Fam PC4000 08205 PDF

FAM-PC4000-08205
Field Assembly
Manual

-6
HYDRAULIC MINING SHOVEL

SERIAL NUMBERS PC4000-6 08205 and up

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2013 Komatsu
Printed in U.S.A.
Komatsu America Corp.
J anuary 2013
This material is property of Komatsu Mining Germany GmbH and is not to be reproduced, used, or
disclosed except in accordance with the written authorization of Komatsu Mining Germany GmbH.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve
the right to make changes or add improvements at any time without incurring any obligation to
install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to
this publication. It is recommended that the customer contact their distributor for information on the
latest revision.
COPYRIGHT
Contents - 1
CONTENTS
2 SAFETY..................................................................................................... 2-7
2.1 SAFETY INFORMATION................................................................................................................... 2-8
2.2 OVERVIEW........................................................................................................................................ 2-9
2.2.1 NORMAL OPERATIONS....................................................................................................... 2-9
2.2.2 REGULAR MAINTENANCE .................................................................................................. 2-9
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................... 2-9
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING
AND TRANSPORTATION OF THE EXCAVATOR................................................................ 2-9
2.3 SOUND PRESSURE LEVEL IN THE OPERATORS CAB. ............................................................ 2-10
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR......................... 2-11
2.4.1 UNDERSTANDING THE MACHINE.................................................................................... 2-11
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR.................... 2-11
2.4.3 PREPARATIONS FOR SAFE OPERATION........................................................................ 2-11
2.4.4 FIRE PREVENTION ............................................................................................................ 2-13
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ....................................... 2-15
2.4.6 BURN PREVENTION .......................................................................................................... 2-17
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 2-17
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES.......................................... 2-18
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC) ................................................................. 2-19
2.4.10 PRECAUTIONS AT JOBSITE ............................................................................................. 2-20
2.4.11 STARTING ENGINE............................................................................................................ 2-25
2.4.12 OPERATION........................................................................................................................ 2-26
2.5 PRECAUTION FOR MAINTENANCE.............................................................................................. 2-32
2.5.1 GENERAL PRECAUTIONS................................................................................................. 2-32
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 2-40
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 2-41
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS....... 2-45
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM................................................................... 2-45
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 2-45
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 2-45
2.7 SPECIAL SAFETY EQUIPMENT..................................................................................................... 2-46
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR FOPS FOR OPERATORS CAB................ 2-47
2.7.2 OBJECT HANDLING........................................................................................................... 2-47
2.7.3 LIGHTING............................................................................................................................ 2-47
2.7.4 WARNING BEACON ........................................................................................................... 2-47
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 2-47
2.8 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLY............................................................ 2-55
2.8.1 WHEN ASSEMBLING THE EXCAVATOR .......................................................................... 2-55
2.8.2 WHEN DISASSEMBLING THE EXCAVATOR .................................................................... 2-55
2.8.3 WHEN TRANSPORTING THE DISASSEMBLED EXCAVATOR........................................ 2-56
3 GENERAL................................................................................................ 3-57
3.1 GENERAL ........................................................................................................................................ 3-58
3.1.1 DELIVERY OF THE EXCAVATOR...................................................................................... 3-58
3.1.2 ASSEMBLING THE EXCAVATOR ...................................................................................... 3-58
3.1.3 LIFTING AND TRANSPORTATION .................................................................................... 3-58
- 2 Contents
3.1.4 PACKING LIST OF A TYPICAL FACE SHOVEL MACHINE ............................................... 3-59
3.1.5 PACKING LIST OF A TYPICAL BACKHOE MACHINE....................................................... 3-60
3.1.6 ELECTRICAL ENERGY....................................................................................................... 3-61
3.1.7 ELECTROMAGNETIC COMPATIBILITY (EMC) ................................................................. 3-61
3.1.8 MONITORING SYSTEM OF THE MACHINE ...................................................................... 3-61
3.2 ASSEMBLY SITE REQUIREMENTS............................................................................................... 3-62
3.2.1 CONFIGURATION OF COMPONENTS ON ERECTION SITE (EXAMPLE) ....................... 3-62
3.2.2 REQUIRED CRANES .......................................................................................................... 3-64
3.2.3 MANPOWER / ASSEMBLY TIME........................................................................................ 3-64
3.2.4 TOOLS AND EQUIPMENT FOR ASSEMBLY..................................................................... 3-65
3.2.5 STANDARD APPLICATION TORQUE CHART................................................................... 3-68
3.2.6 PREPARATIONS FOR ASSEMBLY.................................................................................... 3-71
3.2.7 BASIC DIMENSIONS........................................................................................................... 3-72
3.3 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES............................. 3-73
4 ASSEMBLY SEQUENCE......................................................................... 4-75
4.1 ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES............................................................ 4-76
4.1.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINES STABILITY.. 4-77
4.2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES ................................................................... 4-78
4.2.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINES STABILITY.. 4-79
4.3 ASSEMBLY OF UNDERCARRIAGE............................................................................................... 4-80
4.3.1 ASSEMBLY OF TRACKS.................................................................................................... 4-81
4.3.2 ATTACH CARBODY TO SIDE FRAME............................................................................... 4-82
4.3.3 DETERMINING THE TIGHTENING TORQUE .................................................................... 4-89
4.3.4 SPECIAL HYDRAULIC TORQUE WRENCH....................................................................... 4-93
4.3.5 CLOSING THE TRACKS ..................................................................................................... 4-94
4.3.6 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS ............................................ 4-95
4.3.7 MOUNTING OF TRAVEL GEAR PROTECTION................................................................. 4-98
4.3.8 MOUNTING OF TRAVEL MOTOR PROTECTION HOOD................................................ 4-100
4.3.9 HYDRAULIC TRACK TENSIONING SYSTEM.................................................................. 4-102
4.4 MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE ............................... 4-104
4.5 ASSEMBLY OF MACHINERY HOUSE ROOF.............................................................................. 4-108
4.5.1 MOUNTING OF THE EXHAUST SYSTEM........................................................................ 4-110
4.5.2 MOUNTING OF THE AIR INTAKE SYSTEM..................................................................... 4-113
4.6 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM.................... 4-116
4.7 MOUNTING OF BATTERY BOX AND HYDRAULIC ACCESS LADDER..................................... 4-118
4.8 CONNECTING ENGINE OIL RESERVE SYSTEM........................................................................ 4-124
4.9 PRE-ASSEMBLY OF FACE SHOVEL BOOM............................................................................... 4-128
4.9.1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM........................................ 4-132
4.9.2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS........................ 4-134
4.9.3 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM....................... 4-136
4.9.4 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME......................................................... 4-140
4.10 PRE-ASSEMBLY OF BACKHOE BOOM...................................................................................... 4-142
4.10.1 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM....................... 4-144
4.10.2 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME......................................................... 4-148
4.11 MOUNTING OF COUNTERWEIGHT ............................................................................................. 4-150
4.12 MOUNTING OF THE FUEL TANK................................................................................................. 4-152
Contents - 3
4.12.1 CONNECTING FUEL SYSTEM HOSE LINES .................................................................. 4-154
4.13 ATTACHING THE CAB BASE....................................................................................................... 4-158
4.13.1 MAKING OF ELECTRICAL CABLE CONNECTIONS ....................................................... 4-160
4.13.2 CONNECT CAB HEATER HOSES TO CAB BASE........................................................... 4-162
4.14 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE ..................................... 4-164
4.14.1 CONNECTING THE AIR CONDITIONER HOSES OF THE CAB ..................................... 4-166
4.14.2 INSTALL ORBCOMM ANTENNA...................................................................................... 4-168
4.15 CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE
AND SUPERSTRUCTURE ............................................................................................................ 4-170
4.15.1 CONNECTING HIGH PRESSURE LINES OF THE MAIN PUMPS................................... 4-172
4.16 ATTACHING THE HYDRAULIC OIL RESERVOIR....................................................................... 4-174
4.17 ATTACHING THE HYDRAULIC OIL COOLER............................................................................. 4-176
4.17.1 CONNECTING THE HYDRAULIC HOSE LINES OF THE OIL COOLER CIRCUIT.......... 4-178
4.17.2 CONNECTING THE HOSE LINES OF OIL COOLER FAN MOTORS.............................. 4-180
4.17.3 CONNECTING THE HOSE LINES OF PTO OIL COOLING CIRCUIT.............................. 4-182
4.17.4 CONNECTING THE RETURN OIL HOSE LINE OF RADIATOR FAN MOTOR................ 4-184
4.17.5 CONNECTING THE HOSE LINES FROM RETURN OIL MANIFOLD TO
BACK-PRESSURE PIPE................................................................................................... 4-186
4.18 CONNECTING SWING GEAR HYDRAULIC LINES ..................................................................... 4-188
4.18.1 CONNECTING THE RETURN AND LEAKAGE OIL HOSE LINES................................... 4-189
4.18.2 CONNECTING THE SWING BRAKE PRESSURE HOSES AND PILOT OIL HOSES...... 4-190
4.19 CONNECTING THE RETURN AND PRESSURE OIL HOSES FROM VALVE BLOCK............... 4-192
4.20 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP .................................................. 4-198
4.21 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT.................................................... 4-200
4.21.1 CONNECTING THE PILOT OIL LINE, RETURN OIL LINE AND LEAKAGE OIL LINE
TO THE ROTARY JOINT .................................................................................................. 4-202
4.22 ATTACHING THE HANDRAILS, CATWALKS AND STEPS........................................................ 4-204
4.23 MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES............................................ 4-206
4.24 CENTRAL REFILLING SYSTEM................................................................................................... 4-210
4.24.1 CONNECTING THE REFILLING LINES............................................................................ 4-211
4.25 CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS........... 4-216
4.26 MOUNTING THE CAN-NODE BOXES ONTO THE MACHINERY HOUSE ROOF ...................... 4-218
4.26.1 CONNECTING THE CABLES TO THE CAN-NODES....................................................... 4-219
4.27 PRE-CHECKS PRIOR TO INITIAL START UP............................................................................. 4-220
4.28 FILLING AND BLEEDING THE HYDRAULIC SYSTEM............................................................... 4-222
4.28.1 FILLING THE HYDRAULIC SYSTEM................................................................................ 4-223
4.28.2 BLEEDING THE HYDRAULIC SYSTEM........................................................................... 4-224
4.28.3 BLEEDING THE GEAR PUMP FOR PTO GEAR LUBRICATION..................................... 4-227
4.29 ASSEMBLY FACE SHOVEL ATTACHMENT ............................................................................... 4-228
4.29.1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM............................................... 4-229
