss onto the gauge rails and locate the back of the boss with the back of the gauge rails. If no gauge is available, use a new shroud to locate the boss. • Move the gauge onto the lip, making sure the gauge is centered between the nose bases and the gauge is in contact with fit pad surfaces (1) & (2). • Practice has shown, that the boss will suck down 1/16" during welding. To equalize this use a 1/16" shim under the boss, even if there is no gap between the fit pad (1) and the boss. This will ensure the boss height is correct after welding. • If there is a gap between the fit pad surface (1) and the boss, use a thicker shim accordingly.

AH03510

Page 17 of 18 5.2.3 Welding the bosses The weld surface must be clean and free of any contamination that might prevent a good weld. Follow the preheat interweld and post heat guidelines below. Summary of Welding Specifications • Electrodes: E7016 or E7018 low hydrogen (keep dry!) • Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas. • Preheat: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.) • Interpass: Maintain interpass temperature less than 500°F/260°C. • Postheat: If air temperature is 40°F or lower, postheat 350-400°F, then let air cool. • Remove slag after each pass and peen each bead. Weld the boss to the lip. Make sure that the boss is shimmed, so that the height of the boss will be correct after welding. Weld area (A) completely before welding areas (B) & (C). Welding Guide Weld Location Boss TAB TBB TCB

(A) Depth of weld plug holes mm/in Plug Weld 10/.38 Plug Weld 13/.50 Plug Weld 16/.62

(B) Size of fillet weld-on ends mm/in Fillet 10/.38 Fillet 13/.50 Fillet 13/.50

(C) Size of fillet weld-on ends mm/in Fillet 3/.19 Fillet 6/.25 Fillet 6/.25

5.3 Inspecting Worn Shrouds Toplok shrouds protect the bucket lip and wings from abrasive wear. Use of ESCO 12S abrasion resistant alloy assures long life before change out. • Periodic inspection should be made to determine when to replace a shroud. • Monitor high wear surfaces of the Toplok shroud for wear. • Special “wear indicators” are special panels that will open up to alert the user of the need for changing shrouds.

AH03510

Page 18 of 18

5.4

Installing

Installing the shroud •

Slide the shroud over the lip and boss to install the pin. If installing a new shroud, the pin must have contact with the back of the boss and with the back of the shroud without losing contact at the leading edge.

Installing the pin •

Position the pin in the shroud cavity as shown.

•

A light blow with a hammer will engage the pin.

•

The shroud is now securely attached.

AH03510

PARTS & SERVICE NEWS

COMPONENT CODE:

J1

REF NO.

AH03511

DATE

14th April 2003 Page 1 of 2

SUBJECT:

Pilot Pressure Pump Part No. 907 209 40

PURPOSE:

Good flange connection between main pump and gear pump

APPLICATION:

PC5500

FAILURE CODE:

J100Z9

DESCRIPTION: 1. Control all new pumps before installing. 2. If necessary remachine chamfer that the face of the gear pump fit very well to the main pump. 3. Install this new pump with surface sealing agent “Loctite 510” (Part No. 461 543 40).

AH03511

Page 2 of 2 1.

Remachine this chamfer 2.

AH03511

COMPONENT CODE:

J1

REF NO.

AH03512

PARTS & SERVICE NEWS

DATE

14th April 2003 Page 1 of 1

SUBJECT:

Gear pumps (Part Nos. 907 209 40; 906 442 40; 896 730 40 and 654 930 40)

PURPOSE:

Seal the flange connection

APPLICATION:

H 255; H 455; PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

J100Z9

DESCRIPTION: At replacement of the above mentioned gear pumps the flange of the new pump has to seal additional with surface sealing agent “Loctite 510”. The Part No. of “Loctite 510” is 461 543 40.

AH03512

COMPONENT CODE:

63

REF NO.

AH03528

PARTS & SERVICE NEWS

DATE

Sept. 29, 2003 Page 1 of 1

SUBJECT:

Pilot control safety line

PURPOSE:

Prevention of serious injury or death through high voltage system

APPLICATION:

PC8000-6 Electric Drive

FAILURE CODE:

6300Z9

DESCRIPTION:

The pilot line of the above mentioned excavators is a vital safety equipment. This line controls the security of the following components: §

Fire suppression system (9K3);

§

Flaps at slip ring unit (OS4 and OS4B);

§

HT – switch cabinet (OS10; OS11);

§

Emergency switch at the cable drum (OS15);

§

Flaps at the cable drum (OS17; OS18);

§

Flap at the terminal box of the cable drum (OS19).

If all these components are in normal working order the pilot line is closed. If one component is not in normal working order this line will be interrupted and the power supply of the excavator will be shut off in the external transformer station.

ã

• Make sure that the pilot line is always in proper working order. A defective or missing pilot line can cause serious injury or death.

AH03528

PARTS & SERVICE NEWS

COMPONENT CODE:

46

REF NO.

AH04518a

DATE

June 29, 2005 Page 1 of 2

This PARTS & SERVICE NEWS supersedes the previous issue AH04518 which should be discarded. SUBJECT: Welding procedure for welded counterweight PURPOSE:

Emphasize the importance of expelling the accumulate gases from the counterweight chambers before welding

APPLICATION:

H 255; PC3000; PC5500(SN15011 and up); PC4000; PC8000(SN12037 and up)

FAILURE CODE:

4621Z9

DESCRIPTION:

ã

• Avoid injury or death! • Do not perform welding operation before expelling the accumulated gases from the counterweight chambers! • The gases may explode!

The welded counterweights are filled with a mixture of iron ore and breech blocks. They are not fully filled. It is possible that in the separate chambers explosive gases have collected. There is a risk of explosion during welding, grinding, cutting and drilling without coolant.

The following outlines the proper gas expelling procedure from counterweight (Illustrations 1 and 2) 1. Counterweights with a thread connection point(1): Connect a hose to this point and blow compressed air toward the inside. At these counterweights all chambers are connected to each other. 2. Counterweights without thread connection point: Make the holes (2) larger by means of a 10 mm drill. Blow out carefully all chambers separately through the holes (2).

AH04518a

Page 2 of 2

(1)

(2)

Illustration 2 AH04518a

COMPONENT CODE:

6A

REF NO.

AH05501a

PARTS & SERVICE NEWS

DATE

September 15, 2006 Page 1 of 1

This PARTS & SERVICE NEWS supersedes the previous issue AH05501 which should be discarded. SUBJECT:

Abnormal vibration on hydraulic pipes

PURPOSE:

Reduction of stress on the pipes

APPLICATION:

All types

FAILURE CODE:

6A00GB

DESCRIPTION: To reduce the stress on hydraulic pipes and the flange bolts install a pair* of metal half clamps (weight approx. 5 kg). Start in the middle of the line and check the effect by laying on a hand. Try to optimize the effect by shifting the clamps. Mark the optimal position. *if required two pairs of half clamps can be used Description

Pipe 50x6 (PN)

Pipe 65x8 (PN)

Modification kit (assy.)

938 578 40

938 581 40

AH05501a

PARTS & SERVICE NEWS

COMPONENT CODE:

K1

REF NO.

AH05510

DATE

February 16, 2005 Page 1 of 1

SUBJECT:

Bearing flushing of the A4VS variable displacement axial piston pump

PURPOSE:

Activate the external flushing of bearing by mounting a new pump

APPLICATION:

PC4000 (SN08151 up); PC5500 (SN15011 up); H 455S (SN15007; 15009); PC8000 (SN12037 up); H685SP (SN12020; 12030)

FAILURE CODE:

K100FA

DESCRIPTION: The installed main pumps are provided with an external cooling and lubrication system for flushing of drive shaft bearing and shaft seal. Oil supply is provided from the X4-pressure circuit. To direct the external cooling oil to the bearing and shaft seal it is necessary to turn in the throttle screw all the way. Observe also the information plate fixed at the pump.

Drawing and photos as example

AH05510

COMPONENT CODE:

30

REF NO.

AH05511

PARTS & SERVICE NEWS

DATE

March 23, 2005 Page 1 of 4

This PARTS & SERVICE NEWS supersedes the previous issue No. 21-558 which should be discarded. SUBJECT:

Dual cone seal ring mounting

PURPOSE:

Mounting hints

APPLICATION:

all types

FAILURE CODE:

3047AA

DESCRIPTION: Leaky dual cone seal rings must be replaced, in order to prevent damages through "dry running". Dual cone seals have also to be replaced in case of component repairs. Dual cone seals are precision parts made from chilled cast iron. Therefore, sharp knocks and blows should be avoided. The correct way to install dual cone seals is as follows: • Only remove the seal (1) from its original wrapping just before installing. This protects the super - finished seal faces (2) from damage and contamination. • Seal housing (3) must be free of dirt and machining residues; all edges in the housing bore must be rounded. • The illustration shows the preloaded seal (1). • Install the face seal by means of the assembly tool (4). Pressure is applied directly via the O-ring (5). • For easier assembly, moisten the housing bore and O-rings with spirit (no oil or grease!). • Order number for assembly tool (4), refer to the table on page 2. For the machining dimensions of the assembly tool, refer to the illustration and Fig. on page 3. • The illustration shows the dual cone seal (1) before mounting it with tool (4) into housing (3). AH05511

Page 2 of 4 • Press the seal ring (1) with the special tool like a push button into the housing (3). Take care that afterwards the housing surface (6) lies parallel to the seal face (2). The O-ring (1) must not sit wave-like in the housing bore or bulge partially looped out of the bore. C = correct W = wrong

• Before the seal rings (1) are clamped to the installation dimensions, apply a thin grease or oil film to the seal faces (2), preferably with a soaked chamois leather cloth. Fig. 1 2 3 4 5 6

Description Seal ring Seal face Seal housing Tool O – ring Housing surface

Table for selection of the assembly tool (other tools on inquiry) Part No. Dual Cone Seal 145 800 40 180 472 40 180 624 40 202 986 40 226 424 40 226 425 40 255 058 40 269 454 40 270 460 40

Order-No. Assembly tool 766 311 73 766 308 73 766 312 73 766 315 73 766 322 73 766 317 73 766 314 73 766 312 73 766 316 73

Part No. Dual Cone Seal 323 823 40 324 067 40 461 627 40 461 628 40 696 523 73 696 525 73 804 595 73 963 754

Order-No. Assembly tool 766 323 73 766 309 73 766 318 73 766 307 73 766 310 73 766 311 73 766 313 73 766 321 73

AH05511

Page 3 of 4 Assembly tool (locally made) The assembly tool consists of two half-shells that are closed around the seal ring. The two halves are joined by a hinge. Step (d) grips between the O-ring (5) and the land of the seal ring. The pressure required to insert the seal is then applied directly via the O-ring (5). Measure dimension "b" at the dual cone seal. Determine the machining dimensions "a", "b", "c" and "d" according to this measured dimension in the chart. The dimension "X" can be chosen freely.

∅b mm 95 99 104 110 111 112 121 127 126 139 142 141,5 143 146 157 162 175 159 174,5 177 169 172,5 169 171 170 176 182 194

∅a mm 100 107 118 115 118 120 128 131 134 148 150 149 150 153 163 169 182 166 181,5 185 176 180 175 177 176 183 190 201

∅c mm 89,5 92,5 98 104 105 107 115 121 120 133 135 133 137 137,7 150,5 155 169 153,5 162 168 161 166,5 165 168 165 167,5 177 182,5

d mm 1,8 3,5 3 2,5 4 3 4 3,5 3 3 4 3 4 4 4 3 4,5 3 4 4 2,8 3,5 2 2,5 4 3,5 3 4

∅b mm 191 200 202 213 217 231 229,5 242 254 270,5 282,8 295,5 326 343,5 348 377,5 397 418 458 503 536,5 563 593 611 703 626 753 890

∅a mm 198 208 209 220 225 238 236,5 249 261 279 292 302,5 334 350,5 357 384,5 407 426 468 518 545 578 608 620 710 642 768 898

∅c mm 185 192 196 201 210 220 220,5 232 242,5 258,5 269 282 321 335 342 369 385 410 446 495 528,4 555 585 603 694 618 745 878

d mm 4 4 4 4 4 4 4 4 4 4 4 4 4 4 7 4 4 5 4 7 5 7 7 5 5 7 7 10

AH05511

Page 4 of 4

Assembly tools for mounting of dual cone seal

AH05511

COMPONENT CODE:

25

REF NO.

AH05518

PARTS & SERVICE NEWS

DATE

June 27, 2005 Page 1 of 2

This PARTS & SERVICE NEWS supersedes the previous issue 21 - 503 which should be discarded. SUBJECT:

Swing circle pinion

PURPOSE:

Wear check every 5000 Operating hours

APPLICATION:

PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

2518CA

DESCRIPTION: All swing pinions are surface hardened to ensure a long service life. If the depth of the wear reaches the hardening depth, the wear of the pinion will be rapid. The increased tooth back-lash and the different tooth meshing, could decrease the service life of the slew ring and the swing gear box(es). By means of regular wear check , every 5000 operating hours, the depth of the wear should be compared to the original shape.

AH05518

Page 2 of 2

The following table shows the machines with the pertaining swing gear box(es) and the corresponding hardening depth:

Type

PN Swing gear box

Hardening depth

PC3000

898 100 40 917 915 40 924 352 40 926 795 40 898 100 40 925 864 40 926 795 40 898 100 40 917 915 40 925 864 40 926 795 40 917 915 40 924 325 40 926 325 40

2.0 2.0 2.0 2.0 2.0 1.8 +0.4 2.0 2.0 2.0 1.8 +0.4 2.0 2.0 2.0 2.0

PC4000

PC5500

PC8000

)

• If the depth of the wear reaches the hardening depth, the slew pinion should be replaced, to ensure a proper function of the machine.

AH05518

COMPONENT CODE:

J1

REF NO.

AH05520a

PARTS & SERVICE NEWS

DATE

March 17, 2006 Page 1 of 3

This PARTS & SERVICE NEWS supersedes the previous issue No. AH05520 which should be discarded. SUBJECT:

Installation hints for a new type of gear pump (Pilot pump)

PURPOSE:

Product improvement: Old designs: PN 634 121 40; PN 634 122 40; PN 907 209 40; PN 907 608 40 New design: PN 907 622 40

APPLICATION:

H 455S (#15003 to 15009); PC5500 (# 15011 to 15024)

FAILURE CODE:

J100FA

DESCRIPTION: Modification Kit PN 793 749 73 (refer to Illustrations 1 and 2) Valid for old pumps PN 634 121 40 and PN 634 122 40 Pos.

Part No.

Qty.