4.29.2 ATTACHING THE STICK TO THE BOOM........................................................................ 4-231
4.29.3 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM.................. 4-232
4.29.4 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS............................. 4-232
4.29.5 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS.............................. 4-235
4.29.6 CONNECTING HOSE LINES FROM STICK TO BUCKET CYLINDERS.......................... 4-237
4.29.7 CONNECTING STICK CYLINDERS TO THE STICK........................................................ 4-238
4.30 BLEEDING HYDRAULIC CIRCUITS............................................................................................. 4-240
- 4 Contents
4.30.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT...................................................... 4-241
4.30.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT.................................................... 4-241
4.30.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT....................................... 4-243
4.30.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER.............................................. 4-244
4.30.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS .............................. 4-244
4.30.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS................................................ 4-245
4.31 ATTACHING FACE SHOVEL TO THE STICK.............................................................................. 4-246
4.31.1 ATTACHING BUCKET BACK WALL TO THE STICK ....................................................... 4-247
4.31.2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM CYLINDERS............... 4-249
4.31.3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL............................................ 4-251
4.31.4 CONNECTING GREASE LINES OF THE FACE SHOVEL ATTACHMENT...................... 4-253
4.31.5 CONNECTING GREASE LINES ON THE BUCKET ......................................................... 4-255
4.31.6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS ............................. 4-255
4.32 ASSEMBLY BACKHOE ATTACHMENT....................................................................................... 4-256
4.32.1 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM.................. 4-257
4.32.2 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS ............................. 4-258
4.32.3 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS.............................. 4-259
4.32.4 ATTACHING THE STICK TO THE BOOM ........................................................................ 4-261
4.32.5 CONNECTING HOSE LINES FROM BOOM TO BUCKET CYLINDERS.......................... 4-265
4.33 BLEEDING HYDRAULIC CIRCUITS............................................................................................. 4-266
4.33.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT...................................................... 4-267
4.33.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT.................................................... 4-267
4.33.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT....................................... 4-269
4.33.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER.............................................. 4-270
4.33.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS .............................. 4-270
4.33.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS................................................ 4-271
4.34 ATTACHING BACKHOE BUCKET TO THE STICK...................................................................... 4-272
4.34.1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT ............................. 4-277
4.35 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS............................................... 4-278
5 FINAL CHECKS AND ADJUSTMENTS................................................. 5-279
5.0.1 COMMISSIONING CHECK LIST....................................................................................... 5-281
5.0.2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS ........................................... 5-281
5.0.3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE............. 5-283
5.0.4 PRESSURE COMPENSATION OF SEALED COMPONENTS ......................................... 5-283
5.0.5 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE ........... 5-284
5.0.6 COMMISSIONING OF THE AIR CONDITIONING ............................................................ 5-302
5.1 PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC MANUAL......... 5-306
5.1.1 VISUAL INSPECTION ....................................................................................................... 5-307
5.1.2 TRAVELLING INSTRUCTIONS......................................................................................... 5-307
5.2 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING.................... 5-308
6 DISASSEMBLY OF THE MACHINE...................................................... 6-309
6.0.1 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES ........................................ 6-310
6.0.2 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE ................................. 6-311
6.0.3 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES................................................ 6-312
6.0.4 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE ................................. 6-313
6.0.5 DISPOSAL OF WASTE MATERIAL .................................................................................. 6-314
Contents - 5
- 6 Contents
SAFETY
General Safety Version 2 2 - 7
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.
SAFETY INFORMATION SAFETY
2 - 8 General Safety Version 2
2.1 SAFETY INFORMATION
To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
The safety information in this manual does not replace any safety rules or laws in your area.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
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.
NOTE! This word is used in regard to non-specific safety relevant information.
REMARKS: This word is used for information that is useful to know.
SAFETY OVERVIEW
2.2 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 2-11.
For on site safety information, refer to section 2.4.10 on page 2-20.
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 2-32.
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR
For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 2-45.
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.
SOUND PRESSURE LEVEL IN THE OPERATORS CAB. SAFETY
2.3 SOUND PRESSURE LEVEL IN THE OPERATORS
CAB.
The sound pressure level in the operators 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 operators cab, see Fig. 2-1.
Fig. 2-1
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.4 GENERAL PRECAUTIONS COMMON TO OPERA-
TION 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 operators 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 opera-
tion 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.
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT
2.4.3.4 KEEP MACHINE CLEAN
2.4.3.5 PRECAUTIONS INSIDE OPERATORS COMPARTMENT
When entering the operators 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 operators 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 operators compartment.
Refer to Fig. 2-2:
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.
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. 2-2
Refer to Fig. 2-3:
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, 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. 2-3
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT
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:
NOTICE: Before carrying out grinding or welding work on the machine, remove any flammable materials.
Always follow the precautions below to prepare for action if any
injury or fire should occur, refer to Fig. 2-4.
Be sure that fire extinguishers have been provided and read
the labels to ensure that you know how to use them in emer-
gencies.
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. 2-4
Refer to Fig. 2-5:
Do not smoke or use any flame near fuel or other flamma-
ble substances.
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.
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.
Fig. 2-5
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 specifica-
tions.
When taking the electrical power for the lighting from the machine itself, follow the instructions of this man-
ual.
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, refer to Fig. 2-6.
Fig. 2-6
After escaping with the emergency escape ladder, activate
the engine stop chains ( Fig. 2-7 Pos. 1) to shut down the
engine if they are equipped on your shovel.
Fig. 2-7
2.4.4.3 EMERGENCY EXIT FROM OPERATORS 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 GETTING ON OR OFF THE MACHINE
2.4.5.1 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.
2.4.5.2 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.
2.4.5.3 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. Refer to further information refer to section 2.7 on
page 2-46.
2.4.5.4 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 2-46.
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. 2-8). 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 non-
slip 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. 2-8
2.4.5.5 LEAVING OPERATORS SEAT WITH LOCK
2.4.5.6 LEAVING THE MACHINE
Refer to Fig. 2-9:
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 (Position L). 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 RELIEV-
ING THE PRESSURE IN THE HYDRAULIC SYSTEM in the
OPERATION part of this manual.
Fig. 2-9
When leaving the machine, always lower the work equipment
completely to the ground, turn off the engine, relieve the pres-
sure 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. 2-10). For infor-
mation on relieving the pressure in the hydraulic system, refer
to chapter RELIEVING THE PRESSURE IN THE HYDRAU-
LIC SYSTEM in the OPERATION part of this manual.
Fig. 2-10
2.4.6 BURN PREVENTION
2.4.6.1 HOT COOLANT
2.4.6.2 HOT OIL
2.4.7 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.
Refer to Fig. 2-11:
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. 2-12) 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. 2-11
Refer to Fig. 2-12:
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. 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. 2-12
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
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 modifica-
tion, consult your Komatsu distributor.
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
On jobsites where there is a hazard that falling objects (Fig. 2-13),
flying objects (Fig. 2-14), 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 option-
ally 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.
Fig. 2-13
The above recommendations assume that the conditions are
for standard operations, but it may be necessary to add addi-
tional guards according to the operating conditions on the job-
site. Always contact your Komatsu distributor for advice.
Fig. 2-14
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)
The use of retrofitted electrical and electronic equipment such as radars, computers, radio units and other appli-
ances, working with high frequency electromagnetic waves, can interfere with the electronic control system of the
excavator which can lead to damage to the machine and to personnel.
Only use equipment which meets the requirements of the standard ISO 13766 - Electromagnetic Compatibility for
Earth-Moving Machinery. Obtain advice from authorized electricians regarding the electromagnetic compatibility of
the equipment, prior to installation.
REMARKS: If appliances which interfere with the electronic control system of the excavator are installed, control
of the excavator will be impaired. If a malfunction is experienced, release the operating levers and
the pedals and strike the emergency shut-down button.
Komatsu can not be made liable for any injuries, accidents, product failures or other property dam-
age resulting from installation of non-EMC certified equipment.
2.4.10 PRECAUTIONS AT JOBSITE
Fig. 2-15
2.4.10.1 VISIBILITY FROM OPERATORS SEAT
WARNING
THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGER-
OUS!
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. 2-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels.
The shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operators seat,
and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from out-
side 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 Operators visibility. This standard is not met
and does not apply to large hydraulic mining shovels.
2.4.10.2 CAMERA SYSTEM WITH MONITORS
Komatsu Mining Germany offers optionally camera systems and monitors to improve the overall visibility. See lat-
est 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.
2.4.10.3 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.
2.4.10.4 CHECKING SIGNS AND SIGNALMANS SIGNALS
Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if nec-
essary. 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.
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS
On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-
tions, always check the following to confirm there are no dangers on the jobsite.
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES
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. 2-16).
Take necessary measures to prevent any unauthorized per-
son 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 oper-
ations.
Maintain the travel path on the jobsite so that there is no
obstruction to travel operations.
Fig. 2-16
DANGER
HIGH VOLTAGE!
Do not travel or operate the machine near electric cables
(Fig. 2-17). 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. 2-17
2.4.10.7 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.
2.4.10.8 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 accumu-
late in the chambers of the counterweight.
These gases must be expelled before welding, flame-cutting and grinding operations are carried out on
the counterweight.
REMARKS: Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases
from the counterweight chambers. (See Volume 2 binder)
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 Safety Distance
100 V - 200 V Over 2 m (7 ft)
6,600 V Over 2 m (7 ft)
22,000 V Over 3 m (10 ft)
66,000 V Over 4 m (14 ft)
154,000 V Over 5 m (17 ft)
187,000 V Over 6 m (20 ft)
275,000 V Over 7 m (23 ft)
500,000 V Over 11 m (36 ft)
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 surround-
ings from dust and other inflammable substances and make sure that the premises are adequately venti-
lated as there is a risk of explosion.
2.4.10.9 VENTILATION OF ENCLOSED AREAS
WARNING
POISONOUS FUMES!
Unventilated areas where poisonous fumes can accumulate can kill.
Always ensure adequate ventilation.
Refer to Fig. 2-18:
Operate internal combustion engines and fuel operated heat-
ing systems only on adequately ventilated premises. Before
starting the machine on enclosed premises, make sure that
there is sufficient ventilation.
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. 2-18
2.4.11 STARTING ENGINE
2.4.11.1 WARNING TAG
2.4.11.2 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.
2.4.11.3 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.
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 operators 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.
If there is a "DANGER DO NOT OPERATE!" warning tag dis-
played, it means that someone is carrying out inspection and
maintenance on the machine (Fig. 2-19). 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 per-
sonal injury or death. Do not start the engine or touch the
levers.
Fig. 2-19
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. 2-20) 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. 2-20
2.4.11.4 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.
2.4.12 OPERATION
2.4.12.1 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.
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE
NOTE! Always be sure to carry out the above precautions even when the machine is equipped with mirrors
or camera systems.
Before travelling, set the machine so that sprocket (1) is
behind the operator's seat (Fig. 2-21).
If sprocket (1) is in front of the operator's cab, the machine
moves in the opposite direction from the operation of the ped-
als (front and rear travel is reversed, left and right steering is
reversed). Be extremely careful when operating the machine
in this situation.
Fig. 2-21
Before travelling, check again that there is no one in the sur-
rounding area, and that there are no obstacles (Fig. 2-22).
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. 2-22
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. 2-23)
Fig. 2-23
2.4.12.3 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. 2-24).
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. 2-24
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. 2-25).
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. 2-25
2.4.12.4 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. 2-26).
When travel up slopes, set the operator's cab facing uphill,
when travel down slopes, set the operator's cab facing down-
hill. Always be aware and informed about the firmness and
bearing capacity of the ground under the machine when trav-
elling. Cavaties and underground mines may cause the
ground beneath the excavator to collapse.
Fig. 2-26
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. 2-27).
Fig. 2-27
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. 2-28).
Travel on slippery ground with low speed. Even with slight
slopes there is a hazard that the machine may slip
Fig. 2-28
2.4.12.5 OPERATIONS ON SLOPES
2.4.12.6 PROHIBITED OPERATIONS
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 car-
rying 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. 2-29) that will keep the machine as hori-
zontal as possible.
Fig. 2-29
Never dig the work face under an overhang. There is a haz-
ard that rocks may fall or that the overhang may collapse and
fall on top of the machine (Fig. 2-30).
Fig. 2-30
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. 2-31).
Fig. 2-31
2.4.12.7 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 care-
ful 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 opera-
tions carefully.
2.4.12.8 PARKING THE MACHINE
2.4.12.9 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.
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. 2-32).
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 equip-
ment. The load may spill or the bucket may hit the dump truck
and cause serious injury or property damage.
Fig. 2-32
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 (Fig. 2-33, Pos 1) to
the LOCK position (L), then stop the engine.
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. 2-33
PRECAUTION FOR MAINTENANCE SAFETY
2.5 PRECAUTION FOR MAINTENANCE
2.5.1 GENERAL PRECAUTIONS
Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation,- Lubrica-
tion and Maintenance Manual, including information on the replacement of parts and equipment. These activi-
ties 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 proce-
dures 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 inadver-
tent 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 immedi-
ately 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 2-7.
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 hydrau-
lic 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 2-35. 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 Operators cab before any lubrication or
maintenance work is started.
Block the machine to prevent machine movement
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.
SAFETY PRECAUTION FOR MAINTENANCE
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 pro-
tective 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 operators 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 elec-
trical 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.
2.5.1.2 STOP ENGINE FOR MAINTENANCE
Refer to Fig. 2-34:
Stop 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 and stop
the engine.
Fig. 2-34
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
(Fig. 2-35, Pos 1) to the LOCK position (L).
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. 2-35
2.5.1.3 WARNING TAG
Always attach the DO NOT OPERATE warning tag
(Fig. 2-36) to the work equipment control lever in the opera-
tor'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. 2-36
Before entering the machinery house, switch off maintenance
safety switch (Fig. 2-37)
The maintenance safety switch is located in the machinery
house, next to the entrance door (Pos. 1 on Fig. 2-38).
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.
Fig. 2-37
Fig. 2-38
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 sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out oper-
ations safely.
Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying
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
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS
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 work-
ers 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 2-45.
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. 2-39).
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.
Fig. 2-39
Appoint a leader before starting removal or installation opera-
tions for attachments.
Place attachments that have been removed from the machine
in a stable condition so that they do not fall (Fig. 2-40). And
take steps to prevent unauthorized persons from entering the
storage area.
Fig. 2-40
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT
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 cov-
ers 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 it is necessary to go under the work equipment or the
machine to carry out service and maintenance (Fig. 2-41),
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 sup-
ported 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 sud-
denly drop. This is extremely dangerous. Never work under
the work equipment or the machine.
Fig. 2-41
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. 2-42).
When hitting pins or bucket teeth, there is a hazard that bro-
ken pieces might be sent flying and injure people in the sur-
rounding 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. 2-42
2.5.1.11 PROPER TOOLS
2.5.1.12 ACCUMULATOR
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.
Refer to Fig. 2-43:
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. 2-43
Refer to Fig. 2-44:
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 dam-
age. 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. 2-44
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 equip-
ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.
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 explo-
sion. 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. 2-45).
Fig. 2-45
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. 2-46), 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. 2-46
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.
2.5.3 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
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.
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 inspec-
tion or replacement operation.
If there is any leakage from the piping or hoses, the surround-
ing 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 con-
tacts your eyes directly (Fig. 2-47). 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. 2-47
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.
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 fur-
ther 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 con-
ditions 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.
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 parti-
cles.
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.
2.5.3.9 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 pollu-
tion, 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 sys-
tem, rivers, the sea or lakes. (Fig. 2-48).
Dispose of harmful material, such as oil, fuel, coolant, sol-
vent, filters and batteries in accordance with local environ-
mental regulations and laws.
Fig. 2-48
SAFETY ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
2.6 ADDITIONAL SAFETY INFORMATION
FOR TROUBLESHOOTING AND ADJUSTMENTS
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM
A hands-on approach to inspecting the hoses and pipes of the hydraulic system can only be made when the exca-
vator 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 systems 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 2-12, full face protection and pen-
etration 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 pres-
sure from a safe distance (operators 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.
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.
An operator that has been trained on the machine he is oper-
ating, must always sit in the operator's seat and be ready to
stop the engine at any time. All workers must maintain con-
tact 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. 2-49).
Do not touch any control levers or control pedals. If any con-
trol 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. 2-49
SPECIAL SAFETY EQUIPMENT SAFETY
2.7 SPECIAL SAFETY EQUIPMENT
Fig. 2-50
SAFETY SPECIAL SAFETY EQUIPMENT
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR FOPS FOR
OPERATORS CAB
The Shovel must be equipped with a front guard protective structure OPG Front Guard if it is used for applica-
tions 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. 2-50) before boarding the loader attachment or other unsecured
areas on the Shovel.
The Safety Harness is located in the Cabinet in the Operators Cab.
The illustration (Fig. 2-50) shows the standard use of the safety harness with a strap type fall absorber.
Legend for Fig. 2-50:
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. 2-50).
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 attach-
ment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795.
(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
2.7.5.3 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 sub-
jected 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 sharp-
edged 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 Per-
sonal 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.
2.7.5.5 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.
ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLY
Additional Safety - 55
2.8 ADDITIONAL SAFETY PRECAUTIONS FOR
ASSEMBLY
2.8.1 WHEN ASSEMBLING THE EXCAVATOR
WARNING
ENSURE MACHINE STABILITY!
When assembling the machine, always ensure that at each stage of the process, care is taken to ensure
that the machine remains stable. Failure to do this could result in serious injury or death. For more infor-
mation refer to section "ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES" on page 4-76 or to sec-
tion "ASSEMBLY SEQUENCE OF BACKHOE MACHINES" on page 4-78.
Basic Rules of Safety
Observe the local safety rules.
Make certain the service staff is equipped with the necessary personal protection gear (hard hat, safety shoes,
safety glasses, heavy gloves, hearing protection and reflective clothing).
Organize clear communication network with all involved staff.
Make sure the cranes and all lifting equipment are certified and within dates and, are of the correct capacity.
Prepare a lift plan before any lifting is started.
Nominate an experienced person for control of all lifting operations.
Carry out appropriate measures to prevent anyone from entering the lifting area.
For lifting of components use only the marked attachment points.
When lifting the components pay attention to the center of gravity markings on the components.
Always use tools that are in good condition. Understand how to use the tools before performing any assembly
work.
Follow the steps shown in this manual for assembly.
Prior to INITIAL START-UP make sure that all pre-checks, and if necessary, corrective actions have been car-
ried out in accordance with the separate documentation; COMISSIONING CHECK LIST and PM-CLINIC
PROCEDURE MANUAL. These documentations are delivered with the machine.
2.8.2 WHEN DISASSEMBLING THE EXCAVATOR
WARNING
ENSURE MACHINE STABILITY!
When disassembling the machine, always ensure that at each stage of the process, care is taken to ensure
that the machine remains stable. Failure to do this could result in serious injury or death.
Observe the Basic Rules of Safety as stated under WHEN ASSEMBLING THE EXCAVATOR.
Place the machine in a position suitable for safe and effective disassembling.
Always use tools that are in good condition.
Follow the steps shown in this manual for disassembly.
ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLY
- 56 Additional Safety
2.8.3 WHEN TRANSPORTING THE DISASSEMBLED EXCAVATOR
WARNING
ALWAYS ENSURE SAFETY!
Performing tasks with inadequate safety precautions may result in serious injury or death.
Before lifting or transporting any component of the excavator make sure all necessary safety precautions
are executed.
Make sure to use the fixing points market on the components for tying-down of the components onto the low
loader.
Make sure that all components transported on the low loader are securely fixed against movement.
Observe the operating permits of the low loader used for transportation. They contain the permissible load,
loading width and height.
Observe the federal, state and local laws and regulations for transportation of heavy units. Know the safety
rules and laws before you transport the excavator and its components.
Make sure the low loader and the components of the excavator are equipped with the correct lighting and
warning signs.
Consider the transport dimensions and weights of the components when planning the travel route.
Find out if you must use an escort vehicle or roading permit.
57
3 GENERAL
All stated information correspond to the
present developments and is subject to
possible future changes without prior notice.
GENERAL GENERAL
3 - 58 General
3.1 GENERAL
3.1.1 DELIVERY OF THE EXCAVATOR
The excavator is delivered disassembled into its main components. For the correct dimensions and weights, refer
to the instructions on page 3-72.