Description

01

886 218 40

1

Reduction flange

02

385 243 40

1

Flange seal

03

319 272 99

4

Bolt M12 x 30

04

515 812 98

1

Coupling

05

356 209 40

1

Flange seal

06*

319 272 99

4

Bolt M12 x 30

07*

515 658 40

2

Half flange

08*

356 210 40

1

Quad ring

* Positions 06; 07 and 08 will be used for replacing the old pumps PN 907 209 40 and PN 907 608 40 • Close the main gate valve between hydraulic oil tank and suction tank. • Drain the suction tank. (Use the transfusing pump if so equipped). • Remove all lines from the old gear pump. • Replace this pump (illustration 1)**. • Reinstall the suction line as showed on next page (illustration 2). • Reinstall the pressure line (illustration 3). • Open the main gate valve. • Install the coupling (04). • Bleed the hydraulic pump (refer to Service Bulletin AH01513). • Start the engine and let it run for 15 minutes in low idle for bleeding the lines. • Check the hydraulic oil level at the tank. ** For installation of the new pump refer to the next page. AH05520a

Page 2 of 3 Installation the new pump (PN 907 622 40)

Illustration 1 • • •

Remove the two hexagon bolts (2) and the flange (1) from the new pump. Install the flange (1) by using of the four cylinder head bolts (3) (M12 - 70Nm) at the big main pump. Install the new gear pump by using of the two bolts (2) (M12 – 70 Nm) at the flange (1).

AH05520a

Page 3 of 3

Illustration 2

Illustration 3

AH05520a

COMPONENT CODE:

K1

REF NO.

AH05525

PARTS & SERVICE NEWS

DATE

September 20, 2005 Page 1 of 3

SUBJECT:

Suction elbows of the Main Pumps

PURPOSE:

Hints for sealing

APPLICATION:

PC3000-1; PC4000-6 (to # 08156) PC5500 (to # 15019); PC8000 (to # 12042)

FAILURE CODE:

K1T3AA

DESCRIPTION:

1. 2.

PC3000-1 PC4000; PC5500; PC8000

AH05525

Page 2 of 3 1. PC3000-1 1 2 3 4

Seal Intake Remachining surface Bolt

Illustration 1 as example

• •

In case of leakiness disassemble the suction elbow (2) and remachine the sealing surface (3). Then reassemble the suction elbow (2) by using a new seal (1).

)

• • • •

Install the 4 bolts (4) crosswise and evenly. Final torque: maximum 179 Nm! Replace the intake (2) by a new one if necessary. Check the surface (3) for evenness also of the new intake (2) before installing. Even it out if necessary.

AH05525

Page 3 of 3 2. PC4000; PC5500; PC8000 •

Type PC4000-6 PC5500-6

PC8000-6

In case of leakiness replace the old suction elbow (2) by a new one with an other sealing system (1)(O-ring). Intake (old)

Intake (new)

O - ring

891 451 40

928 335 40

517 582 98

624 085 40

928 706 40

517 582 98

624 085 40

928 706 40

517 582 98

894 317 40

928 287 40

517 582 98

894 321 40

928 285 40

517 582 98

894 322 40

928 288 40

517 582 98

894 323 40

928 289 40

517 582 98

624 085 40

928 706 40

517 582 98

• Screw in the 4 bolts (4) crosswise and evenly. • Final torque: maximum 179 Nm!

Illustration 2 as example AH05525

PARTS & SERVICE NEWS

COMPONENT CODE:

26

REF NO.

AH05535c

DATE

May 21, 2007 Page 1 of 22

This PARTS & SERVICE NEWS supersedes the previous issue AH05535b which should be discarded. SUBJECT:

Hints for replacing by the slewing gear of an other manufacturer

PURPOSE:

Revision

APPLICATION:

PC3000 (#06193 and up); PC4000 (#08152 and up); PC5500 (#15018 and up); PC8000 (#12041 and up)

FAILURE CODE:

2600CA

DESCRIPTION: • New swing gears will be delivered without gear oil. • After replacing the swing gear, fill in oil according to the Maintenance Manual. REMARK The machines can be equipped either with a swing machinery of manufacturer "L&S" Part No. 926 795 40 or of manufacturer "Siebenhaar" Part No. 925 864 40 or 936 560 40. Refer to the data plate on each swing machinery housing to find out the manufacturer of the swing machinery. Both swing gears are replaceable by using of a special modification kit. Lubricants

Filling Capacities (liters)

AH05535b

Page 2 of 22

1.

Description (general)

2.

Overview 2.1 Swing Machinery manufactured by "L&S" 2.2 Swing machinery manufactured by “Siebenhaaar”

3.

Modification kits 3.1 Modification kit PC3000-6 3.1.1

Replacing “L+S” gear to “Siebenhaar” gear

3.1.2

Replacing “Siebenhaar” gear to “L+S” gear

3.2 Modification kit PC4000-6 3.2.1

Replacing “L+S” gear to “Siebenhaar” gear

3.2.2

Replacing “Siebenhaar” gear to “L+S” gear

3.3 Modification kit PC5500-6 3.3.1

Replacing “L+S” gear to “Siebenhaar” gear

3.3.2

Replacing “Siebenhaar” gear to “L+S” gear

3.4 Modification kit PC8000-6 3.4.1

Replacing “L+S” gear to “Siebenhaar” gear

3.4.2

Replacing “Siebenhaar” gear to “L+S” gear

AH05535b

Page 3 of 22 1.

Description (general)

1. Remove the bolts at the hydraulic motor. 2. Remove the motor with connected hoses and place it beside or if this it not possible, disconnect the hydraulic lines and block the ports. 3. Disconnect the lubrication lines below the gearbox. 4. Remove all fastening bolts from the gearbox. 5. Install 2 eye bolts to lift the gearbox assy. 6. Remove the gearbox from the superstructure frame. 7. Clean the flange area at the superstructure free of grease, oil, dust and paint. 8. Insert the new gearbox and mount it with the new bolts and the washers to the superstructure 9. Cover the bolt heads with plugs. 10. Swap the drain valves and the breather filters from the old to the new gearbox. 11. Remove the cover below the gearbox and connect the lubrication lines. 12. Reinstall the cover with bolts. 13. Reinstall the motor with bolts. 14. Reconnect all hydraulic lines. 15. Fill in oil to the max. oil level markings*. 16. Install the cover plates (PC3000; PC4000). * "L&S" gear (Part No. 926 795 40) 2 oil chambers: (gear housing; motor adapter housing); "Siebenhaar" (Part No. 925 864 40 or 936 560 40) Three oil chambers: (gear housing; motor adapter housing, brake housing)

AH05535b

Page 4 of 22 2.

Overview

2.1

Swing Machinery manufactured by "L&S"

Legend for illustration 1 Swing gears (1) Oil level gauge (2) Oil filler plug (3) Breather filter (10) Drain couplings or evacuation nozzles for Wiggins system Motor Adapter Housing (4) Oil level gauge and filler opening. (5) Breather filter (6) Oil drain plug

Illustration 1

AH05535b

Page 5 of 22 2.2

Swing machinery manufactured by “Siebenhaaar”

Legend for illustration 2 (1) Swing machinery (2) Brake housing (3) Compensator oil tank for swing machinery (4) Oil level gauge for swing machinery (5) Oil drain plug for motor adapter housing (6) Oil level gauge for motor adapter housing (7) Breather filter for brake housing (8) Oil level gauge for brake housing (9) Oil drain plug for brake housing (10) Breather filter (11) Drain coupling or evacuation nozzle for Wiggins system

For avoiding overheating of the disks inside the brake a correct adjustment of the brake oil level (8) is necessary.

)

• Too high oil level reduces the life time of the brake.

AH05535b

Page 6 of 22 Swing machinery manufactured by “Siebenhaaar”

Illustration 2

AH05535b

Page 7 of 22 3.

Modification kits

3.1

Modification kit PC3000-6

3.1.1 Replacing “L+S” gear to “Siebenhaar” gear (PC3000-6; illustration 3) Modification Kit: PN 794 853 73 Pos.

Part No.

Qty.

Description

10

323 460 40

1

Bleeder valve

11

517 676 98

34

Bolt

12

516 920 98

34

Washer

15

507 037 98

2

Nut

16

340 465 99

2

Washer

22

907 142 40

34

Plug

30

307 824 99

2

Bolt

31

374 428 99

1

Union

32

517 905 98

1

Hose assy.

33

500 141 98

2

Union

34

372 174 99

1

Union

35

334 601 99

2

Nut

36

340 469 99

2

Washer

37

0443452511

1

Clip

38

340 467 99

2

Washer

AH05535b

Page 8 of 22

Illustration 3 AH05535b

Page 9 of 22 3.1.2 Replacing “Siebenhaar” gear to “L+S” gear (PC3000-6; illustration 4) Modification Kit: PN 794 867 73 Pos.

Part No.

Qty.

Description

10

323 460 40

2

Bleeder valve

11

517 013 98

34

Bolt

20

872 200 40

1

Union

30

925 833 40

1

Pipe

31

517 489 98

1

Socket

32

906 868 40

1

Olive

33

371 264 99

1

Union nut

34

517 490 98

1

Union

35

907 568 40

1

Dipstick

36

921 815 40

1

Cover

37

319 159 99

7

Bolt

38

504 149 98

7

Washer

39

517 073 98

2

Union

40

371 273 99

2

Union nut

41

906 346 40

4

Olive

42

215 627 99

1

Pipe 400 mm

43

517 074 98

1

Union

44

371 258 99

2

Union nut

45

907 228 40

1

Union

AH05535b

Page 10 of 22

Illustration 4 AH05535b

Page 11 of 22 3.2

Modification kit PC4000-6

3.2.1 Replacing “L+S” gear to “Siebenhaar” gear (PC4000-6; illustration 5) Modification Kit: PN 794 868 73 Pos.

Part No.

Qty.

Description

11

515 791 98

34

Bolt

12

516 920 98

34

Washer

15

374 428 99

1

Union

16

507 037 98

10

Nut

17

512 545 98

10

Washer

18

507 488 98

10

Pin bolt

19

506 129 98

10

Washer

20

904 613 40

1

Cover plate rear r.h.

21

904 618 40

1

Cover plate front r.h.

22

904 614 40

1

Cover plate rear l.h.

23

904 617 40

1

Cover plate front r.h.

24

307 827 99

2

Bolt

26

907 142 40

34

Plug

27

914 777 40

1

Pinion cover l.h.

28

914 775 40

1

Pinion cover r.h.

29

510 213 98

2

Thread pin

30

340 112 99

2

Washer

31

512 545 98

2

Washer

32

334 600 99

2

Nut

AH05535b

Page 12 of 22

Illustration 5 AH05535b

Page 13 of 22 3.2.2 Replacing “Siebenhaar” gear to “L+S” gear (PC4000-6; illustration 6) Modification Kit: PN 794 869 73 Pos.

Part No.

Qty.

Description

15

872 200 40

1

Union

20

922 584 40

1

Cover plate

21

922 583 40

1

Cover plate

22

922 586 40

1

Cover plate

23

922 587 40

1

Cover plate

25

516 919 98

34

Bolt

28

921 815 40

1

Cover

29

319 159 99

7

Bolt

30

517 073 98

2

Union

31

371 273 99

2

Union nut

32

906 346 40

2

Olive

33

215 627 99

1

Pipe 400 mm

34

517 074 98

1

Union

35

371 258 99

2

Union nut

36

906 346 40

2

Olive

37

907 228 40

1

Union

38

371 257 99

1

Union nut

39

907 080 40

1

Olive

40

922 580 40

1

Cover

41

922 587 40

1

Cover

42

517 489 98

1

Socket

43

517 490 98

1

Union

44

906 868 40

1

Olive

45

371 264 99

1

Union nut

46

215 787 99

1

Pipe 400 mm

47

907 569 40

1

Dipstick

49

399 907 99

1

Seal ring

AH05535b

Page 14 of 22

Illustration 6

AH05535b

Page 15 of 22 3.3

Modification kit PC5500-6

3.3.1 Replacing “L+S” gear to “Siebenhaar” gear (PC5500-6; illustration 7) Modification Kit: PN 794 870 73 Pos.

Part No.

Qty.

Description

10

323 460 40

2

Bleeder valve

12

307 827 99

2

Screw

15

339 907 99

2

Seal ring

24

516 920 98

34

Washer

25

517 612 98

34

Bolt

26

907 142 40

34

Plug

AH05535b

Page 16 of 22

Illustration 7 AH05535b

Page 17 of 22 3.3.2 Replacing “Siebenhaar” gear to “L+S” gear (PC5500-6; Illustration 8) Modification Kit: PN 794 871 73 Pos.

Part No.

Qty.

Description

17

921 815 40

1

Cover

18

907 131 40

1

Union

19

214 140 99

1

Pipe 85 mm

20

374 460 99

1

Socket

21

872 200 40

1

Union

22

371 279 99

2

Union nut

23

906 979 40

2

Olive

24

516 929 98

34

Washer

25

517 889 98

34

Bolt

26

907 142 40

34

Plug

27

907 228 40

1

Union

28

517 074 98

1

Union

29

371 258 99

2

Union nut

30

907 227 40

4

Olive

31

517 073 98

2

Union

32

371 273 99

2

Union nut

34

215 627 99

1

Pipe 200mm

35

319 159 99

7

Bolt

36

504 149 98

7

Washer

50

517 489 98

1

Socket

51

517 490 98

1

Union

52

906 868 40

1

Olive

53

371 264 99

1

Union nut

54

215 787 99

1

Pipe 400 mm

55

907 569 40

1

Dipstick

AH05535b

Page 18 of 22

Illustration 8 AH05535b

Page 19 of 22 3.4 Modification kit PC8000-6 3.4.1 Replacing “L+S” gear to “Siebenhaar” gear (PC8000-6; illustration 9) Modification Kit: PN 794 872 73 Pos.

Part No.

Qty.

Description

2

904 613 40

1

Cover plate r.h.

3

904 618 40

1

Cover plate l.h.

7

517 612 98

34

Bolt

8

516 920 98

34

Washer

9

907 142 40

34

Plug

10

323 460 40

3

Bleeder valve

12

307 827 99

2

Bolt

13

374 428 99

1

Union

AH05535b

Page 20 of 22

Illustration 9 AH05535b

Page 21 of 22 3.4.2 Replacing “Siebenhaar” gear to “L+S” gear Modification Kit: PN 794 873 73 Pos.

Part No.

Qty.

Description

2

898 288 40

1

Cover plate

3

914 737 40

1

Cover plate

7

374 460 99

1

Screwed socket

8

371 279 99

2

Union nut

9

906 979 40

2

Olive

10

914 736 40

1

Pipe 85 mm

11

907 131 40

1

Union

12

921 815 40

1

Cover

13

319 159 99

7

Bolt

14

907 569 40

1

Dipstick

15

906 868 40

1

Olive

16

371 264 99

1

Union nut

17

925 830 40

1

Pipe 350 mm

19

517 489 98

1

Socket

20

517 490 98

1

Union

22

872 200 40

1

Union

23

516 919 98

34

Bolt

26

517 073 98

2

Union

27

371 273 99

2

Union nut

28

906 346 40

4

Olive

29

215 627 99

1

Pipe 200 mm

30

907 228 40

1

Union

31

517 074 98

1

Union

32

371 258 99

2

Union nut

AH05535b

Page 22 of 22

Illustration 10 AH05535b

COMPONENT CODE:

8D

REF NO.