To assemble the excavator, follow the instructions in this manual.
REMARKS: Various bolts used e.g. for transport security, blanking plates etc. will be re-used during final assem-
bly. These small parts are stored in separate boxes.
NOTICE
The use of genuine Komatsu spare parts is recommended to assure safe mounting and operation of the
machine.
3.1.2 ASSEMBLING THE EXCAVATOR
Personnel entrusted with work on the machine must have read the Assembly Procedure Manual, the Opera-
tion and Maintenance Manual and in particular the section on SAFETY before beginning work. Reading the
instructions after work has commenced is too late.
Assembling the excavator must only be carried out by personnel with special knowledge of the excavator.
Improper assembling procedures can cause severe accidents with personal injury.
If there are any questions concerning the assembly procedure, contact your local Komatsu Distributor.
3.1.2.1 CHECKS PRIOR TO INITIAL START-UP
Prior to initial start-up make sure that all pre-checks, and if necessary, corrective actions have been carried out
in accordance with the separate documentation; COMISSIONING CHECK LIST and PM-CLINIC PROCE-
DURE MANUAL. These documentations are delivered with the machine. Special attention must be paid to
high voltage related equipment.
Perform the checking procedures listed in section -FINAL CHECKS AND ADJUSTMENTS- on page 5-279.
3.1.3 LIFTING AND TRANSPORTATION
WARNING
Performing tasks with inadequate safety precautions may result in serious injury or death. Before unload-
ing any component of the excavator make sure all necessary safety precautions are executed.
Ensure that all lifting equipment, tools and hoists are in good condition and of sufficient lifting capacity.
Use exclusively approved handling equipment.
Secure the components safely before removing the tying-down straps, ropes or chains.
When lifting components make sure that the handling elements do not cause damage to the component.
GENERAL GENERAL
General 3 - 59
3.1.4 PACKING LIST OF A TYPICAL FACE SHOVEL MACHINE
GENERAL GENERAL
3 - 60 General
3.1.5 PACKING LIST OF A TYPICAL BACKHOE MACHINE
GENERAL GENERAL
General 3 - 61
3.1.6 ELECTRICAL ENERGY
All work on medium and high voltage systems has to be carried out by authorized Electricians having the per-
mission to work on medium and high voltage systems.
All safety devices requested by the National Safety Administration must be available and used for work on the
medium and high voltage systems.
3.1.7 ELECTROMAGNETIC COMPATIBILITY (EMC)
The use of retrofitted electrical and electronic equipment such as radars, computers, radio units and other appli-
ances, working with high frequency electromagnetic waves, can interfere with the electronic control system of the
excavator which can lead to damage to the machine and to personnel.
Only use equipment which meets the requirements of the standard ISO 13766 - Electromagnetic Compatibility for
Earth-Moving Machinery. Obtain advice from authorized electricians regarding the electromagnetic compatibility of
the equipment, prior to installation.
REMARKS: Installation of appliances which interfere with the electronic control system of the excavator can lead
to a malfunction of the control system.
Komatsu can not be made liable for any injuries, accidents, product failures or other property dam-
age resulting from installation of non-EMC certified equipment.
3.1.8 MONITORING SYSTEM OF THE MACHINE
The machine is equipped with the KOMTRAX-Plus monitoring system including X2 Controller and CAN-Bus
Network.
ASSEMBLY SITE REQUIREMENTS GENERAL
3 - 62 General
3.2 ASSEMBLY SITE REQUIREMENTS
Assembly Site Requirements
Well leveled and compacted ground approximately 50 x 50 m (165 x 165 ft.)
A container to store the tools, to keep the paper work and for sheltering
3.2.1 CONFIGURATION OF COMPONENTS ON ERECTION SITE
(EXAMPLE)
Legend for Fig. 3-51
Fig. 3-51
(1) Carbody
(2) Superstructure platform
GENERAL ASSEMBLY SITE REQUIREMENTS
General 3 - 63
Legend for Fig. 3-51 (continued)
(3) Machinery house
(4) Boom and stick cylinders
(5) Boom
(6) Counterweight
(7) Fuel tank
(8) Cab base
(9) Cab
(10) Hydraulic oil reservoir
(11) Hydraulic oil cooler
(12) Box with railings, cat walks and steps
(13) Box with fire suppression equipment
(17) Stick
(19) Bucket back wall
(20) Bucket clam shell
3 - 64 General
3.2.2 REQUIRED CRANES
3.2.3 MANPOWER / ASSEMBLY TIME
*) Based on standard transport.
REMARKS: Schedule may change, depending on site preparation, manpower, daily working hours and regula-
tions. Training time may vary, depending on knowledge and number of people.
Units Capacity Period of Availability
1 90 metric tons 1st to 3rd day
1 60 metric tons 1st to 5th day
1 25 metric tons 3rd to 7th day
Manpower (10 hour shifts)
1 Supervisor KMG or Dealer 13 days
6 Customer mechanics 12 days
Time Schedule
Responsible Department No. of 10 hour days
Assembly *) Service 10
Setting and
Testing
Service 2
Customer
Acceptance
Service 1
Operator
Training
Service (if requested) 5
Maintenance
Training
Service (if requested) 5
General 3 - 65
3.2.4 TOOLS AND EQUIPMENT FOR ASSEMBLY
Designation Specification Qty.
5 pole extended cable 100 m 01
Allen keys Set 01
Cable connector Set 01
Cable roller 50 m 01
Cable set (for the Multi-meter) P/N 232 496 40 02
Cables with connectors 1,5 mm 30 m 01
Chain pull 6 metric tons 04
Cleaning rags 02
Combination pliers 01
Combination spanner 01
Contactless revolution counter 0 - 2500/min 01
Cordless headphone intercom Part No. 232 621 40 01
Cordless impact wrench 1/2 140Nm 01
Cordless Impact Wrench 1/2
P/N 793 828 73
Range to 140Nm 01
Crimp pliers Part No. 792 536 73 01
Double end open spanner each 7 mm up to 55 mm 01
Electric hydraulic power pack 1.0 l per min; to 700 bar; 230 V
01
Electric welding machine 01
Hand drill 01
hand lamp 01
Hex keys (Allen keys) L-type 2 up to 19 mm 01
High pressure twin hoses (PN795 923 73) NW6 (for Electric hydraulic power pack)
01
Hydraulic jacks 10 metric tons 02
Hydraulic jacks 50 metric tons 02
Hydraulic torque wrench 0 9900 Nm 01
Impact wrench 3/4 01
Impact wrench 1/2 01
Level gauge 01
Multi-meter P/N 232 619 40 02
3 - 66 General
Lights for the illumination of the working area
01
Pipe pliers 01
Pressure gauge 15 bar 01
Pressure gauge (factory supplied) 400 bar 06
Pressure gauge (factory supplied) 60bar 03
Pressure gauge (factory supplied) 25 bar 03
Pry bar (in cab box) 50 mm x 1000 mm length 01
Ratchet 1/2 01
Ratchet 3/4 01
Ropes 30 metric tons - 8 m length 04
Ropes 12 metric tons - 8 m length 04
Screw driver Set 01
Screw driver sockets for 1/2 drive 5, 6, 8, 10. 12, 14 mm 01
Screw driver sockets for 3/4 drive 14, 17, 19 mm 01
Shackles 50 metric tons 023
Shackles 35 metric tons 04
Shackles 5 metric tons t 04
Shackles 1 metric ton 04
Side cutter 01
Single ended open spanner each 41/46/50/55/60/65mm 01
Sledge hammer 5 kg 01
Socket for 3/4 Ratchet 24 mm up to 36 mm 01
Sockets for Ratchet each 13 mm up to 19 mm 01
Sockets HD for hydraulic torque wrench
30/32/36/41/46/55/65 mm 01
Telescopic fork lift 6 metric tons 01
Thread cutting set From M6 to M48 01
Electronic unipolar voltage meter 5-10 kV Part No. 232 389 40
3-6 kV Part No. 232 390 40
01
Universal grounding short-circuit device (electric
version only)
Part No. 232 386 40 01
Insulation tester (electric version only) Part No. 232 387 40 013
Phase-sequence indicator (electric version only) Part No. 232 388 40 01
Shock pulse measuring instrument Part No. 232 593 40 01
Shock pulse transducer (electric version only) Part No. 232 594 40 01
General 3 - 67
Shock pulse transducer (electric version only) Part No. 232 595 40 01
Clip-on ammeter (1000 A ac/dc) Part No. 232 827 73 01
Tightening tool for connecting bolts Carbody to
Side Frame (PN793 376 73) including special
tightening nut
This tool is required to ensure:
- that the reaction torque is
supported at the bottom of the
adjacent bolt
- that no bending moment affects
the adjacent bolt
Only usable with torque wrench (PN793
374 73)
REMARKS: If the specified tools and
the prescribed assembly
procedure are not used for
attaching the side frames
to the carbody KMG will
not carry the warranty for
the undercarriage.
01
Tip pliers 01
Torque wrench - 3/4 Range 250-600 Nm 01
Torque wrench - drive 1/2 Range 0-250 Nm 01
Wooden blocks 300 x 300 x 1000 mm 20
Wooden blocks 300 x 300 x 2500 mm 10
3 - 68 General
3.2.5 STANDARD APPLICATION TORQUE CHART
3.2.5.1 METRIC STANDARD THREAD
Bolt size
(mm)
Wrench size (mm) Tightening torque MA (Nm)
Quality Grades
8.8 10.9 12.9
M 8 6 13 21 31 36
M 10 8 17 43 63 73
M 12 10 19 74 108 127
M 14 12 22 118 173 202
M 16 14 24 179 265 310
M 18 14 27 255 360 425
M 20 17 30 360 510 600
M 22 17 32 485 690 810
M 24 19 36 620 880 1030
M 27 19 41 920 1310 1530
M 30 22 46 1250 1770 2080
M 33 24 50 1690 2400 2800
M 36 27 55 2170 3100 3600
M 39 60 2800 4000 4700
M 42 32 65 3500 4950 5800
M 45 70 4350 6200 7200
M 48 35 75 5200 7500 8700
M 52 80 6700 9600 11200
M 56 41 85 8400 12000 14000
M 60 90 10400 14800 17400
M 64 46 95 12600 17900 20900
M 68 100 15200 21600 25500
General 3 - 69
3.2.5.2 METRIC FINE THREAD
The torque values given in the chart are only valid for bolts manufactured according to DIN (German Standard).
Threads and bolt heads must be lubricated with grease KP2K.
The contact surfaces of parts which should be screwed together have to be free of grease.
3.2.5.3 SPECIAL TIGHTENING TORQUES
Special tightening torques are given in this manual wherever required. Pay special attention to the tightening
method of the mounting bolts connecting the undercarriage side frames to carbody and the tightening method of
swing circle mounting bolts, refer to the latest edition of Parts & Service News AH00511 for swing circle mounting
procedure.
Bolt size
(mm)
Wrench size (mm) Tightening torque MA (Nm)
Quality Grades
8.8 10.9 12.9
M 8x1.00 6 13 23 33 39
M 10x1.00 8 17 48 70 82
M 12x1.25 10 19 81 119 139
M 14x1.50 12 22 127 187 219
M 16x1.50 14 24 191 280 330
M 18x2.00 14 27 270 385 450
M 20x2.00 17 30 380 540 630
M 22x2.00 17 32 510 720 850
M 24x2.00 19 36 680 960 1130
M 27x2.00 19 41 990 1410 1650
M 30x2.00 22 46 1380 1960 2300
M 33x2.00 24 50 1850 2650 3100
M 36x3.00 27 55 2300 3250 3850
M 39x3.00 60 3000 4200 4950
M 42x3.00 32 65 3750 5300 6200
M 45x3.00 70 4600 6600 7700
M 48x3.00 35 75 5700 8100 9500
M 52x3.00 80 7300 10400 12100
M 56x4.00 41 85 8900 12600 14800
M 60x4.00 90 11000 15600 18300
M 64x4.00 46 95 13300 19000 22200
M 68x4.00 100 16100 22900 27000
3 - 70 General
3.2.5.4 TORQUE CHARTS FOR FLANGE JOINTS
Fig. 3-52
General 3 - 71
3.2.6 PREPARATIONS FOR ASSEMBLY
WARNING
Performing tasks with inadequate safety precautions may result in serious injury or death.
Before unloading any component of the excavator make sure all necessary safety precautions are exe-
cuted.
Make sure that all lifting equipment, tools and hoisting devices are in good condition and of sufficient lifting
capacity.
Use exclusively approved handling equipment.
Secure the components safely before removing the tying-down straps, ropes or chains. The following pages
show the dimensions, weights, center of gravity and attachment points of all components.
When lifting components make sure that the handling elements do not cause damage to the component.
Place the components in such a way that no later movement is necessary.
All pins, bushings, bores, bearings and contact surfaces of components must be clean.
Strictly obey all relevant local safety regulations!
High voltage installation works must be carried out by authorized specialists only.
3 - 72 General
3.2.7 BASIC DIMENSIONS
Fig. 3-53
Service Weights (Approximate)
Face Shovel Backhoe
With standard attachment and 1200 mm track pads With standard attachment and 1200 mm track pads
388 t 394 t
With standard attachment and 1500 mm track pads With standard attachment and 1500 mm track pads
393 t 399 t
GENERAL GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES
General 3 - 73
3.3 GENERAL INSTALLATION PROCEDURES FOR
HYDRAULIC HOSE LINES
To avoid damage to the hydraulic hose lines, follow the installation procedures listed below.
Pay attention to the natural curvature of the hose.
Do not twist the hose during installation
Install 90 (bent) fittings first.
GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES GENERAL
3 - 74 General
Note the change of length, dependant on the pressure.
Pay attention to the radius when bending.
Pay attention to the radius when bending.
75
4 ASSEMBLY SEQUENCE
ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES ASSEMBLY SEQUENCE
4 - 76 Assembly Sequence
4.1 ASSEMBLY SEQUENCE OF FACE SHOVEL
MACHINES
Fig. 4-54
ASSEMBLY SEQUENCE ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES
Assembly Sequence 4 - 77
4.1.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE
MACHINES STABILITY
NOTICE
In order to maintain the stability of the machine throughout the single assembly stages follow the
sequence shown in Fig. 4-54. Any other assembly sequence will impair the stability and can cause turn
over of the machine.
The numbering in Fig. 4-54 is the guideline for the assembly steps.
1. Assembly of the Undercarriage
2. Mounting of the Superstructure Platform
3. Mounting of the Machinery house
4. Mounting of the Boom Cylinders and the Stick Cylinder to the Boom
5. Mounting of the Boom
6. Mounting of the Counterweight
7. Mounting of the Fuel Tank
8. Mounting of the Cab Base
9. Mounting of the Cab with Support Frame
10. Mounting of the Hydraulic Oil Reservoir
11. Mounting of the Hydraulic Oil Cooler
12. Mounting of the Hand Rails, Cat Walks and Steps
13. Mounting of the Fire Suppression Equipment
14. Connection of Electric Cables (not shown)
15. Filling the Hydraulic System (not shown)
16. Pre-checks prior to Initial Start-up (not shown)
17. Mounting of the Stick
18. Mounting of the Stick Cylinders to the Stick
19. Mounting of the Face Shovel Back Wall
20. Mounting of Face Shovel Clam Shell
ASSEMBLY SEQUENCE OF BACKHOE MACHINES ASSEMBLY SEQUENCE
4.2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES
Fig. 4-55
ASSEMBLY SEQUENCE ASSEMBLY SEQUENCE OF BACKHOE MACHINES
4.2.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE
MACHINES STABILITY
NOTICE
In order to maintain the stability of the machine throughout the single assembly stages follow the
sequence shown in Fig. 4-55. Any other assembly sequence will impair the stability and can cause turn
over of the machine.
The numbering in Fig. 4-55 is the guideline for the assembly steps.
1. Assembly of the Undercarriage
2. Mounting of the Superstructure Platform
3. Mounting of the Machinery house
4. Mounting of the Boom Cylinders and the Stick Cylinder to the Boom
5. Mounting of the Boom
6. Mounting of the Counterweight
7. Mounting of the Fuel Tank
8. Mounting of the Cab Base
9. Mounting of the Cab with Support Frame
10. Mounting of the Hydraulic Oil Reservoir
11. Mounting of the Hydraulic Oil Cooler
12. Mounting of the Hand Rails, Cat Walks and Steps
13. Mounting of the Fire Suppression Equipment
14. Connection of Electric Cables (not shown)
15. Filling the Hydraulic System (not shown)
16. Pre-checks prior to Initial Start-up (not shown)
17. Mounting of the Stick
18. Mounting of the Stick Cylinders to the Stick
19. Mounting of the Bucket
ASSEMBLY OF UNDERCARRIAGE ASSEMBLY SEQUENCE
4.3 ASSEMBLY OF UNDERCARRIAGE
Fig. 4-56
ASSEMBLY SEQUENCE ASSEMBLY OF UNDERCARRIAGE
4.3.1 ASSEMBLY OF TRACKS
Fig. 4-56
1. Place the single track strings on level ground consider spacing for later positioning of side frame. Make sure
the three lugs (1) of the track pads pointing to the front (guide wheel side).
2. Connect the track pads by inserting pins (2).
3. Secure pins (2) with bolts (3). When inserting the bolts take care that the hardened side (H) of the bolt head
points towards the pins. The hardened side of the bolt head has a paint marking.
4. Tighten nuts (4) and secure in place by welding the nuts to the bolts.
4.3.2 ATTACH CARBODY TO SIDE FRAME
Fig. 4-57
4.3.2.1 ATTACH CARBODY TO SIDE FRAME
Fig. 4-57
NOTICE
Before lowering the side frame onto the track, turn the bottom rollers, top rollers and the guide wheel so
that the oil filler plugs are in the oil level checking position between 2:30 and 3:0 oclock. These oil levels
have to be checked in the course of the final inspection before commissioning.
Place the side frame onto the front portion of the track with the guide wheel at the front of the track.
Ensure that the first three track pads remain free to move so that the track ends can be connected easier.
Assembly sequence
1. Thoroughly clean the mating faces of carbody and side frames.
2. Place the RH side frame onto the track. Align the side frame exactly in a horizontal position. Place
spirit level gauge onto steel structure of side frame from the outside.
3. Attach carbody to the crane. Make sure the oil supply lines for the travel motors pointing in direction
of the travel motors, see Fig. 4-60 on page 4-87.
4. Align carbody with the side frame. Insert the corresponding hydraulic lines for the track tensioning
system into the side frame before attaching the carbody to the side frame, see Fig. 4-60 on
page 4-87.
5. Clean all bolts. Lubricate all bolts (head supporting surface and thread) with
International Compound No. 2 (PN 324 969 40).
Clean upper and lower surface of resilient sleeves and contact area completely
so that they are free of paint.
REMARKS: Before inserting the mounting bolts check to make sure the threads of all bore holes
are completely clean and are not obstructed by foreign matter.
6. Insert all standard mounting bolts (2 x 32) with resilient sleeves.
NOTICE
Let the carbody attached to the crane until all standard mounting bolts are inserted and
slightly tightened. This allows a limited repositioning of the carbody in case the bores in the
carbody and side frame are not exactly aligned.
REMARKS: The two measuring bolts (1) will be installed later, see instructions on page 4-89.
7. With all standard mounting bolts inserted, tighten all bolts with 2100 Nm.
8. Support carbody with two wooden blocks in such a way that the free side is approx. 200 mm higher
than the attached side. (This makes it easier to attach the 2nd side frame).
Fig. 4-58
Attach Side Frame to Carbody (continued)
NOTICE
Ex works, the side frames are delivered with locking blocks placed between guide wheel sliding blocks
and stop plates. These locking blocks are used to prevent moving of the guide wheel during transporta-
tion of the side frames. Be sure to remove these locking blocks before closing the crawler tracks.
9. Lift the second side frame using the crane and align with the carbody, see Fig. 4-59 on next page.
Insert the corresponding hydraulic lines for the track tensioning system into the side frame before
attaching the side frame to the carbody.
10. Clean and lubricate all bolts (head supporting surface and thread) with Interna-
tional Compound No. 2 (PN 324 969 40).
Clean upper and lower surface of resilient sleeves and contact area completely
so that they are free of paint.
REMARKS: Before inserting the mounting bolts check to make sure the threads of all bore holes
are completely clean and are not obstructed by foreign matter.
11. Insert all standard mounting bolts (2 x 32) with resilient sleeves.
NOTICE
Let the side frame attached to the crane until all standard mounting bolts are inserted and
slightly tightened. This allows a limited repositioning of the side frame in case the bores in
the side frame and carbody are not exactly aligned.