AH05546

PARTS & SERVICE NEWS

DATE

December 6, 2005 Page 1 of 2

SUBJECT:

Automatic lubrication system - Vent valve (PN 769 879 73)

PURPOSE:

Hints for trouble shooting

APPLICATION:

All types with “Lincoln” Lubrication System

FAILURE CODE:

8D00ME

DESCRIPTION:

Manual actuation (Vent valve: PN 769 879 73)

FUNCTION: The solenoid gets energized when the lubrication starts. The connection from A to B gets closed, thus a pressure build-up is possible. The solenoid gets de-energized, as soon as the lubrication cycle is finished. This causes opening of the connection A to B, thus the supply line to the lubricant barrel is open. The lubricant flows from A to B. TASK (Refer to illustration next page): By the function of the vent valve (7) the lubricant supply line gets pressure released, after the lubrication cycle is finished. The injector pistons can move into their initial position.

AH05546

Page 2 of 2

Troubleshooting: The solenoid valve (7) sometimes is blocked by dirt and causing that the pumping pressure will be not built correctly due to bypassed pressure back to grease barrel. On the monitor in the operators cab any failure in lubrication system will be indicated. Manual actuation

To make easy troubleshooting the 2/2 – Directional valve (7) is equipped with the possibility of manual actuation. The valve had a push button on the top to verify whether the electric problem or the vent valve itself causing the lubrication pressure bypassed. For manual actuating of the valve (7) push down the pin on top of the valve e.g. with a screwdriver.

AH05546

COMPONENT CODE:

PARTS & SERVICE NEWS

REF NO. DATE

AH06524 September 6, 2006 Page 1 of 2

This PARTS & SERVICE NEWS supersedes the previous issue 21 – 199b which should be discarded. SUBJET:

Hydraulic cylinder

PURPOSE:

Hints for bleeding

APPLICATION:

All types

FAILURE CODE:

H100BJ

DESCRIPTION: To avoid damages to the hydraulic system caused by air in the cylinders, a bleeding procedure has to be carried out after each opening or cylinder exchange. • Read the safety instruction in the Operation and Maintenance Manual carefully, before starting any work on the excavator.

1. Standard procedure for bleeding of hydraulic cylinder 1. Run the engine at low idle. PC5500 and PC8000: Start for the bleeding procedure only one engine. Electric driven excavators: Set the service switch S155 (X2 – main board) to position “2” for “QMIN” control of the main pumps. 2. Extend and retract each cylinder 4 or 5 times without going to the end of its stroke (stop approx. 100 mm before the end of the stroke). At first there can be a large amount of air inside the cylinders, so the cylinder may not move for the first ten seconds. In such cases, do not operate the joy stick to the end of its travel. Be carefully! 3. Keep the engine running at low idle/or QMIN* and operate each cylinder from a point 100 mm from the end of its stroke slowly (take at least 10 seconds) to the end of its stroke (fully extended) and hold the work equipment joy stick at the full stroke position for 3 minutes.

AH06524

Page 2 of 2 4. Next run the engine at high idle/or QMAX* and operate each cylinder from a point 100 mm from the end of its stroke slowly (take at least 10 seconds) to the end of its stroke (fully extended) and hold the work equipment joy stick at the full stroke position for 1 minutes. 5. Repeat steps 2 – 4 if necessary. 6. Make sure that the switch S155 is set to the “0” position as soon as the bleeding procedure of the hydraulic cylinders is finished.* * Electric driven excavator

• After bleeding the cylinders check oil level in the hydraulic tank according to the Maintenance Manual and add oil if necessary.

AH06524

COMPONENT CODE:

30

REF NO.

AH06529

PARTS & SERVICE NEWS

DATE

July 31, 2006 Page 1 of 7

SUBJET:

Track group – Hints for sprocket exchange

PURPOSE:

Sprocket exchange in case of normal wear

APPLICATION:

PC5500-6 (#15026 and up)

FAILURE CODE:

3000CA

DESCRIPTION: 1.

Sprocket types 1.1

Standard sprocket

1.2

Oversize sprocket

2.

Removal sprocket

3.

Determination of the Axial Play

4.

Remachining

5.

Radial wear determination

6.

Assembly

7.

Torque Data for Standard Application

AH06529

Page 2 of 7 1.

Sprocket types

1.1 Standard sprocket The standard sprocket has to be used in case of assembling new machine or regenerating the track group in connection with new track pads. 1.2 Oversize sprocket The oversize sprocket has to be used to compensate chain elongation, wear on sprocket diameter and wear in the roller path on track pads, caused by the wear of the chain, if the X-dimension / circular pitch come up to 0.5 mm (refer to Service Bulletin AH02521 latest edition). This retrofitting assures assembly condition of the X – dimension of a new machine, furthermore the service life of the track group will be increased. The oversize sprocket is available without a sprocket hub, if the old one is reuseable. For the part no. of sprockets and the mounting procedure, refer to the following pages, the table below and the part catalogue of your machine. The conversion of the sprockets is time- and cost-intensive, so it is recommended to exchange the final-drive bearings at the same time if the dimensions have reached the wear tolerances, to avoid a standstill of the machine for the final-drive bearing exchange only. Before placing the order, pay attention to Service News AH00515 (latest version) and Parts Catalogue for correct choice of the bush type. Basically, all seals (13, 23, 27, 28 refer to illustration 1) have to be replaced.

)

• The difference between the standard version (NT) and the very low temperature version (TT) are only the bolts. The sprocket and the hub are the same. PC5500

Part number

Standard sprocket with hub

929 320 40

Oversize sprocket with hub

938 778 40

Drive sprocket standard

933 626 40

Drive sprocket oversize

938 777 40

AH06529

Page 3 of 7 2. Removal sprocket • • • • • • • • • •

Remove the drain plug and the filler plug and drain the lubricating oil of the final drive housing (refer to the Maintenance Manual). Suspend travel gear (02) to a crane; remove mounting bolts (31). Remove travel gear by using pulling bolts; put aside. Remove cover (14). Suspend sprocket (01) to a crane and underpin it from below. Pull out drive shaft (06). Remove mounting bolts (12) in flange bearing (08); loosen by using pulling bolts; extract. Extract hollow shaft (32) to cover side (14) and remove it by using the crane or a fork-lift. Lift sprocket (01) out. Remove mounting bolts (12) in flange bearing (25); loosen by using pulling bolts; extract.

Illustration 1 AH06529

Page 4 of 7

Illustration 2

AH06529

Page 5 of 7 3.

Determination of the Axial Play

After removal, all seals have to be renewed. • • • • • • • • • • •

Slide O-ring (26) over flange bearing (6). Mount flange bearing (6) without dual-cone seal (17). Pay attention to the lubrication-grooves position; they have to be displaced by 22.5° to the vertical line. Mount all bolts (61) and tighten according to tightening torques (M30 / 1770Nm). Suspend the sprocket to a crane; insert without dual-cone seals (17). Mount hollow shaft (32) and slide against collar “B”. By this, the sprocket (1) is moved against the collar “A” of the bushing. Mount flange bearing (5) with 3 bolts (61) without dual-cone seal (17). Measure dimension “X”. Slide sprocket (1) to direction “C” until the hollow shaft (32) rests against the collar “D” of the flange bushing. Measure dimension “Y”. The axial play result in X minus Y . Type PC5500-6

4.

Original axial play 0.2 – 0.9 mm

Wear limit 2,75 mm

Remachining

If the amount of axial play exceeds 0.9 mm, area E has to be remachined until the original dimension, is reached. If the amount of axial play is less than 0.2 mm, area F has to be remachined until the original dimension, is reached. • 5.

Suspend sprocket (1) to crane, pull out hollow shaft (32), lift sprocket (1) out. Radial wear determination

The radial play after installation amounts maximally to 0.77 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed. For determination of the bushings check the inner diameter (D) several times. If the maximal value reaches 482.7 mm the bushings must be changed.

AH06529

Page 6 of 7

Illustration 3

AH06529

Page 7 of 7 6. • • • • • • • • • • • • • •

Assembly Mount dual-cone seal (17) according to Service Bulletin AH05511 into flange bearing (6). Mount dual-cone seals (17) according to Service Bulletin AH05511 into sprocket. Place sprocket into the side frame by using a crane, align and underpin sprocket in mounting position. Mount hollow shaft (11). Mount dual-cone seal (17) according to Service Bulletin AH05511 into flange bearing (5). Mount flange bearing (5). The lubrication grooves of the bushing (5.2) have to be displaced by 22.5° to the vertical line. Tighten bolts (61) according to the tightening torques (M30 / 1770Nm). Insert O-ring (25) into the cover (7). Mount cover (7) with bolts (21). Tighten bolts (21), according to the tightening torques (M12 / 74Nm). Insert O-ring (27). Suspend travel gear (14) to a crane and mount to side frame. Tighten bolts (59) according to the tightening torques (M36 / 3100Nm). Refill oil and check levels.

) 7.

• When selecting tightening torques, observe size and quality grade of the bolts.

Torque Data for Standard Application Bolt dia. [mm] M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36

Wrench size [mm] 17 19 22 24 27 30 32 36 41 46 50 55

8.8 43/32 74/54.6 118/87 179/132 255/188 360/265 485/358 620/457 920/679 1250/922 1690/1246 2170/1600

Tightening torque Nm/lbs.ft. Quality grades 10.9 63/47 108/80 173/128 265/196 360/265 510/376 690/509 880/649 1310/966 1770/1305 2400/1770 3100/2286

12.9 73/54 127/94 202/149 310/229 425/313 600/443 810/597 1030/760 1530/1128 2080/1534 2800/2065 3600/2655

Insert all bolts lubricated with MPG, KP2K type lubricant.

AH06529

COMPONENT CODE:

32

REF NO.

AH06530

PARTS & SERVICE NEWS

DATE

July 24, 2006 Page 1 of 2

SUBJET:

Relieving of the track chain tension

PURPOSE:

Hints for working at the crawler unit

APPLICATION:

PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

3200FA

DESCRIPTION:

)

• Read the safety instruction in the Operation and Maintenance Manual carefully, before starting repair works.

For avoiding damages at the travel brakes (4) the following procedure should be used: • Turn the superstructure (90°) and lift the machine. • Shut off the engine. • Open cock (2) for releasing the pressure. • Close cocks (1) and cock (3) if installed. • Close cock (2) (important!). • Now the engine can be started and the sprocket can be turned to the working position. The travel brake is released by pilot pressure.

Illustration as example AH06530

Page 2 of 2

AH06530

COMPONENT CODE:

K1

REF NO.

AH06542

PARTS & SERVICE NEWS

DATE

October 5, 2006 Page 1 of 2

SUBJECT:

Swash plate pump H-A4VSO500

PURPOSE:

Efficient Performance at an altitude of more than 1000 m above sea level

APPLICATION:

PC5500-6

FAILURE CODE:

K100PB

DESCRIPTION: The H-A4VSO500 is a variable displacement axle piston pump in swash plate design intended for drives in open circuit operation. For efficient performance at an altitude of more than 1000 m above sea level the maximum displacement at one revolution of the pump has to be reduced according to the following table. Vg max (revolutions per min)

Altitude* (m)

Turn in setting screw (3) (revolutions)

Q max (l/min)

Diesel

Electric

Diesel

Electric

Diesel

Electric

0

500

500

735

700

0

0

about 1400

460

483

676

676

1¾

¾

about 2900

418

440

615

615

3½

2½

about 3200

405

426

596

596

4¼

3¼

about 4700

355

373

522

522

6¼

5½

•

For adjustments of other altitudes please contact our Service Department.

)

• All spare part pumps will be delivered with standard adjustment. • When installing these pumps at an altitude of more than 1000 m an alteration according to the table above has to be carried out. • If the excavator is displaced to a mine site above an altitude over 3000 m the engine needs also a corresponding adjustment.

Adjustment 1. Unscrew box nut (1). 2. Loosen the lock nut (2). 3. Turn in the stop bolt (3) with an allen key according to the table above. (The distance “X” has to be reduced.) 4. Tighten the lock (2) nut and screw on box nut (1). AH06542

Page 2 of 2 Illustration 1

AH06542

PARTS & SERVICE NEWS

COMPONENT CODE:

J1

REF NO.

AH06543a

DATE

September 20, 2007 Page 1 of 3

This PARTS & SERVICE NEWS supersedes the previous issue AH06543 which should be discarded. SUBJECT:

Gear pumps PN 907 622 40 and PN 940 048 40 (supplied from the company “Kracht”) (Pilot pressure pump; gear oil pump; circulation pump)

PURPOSE:

Increasing of the life time Releasing of a new type of shaft seal rings (Product improvement!)

APPLICATION:

PC5500-6 (PN 15018; 15019, 15022; 15023; 15025;15027; 15032; 15035; 15038, 15040 to 15046; 15048 to 15053, 15055; 15056; 15060; 15062)

FAILURE CODE:

J100AA

DESCRIPTION:

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

Please check the strainer (35); it must be clean (illustration 1). Dirt and paint have to be removed. For increasing of the lifetime, a new type of shaft seal (Positions 17 and 32 - PN 793 357 73) was released for the above mentioned pumps. With order of an old shaft seal the new type will be supplied automatically.

AH06543a

Page 2 of 3

35 Illustration 1

Illustration 2

Illustration 3

AH06543a

Page 3 of 3 Installation hints for the shaft seals • Grease the shaft seals inside and outside before installation (illustration 3). • Use mounting sleeves according to illustration 4. • To avoiding of corrosion coat the adapter surface and the pump surface (illustration 2 and 3) with one of the following types of grease before mounting the pump to the adapter: - CASTROL OPTIMOL PASTE WHITE T - STABYL L 120 Do not close the strainer (35) with grease.

Illustation 4 AH06543a

COMPONENT CODE:

H2

REF NO.

AH06545

PARTS & SERVICE NEWS

DATE

November 22, 2006 Page 1 of 3

SUBJECT:

Hydraulic cylinder bushings

PURPOSE:

Installation hints

APPLICATION:

All types

FAILURE CODE:

H2Z6CA

DESCRIPTION:

)

• Pay attention to the position of the lubricating holes and the lubrication grooves when installing new bushes to ensure good lubrication and maximum lifetime. • Install the bushes as shown at the next pages.

AH06545

Page 2 of 3

AH06545

Page 3 of 3

AH06545

COMPONENT CODE:

26

REF NO.