REMARKS: The two measuring bolts (1) will be installed later, see instructions on page 4-89.
12. With all standard mounting bolts inserted, tighten all bolts with 2100 Nm.
13. Lift the undercarriage high enough so that it is possible to remove the two wooden blocks.
NOTICE
Use the attachment points on the carbody only for lifting the carbody without side frames.
Fig. 4-59
Fig. 4-60
Fig. 4-61
4.3.3 DETERMINING THE TIGHTENING TORQUE
The tightening torque for all fastening bolts is determined by using the four measuring bolts (7) Fig. 4-61, which
have the same dimensions. The axial tension force of all bolts is determined by the values ascertained from the
measuring bolts. This has to be achieved during the initial assembly and after the first 1000 operating hours.
The four specially prepared measuring bolts supplied together with the normal fastening bolts can be recognized
by the machined recess at the shaft end of the bolts (7). The measuring device used to determine the tightening
torque is composed of the following items and is supplied with each new machine.
Measuring Device Part Number 928 476 40 consisting of items 1 - 4
Procedure to determine the tightening torque during the initial assembly
(The side frame is attached and all bolts provisionally tightened to 2100 Nm)
Position Part name Part No. Quantity
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
Additional Parts
5 Bolt M10x25 307 777 98 2
6 Washer 517 122 98 2
7 Measuring bolt
Normal temperature (NT)
933 613 40 4
7 Measuring bolt
Low temperature (TT)
934591 40 4
1. Lubricate the four measuring bolts (7), Fig. 4-61 (head supporting surface and thread) with
International Compound No. 2 (PN 324 969 40) and insert the bolts at the outer upper corner
as shown in the illustration.
2. Tighten the four measuring bolts (7) to 150 Nm.
3. Apply the measuring device (parts 1 - 6).
4. Set the dial gauge (2) to zero.
5. Attach the special hydraulic torque wrench, see Fig. 4-63 to measuring bolt (7).
6. Adjust the torque on the hydraulic torque wrench to 2100 Nm and tighten the measuring bolt.
7. Increase the pressure in 10 bar steps until the measuring bolt has reached the required
elongation of 0.93 mm.
8. Note and list the pressure and the change of the bolt length on paper.
9. Repeat this procedure on all 4 measuring bolts.
10. Add the 4 pressure results and then divide by 4 to obtain an average value.
11. With this average pressure tighten all other mounting bolts.
Fig. 4-62
Procedure to determine the tightening torque after the first 1000 operating hours
NOTICE
Do not re-lubricate the bolts.
Do not loosen more than one bolt at a time
REMARKS: The recorded data of the measuring bolts (determined pressure and change of length) taken during
the first assembly should be send to the KMG Service Department together wit the PM-Clinic report.
Refer to Parts & Service News No. AH11507 for a typical record form sheet.
1. Loosen all 4 measuring bolts (7), Fig. 4-62. Do not lubricate them again.
2. Tighten the 4 measuring bolts (7) to 150 Nm.
3. Apply the measuring device (parts 1 - 6).
4. Set the dial gauge (2) to zero.
5. Attach the special hydraulic torque wrench (1), Fig. 4-63 to measuring bolt (7).
6. Adjust the pressure at the hydraulic torque wrench to 2100 Nm and tighten the measuring
bolt.
7. Increase the pressure in 10 bar steps until the measuring bolt has reached the required
elongation of 0.93 mm.
8. Note and list the pressure and the change of the bolt length on paper.
9. Repeat this procedure on all 4 measuring bolts.
10. Add the 4 pressure results and then divide by 4 to obtain an average value.
11. Now loosen only one of the other mounting bolts (M48) and tighten to the determined aver-
age pressure.
12. Repeat this procedure step by step on all mounting bolts.
Fig. 4-63
4.3.4 SPECIAL HYDRAULIC TORQUE WRENCH
REMARKS: For quick and smooth tightening process it is recommended to use pump sets with hydraulic oil
cooler only.
For more information regarding special tools refer to the Parts Catalog TOOLS AND ACCESSO-
RIES.
(1) Application of the hydraulic torque wrench
(2) Special wrench socket with supporting bar (PN 793 376 73)
(3) Hydraulic wrench (PN 793 374 73)
(4) Electric-hydraulic pump set with oil cooler (PN 793 375 73)
4.3.5 CLOSING THE TRACKS
NOTICE
Ex-works, the side frames are delivered with locking blocks placed between guide wheel sliding blocks
and stop plates. These locking blocks are used to prevent moving of the guide wheel during transporta-
tion of the side frames. Be sure to remove these locking blocks before closing the crawler tracks.
Fig. 4-64
1. Lift the rear end of the track with a crane and fold it over the sprocket, top rollers and guide wheel,
see detail -A-.
2. Align the holes (3) of the two open track pads and connect the track pads by inserting pins (2) from both sides.
3. Secure pins (2) with locking bolts (4). When inserting the bolts take care that the hardened side (H) of the bolt
head points towards the pins. The hardened side of the bolt head has a paint marking.
4. Tighten nuts (5) and secure in place by welding the nuts to the bolts.
REMARKS: For welding follow the welding precautions given in the Operation and Maintenance Manual, section
WELD REPAIRS.
Fig. 4-64
4.3.6 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS
Fig. 4-65
Fig. 4-66
Connect Hydraulic Lines and Breather Filter Lines (continued)
REMARKS: If travel motor protections are ordered, install these motor protections before connecting the hydrau-
lic and breather filter lines. See Fig. 4-68 for more information.
Legend for Fig. 4-65 and Fig. 4-66
(1) LH travel brake valve block - Line connections to travel motor (2)
Port A on travel brake valve to upper port A on travel motor
Port B on travel brake valve to lower port B on travel motor
(2) LH travel motor
(3) RH travel brake valve block - Line connections to travel motor (4)
Port A on travel brake valve to lower port A on travel motor
Port B on travel brake valve to upper port B on travel motor
(4) RH travel motor
(5) Breather filters
(6) Breather filter line connector on final drive housing
(7) Breather filter line connector on travel gear box
(8) Breather filter line connector on motor adapter housing
(9) Hose clamps
4.3.7 MOUNTING OF TRAVEL GEAR PROTECTION
Fig. 4-67
Mounting travel gear protection
REMARKS: Travel gear protection and motor protection are special equipment.
1. Attach the gear box protection (1) to the intermediate plates (2) using the twelve mounting bolts (4), resilient
sleeves (3) and nuts (5) with washers. Tighten bolts (4) to 1770 Nm.
2. If so equipped, install the motor protections, see Fig. 4-68 for more information.
(1) Gear box protection
(2) Intermediate plates for mounting the gear box protection (1). Two plates for each gear box
mounted ex works.
(3) Resilient sleeves
(4) Mounting bolts M30 x 160 mm for mounting the gear box protection to the intermediate plate.
Twelve bolts for each gear box.
(5) Nut M30. Twelve nuts for each gear box.
(6) Travel motor protection (special equipment)
4.3.8 MOUNTING OF TRAVEL MOTOR PROTECTION HOOD
Fig. 4-68
Mounting of the travel motor protection hood
1. Attach the motor protection hood (1) to the intermediate plates (2) using the sixteen mounting bolts (4), resil-
ient sleeves (3) and nuts (5) with washers. Tighten bolts (4) to 880 Nm.
2. Remove the covers of the protection hood and connect the hydraulic lines and breather filter lines. See
Fig. 4-65 for more information.
3. Attach the covers on the motor protection hood.
(1) Travel motor protection hood
(2) Intermediate plate for mounting the motor protection hood (1). One plate per gear box mounted
ex works.
(4) Mounting bolts M24 x 130 mm for mounting the motor protection hood to the intermediate plate.
Sixteen bolts for each protection hood.
(5) Nut M24. Sixteen nuts for each protection hood.
(6) Lines to gear box and final drive
(7) Gear box protection (if so equipped)
4.3.9 HYDRAULIC TRACK TENSIONING SYSTEM
Fig. 4-69
4.3.9.1 HYDRAULIC TRACK TENSIONING SYSTEM
NOTICE
Do not open cocks before all hydraulic lines are securely connected. The lines in the side frame are under
pressure!
REMARKS: The valve position (open or closed) is not depending on the lever position.
For the real status of the valve look at the groove on the square head (4) of the valve (below the
lever).
Check to make sure that the cock (1) is closed, cock (2), if so equipped, is open and cocks (3) in both
side frames are in open position before operating the machine.
(1) Pressure relief cock for hydraulic track
tensioning system
Ex-works
Working position
Closed
Closed
(2) Shut-off cock in supply line
(on earlier machines only)
Ex-works
Working position
Closed
Open
(3) Shut-off cock in side frames Ex-works
Working position
Closed
Open
(4) Marking below the washer shows the
valve position
O Open
C closed
(5) Connect pressure line from carbody to
the T-union
(6) Test connector on tensioning cylinders
MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE ASSEMBLY SEQUENCE
4.4 MOUNTING SUPERSTRUCTURE PLATFORM ONTO
UNDERCARRIAGE
Fig. 4-70
ASSEMBLY SEQUENCE MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE
NOTICE
The basic information regarding handling and mounting of the slew ring are contained in the Parts & Ser-
vice News No. AH00511. The latest edition of this bulletin is filed in the Operation and Maintenance Manual
of your machine.
It is good practise to study this bulletin before beginning assembling of the slew ring.
REMARKS: Make sure that the cranes and lifting gear are of sufficient capacity for lifting the superstructure plat-
form.
Weight of the superstructure platform approx: 57500 kg.
1. Attach the superstructure to the cranes. Use only slings for fastening to the boom cylinder foot bearing pins.
Do not use wire ropes or chains as such metallic parts would damage the machined surface of the pins.
2. Lift up the superstructure platform. Very carefully clean the contact surfaces of the slew ring and the carbody.
3. Check to make sure that the S markings of the inner and outer ring of the slew ring are positioned 90 to the
left in regard to the main load area. See illustration in Parts & Service News AH00511 latest edition for correct
position of the S markings.
4. Install the two centering pins (1) using tool (4).
5. Align superstructure platform to the carbody and lower it.
6. Align driver lever (6) on the rotary joint with yoke (5) on superstructure platform. Make sure the yoke (5)
engages smoothly to lever (6) when lowering the superstructure platform.
(1) Centering pins
(2) Slew ring
(3) Carbody
(4) Mounting tool
(5) Yoke on superstructure platform
(6) Driver lever on rotary joint
(7) Mounting bolts slew ring to carbody (M36 x 220 mm).
Quantity: 100 including the 8 measuring bolts.
(8) Washers. Quantity: 100
MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE ASSEMBLY SEQUENCE
Fig. 4-71
ASSEMBLY SEQUENCE MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE
Mounting Superstructure Platform onto Undercarriage (continued)
7. Further lower superstructure platform so that there is very little clearance between slew ring and center car-
body. Take care the centering pins (1) move into the corresponding holes in the carbody flange.
8. Prepare all bolts (7) and washers (8) and apply the special grease, (compound PN 324 969 40) to the threads
and to the head surface of the bolts and to the washers.
9. Lower superstructure completely onto the carbody.
10. Install all slew ring fastening bolts (7) with washers (8) and pre-tighten to the value specified in Parts & Service
News AH00511 last edition.
REMARKS: In order to facilitate identification of the measuring bolts at the first retightening procedure after 1000
operating hours, apply paint markings on the head surface of the eight measuring bolts.
11. Remove the two centering pins (1) using mounting tool (4).
12. Unhook Superstructure from the cranes.
13. Tighten all bolts (7) cross-wise with the value determined according to the Parts & Service News AH00511 last
edition.
ASSEMBLY OF MACHINERY HOUSE ROOF ASSEMBLY SEQUENCE
4.5 ASSEMBLY OF MACHINERY HOUSE ROOF
Fig. 4-72
ASSEMBLY SEQUENCE ASSEMBLY OF MACHINERY HOUSE ROOF
4.5.0.1 MOUNTING OF MACHINERY HOUSE RAILINGS
WARNING
Falling from high places can cause serious injury or death.
Before starting work on the machinery house roof, mount the railings (1, 2, 3 and 4) Fig. 4-72 and attach
the safeguarding ribbons (5) on the counterweight side of the machinery house.
REMARKS: The sectional view E - E is shown in Fig. 4-74.
(1) RH railing
(2) Front railing
(3) Front railing
(4) LH railing
(5) Safeguarding ribbons
(6) Mounting bolt M12 x 130 (standard tightening torque for quality grade 8.8)
(7) Mounting bolt M12 x 140 (standard tightening torque for quality grade 8.8)
(8) Nut with washer
4.5.1 MOUNTING OF THE EXHAUST SYSTEM
Fig. 4-73
Fig. 4-74
4.5.1.1 MOUNTING OF EXHAUST SYSTEM
NOTICE
In order to prevent exhaust emissions into the machinery house it is essential to ensure tightness of the
exhaust system. Keep the dimensions at the overlapping connections between elbow (4) and muffler pipe.
Place the pipe clamp (6) as shown in Fig. 4-74 and tighten securely.
(1) Flexible pipe with elbows (3 and 4) assembled ex works
(2) Flexible pipe
(3) Exhaust elbow
(4) Exhaust elbow
(5) Exhaust elbow mounting bolts M16 x 65. Eight for each elbow. Tightening torque 179 Nm.
(6) Pipe clamp
(7) Casing with muffler
(8) Muffler
(9) Muffler casing mounting bolt M16 x 90. Tightening torque 265 Nm.
(10) Resilient sleeve
(11) Cover of muffler casing. When attaching cover (11) to the casing (7) take care that the silicone
sealing (12) between cover and casing is in place and not damaged.
(12) Silicone sealing
(13) Muffler cover mounting bolt M10 x 30 (standard tightening torque for quality grade 8.8)
(14) Nut with washer
(15) Insulation covering, fasten with the buckles and straps provided.
4.5.2 MOUNTING OF THE AIR INTAKE SYSTEM
Fig. 4-75
Fig. 4-76
4.5.2.1 MOUNTING OF THE AIR INTAKE SYSTEM
REMARKS: Remove acorn nuts from air intake pipes (5) and install filter element restriction sensors 52B018-1
and 52B019-1.
Install the air intake system according to Fig. 4-75 and Fig. 4-76.
Tightening
torque Nm
(1) Air cleaner brackets
(2) Mounting bolts, M16 x 90 265
(3) Air cleaner
(4) Mounting bolts, 5/8 x 3 inch 265
(5) Air intake pipe
(6) Pipe clamp
(7) Clamp nuts M10 30 max
(8) Bellow-type seal
(9) Profile gasket
(10) Elbow
(11) Hose clamp
(12) Elbow with hose clamps
(13) Cold starting aid fluid cylinder bracket
REMARKS: Due to safety regulations the cold starting aid fluid cylinders are not deliv-
ered ex works. Purchase the cold starting aid fluid cylinders locally.
(14) Cold starting aid valve
(15) Hose lines from intake manifold
(16) Cable for cold starting aid valves 52Q502a-1 and 52Q502b-1
(17) Air duct
(18) Mounting bolts, M16 x 80 265
(19) Nuts M10
(20) Self locking nuts M10
MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM ASSEMBLY SEQUENCE
4.6 MOUNTING MACHINERY HOUSE ONTO THE
SUPERSTRUCTURE PLATFORM
Fig. 4-77
ASSEMBLY SEQUENCE MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM
4.6.0.1 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE
PLATFORM
WARNING
Falling from high places may cause serious injury or death.
Always wear a safety harness when working on elevated places. Most of the following operations require
the use of men safety cages on elevator working platforms.
1. Remove the protective coating from the mating surfaces of machinery house and superstructure platform.
2. Prepare all mounting bolts (2 and 3) with washers (4) and lubricate the bolts head and thread and the washers
with multi purpose grease. Do not use the special compound used for the slew ring bolts.
3. Attach the clevises of the ropes to the lifting brackets (1) and lift machinery house with two cranes over the
superstructure platform.
4. Lower the machinery house until two bolts (2) with washers (4) can be inserted as guiding tool.
5. Lower the machinery house fully and insert all bolts (2 and 3) with washers (4).
Tighten the bolts with 1770 Nm. (This must be done directly because at a later assembly stage it will be difficult
to reach the bolts).
6. Remove lifting brackets (1).
REMARKS: For connection of hydraulic lines from machinery house to the superstructure refer to Fig. 4-109.
Required accessories Safety Harness according to DIN EN 361, refer to the Operation and
Maintenance Manual for more information.
Mobile elevator working platform.
Two cranes.
Weight Pre-assembled machinery house, approx: 32000 kg.
(1) Lifting brackets
(2) Mounting bolts M30 x 440, Qty. 18. Tightening torque 1770 Nm.
(4) Washers, Qty. 26.
(5) Leakage oil reservoir. Installed ex works. If, for transport reasons, the reservoir is deliv-
ered separately, install at the mine site.
(8) Profile packing used on several places of the superstructure
MOUNTING OF BATTERY BOX AND HYDRAULIC ACCESS LADDER ASSEMBLY SEQUENCE
4.7 MOUNTING OF BATTERY BOX AND HYDRAULIC
ACCESS LADDER
Fig. 4-78
ASSEMBLY SEQUENCE MOUNTING OF BATTERY BOX AND HYDRAULIC ACCESS LADDER
Fig. 4-79
Fig. 4-80
Fig. 4-81
WARNING
Falling from high places may cause serious injury or death. Always wear a safety harness when working
on elevated places. Use men safety cage on the elevator working platform when mounting the ladder.
Legend for Fig. 4-78 to Fig. 4-82
Fig. 4-82
(1) Battery box with access ladder platform
(3) Mounting bolts M24 x 48. Qty. 12. Tightening torque 880 Nm.
(5) Mounting flanges
(6) Railing on battery box
(7) Ladder
(8) Railing on ladder platform
Legend for Fig. 4-78 to Fig. 4-82 (continued)
Assemble the ladder system on the ground as far as possible.
(9) Bearing assembly, delivered separately.
(10) Washer
(11) Self locking nuts (M48), to prevent damage to the locking insert, the nuts are delivered sepa-
rately.
(12) Ladder lift cylinder, installed in platform (1).
(13) Lift cylinder piston rod eye, connect to ladder lever (7) by means of parts (14, 15 and 16) and
lubricate both cylinder eyes.
(14) Pivot pin
(15) Washer
(16 Cotter pin
(17) Nuts M12 for fastening railings (6), standard tightening torque for quality grade 8.8.
(18) Locking plates. Use the locking plates for securing all bolt connections.
(19) Bolts M12 x 130 for fastening railings (6), standard tightening torque for quality grade 8.8.
(22) Proximity switch, monitors ladder position and controls ladder moving speed.
(23) Proximity switch, cuts out pilot control and actuates hydraulic swing brake with ladder in com-
pletely lowered position.
(24) Ladder stop bar
(25) Mounting bolts M12 x 80. Qty. 4. Tightening torque 108 Nm.
(27) Hydraulic line from central valve bank in pump compartment to lift cylinder piston side
(28) Hydraulic line from central valve bank in pump compartment to lift cylinder rod side
(29) Battery main switch keys
1. Prepare bearing assemblies (9) with washers (10). Attach ladder assembly to platform (1).
2. Tightening procedure of self locking nuts (11).
Screw on the nuts until they have contact with the brackets on platform (1). Then tighten the nuts
further by turning them through an angle of 45 (1/8 turn). Clamping torque of nuts (11).
New nuts: 200 Nm. Used nuts: 26 Nm minimum.
3. Mount the platform (1) with ladder (7) to the superstructure platform (2). Mount the railings (6 and
8). Connect ladder lifting cylinder (12) and lubricate both eyes of the cylinder.
4. Make sure both pivot pins (14) are properly secured with cotter pins (16).
5. Check hydraulic lines (27 and 28) for damages and connect to the hydraulic cylinder (12).
6. Install the stop bar (24). Connect the cables according to the electric circuit diagram.
7. Functional test of the ladder will be performed during the final inspection.
CONNECTING ENGINE OIL RESERVE SYSTEM ASSEMBLY SEQUENCE
4.8 CONNECTING ENGINE OIL RESERVE SYSTEM
Fig. 4-83
ASSEMBLY SEQUENCE CONNECTING ENGINE OIL RESERVE SYSTEM
Fig. 4-84
CONNECTING ENGINE OIL RESERVE SYSTEM ASSEMBLY SEQUENCE
4.8.0.1 CONNECTING ENGINE OIL RESERVE SYSTEM
1. Connect reserve oil lines (2 and 8) as shown in Fig. 4-83 and Fig. 4-84.
2. Connect breather line (11) from crankcase to reserve tank.
3. Connect oil refilling line from service arm to union (15).
4. Connect the electrical cables to the oil level sensors 63B103 and 63B106.
5. Connect the electrical cables to the heating parts 63B204 and 63E212 (if so equipped).
REMARKS: When filling the reserve tank and engine oil pan take care not to overfill. If the engine and reserve
tank is overfilled, there is no room in the tank to draw the oil level down in the engine. In this case
pump P1 is never receiving air. It will continue to pump oil from the engine to the tank, but because
the tank is full, the oil will be short-circuited back to the engine and the engine remains overfilled.