AH07509

PARTS & SERVICE NEWS

DATE

May 29, 2007 Page 1 of 7

SUBJECT:

Swing gear brake manufactured by “Siebenhaar” (Swing gear PN 902 550 40 and PN 925 864 40)

PURPOSE:

Hints for replacement of the brake assy.

APPLICATION:

PC3000; PC4000; PC5500

FAILURE CODE:

2600FA

DESCRIPTION:

Note In case of a brake failure we recommend to rebuild the brake assembly according to the procedure given below. This method allows later a quick and efficient exchange of the complete brake assembly. 1. Modification kits 1.1 Modification kit for swing gear PN 902 550 40 (PC4000-6 #08152; 08153; 08154) 1.2 Modification kit for swing gear PN 925 864 40 2. Modification instructions 2.1 Disassembly 2.2 Assembly 3. Appendix 3.1 Spare Parts Catalogue page 991 – 0737 3.2 Spare parts Catalogue page 991 – 0715

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also observed.

AH07509

Page 2 of 7

AH07509

Page 3 of 7 1. Modification kits 1.1 Modification kit for swing gear PN 902 550 40 (PC4000-6 #08152; 08153; 08154) Pos.

Part No.

Qty.

Description

1

796 050 73

1

Adapter

2

795 836 73

1

Disc brake

3

972 122

1

O - Ring

4

516 354 98

1

O - Ring

5

501 532 98

1

Hexagon head socket pipe plug

6

339 796 99

1

Seal ring

After conversion the following page of Spare Parts catalogue apply: 991 – 0737.

1.2 Modification kit for swing gear PN 925 864 40 Pos.

Part No.

Qty.

Description

1

795 840 73

1

Adapter

2

795 836 73

1

Disc brake

3

972 122

1

O - Ring

4

516 354 98

1

O - Ring

5

501 532 98

1

Hexagon head socket pipe plug

6

339 796 99

1

Seal ring

After conversion the following page of Spare Parts catalogue apply: 991 – 0715.

AH07509

Page 4 of 7

AH07509

Page 5 of 7 2. Modification instructions 2.1 Disassembly 1. 2. 3.

The oil must be drained completely before the modification of the gearbox, in accordance to the Maintenance Manual of the shovel. Take off all oil fittings of the gear to attach them later to the new adapter. Take off all hydraulic pipes from the brake.

W 4. 5. 6. 7. 8. 9.

• Unscrewing or removing of hydraulic pipes under pressure resp. of connections is hazardous. Take care that - in case of works at the brake (mounting, dismounting) -the brake and the belonging hydraulic pipes are depressurized.

Remove all fixing screws of the motor and take off the motor from the gear. Remove the 24 fixing bolts (1) (M24 x 550) of the gear (1). Remove the 4 fixing bolts (2) (M16x360) of the adapter (3). By means of 2 pulling screws loosen adapter (3). Install 2 eye bolts M16 to the adapter (3). Lift off the adapter (3) with attached brake by adequate lifting device. First lift up approx. 150 mm.

W ã

• If the sun gear is lifted together with the assy. secure it against falling down before lifting up completely. • Do not open the brake cause of DANGER OF ACCIDENT. Under no circumstances you have to unscrew the red marked screws.

AH07509

Page 6 of 7

AH07509

Page 7 of 7

2.2

Assembly 1. Centre the new adapter (1) with put on O-ring (4) into the gear and fasten it with 4 bolts (M16x360). 2. Fasten the gear with 24 bolts (M24 x 550) back to the machine. 3. Centre the new pre-assembled brake (2) with put on O-ring into the adapter and fasten it with 8 bolts (M16 x 210). 4. Insert the new O-ring (3) in the groove provided for this purpose at the motor pivot. The motor pivot has to be pushed into the disc carrier. Centre the motor into the motor flange and fasten it.

)

• To prevent premature wear at the involute spline joint (motor/gear driving shaft), the room between motor and gear gets an oil filling according Maintenance Manual..

5. Fasten the oil fittings back to the gear and the hydraulic pipes back to the brake. 6. Fill the gear and the brake housing with oil according to the instructions in the Maintenance Manual.

)

• Too high oil level in the brake housing reduces the life time of the brake. Screw in the gauge, see detail ”A”. Remove the gauge. The oil level should be 1. At the lower mark of the gauge in case the oil is cold. 2. At the upper mark of the gauge in case the oil is warm.

7. Connect the brake to the hydraulic system.

AH07509

PARTS & SERVICE NEWS

COMPONENT CODE:

30

REF NO.

AH07526

DATE

September 27, 2007 Page 1 of 5

SUBJECT:

Bolted undercarriage: Protective coating on the flange plates

PURPOSE:

References to renew the protective coating

APPLICATION:

PC5500-6

FAILURE CODE:

3010Z9

DESCRIPTION:

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

Check the coated surfaces for spots that may be damaged before assembling or reassembling. Spots less than 20 cm² are acceptable. In case of bigger damages the whole surface coating has to be renewed. 1. Spots less than 20 cm² - Remove carefully all loosen parts of the coated surface. - Assemble the undercarriage as described in the Assembling Manual. 2. Spots more largely than 20 cm² - Remove the whole surface coating carefully. - Close the tap holes with plugs (PN 932 313 40). - Clean the surface oil-free and grease-free. - Machine the surface with a vibration grinder (emery paper grain 60). If abrasive blast cleaning is available, this could be done alternatively according to the attached data sheet. - Clean the surface with special dust clothes (PN 932 911 40). - Prepare and use the protective coat according to the attached data sheet.

)

• For laying on the surface coating a conventional air spray has to be used (no brush or roller). • The prescribed dry layer thickness amounts to 75 µm, according to 125 µm wet layer thickness. • Cure is a function of temperature, humidity and airflow. The film will exhibit full cure in 5 days at 20°C and 7 days at 10°C (relative humidity between 50 and 60%) • Two pack size (PN 674 997 40) are needed for renew the whole coating of an undercarriage.

AH07526

= >?@ABC ®

R e d o x

S C

S i l i c a t e ( F o r m e r l y :

5 1 1 5 )

Product Description

A two component, low VOC, water borne alkali metallic zinc silicate primer.

Intended Uses

As a high performance corrosion resistant primer for use on correctly prepared steel substrates in new construction situations. Suitable for use where a high friction grip is required in accordance with TL 918 300, Page 85.

Practical Information for Interzinc 697

Interzinc 697

Protective Coatings

Interzinc 697 S i l i c a t e ( F o r m e r l y :

®

Application

Mixing

Colour

Grey

Gloss Level

Matt

Volume Solids

60%

Typical Thickness

75 microns (3 mils) dry equivalent to 125 microns (5 mils) wet

Mix Ratio

Theoretical Coverage

8 m2/litre at 75 microns d.f.t and stated volume solids 321 sq.ft/US gallon at 3 mils d.f.t and stated volume solids

Practical Coverage

Allow appropriate loss factors

Working Pot Life Airless Spray Air spray (Conventional) Brush

Temperature

Touch Dry†

Hard Dry†

Overcoating Interval with recommended topcoats Minimum Maximum

5°C (41°F) 15°C (59°F) 25°C (77°F) 40°C (104°F)

45 minutes 30 minutes 25 minutes 15 minutes

4 hours 1½ hours 45 minutes 30 minutes

N/A N/A N/A N/A

Flash Point

Base (Part A) >100°C (212°F)

Powder (Part B) N/A

Product Weight

3,62 kg/l (30,2 lb/gal)

VOC

0 g/l (0 lb/gal)

Interzinc 697 is supplied in 2 parts, a liquid Binder base component (Part A) and a Powder component (Part B). Powder (Part B) should be slowly added to the Liquid Binder (Part A) whilst stirring with a mechanical agitator. DO NOT ADD LIQUID TO POWDER. Material should be filtered prior to application and should be constantly agitated in the pot during spraying. Once the unit has been mixed it should be used within the working pot life specified 1 part (Part A) : 0.7 parts (Part B) by volume 1 part (Part A) : 4 parts (Part B) by weight 20°C (68°F) 8 hours Not Suitable Recommended Use suitable proprietary equipment.

Suitable - small areas Typically 50-75 microns (2-3 mils) can be only achieved Roller Suitable - small areas Typically 50-75 microns (2-3 mils) can be only achieved Thinner DO NOT THIN Cleaner Clean potable water, International GTA991 Work Stoppages Do not allow material to remain in hoses, gun or spray equipment. Thoroughly flush all equipment with clean water followed by International GTA991. Once units of paint have been mixed they should not be resealed and it is advised that after prolonged stoppages work recommences with freshly mixed units. Clean Up Clean all equipment immediately after use with clean water followed by International GTA991. It is good working practice to periodically flush out spray equipment during the course of the working day. Frequency should depend upon amount sprayed, temperature and elapsed time, including any delays. All surplus materials and empty containers should be disposed of in accordance with appropriate regional regulations/legislation.

N/A N/A N/A N/A

† Drying times are dependent upon ambient conditions. The figures quoted above have been determined at the quoted temperature and 60% relative humidity.

Page No. 1 of 4

5 1 1 5 )

All surfaces to be coated should be clean, dry and free from contamination. Prior to paint application all surfaces should be assessed and treated in accordance with ISO 8504:1992. Oil or grease should be removed in accordance with SSPC-SP1 solvent cleaning. Strict adherence to all cleanliness standards is essential for application of water based coatings. Abrasive Blast Cleaning Abrasive blast clean to Sa2½ (ISO 8501-1:1988) or SSPC-SP6. If oxidation has occurred between blasting and application of Interzinc 697, the surface should be reblasted to the specified visual standard. Surface defects revealed by the blast cleaning process, should be ground, filled, or treated in the appropriate manner.

Drying Time

E N G 0 5 0 4

S C

Surface Preparation

Method of Application Airspray, Brush, Roller

Regulatory Data

R e d o x

Mixed >100°C (212°F)

(Calculated)

E N G 0 5 0 4

Page 2 of 4

= >?@ABC ®

R e d o x

S C

S i l i c a t e ( F o r m e r l y :

5 1 1 5 )

Product Description

A two component, low VOC, water borne alkali metallic zinc silicate primer.

Intended Uses

As a high performance corrosion resistant primer for use on correctly prepared steel substrates in new construction situations. Suitable for use where a high friction grip is required in accordance with TL 918 300, Page 85.

Practical Information for Interzinc 697

Interzinc 697

Protective Coatings

Interzinc 697 S i l i c a t e ( F o r m e r l y :

®

Application

Mixing

Colour

Grey

Gloss Level

Matt

Volume Solids

60%

Typical Thickness

75 microns (3 mils) dry equivalent to 125 microns (5 mils) wet

Mix Ratio

Theoretical Coverage

8 m2/litre at 75 microns d.f.t and stated volume solids 321 sq.ft/US gallon at 3 mils d.f.t and stated volume solids

Practical Coverage

Allow appropriate loss factors

Working Pot Life Airless Spray Air spray (Conventional) Brush

Temperature

Touch Dry†

Hard Dry†

Overcoating Interval with recommended topcoats Minimum Maximum

5°C (41°F) 15°C (59°F) 25°C (77°F) 40°C (104°F)

45 minutes 30 minutes 25 minutes 15 minutes

4 hours 1½ hours 45 minutes 30 minutes

N/A N/A N/A N/A

Flash Point

Base (Part A) >100°C (212°F)

Powder (Part B) N/A

Product Weight

3,62 kg/l (30,2 lb/gal)

VOC

0 g/l (0 lb/gal)

Interzinc 697 is supplied in 2 parts, a liquid Binder base component (Part A) and a Powder component (Part B). Powder (Part B) should be slowly added to the Liquid Binder (Part A) whilst stirring with a mechanical agitator. DO NOT ADD LIQUID TO POWDER. Material should be filtered prior to application and should be constantly agitated in the pot during spraying. Once the unit has been mixed it should be used within the working pot life specified 1 part (Part A) : 0.7 parts (Part B) by volume 1 part (Part A) : 4 parts (Part B) by weight 20°C (68°F) 8 hours Not Suitable Recommended Use suitable proprietary equipment.

Suitable - small areas Typically 50-75 microns (2-3 mils) can be only achieved Roller Suitable - small areas Typically 50-75 microns (2-3 mils) can be only achieved Thinner DO NOT THIN Cleaner Clean potable water, International GTA991 Work Stoppages Do not allow material to remain in hoses, gun or spray equipment. Thoroughly flush all equipment with clean water followed by International GTA991. Once units of paint have been mixed they should not be resealed and it is advised that after prolonged stoppages work recommences with freshly mixed units. Clean Up Clean all equipment immediately after use with clean water followed by International GTA991. It is good working practice to periodically flush out spray equipment during the course of the working day. Frequency should depend upon amount sprayed, temperature and elapsed time, including any delays. All surplus materials and empty containers should be disposed of in accordance with appropriate regional regulations/legislation.

N/A N/A N/A N/A

† Drying times are dependent upon ambient conditions. The figures quoted above have been determined at the quoted temperature and 60% relative humidity.

Page No. 1 of 4

5 1 1 5 )

All surfaces to be coated should be clean, dry and free from contamination. Prior to paint application all surfaces should be assessed and treated in accordance with ISO 8504:1992. Oil or grease should be removed in accordance with SSPC-SP1 solvent cleaning. Strict adherence to all cleanliness standards is essential for application of water based coatings. Abrasive Blast Cleaning Abrasive blast clean to Sa2½ (ISO 8501-1:1988) or SSPC-SP6. If oxidation has occurred between blasting and application of Interzinc 697, the surface should be reblasted to the specified visual standard. Surface defects revealed by the blast cleaning process, should be ground, filled, or treated in the appropriate manner.

Drying Time

E N G 0 5 0 4

S C

Surface Preparation

Method of Application Airspray, Brush, Roller

Regulatory Data

R e d o x

Mixed >100°C (212°F)

(Calculated)

E N G 0 5 0 4

Page 2 of 4

Interzinc 697 S i l i c a t e ( F o r m e r l y :

R e d o x

Product Characteristics

Interzinc 697 S C

S i l i c a t e ( F o r m e r l y :

5 1 1 5 )

Apply by airspray. Thoroughly flush equipment with International 991 thinner, or alcohol, followed by water prior to use. To obtain maximum edge protection and film build, airspray application is recommended. Application by other methods, e.g. brush or roller, may require more than one coat.

R e d o x

S C

5 1 1 5 )

Further information regarding industry standards, terms and abbreviations used in this data sheet can be found in the following sections of the International Protective Coatings data manual:

Additional Information

With all water based coatings careful control of application conditions is required to ensure good long term performance. International Protective Coatings have available a set of working procedures relating to the application of water borne paints which are available on request. The following basic parameters must be adhered to:

•

Definitions & Abbreviations

•

Surface Preparation

•

Paint Application

•

Theoretical & Practical Coverage

Individual copies of these information sections are available upon request.

Interzinc 697 must be protected from freezing at all times during storage. Safety Precautions

The minimum steel temperature for application must be above 10°C (50°F), and be at least 3°C (5°F) above dew point. Ideally, the relative humidity during application and cure should be kept between 50 and 60%, otherwise drying and overcoating times will be severely extended.

This product is intended for use only by professional applicators in industrial situations in accordance with the advice given on this sheet, the Material Safety Data Sheet and the container(s), and should not be used without reference to the Material Safety Data Sheet (MSDS) which International Protective Coatings has provided to its customers. All work involving the application and use of this product should be performed in compliance with all relevant national Health, Safety & Environmental standards and regulations.

Good airflow is essential around the object being painted [minimum air speed 0.1m/sec (4 inches/sec)]. Minor areas which are difficult to ventilate should be brush applied to prevent overapplication.

In the event welding or flame cutting is performed on metal coated with this product, dust and fumes will be emitted which will require the use of appropriate personal protective equipment and adequate local exhaust ventilation.

Application below the minimum film forming temperature (M.F.F.T.) of the coating and/or poor ventilation will result in poor film coalescence and will result in a powdery cracked film which will require removal and re-application.

If in doubt regarding the suitability of use of this product, consult International Protective Coatings for further advice.

Maximum continuous dry temperature resistance for Interzinc 697 is 400°C (752°F). Cure is a function of temperature, humidity and airflow. Normally films at 75 microns (3 mils) dry film thickness will exhibit full cure in 5 days at 20°C (68°F) and 7 days at 10°C (50°F).

1.4 litre unit

Pack Size

Interzinc 697 Base Interzinc 697 Powder

1 kg in a 1 litre container 4 kg in a 4 litre container

For availability of other pack sizes contact International Protective Coatings Shipping Weight

Storage

U.N. Shipping No. Non-hazardous 1.4 litre unit

1.05 kg (2.31 lb) Base (Part A) 4.36 kg (9.61 lb) Powder (Part B)

Shelf Life

12 months minimum at 25°C (77°F). Subject to re-inspection thereafter. Store in dry, shaded conditions away from sources of heat and ignition.

Disclaimer Systems Compatibility

The information given in this sheet is not intended to be exhaustive and any person using the product for any purpose other than that specifically recommended in this sheet without first obtaining written confirmation from us as to the suitability of the product for the intended purpose does so at his own risk. Any warranty, if given, or specific Terms & Conditions of Sale are contained in International’s Terms & Conditions of Sale, a copy of which can be obtained on request. Whilst we endeavour to ensure that all advice we give about the product (whether in this sheet or otherwise) is correct we have no control over either the quality or condition of the substrate or the many factors affecting the use and application of the product. Therefore, unless we specifically agree in writing to do so, we do not accept any liability whatsoever or howsoever arising for the performance of the product or for any loss or damage (other than death or personal injury resulting from our negligence) arising out of the use of the product. The information contained in this sheet is liable to modification from time to time in the light of experience and our policy of continuous product development.

Interzinc 697 is only recommended for application to correctly prepared steel substrate. Interzinc 697 is not normally overcoated.

It is the user’s responsibility to check that this sheet is current prior to using the product. Issue date: 28/05/2004 Copyright © International Paint Ltd.

and International are trademarks.

International Protective Coatings World Centre P.O Box 20980 Oriel House 16 Connaught Place London, W2 2ZB England

Asia Region 3 Neythal Road Jurong Town Singapore 628570

Tel: (44) 20 7479 6000 Tel: (65) 663 3066 Fax: (44) 20 7479 6500 Fax: (65) 266 5287

Page No. 3 of 4

E N G 0 5 0 4

Page No. 4

Australasia Region 115 Hyde Road Yeronga Brisbane Queensland Australia

Europe Region P.O Box 20980 Oriel House 16 Connaught Place London, W2 2ZB England

Middle East Region PO Box 37 Dammam 31411 Saudi Arabia

North America Region 6001 Antoine Drive Houston Texas 77091

Tel: (61) 7 3892 8888 Fax: (61) 7 3892 4287 H&S (61) 1800 807 001

Tel: (44) 20 7479 6000 Tel: (966) 3 812 1044 Tel: (1) 713 682 1711 Fax: (44) 20 7479 6500 Fax: (966) 3 812 1169 Fax: (1) 713 684 1514

South America Region Av Paiva 999, Neves, Sao Gonçalo, Rio de Janeiro Brazil

Tel: (55) 21 624 7100 Fax: (55) 21 624 7123

E N G 0 5 0 4

Interzinc 697 S i l i c a t e ( F o r m e r l y :

R e d o x

Product Characteristics

Interzinc 697 S C

5 1 1 5 )

Apply by airspray. Thoroughly flush equipment with International 991 thinner, or alcohol, followed by water prior to use. To obtain maximum edge protection and film build, airspray application is recommended. Application by other methods, e.g. brush or roller, may require more than one coat.

S i l i c a t e ( F o r m e r l y :

R e d o x

Additional Information

S C

5 1 1 5 )

Further information regarding industry standards, terms and abbreviations used in this data sheet can be found in the following sections of the International Protective Coatings data manual:

With all water based coatings careful control of application conditions is required to ensure good long term performance. International Protective Coatings have available a set of working procedures relating to the application of water borne paints which are available on request. The following basic parameters must be adhered to:

•

Definitions & Abbreviations

•

Surface Preparation

•

Paint Application

•

Theoretical & Practical Coverage

Individual copies of these information sections are available upon request.

Interzinc 697 must be protected from freezing at all times during storage. Safety Precautions

The minimum steel temperature for application must be above 10°C (50°F), and be at least 3°C (5°F) above dew point. Ideally, the relative humidity during application and cure should be kept between 50 and 60%, otherwise drying and overcoating times will be severely extended.

This product is intended for use only by professional applicators in industrial situations in accordance with the advice given on this sheet, the Material Safety Data Sheet and the container(s), and should not be used without reference to the Material Safety Data Sheet (MSDS) which International Protective Coatings has provided to its customers. All work involving the application and use of this product should be performed in compliance with all relevant national Health, Safety & Environmental standards and regulations.

Good airflow is essential around the object being painted [minimum air speed 0.1m/sec (4 inches/sec)]. Minor areas which are difficult to ventilate should be brush applied to prevent overapplication.

In the event welding or flame cutting is performed on metal coated with this product, dust and fumes will be emitted which will require the use of appropriate personal protective equipment and adequate local exhaust ventilation.

Application below the minimum film forming temperature (M.F.F.T.) of the coating and/or poor ventilation will result in poor film coalescence and will result in a powdery cracked film which will require removal and re-application.

If in doubt regarding the suitability of use of this product, consult International Protective Coatings for further advice.

Maximum continuous dry temperature resistance for Interzinc 697 is 400°C (752°F). Cure is a function of temperature, humidity and airflow. Normally films at 75 microns (3 mils) dry film thickness will exhibit full cure in 5 days at 20°C (68°F) and 7 days at 10°C (50°F).

Pack Size

1.4 litre unit

Interzinc 697 Base Interzinc 697 Powder

1 kg in a 1 litre container 4 kg in a 4 litre container

For availability of other pack sizes contact International Protective Coatings Shipping Weight

Storage

U.N. Shipping No. Non-hazardous 1.4 litre unit

1.05 kg (2.31 lb) Base (Part A) 4.36 kg (9.61 lb) Powder (Part B)

Shelf Life

12 months minimum at 25°C (77°F). Subject to re-inspection thereafter. Store in dry, shaded conditions away from sources of heat and ignition.

Disclaimer Systems Compatibility

Interzinc 697 is only recommended for application to correctly prepared steel substrate. Interzinc 697 is not normally overcoated.

The information given in this sheet is not intended to be exhaustive and any person using the product for any purpose other than that specifically recommended in this sheet without first obtaining written confirmation from us as to the suitability of the product for the intended purpose does so at his own risk. Any warranty, if given, or specific Terms & Conditions of Sale are contained in International’s Terms & Conditions of Sale, a copy of which can be obtained on request. Whilst we endeavour to ensure that all advice we give about the product (whether in this sheet or otherwise) is correct we have no control over either the quality or condition of the substrate or the many factors affecting the use and application of the product. Therefore, unless we specifically agree in writing to do so, we do not accept any liability whatsoever or howsoever arising for the performance of the product or for any loss or damage (other than death or personal injury resulting from our negligence) arising out of the use of the product. The information contained in this sheet is liable to modification from time to time in the light of experience and our policy of continuous product development. It is the user’s responsibility to check that this sheet is current prior to using the product. Issue date: 28/05/2004 Copyright © International Paint Ltd.

and International are trademarks.

Deutschland: H & S Beschichtungssysteme Vertriebs GmbH | Niekamp 24 | 59399 Olfen | Telefon +49 (25 95) 34 35 / 30 16 | Telefax +49 (25 95) 91 20 | [email protected]

Page No. 3 of 4

Page No. 4

COMPONENT CODE:

L5

REF NO.

AH08503

PARTS & SERVICE NEWS

SUBJECT:

Track drive

PURPOSE:

Complete track drive protection

APPLICATION:

PC5500-6 (SN 15026 and up)

FAILURE CODE:

L510FA

DATE

January 18, 2008 Page 1 of 6

DESCRIPTION:

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

For heavy duty use we recommend to install the complete drive protection according to the drawings below.

1.

Gear box protection (PN 946 692 40)

2.

Motor protection (PN 936 640 40) (only for diesel drive shovels with L&S travel gears)

AH08503

Page 2 of 6

Illustration 1

AH08503

Page 3 of 6 1.

Gear box protection (PN 946 692 40)

Illustration 2 • •

Install the 4 intermediate plates (02) by using the new bolts (03) and washers (04) (remove the respective bolts from the gear box). Mount the protecting cage (01) by using the bolts (05) as shown.

)

• Pay attention to the hydraulic hoses.

AH08503

Page 4 of 6 1.

Gear box protection (PN 946 692 40) Pos.

Part No.

Qty.

Description

01

946 685 40

2

Protecting cage

02

946 684 40

4

Intermediate plate

03

518 354 98

20

Bolt

04

255 056 40

20

Washer

05

517 876 98

24

Bolt

06

621 707 40

24

Resilient sleeve

07

501 133 98

24

Nut

08

255 057 40

24

Washer

AH08503

Page 5 of 6 2.

Motor protection (PN 936 640 40)

Illustration 3 • • •

Mount the intermediate plates (01) by using bolts (07) (existing bolts have to be replaced); Install the bolt protection (04) with bolts (07) (not necessary by mounting the gear box protection); Now install the motor protection assy. by using the bolts (08); the washers (9) and the nuts (10).

)

• Pay attention to the hydraulic hoses.

AH08503

Page 6 of 6 2.

Motor protection (PN 936 640 40) (only for gears delivered by L&S - SN 15026 and up)

Pos.

Part No.

Qty.

Description

01

936 639 40

2

Intermediate plate

02

936 631 40

1

Motor protection left

03

936 632 40

1

Motor protection right

04

936 647 40

2

Bolt protection travel gear

05

936 641 40

2

Cover

06

936 642 40

6

Cover

07

517 967 98

40

Bolt

08

304 331 99

20

Bolt

09

316 213 99

40

Washer

10

332 359 99

20

Nut

11

307 800 99

20

Nut

12

324 741 40

2

Plug

AH08503

COMPONENT CODE:

55

REF NO.

AH08504

PARTS & SERVICE NEWS

DATE

August 7, 2008 Page 1 of 2

SUBJECT:

Windscreen

PURPOSE:

Mounting hints

APPLICATION:

PC4000; PC5500; PC8000

FAILURE CODE:

5532PB

DESCRIPTION:

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

A different holes pattern is used since January 2007 for the frame of the windscreen. We offer two types of windscreens for replacement of a damaged one: 1. Windscreen with mounting holes in the frame and 2. Windscreen without mounting holes. We recommend using windscreen with new holes pattern in the frame, also for shovels, delivered before 2007. Advantages: • Only one fitting of new bore holes in the cab. • In case of a next windscreen exchange the same holes can be used.

AH08504

Page 2 of 2

Pos. 01

Pos.

Part No.

769 528 73 12 mm; green; drilled 12 mm; green; 797 251 73 undrilled

Part No. 793 739 73 797 253 73

01

Description

796 564 73 797 254 73

Description 12 mm; green; drilled 12 mm; green; undrilled 19 mm, with splinter shield foil coating; drilled 19 mm, with splinter shield foil coating; undrilled

AH08504

COMPONENT CODE:

71

REF NO.

AH08507

PARTS & SERVICE NEWS

DATE

April 9, 2008 Page 1 of 9

SUBJECT:

Steel structure

PURPOSE:

Repair welding procedure

APPLICATION:

PC3000-6; PC4000-6; PC5500-6; PC8000-6

FAILURE CODE:

7100FE

DESCRIPTION:

W Content 1. 2. 3. 4. 4.1 4.2 5. 6. 7. 8.

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

Introduction General Protective Measures Steps of the weld repair procedure Selection of appropriate electrodes and welding rods Selection of appropriate electrodes Selection of appropriate welding rods Preparation of the defective Part Carrying out the Weld Repair Post heating Inspection of Repair

AH08507

Page 2 of 9

1. Introduction Weld repairs can cause severe damage to an entire structure if performed incorrectly. Therefore we recommend consulting your Komatsu Service Organization in order to avoid improper welding procedures. If cracks are found in the steel construction of your excavator, please inform our service department as soon as possible. Attach suitable information material (photos, catalogue drawings etc.) showing the location and nature of the crack. 2. General Protective Measures Welding operations can cause damage to electronic components (Computers, Control Units, Sensors etc.) in case the welding current goes through these units. Therefore protective measures are necessary before any weld repair is started. 1. Observe the prevailing safety and fire prevention regulations. Get advice from authorized Electricians for all medium and high voltage systems related questions. 2. Before any weld repair is started, a survey should be made of the area and all safety considerations satisfied such as fuel tanks, hydraulic oil reservoirs, oil lines, electrical cables and synthetic materials. 3. Remove the battery main switch keys and switch off all circuit breakers, refer to the Operation Manual of the Excavator for more information. 4. Attach the welding ground directly to the part that is being repaired. Do not allow welding current to go through bearings. Welding current could arc the bearings, resulting in severe damage to the bearing. 3. Steps of the weld repair procedure 1. Clean the damaged part or area to be repaired. 2. Inspect the worn or fractured area by visual inspection and/or non-destructive testing. 3. Determine the type of material to be repaired. 4. Determine the welding electrode or the welding wire and process to be used. 5. Preheat before welding. 6. Weld by using appropriate welding techniques. 7. Post heat. 8. Make a survey of the repair welding.

AH08507

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4. Selection of appropriate welding electrodes and welding wires Table 1: The components shown in illustrations 3 and 4 are made of six different materials (a, b, c, d, e or f) as shown in the table below. Material designation

former

present

international

a

St52-3N

S355J2G3

1.0570 (17G1S)

b

GS24Mn6V

GS24Mn6V

1.1118

c

StE690

S690Q

1.8931

d

GS18NiMoCr36

GS18NiMoCr36

1.6759

e

TStE355

P355NL1

1.0566

f

Hardox 400

4.1 Selection of appropriate welding electrodes Table 2: The following welding electrodes are required for the weld repairs: Key number

Welding Electrode (AWS)

4 5* 7* 9*

E 7016 E 7018-G E 8018-G E 100 18-G

* Hydrogen content less than 5mg per 100ml

Table 3: Types of welding electrodes to be used for the different materials (a to f) Material a b c d e f

a 4 4 4 4 4 7

b 4 4 7 5 7

c 4 7 9 9 7

d 4 5 9 9 7

f 7 7 7 7 7 7

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Example: Selection of the correct welding electrode for weld repair a crack in the welded joint between material (a) and (c). The table 4 shows the correct electrode with key number 4 in the red shaded field. Table 4 Material a b c d e f

a 4 4 4 4 4 7

b 4 4 7 5 7

c 4 7 9 9 7

d 4 5 9 9 7

f 7 7 7 7 7 7

4.2. Selection of appropriate welding wires Table 5: The following welding wires are required for the weld repairs Key number

Welding wire (AWS)

21 25/25a 30 32

ER70 S6 ER100 S1 E70 T5 E90 T5-G

Table 6: Types of welding wires to be used for the different materials (a to f) Welding wires a b c d e f

a 21; 30 21; 30 21; 30 21; 30 21; 30 25; 32

b 21; 30 21; 30 21; 30 21; 30 21; 30 ---

c 21; 30 21; 30 25; 25a; 32 32 21; 30 25; 25a; 32

d 21; 30 21; 30 25; 25a; 32 32 21; 30 ---

f 25; 25a; 32 --25; 25a; 32 --25; 25a; 32 25; 25a; 32

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5. Preparation of the defective Part • Clean the fractured area or worn part of all oil, grease, paint, moisture, dirt, rust, spalled material or any other materials, which may be detrimental to a weld. • Inspect the fractured areas carefully by non-destructive testing such as magnetic particle or dye penetrant inspection. • When removing cracks, a V groove should be made with a 30° to 45° angle. Remove defective material up to the bottom of the crack.

Illustration 1 Use electrodes out of a freshly opened can or from an electrode holding oven. Dry the electrodes according to the instructions of the electrode manufacturer. Preheating of the part before preparing it for weld repair is essential to reduce the thermal shock. The preheat temperature depends on the composition of the material, see table 7 for the required temperature. Measure the temperature beside the joint at a distance equal to the sheet metal thickness using suitable temperature indicating devices. Table 7 Material S355J2G3 P355NL1

S690Q

GS24Mn6V GS18NiMoCr3 Hardox 400

Groove depth (mm) <10

Preheat temperature (°C) 20

Interpass temperature (°C) 220

10 - 20 20 - 50 10 10 - 20 >20 <10 10 - 20 >20

50 100 50 100 150 50 100 150

220 220 150 180 220 150 180 180

>10

150

200

Post heat temperature (drop per hour)

50 degree. max.

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6. Carrying out the Weld Repair

) • •

•

• •

• All weld repairs should be carried out by qualified and experienced welders. • Provide the necessary equipment such as the correct clothing, head gear, exhausts systems or respirators and if required platforms for safe access to the repair area. It is important to maintain the preheat temperature according to table 7 throughout the repair. The interpass temperature should never exceed the maximum permissible value shown in table 3. Measure the temperature beside the joint at a distance equal to the sheet metal thickness using suitable temperature indicating devices. All cracks through the parent material will require a welding from both sides, see illustration 1. The Service Bulletin No. 21-594 contains instructions for making a “Man Hole” which is necessary for weld repairs from inside the boom or stick. When welding in a vertical position always weld using the vertical up technique. Properly applied multiple pass welding is the required procedure, illustration 2. Use a blunt-nosed chisel (C) to calk the weld beads (A and B) with the groove wall before welding the space between the beads (A and B). Repeat the calking of beads (A and B) at each weld layer.

Illustration 2 • •

Once a repair has been started by preheating and welding, the part should be worked on until completed. A recommended technique for repair is to butter the groove with weld metal. Buttering is the addition of one or more layers of weld metal to the face of the joint or surfaces to be welded.

AH08507

Page 7 of 9 •

•

After the welding has been completed, check the repair for any undercuts, overlaps or any other notch type discontinuity while the preheat is still up to temperature. Make any repair necessary at this time. After the repair cools, grind all butt-welded repairs smooth using 36 or finer grit grinding material. All grinding marks should be parallel to the direction of primary stress if possible. Make sure there is a smooth transition between the weld metal and the parent plate.

7. Post heating •

Maintain the preheat temperature according to table 7 for at least 15 minutes after the weld repair is finished and then cool the repair area slowly, refer to table 3 for maximum allowable temperature drop per hour.

8. Inspection of Repair •

• •

)

Inspect the completed weld after it has cooled to the ambient temperature by non-destructive procedures as dye penetrant, or magnetic particle inspection and ultrasonic inspection, if possible. A final inspection of the weld repair should be made after 24 hours in order to detect hydrogen induced cracks. If surface defects are found, remove all defects by grinding to a maximum depth of 1.5 mm. Larger defects have to be removed according to the repair procedures described on the preceding pages. Grind welds so they blend in with the parent material. All spot welding also require preheating and post heating. • It is not recommended to weld on reinforcement plates as the main stress will remain ~float~ through the steel structure regardless how many additional plates would be applied to the structure.

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Illustration 3 AH08507

Page 9 of 9

Illustration 4 AH08507

COMPONENT CODE:

71

REF NO.

AH08508

PARTS & SERVICE NEWS

DATE

June 13, 2008 Page 1 of 3

SUBJECT:

Bushings of the attachment and at the undercarriage

PURPOSE:

Wear checking procedure

APPLICATION:

PC3000-1; PC3000-6; PC4000-6; PC5500-1; PC5500-6; PC8000-1; PC8000-6

FAILURE CODE:

7100CA

DESCRIPTION:

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

)

• For installation of bushes please refer also to Parts & Service news AH06545.

1. Bushings of the attachment 2. Bushings between bolted track frame and undercarriage (depends on the execution)

AH08508

Page 2 of 3 1. Bushings of the attachment

Illustration 1 Example for determining the clearance of the boom cylinder bushes (The procedure for the other attachment bushes is analogues.) 1. Place the attachment on the ground as shown on illustration 1. 2. Raise the attachment a little bit from the ground. 3. Make a line with a felt pen from boom bearing to the boom cylinder barrel (a = 30 cm). 4. Make a 2nd line with a felt pen from boom bearing to the boom cylinder piston rod (b = 30 cm). 5. Press the attachment on the ground so far that the chains at “c” just remove from the ground. 6. Measure the distances at “a” and “b”.

)

• We recommend to renew the bushes if the clearance reaches a value of about 3 mm.

AH08508

Page 3 of 3 2. Bushings between bolted track frame and undercarriage 1. Position the machine in a position so that the track frame can be lifted of the ground.

2. Install a dial gauge so that the dial gauge magnetic portion is on the side frame. 3. Set the pointer on to the car body and set to zero.

4. Raise the track frame slowly off the ground until the dial gouge stops moving. Record the measurement.

)

• We recommend to renew the bushes if the clearance reaches a value of about 3 mm.

AH08508

COMPONENT CODE:

6B

REF NO.

AH09505

PARTS & SERVICE NEWS

DATE

May 15, 2009 Page 1 of 4

SUBJECT:

Hoses between boom and stick

PURPOSE:

Hose standardization and routing improvement

APPLICATION:

PC5500-6 (SN to 15077)

FAILURE CODE:

6B00FA

DESCRIPTION:

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

We recommend replacing the hydraulic lines on the stick according to the description at the following pages and the hydraulic hoses between stick and boom. Advantages: • All 6 hydraulic hoses with the same length and straight hose connectors. • Only one clamp rail for the hoses necessary. • Routing improvement.

AH09505

Page 2 of 4 Description (refer to drawing below) 1. Remove the both l.h. hydraulic hoses (1) between stick and boom and all pipes on the stick (4 to 9). 2. Install the new blocks (3). 3. Install the new pipes (4 to 9) to the stick. 4. Install the two new hoses (1) and the new clamp rail (2). 5. Bleed the new hydraulic hoses /lines refer to Parts & Service News AH06524.

Modification kit PN 952 783 40 (Refer to drawing below) Pos. 1* 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Part No. 940 328 40 952 786 40 952 701 40 952 788 40 952 789 40 952 792 40 952 794 40 952 791 40 952 793 40 947 597 40 934 005 99 534 004 99 504 818 98 308 581 99 319 323 99 322 430 40 319 313 99 504 662 98 385 243 40 319 305 99 952 790 40

Qty. 2 1 2 1 1 1 1 1 1 1 2 2 2 4 8 2 40 40 8 8 1

Description Hose NW 50 x 3200 Clamp rail assy. SAE-L-Block 2” Pipe assy. 65 x 8 2” Pipe assy. 65 x 8 2” Pipe assy. left Pipe assy. left Pipe assy. right Pipe assy. right Plate 100x8x240 Plate Plate Clamp set Bolt M 10 x 70 Bolt M 20 x 90 Pipe 38x5x260 Bolt M 20 x 120 Nut M 20 Flange Seel Bolt M 20 x 60 Angle Bracket

* Different Parts for cold weather design (- 50°C) 1 940 765 40 2 Hose NW 50 x 3200

AH09505

Page 3 of 4

Illustration 1 AH09505

Page 4 of 4

AH09505

PARTS & SERVICE NEWS

COMPONENT CODE:

71

REF NO.

AH09522

DATE

June 16, 2009 Page 1 of 1

SUBJECT:

Wishbone and rod

PURPOSE:

Prevent pin seizure

APPLICATION:

PC3000BH; PC4000BH; PC5500BH; PC8000BH

FAILURE CODE:

716BFR

DESCRIPTION:

W )

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

• We recommend filling the chambers, shown on the drawing below, with grease to prevent pin seizure, pin rotating and breaking off the retainer for the pin. Grease filling

AH09522

Supplier’s documentation

9 SUPPLIER’S DOCUMENTATION

Version 2010/1

PC5500-6E

9 -1

Supplier’s documentation

Contents of this chapter: AVANTI HYTORQUE

9 -2

PC5500-6E

Version 2010/1

XXI/Avanti/Stealth SERIES Operational Manual

July 2004

Table of Contents XXI/Avanti/Stealth SERIES Operational Manual

SECTION I IMPORTANT SAFETY INSTRUCTIONS SECTION II BEFORE USE

2-1 Working Pressure 2-2 Hydraulic Connections 2-3 Electrical Connections 2-4 Air Connections

SECTION III OPERATION

3-1 General 3-2 Connecting the System 3-3 Drive Direction Change 3-4 Reaction Arm XXI/Avanti 3-5 Setting Torque 3-6 Setting Pump Pressure 3-7 Tightening Procedures 3-8 Operating the XXI, Avanti & Stealth Systems 3-9 Loosening Procedures

SECTTION IV 4-1 Tool set up and operation USE WITH LoaDISC 4-2 LoaDISC Tensioning WASHER & CLAMP-NUT 4-3 LoaDISC De-tensioning 4-4 LoaDISC Lubrication 4-5 CLAMP-NUT Tensioning 4-6 Clamp-nut De-tensioning 4-7 Clamp Lubrication SECTTION V 5-1 General Information OPERATION 5-2 Hydraulic Connections HYTORC POWER PACKS 5-3 Prior to Use 5-4 Operation –Electric Pump-5-5 Operation –Air Pump-5-6 Automatic Pump 5-7 Starting with Automatic System SECTION VI HELPFUL INFORMATION

Tool Dimensions & Parts List Field-proven Torquing Procedure Pressure/Torque & Pressure/Load Conversion Chart Recommended Torque For ASTM A193 Grade B7 Studs

INTRODUCING THE NEW GENERATION HYTORC

Thank you for buying the NEW HYTORC FREEDOM-LINE! This manual is designed to provide you with the basic knowledge required to operate and maintain your HYTORC bolting equipment. Please read this manual carefully and follow the instructions provided. If you have any questions regarding HYTORC bolting equipment, please call us at 201-512-9500 or contact us at [email protected]. Your purchase of HYTORC bolting equipment entitles you to the following services at no extra cost to you. Free on-site training in the application and operation of your HYTORC bolting equipment * Free semi-annual training * Free annual tool inspection. * Free loner tools in case of failure under warranty * Free engineering assistance by calling 1-800-FOR-HYTORC or our international office. Your local HYTORC bolting specialist is available around the clock for your convenience. Should you require any assistance, please contact us to obtain our local specialist’s information. World-wide Warranty HYTORC bolting equipment is engineered to the latest technological standards and is accompanied by our exclusive 12 word, 12-month warranty: “YOU BREAK IT UNDER NORMAL USE, WE FIX IT FREE OF CHARGE!” If your HYTORC equipment cannot be repaired on site, FREE loaner equipment will be made available to you upon request, while under warranty.

INTRODUCTION

HYTORC tools are uniquely multi-purpose. They can be used as accurate bolting equipment on conventional nuts in open or confined spaces. They also can be used as reaction arm free tensioning equipments, when used with HYTORC LoaDISC washer or HYTORC-Clamp, Hydraulically Actuated Mechanical Tensioner. SECTION I IMPORTANT SAFETY INSTRUCTIONS HYTORC tools are designed for the safety of operators. However, they are powerful tools and certain safety precautions should be observed to avoid accidents or personal injury. The following tips will assist you. READ ALL INSTRUCTIONS KEEP WORK AREA CLEAN AND WELL LIT CONSIDER WORK AREA ENVIRONMENT

Electric pumps should never be used in any atmosphere which can be considered potentially volatile. If there is any doubt, use an air pump.

Also note: Metal to metal contact can cause sparks. Precautions must be taken. AVOID PREMATURE TOOL STARTING

The pump remote control should be operated by a designated operator and ensure “ALL CLEAR” prior to starting and to avoid premature tool starting.

STAY CLEAR DURING OPERATION

In most cases, the tool will allow “hands free” operation. If the tool must be reset on bolt during operation, make sure the remote control operator is aware of turning the pump off.

IMPORTANT NOTE: NEVER HOLD THE TOOL DURING OPERATION! GUARD AGAINST ELECTRIC SHOCK

Ensure the pump is properly grounded and the proper voltage is used.

STORE EQUIPMENT PROPERLY

When not in use, tools and accessories should be properly stored to avoid deterioration.

USE THE RIGHT TOOL Do use tools or attachments suitable for the applications. *refer to our recommended torque/load chart PROPER SAFETY ATTIRE

When handling/operating hydraulic equipment, wear work gloves, hard hats, safety shoes, safety glasses and other applicable clothing.

MOVING EQUIPMENT

Do not use hydraulic hoses, uniswivels, pump power or remote cords as means of moving the equipment.

SECTION I IMPORTANT SAFETY INSTRUCTIONS -continued from the previous pageHOSES

Do not kink hoses. Inspect and replace if damaged.

SHROUDS AND COVER PLATES

All tools are equipped with shrouds and/or cover plates to prevent contact with the moving internal parts. Do not use tools without these safety covers. If the covers are missing or damaged, replace immediately.

MAINTAIN TOOLS

For the best results, inspect tools, power packs, hoses, connectors, electric lines and accessories for visual damage before each usage. Always follow instructions for proper tool and pump maintenance.

SAFETY ALERT

Do not use power equipment under the influence of any mood altering substance.

PRIOR TO OPERATION

Ensure that all hydraulic connectors are securely connected. Verify that the hydraulic hoses are not kinked. Insure the square drive and its retainer are fully and securely engaged.

PRIOR TO USE (if use with reaction arm)

Before placing your tool on the application, cycle it to ensure proper function. If using the torque mode, locate a solid and secure reacting point. Be sure the reaction arm is retained firmly and positioned to face the same direction as the square drive. Be sure the hydraulic hoses are free of the reacting point. Pressurize the system momentarily; if the tool tends to “ride up” or to “creep”, stop and adjust the reaction arm to a solid and secure position.

NOTE: Remain clear of the reaction arm during operation and never put body parts between reaction arm and reaction surface. ALWAYS USE QUALITY ACCESSORIES

Use genuine HYTORC accessories. Use correct size accessories and engage them fully. Stay clear of all moving accessories during operation.

DO NOT USE FORCE

Do not apply any impact by using hard objects on bolting equipment or accessories. This may cause malfunction or breakage.

ALWAYS CONSULT

Please contact HYTORC for any questions related to our equipment or your bolting needs. Safety is always the number one priority.

SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC READ CAREFULLY: Most malfunctions, in new equipment, are the result of improper operation and/or set-up. PREPARATION: Remove HYTORC equipment from shipping container. INSPECTION: Visually inspect all components for any damage during transportation. If damages are found, notify HYTORC immediately. 2-1 Working Pressure The tool’s maximum working pressure is 10,000 PSI (700kg/cm2, 690 Bar) Make sure that all hydraulic equipment used is rated for 10,000 PSI operating pressure. To set pump pressure for XXI models to 10,000 PSI for both advance & retract, locate selector valve underneath the couplers. Turn the pump off and loosen the lock nut. Turn the center screw counter-clockwise until it stops. Tighten the lock-nut. For Avanti & Stealth models, turn the center screw clockwise until it stops. Tighten the lock-nut to set the pump pressure to 1,500 PSI for retract. 2-2 Hydraulic Connections With older style pumps, (SST-10, SST-20), the retract side of the system may remain pressurized after the pump has been switched “off”. This trapped pressure makes it impossible to loosen the retract-side fittings by hand. To release the pressure, find the 5/16 manual override holes in the end of the black solenoids on the pump. With a welding rod, Allen-key or similar device, push in on the ends of both solenoids, each in turn, and the residual pressure will be released. All fittings will, then, be hand tightened again. Hoses and couplers must be free and unobstructed before and during the operation of the tool. External impact on the couplers may break off the fittings. Current pump models are equipped with an auto-pressure relief. Never disconnect or connect any hydraulic hoses or fittings without first unloading wrench and the pump. Double check the gauge reading to assure pressure has been released. When making connections with quick disconnect couplings, make sure the couplings are fully engaged. Threaded connections such as fittings and gauges must be clean and securely tightened and leak free. CAUTION: Loose or improper threaded fittings can be potentially dangerous if pressurized. Severe over tightening can cause premature thread failure. Never grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury.

SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC -continued from the previous page2-3 ELECTRICAL CONNECTIONS Ensure proper power availability to prevent motor failure or dangerous electrical overloading. Compare the motor nameplate for required amperage. Do not use electric pump, if three prong electrical plug is not whole. Minimize the length of extension cords and be sure they are of adequate wire size, with ground connectors. Extension cord up to 50 feet should be #10 AWG gauge. CAUTION: Electric motors may spark. Do not operate in an explosive atmosphere or in the presence of conductive liquids. Use an air pump instead. 2-4 AIR CONNECTIONS Ensure that you have sufficient air flow of 80 psi ( 50 cfm) to operate your pneumatic pump. If in doubt, compare the pump manufacturer’s recommended air flow rating prior to pressurizing pump. Improper air flow may damage the pump motor. For best results, use air hose larger than 3/4 “ diameter. Use of a filter regulator lubricator (FRL) is highly recommended. (diagram below) AIR ADJUSTMENT KNOB AIR FLOW ON/OFF LEVER

OIL LUBRICATOR ADJUSTMENT KNOB FILTER CAP

AIR PRESSURE GAUGE CONDENSATION BOWL

DRIER 1. 2.

Adjust flow to 1-2 drops per minute. Fill half way with grade 46 hydraulic oil supplied.

AUTO WATER DRAIN PORT

SECTION III OPERATION – Torquing Conventional Nuts 3-1 General All HYTORC tools are supplied completely assembled and are ready to use. A HYTORC Hydraulic Power Pack, for use with your HYTORC tools, is recommended to provide the speed, pressure and portability that makes your HYTORC SYSTEM more efficient and accurate. The SYSTEM accuracy of your HYTORC tool is +-3% based upon manufacturer’s specifications. This accuracy maybe certified through calibration by HYTORC or any other qualified calibration facility whose program is traceable to the National Institute of Standards and Technology (N.I.S.T.) Using a calibrated gauge enhances the accuracy of your HYTORC SYSTEM. 3-2 Connecting the SYSTEM The wrench head and power pack are connected by a 10,000 PSI operating pressure (40,000 PSI burst) twin line hose assembly. Each end of the hose have one male and one female connector to assure proper interconnection between pump and wrench head. IMPORTANT:

To avoid tool malfunction, do not reverse connectors.

Connect the twin line hose to the uniswivel as shown below. Make sure male couplers are connected to female couplers. During the operation, check the connection to ensure the couplers are not loose. Insure the connectors are fully engaged and screwed snugly and completely together.

Connect to tool

Connect to pump

*Connect male end of hose to female end of both tool and pump & female end of hose to male end on both tool and pump

From hose

From hose

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-3 Drive Direction Change Avanti tools To remove the square drive, disengage the drive retainer assembly by depressing the retaining round button and gently pulling on the square end of the square drive. The square drive will slide out. To insert the drive in the tool, place the drive in the desired direction, engage drive spline and ratchet spline, then twist bushing until engage to the housing spline. Push drive through ratchet. Depress drive retainer button, engage retainer with drive and release button to lock.

Button Drive Retainer

Square Drive

The diagram on the right illustrates the direction that the square drive should face for tightening and loosening of a standard right hand fastener.

Loosening

Tightening

Stealth tools The Stealth tools use interchangeable ratcheting links. For tightening, simply engage the nut with the right side of the link facing down. For loosening, the left side of the link faces down. Ratcheting link can be detached from the Stealth power head by pulling the power head out while pressing the button shown below.

STEALTH MADE IN U.S.A.

STEALTH

MADEIN USA

Loosening

Link release button

3-4 Reaction Arm

Please read operating instructions prior to use, and use common sense.

Tightening

KEEP HANDS OFF DURING OPERATION!

The Avanti can be used with a 360 degree adjustable universal reaction arm.

Make sure the reaction arm spline is fully engaged on the square drive spline. Secure the position by tightening the set screw on the reaction arm. *ALWAYS USE A SAFETY HANDLE

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-5 Setting Torque Once the SYSTEM is fully connected and the proper power supply is available, it is time to adjust the pump pressure to the level needed on your job. When tightening, use the manufacturer’s specifications to determine the torque value ultimately required. Appendix I – which is presented as a guideline for comparison only – gives typical torque values specified for the most commonly encountered fasteners. Torque sequence varies from plant to plant and even within the same plant may vary depending on the gasket material and other factors. Always abide by on-site-procedures. Always refer to the pressure-torque conversion table that came with the tool. 3-6 Setting the Pressure on the Pump

T Handle

To set the pressure on the pump, follow this procedure. 1. Loosen the knurled locking ring below the “T” handle on the pump’s external pressure regulator. Then turn the “T” handle counterclockwise until it turns freely and easily. 2. Turn the pump “ON”. Using the pump’s remote control pendant, push down the advance switch (or button on air pump) and hold it.

Locking Ring

3. While holding the pump in the advance mode, slowly turn the “T” handle clockwise and observe the pump pressure gauge rise. NOTE: Always adjust the regulator pressure up – never down. 4. Once the desired pressure is reached. Turn off the pump and “LOCK IN” the pressure by tightening the knurled lock nut. Turn on the pump once more and pressurize to verify the pressure is maintained. 3-7 Applying the Avanti – the Tightening Process 1. Once your target pressure is set, cycle the tool three or four times to full pressure. Cycling the tool ensures that the system is operating properly and removes trapped air, if any. 2. Place the proper size driving unit on the square drive and secure properly. 3. Place the tool on the bolt, making sure that everything is fully engaged. Further ensure that the drive retainer is engaged. 4. Make sure the reaction arm is firmly abutted against a stationary object. 5. When positioning the wrench, make sure that the hose connections are well clear of any obstructions. 6. After all the above are confirmed, apply momentary pressure to the SYSTEM to ensure proper tool placement.

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-7 Applying the Stealth – the Tightening Process 1. Once the target pressure is set (refer to 3-6) Cycle the tool several times to full pressure to assure proper operation. 2. Place the right side of the ratchet link directly over the nut. Ensuring the hex is fully engaged and the reaction pad portion of the link abuts solidly against an adjacent nut or other stationary object. (see 3-3 for proper tool placement) 3. Ensure hose connections are clear of any obstacles. 4. After all the above are confirmed, apply momentary pressure to the SYSTEM to assure the reaction point is stable. 3-8 Operating the Avanti and Stealth SYSTEMS 1. By pushing down on the remote control button in the advance position, the rear of the tool will be pushed back until the reaction surface will contact its reaction point. 2. Continue to hold down the advance button as the socket turns until you hear a “CLICK” which will signify the hydraulic cylinder inside the tool is fully extended and will not turn the socket further. 3. Continuing to hold down the remote control button will result in a rapid buildup of pressure to the point of where the gauge reads what was preset prior to applying the wrench. IMPORTANT: The reading of full preset pressure after the cylinder is extended DOES NOT INDICATE that this pressure (torque) is applied to the bolt. It only indicates that the cylinder is fully extended and cannot turn the nut further until the tool automatically resets itself. Releasing the remote control button will retract the cylinder. The tool will automatically reset itself and the operator will hear a “CLICK” indicating he can again push the remote control button and the socket will turn. Each time the cylinder is extended and retracted, it is called a cycle. Successive cycles are made until the tool “STALLS” at the preset Torque/PSI with an accuracy of +-3%. Repeatability is +-1%. IMPORTANT: ALWAYS ATTEMPT ONE FINAL CYCLE TO INSURE THE “STALL” POINT HAS BEEN REACHED. NEVER HOLD THE TOOL DURING OPERATION. Use safety handle to set and remove tools.

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-8 Operating the Avanti and Stealth SYSTEMS Releasing “LOCKED-ON” tools. Should the tool “LOCK-ON” after the final cycle, slide the slider (or the lever on Avanti) with the pump off or in retract position. Turn the pump back on and while maintaining the pressure, cycle Avanti in the pump’s manual mode. Should Stealth “LOCK-ON”, advance pump pressure and while advancing, press down on the release button located on the sides of the ratchet link. Once you are able to press down the button without resistance, continue holding the button down and release the advance pressure on the pump. Shut off the pump, and remove the tool from the nut.

Avanti Release Procedure

Disengage lever

1)

Push lever to position A

2)

Cycle tool in manual mode, release advance button

3)

Shut pump off

4)

Remove tool and reset lever to position B

Stealth Release Procedure STEALTH

1)

Push remote to full pressure for final stroke

2)

Disengage the reaction pawl by holding the button in the direction of arrow

3)

Release the rocker switch

4)

Shut pump off

5)

Remove tool

MADE IN U. S.A.

Disengage button

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-9 Loosening Procedures Avanti and Stealth SYSTEM First, set the pump to 10,000PSI. Set the tools for the loosening mode (Refer to 3-3), assuring the reaction surface abuts squarely off a solid reaction point. Press and hold the remote control button down. Pressure will decrease as the socket begins to turn. As the cylinder extends fully, you will hear a “CLICK”. Release the remote control button and the cylinder automatically retracts, at which time you again hear a “CLICK”. Repeat this process until the fastener can be removed by hand. NOTE: If the bolt does not loosen with the above procedure, it is an indication that you may require the next larger size tool to loosen the bolt. Corroded nuts and thread galling on bolts can cause difficulty in loosening. Please consult your HYTORC bolt specialist.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp 4-1 Tool Set up and Operation When used in conjunction with the HYTORC LoaDISC Washer or Clamp, the operation is essentially the same as with the conventional nuts, but with one notable exception: THERE ARE NO REACTION FORCES TO CONSIDER OR PROVIDE FOR! The reaction forces are absorbed through the fastener assembly itself. Each individual customer order for LoaDISC or Clamps will be provided with specific installation instructions for each application. However, the following general guidelines outline correct installation procedures. 4-2 HYTORC LoaDISC Tensioning 1. Do not use grease or lubricants on LoaDISC , nut, bolt or joint face. LoaDISC is “DRY LUBE” protected. 2. Place the LoaDISC over the bolt with the flat surface firmly against joint face. 3. Install the nuts on the bolt and hand tighten snugly on both sides of assembly. 4. Set required pump pressure. 5. Place tooling to engage a nut and the LoaDISC with “TIGHTENING” side facing the operator.

-continued to the next page-

DRIVE SOCKET

HOLDING SOCKET

Soft Joint LoaDISC

Reusable LoaDISC

Hard Joint LoaDISC

Limited Clearance

HEX NUT

DISC WASHER THREADED SEGMENT

LoaDISC

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-2 HYTORC LoaDISC Tensioning 6. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until tool “STALLS OUT” 7. Should tool rotate during initial pressurizing: A. Insure both socket and sleeve are fully engaged. B. Insure that joint faces are free from grease and oil. *Also refer to the trouble shooting section (4-4) LoaDISC Driver Installation for Tensioning LOCK-RING 'NEUTRAL' POSITION

PLACE DRIVER NUT/LoaDisc

ROTATE 'CW' BY HAND, TO SNUG LoaDisc TO FLANGE

LoaDisc LOCK-GROOVE

NOTE:

ROTATE DRIVER ASSEMBLY 'CCW' DIRECTION FOR TIGHTEN MODE

TIGHTEN 'CCW' DIRECTION

LOOSEN 'CW' DIRECTION

1

2

3

* DO NOT GRAB A SWIVEL DURING OPERATION! * DO NOT PLACE TOOL HOUSING * TO ABUT AGAINST STATIONARY OBJECTS * DO NOT STAND UNDERNEATH OR CLOSE TO TOOL * DO NOT RE-USE SINGLE-TIME USE LoaDISC

VERIFY ROTATE LOCK-RING

LOCK-RING ENGAGE LoaDisc LOCK-GROOVE

4

5

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-3 HYTORC LoaDISC De-tensioning 1. Set pump to maximum pressure. 2. Place tooling to disengage the nut and the LoaDISC with “LOOSENING” side facing the operator. 3. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until the nut is loose. 4. Should tool rotate during initial pressurizing: A. Insure both socket and sleeve are fully engaged. B. Insure that joint faces are free from grease and oil. *Also refer to the trouble shooting section (4-4)

ROTATE DRIVER ASSEMBLY 'CW' DIRECTION FOR LOOSEN MODE

LoaDISC Driver Installation for De-tensioning

VERIFY ROTATE LOCK-RING

3

4

5

Releasing “LOCKED-ON” tools. (Refer to 3-8 for Avanti and Stealth) Should the tool “LOCK-ON” after the final cycle, slide the slider with the pump off or in retract position. Turn the pump back on and while maintaining the pressure, cycle XXI in the pump’s manual mode. the pump. Shut off the pump, and remove the tool from the nut. XXI Release Procedure HYT RC

1)

Push slide cover up to position A

2)

Cycle tool in manual mode, release advance button

3)

Shut pump off

4)

Remove tool and reset slide cover to position B

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-4 HYTORC LoaDISC Lubrication Instruction & Trouble Shooting STEP 1:

Make sure all threads and surfaces are free of dirt or grit.

STEP 2:

Apply spray lube TS801 moly spray to nut per procedure indicated below. Allow spray lube to dry (spray lube is shipped with LoaDISC order). Refer to the Dry-lube container label for a drying time. Do Not Apply Lube to LoaDISC

STEP 3:

Clean and dry protruding stud threads and nut seat surfaces.

STEP 4:

Install LoaDISC with flat side against joint, turn till snug.

STEP 5:

Install lubricated hex nut on top of LoaDISC , snug against top surface of LoaDISC .

LoaDISC Application of Spray TS801

NOTE: *Allow sufficient time for spray to dry before use. Hex nut can be reused, if re-lubricated per illustration. NO NOT REUSE ONE TIME USE LoaDISC

HYTORC LoaDISC Trouble Shooting SYMPTOM Driver does not lock

CAUSE Lock ring misaligned with LoaDISC

SOLUTION Check for excessive stud protrusion Check that holding socket is flush to flange surface

LoaDISC groove damaged

Replace LoaDISC

Missing or damage lock-ring

Replace lock-ring

LoaDISC not snug against

flange surface

Tighten LoaDISC to flange surface with driver assembly (CW direction)

Driver un-locks during verification

Worn lock-ring

Replace lock-ring

Driver un-locks during use

Lock-ring rotated in wrong direction

Rotate Holding socket and lock-ring •CCW toward ‘T’ for Tighten •CW toward ‘L’ for Loosen

Driver does not un-lock after torque procedure

Stud driven up into bottom of drive socket

Check for excessive stud extension.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-5 HYTORC Clamp Installation - Tensioning The HYTORC Clamp is provided with lubrication and is shipped ready for use. For re-lubrication, please refer to lubrication Instructions. (4-6) 1. Thread the Clamp down on the stud, turn the Puller Sleeve to contact the flange, contacting the flange or the spot face firmly. The Clamp should fit easily onto the spot face. 2. The Puller Sleeve, when properly installed, should protrude no more than 1/16 (15mm) past the top of the Nut (outside sleeve). If the Puller Sleeve is raised beyond 1/16”, hold the Puller Sleeve or the Bridge by hand and turn the Nut counter-clockwise (loosen direction) until the Puller Sleeve protrudes no more than 1/16” past the top of the Nut. After adjusting the Nut, turn the entire Clamp assembly down to contact the flange or the spot face firmly. 3. Before using XXI tool on the Clamp, make sure the tool and the drive member are set properly. The castellated drive and the splined reaction member should stick out on the right side for tensioning. Cycle the tool and the drive a few times to ensure that the tool is properly operating. Repeat this step only when you change the tool or the drive. 4. Refer to the load chart supplied with the Clamp and set the pump pressure to achieve the desired load. Do not engage drive on the Clamp while setting the pump pressure. Turn the pressure regulator counter-clockwise to set it below the target pressure. While holding the advanced button on the remote control, slowly turn the pressure regulator clock wise to increase the pressure to the desired value. Ensure the pressure value is set properly by holding the advanced button. 5 Before applying the tool and the drive, engage the splined reaction member to the Puller Sleeve first. Then engage the castellated drive to the castellated section of the Nut. Turn the drive manually until both castellation are fully engaged. IMPORTANT: If the castellated teeth do not fully engage, the Puller Sleeve is sticking up too far or stud protrusion is more than maximum value. Refer back to Step 3. Then reposition the Puller Sleeve and check stud protrusion. 6 Apply the pump pressure to tension the Clamp, until the target pressure is reached. To ensure that the proper tension has been applied to the stud, allow the tool to fully retract then advance to the target pressure a final time. 7 Repeat 5 & 6 until all bolts are fully tensioned.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-6 HYTORC Clamp Installation - Detensioning 1. Before using XXI or Avanti tool on the Clamp, make sure the tool and the drive member are set properly. The castellated drive and the splined reaction member should stick out on the left side for detensioning. Cycle the tool and the drive a few times to ensure that the tool is properly operating. Repeat this step only when you change the tool or the drive. 2. Detensioning, in general, requires higher pump pressure. Refer to the load chart and set the pump pressure slightly higher than the value used for tensioning. Turn the pressure regulator counter clockwise to set it below the target pressure. While holding the advanced button on the remote control, slowly turn the pressure regulator clockwise to increase the pressure to the desired value. Ensure the pressure value is set properly by holding the advanced button. 3. Remove drive from tool, engage the splined reaction member to the Puller Sleeve first. Then engage the castellated drive to the castellated section of the Nut. Turn the drive manually until both castellation are fully engaged. Place tool on drive with “LOOSEN” side facing the operator. Install drive retainer. 4. Apply the pump pressure to detension the Clamp, until it can be turned by hand. 5. Repeat 3 & 4 until all bolts are fully tensioned. On applications that require two or three passes to tension, it is advised to detension the last few bolts in two passes. If corrosion makes it impossible for the Clamp to be turned by hand even after detensioning, use the hex/spine adaptor. To use the hex/spline adaptor, insert the male spline of the adaptor into the female spline of the Puller Sleeve. Place a wrench over the hex of the adaptor and rotate the Sleeve off the bolt.

NOTE: Before reusing the Clamps, it is imperative that the Clamps are properly cleaned and re lubricated to prolong their life. Refer to the lubrication instruction on the next page.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-7 HYTORC Clamp Lubrication Instruction The Clamp Lubrication Instructions: (Use a clean stiff bristle brush) STEP 1:

Make sure all threads and splines are free of dirt or grit. Generously grease internal threads on the Jack-up Sleeve with a brush to get full coverage to the thread root.

STEP 2:

Generously grease external threads on the Puller Sleeve with a brush to get full coverage to the thread root.

STEP 3:

Grip the bottom splined section and internal threads of the Jack-up Sleeve into the Jack-up Sleeve as the arrow indicates. Leave the bottom splined section sticking out the bottom.

STEP 4:

Turn the assembled parts upside-down. Spread excess grease around to coat bottom surface of the Jack-up Sleeve and splines. Apply grease on the splines if coating is thin.

STEP 5:

Apply grease to internal splines on the Washer to get full coverage to the spline root. Coat top surface of the Washer.

STEP 6:

Slide the Washer to the assembled Sleeves as the arrow indicates. When the Puller Sleeve and the Washer are in contact, the Puller Sleeve and the Washer bottoms should be flush with each other. Rotate the Jack-up Sleeve while holding the Washer to achieve this desired condition.

SECTION V OPERATION – HYTORC Power Packs 5-1 HYOTRC Power Packs General Information All HYTORC Power Packs operate at a pressure range from 500 to 10,000 PSI and are fully adjustable. They have been engineered and designed for portability and high flow for increased speed. Before using your HYTORC Power Pack, check the following points: • • • • •

Is the reservoir filled with oil? Where is the closest electrical outlet at the job site? (Electric pump only) Is there enough air pressure (100 PSI) and flow (50 CFM) at the job site? (Air units only) Is the gauge mounted and rated for 10,000 PSI Is the oil filler plug securely in place?

The Power Packs maximum working pressure is 10,000 PSI (700 kg/cm2, 690 Bar) Make sure all hydraulic equipment and accessories are rated for 10,000 PSI operating pressure. 5-2 Hydraulic Connections When making a connection with quick connect couplings, make sure the couplings are fully engaged. Threaded connectors such as fittings, gauges etc. must be clean and securely tightened and leak free. CAUTION: Loose or improperly threaded couplers can be potentially dangerous if pressurized. Severe over tightening can cause premature thread failure. Knurled sleeve on couplers need to be only hand tight. Never grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury. Do not subject the hose to potential hazard such as sharp surfaces, extreme heat or heavy impact. Do not allow the hose to kink and twist. Inspect the hose for wear before each usage. 5-3 Prior to Use Do not use a power or extension cord that is damaged or has exposed wiring. All single phase motors come equipped with a three prong grounding type plug to fit the proper grounded type electrical outlet. Do not use a two prong ungrounded extension cord as the pump’s grounded type electrical outlet. Compare motor nameplate against power availability to prevent motor burnout or dangerous electrical overloading. *For electric cord extension, refer to below chart 0-25 Foot Extension 26-50 Foot Extension 51-75 Foot Extension 76-100 Foot Extension

Use size 12 gauge cord Use size 10 gauge cord Use size 8 gauge cord Use size 6 gauge cord

Check hydraulic oil level to prevent possible pump burnout. Look at oil fill level on the oil sight gauge. The oil level should be approximately 2” from the top of the reservoir plate-with motor off. Add HYTORC oil as necessary. Air Pump Oil Sight Gauge

*Do not mix different grades of oil.

Electric Pump Oil Sight Gauge

SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-3 Prior to Use -ContinuedMake sure all desired gauge, valve, hose and quick coupler connections are tight and secure. The gauge permits the operator to monitor the load on the wrench. *Calibrated gauges are available for most application. Before starting your HYTORC pump, connect your hydraulic hoses to both the pump and torque wrench. (Refer to 3-2) 5-4 Operation Electric Pump Push the rocker switch on the hand control pendant in the OFF position. Then, depress and release the safety button. NOTE: The safety button is an added feature designed to prevent premature starting and should only be depressed by the tool operator. Safety Button

Push the rocker switch to advance position and release it. This will start your pump and place it in the retract position. Your HYTORC electric pump has been designed with an auto shut off system. The pump will shut off after approximately 20 seconds of non-cycling. This will prevent overheating or unnecessary wear and results in longer life of your pump. To restart the pump, depress the safety button again.

OFF Retract/Neutral Advance

Rocker Switch

5-5 Operation Air Pump Before connecting air supply line to the Air Filter Lubricator, make sure the Air Flow Lever is in the OFF position. Then connect air supply line. Open the Air Flow Lever. Check the PSI reading on the Air Pressure Gauge. It should be at 100 psi. Depress the Air Adjustment Knob to increase psi reading. Air Adjustment Knob Air Flow Lever Adjust lubricator to approximately one drop per Lubricator Adjust Minute. *Before operating your HYTORC air pump, check for air leaks on the air hoses/tubing. Air Pressure gauge

SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-5 Operation Air Pump To start the pump, depress the advance button and release it. This will put the tool in the retract mode. To advance the tool, depress the advance button and hold it down. When you are done, depress the stop button and the motor will stop. NOTE: The pump is still pressurized. To release the air pressure from the pump, put the Air Flow Lever in the OFF position, then depress the advance button on the air remote control. This will purge the air in the motor. Now it is safe to disconnect your air supply line.

Advance Button Stop Button

5-6 Operation of automatic pump Before operating automatic pump, the cable line attached to each hose must be connected securely with the appropriate receptacle on the pump manifold and the receptacle on the tool.

Securely connect

NOTE: Connect only the number of tools used on the application to the pump.

Set pump pressure to achieve desired torque value. (refer to 3-5 and 3-6)

SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-7 Starting with automatic operation MANUAL MODE For manual operation, depress the Mode [M] 3-position rocker switch to the ‘MANUAL’ position. Hold down the Control [C] rocker switch in the ‘RUN’ position to advance the tool(s). The switch will toggle to the ‘NEUTRAL’ position when released, retracting the tool(s). Depress the Control [C] switch to the ‘OFF’ position to turn off the system. AUTOMATIC MODE

CONTROL SWITCH

PERSS FOR RUN (TOOL ADVANCE) RELEASE (TOOL RETRACT) (NEUTRAL)

PRESS FOR PUMP OFF

Initialize Computer: To operate the automatic system, the computer has to recognize how many tools are attached to the system. To accomplish this, attach the required number of tools to both hydraulic and electric lines. Then cycle system in manual mode for at least one full cycle.

PRESS FOR TIGHTENING NEUTRAL LOOSENING PRESS FOR MANUAL

MODE SWITCH AUTOMATIC TIGHTENING MODE Initialize the computer (see above). Without shutting pump off, push Mode switch [M] into ‘TIGHTENING’ position. Press and hold control switch [C] in ‘RUN’ position. As long as the run switch is held depressed, the pump will function in automatic tightening mode. The tool(s) will continue to cycle until the preset torque Is achieved. Allow sufficient time to be sure that the tool(s) have stopped rotating before releasing the run switch. The pump motor will automatically shut off after 20 seconds, allowing the tool(s) to return to the retract position. The ‘OFF’ position on the Control switch turns off the system. AUTOMATIC LOOSENING MODE Initialize the computer (see above). Without shutting pump off, push Mode switch [M] into ‘LOOSENING’ position. Press and hold control switch [C] in ‘RUN’ position. As long as the run switch is held depressed, the pump will function in automatic loosening mode. The tool(s) will continue to cycle until the Control switch is released. Cycle tool(s) until nuts are free and can be removed by hand. Release the Control switch and depress the Control switch to the ‘OFF’ position to complete the loosening cycle.