Moreover, the oil will overflow via the breather line.
For filling instructions of reserve tank and oil pan, refer to the Operation and Maintenance Manual. At the first start-
up loosen supply line (6) on the oil pan to ensure that all air is removed and pump P2 is feeding oil to the oil pan.
(1) Reserve oil tank, integrated part of the RH main frame side member
(2) Suction line from reserve tank to the oil filters (3)
(3) Oil filters of the reserve system
(4) Suction line from oil filters (3) to pumping unit pump P2
(5) Pumping unit located on the inside of the power frame
Pump P1 for withdrawal of oil from engine oil pan and feed-back to reserve tank
Pump P2 for oil supply from reserve tank to engine oil pan
(6) Supply line from pumping unit pump P2 to engine oil pan
(7) Withdrawal oil line from oil pan to pumping unit P1
(8) Oil feed-back line to reserve tank
(9) Radial groove indicates connection point for oil feed-back line (8) to reserve tank
(10) Power supply and signal cable (52G045)
(11) Breather line from crankcase to reserve tank
(12) Union for breather line (11)
(13) Union for suction line (2)
(14) Union for feed-back line (8)
(15) Union for oil refilling line from service arm
(16) Oil level sight gauge
(17) Reserve tank oil drain plug
63B103 Oil level sensor (refill indication)
63B106 Oil level sensor (Warning, oil level too low, reserve pump OFF)
63B204 Thermostat for immersion heater element (on machines with pre-heating system only)
63E212 Immersion heater element (on machines with pre-heating system only)
ASSEMBLY SEQUENCE CONNECTING ENGINE OIL RESERVE SYSTEM
Operating Principles
With the engine running, oil is circulated between the engine oil pan and the reserve tank by the two electrically
driven pumps P1 and P2 within the single pumping units (5).
Pump P1 draws oil from the oil pan at a preset control point (favorable running oil level). Oil above this point is
withdrawn and transferred to the reserve tank. This lowers the oil level in the oil pan until air is drawn.
Air reaching pump P1 activates pump P2, which supplies oil from reserve tank to the oil pan and raises the oil level
until air is no longer drawn by pump P1. Pump P2 turns off.
Pump P1 commands pump P2 i.e. pump P1 is running all the time while pump P2 runs only when pump P1 is
drawing air.
NOTICE
Prior to first engine start up make certain the engine oil pan and the reserve tank is filled with the specified
engine oil to the correct level. For the filling procedure refer to the Operation and Maintenance Manual of
your machine.
To ensure proper operation of the reserve system in combination with the CENTINEL oil burning system
check the oil level in the engine oil pan after every 3 operating hours during the first 24 hours of operation.
The oil level in the oil pan should always stay between the MIN and MAX marking on the oil level gauge. If
the oil level is below the MIN marking or above the MAX marking there is a malfunction in the reserve sys-
tem and/or CENTINEL oil burning system. Check the items listed in the Trouble Shooting Chart below.
Trouble Shooting Chart - Engine Oil Reserve System and CENTINEL Oil Burning System
1. Check the reserve system hose lines for correct connection.
2. Check power supply and signal cable (52G045) for correct connection on the pumping units.
3. Check the indication of the reserve system monitoring light 11P143-1 located on the low voltage
switch board in the cab base. Refer to the Operation and Maintenance Manual for blink code expla-
nation.
4. Check the CENTINEL oil control valve.
5. Check the CENTINEL Electronic Control Module [ECM]. The ECM will log fault codes. For access
to logged fault codes use the service tool INSITE.
6. Check the engine monitoring system CENSE for fault codes related to the CENTINEL system,
using the INSITE service tool.
PRE-ASSEMBLY OF FACE SHOVEL BOOM ASSEMBLY SEQUENCE
4.9 PRE-ASSEMBLY OF FACE SHOVEL BOOM
Fig. 4-85
ASSEMBLY SEQUENCE PRE-ASSEMBLY OF FACE SHOVEL BOOM
Fig. 4-86
Fig. 4-87
Legend for Fig. 4-85 to Fig. 4-87
1. With the boom resting safely on the ground, install railings (1) with catwalks.
2. Tighten the mounting bolts and nuts with the special torque shown in Fig. 4-86.
3. Insert the counter sunk bolts (9) with nonskid disks and tighten securely.
4. Attach clamp rails (13 and 14) Fig. 4-87. Observe the dimensions (F and G) given in the illustration for placing
the rails on the hose arrangement.
Take care the contact plate (H) of the rail (13) points to hose support (16).
5. Check to make sure that all mounting bolts and nuts are tightened with the correct torque as shown in
Fig. 4-86.
(1) Railings on boom
(2) Pipe clamps
(3) Bracket plate with thread block (7) for grating (8)
(4) Plate
(5) Mounting bolt. Observe special torque shown in the illustration.
(6) Nut with washer. Observe special torque shown in the illustration.
(7) Thread block
(8) Grating
(9) Slotted counter sunk bolt M8 x 40 with nonskid plastic disk
(11) Nut with washer. Observe special torque shown in the illustration.
(12) Mounting bolt with washer. Observe special torque shown in the illustration.
(13) Lower hose clamp rail with contact plate (H). Observe dimension (F) when attaching the clamp
rail. Take care the contact plate (H) points to hose support (16).
(14) Upper hose clamp rail. Observe dimension (G) when attaching the clamp rail.
(15) Hose group
(16) Hose support
(17) Control block carrier
(18) Distributor manifold
4.9.1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM
Fig. 4-88
Check all pipe clamps (1) with ring bolts (3) for good condition and correct fastening. Take necessary
action if wrong condition or defective fastenings have been found.
(1) Pipe clamps with swivel type ring bolts
(2) Bolt M16 x 170.
REMARKS: Special torque for bolt (2): 120 Nm
(3) Swivel type ring bolt. Attachment point for men safety harness with strap-type fall absorber.
CAUTION
DO NOT attach any other object to the ring bolts (3). Use only for attaching the strap-type
fall absorber in connection with safety harness. Refer to the Operation and Maintenance
Manual of your machine for handling instructions of the fall-arrest system.
(4) Grease injector banks
(5) Grease lines to the bearings
4.9.2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT
PINS
Fig. 4-89
General Installation Instructions for Attachment Pins Fig. 4-89
REMARKS: The instructions given below show, as an example, the pin installation procedure for connecting the
boom cylinders to the boom. However, the basic installation method applies to all attachment pins.
Whenever installing an attachment pin use the method below in conjunction with the individual cylin-
der installation procedure.
WARNING
Accidental movement of a cylinder may cause serious injury or death.
When attaching cylinders never reach inside the joints. If securing elements of the cylinder fail, a shearing
action can occur through sudden moving out of the cylinder from the joint.
Required accessories
Personal protection gear (hard hat, safety shoes, safety glasses and heavy gloves).
Aluminum Anti-Seize paste Part No. 509 623 98 (4.5 kg container delivered with the machine).
Multi-Purpose Grease, same quality as used for the Central Lubrication System.
Push rod for pin installation, part of the tool set delivered with the machine.
With boom and cylinders safely resting on the ground, prepare the bearings and pins of boom and cylinders as fol-
lows.
REMARKS: Thoroughly clean the pins and bushings of boom and cylinders. These parts should be completely
free of the protective coating.
1. Carefully remove pin seals from bushing grooves (1).
2. Completely fill the bushing grooves with the specified grease (2).
3. Insert pin seals into bushing grooves (3) and center the seal rings within their grooves. Use the grease to keep
the seal rings centered in place.
4. Apply the specified grease to the bearing bushings (4).
5. Apply the Aluminum Anti-Seize paste to the pin fixing point on the attachment bearing (5).
6. Apply the Aluminum Anti-Seize paste to the fixed portion (6) of pin (8).
7. Lift the boom cylinder bottom side (7) and align with bearing (5). Make sure seal rings are in centered position.
8. Install pin (8).
9. Secure the pin with locking parts (9, 10, 11 and 12).
10. Continue according to section "ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM" on
page 4-136.
4.9.3 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE
BOOM
Fig. 4-90
REMARKS: Make sure that the cranes and lifting gear are of sufficient capacity for lifting the boom.
Use only slings for lifting the mounting pins of the boom and cylinders. Do not use wire ropes or
chains as such metallic parts would damage the machined surface of the pins.
WARNING
Always wear a safety harness when working on the attachment. Most of the following operations require
Two cranes and four chain hoists.
Weights Boom with attached stick and boom cylinders: 38500 kg.
Boom cylinder: 4100 kg
Stick cylinder: 2800 kg
Pin boom cylinder / boom: 150 kg.
Pin stick cylinder / boom: 58 kg
(1) Boom
(2) Wooden blocks
(3) Boom cylinder
(4) Locking bars
(5) Boom cylinder mounting pin
(6) Cover
(7) Bolt
(8) Seal rings installed in the cylinder bushings
(9) Stick cylinder
(9L) LH stick cylinder seen from below
(9R) RH stick cylinder seen from below
(10) Seal rings installed in the boom bearings for the stick cylinders
(11) Stick cylinder mounting pin
(12) Locking bar
(13) Bolt
(14) Chain hoists for securing boom and stick cylinders to the boom
(15) Pipe lines to rod side of stick cylinders
Fig. 4-91
Attach Face Shovel Boom Cylinders and Stick Cylinders to the Boom (continued)
WARNING
Inadvertent movement of piston rods may cause serious injury or death.
Always secure piston rods in retracted position by means of suitable lashing straps.
REMARKS: For installation of pins (5 and 11) Fig. 4-91 use only the push rod delivered with the machine. The
use of hammers or other pushing tools could damage the pin seals.
Prepare pins, seal rings and bushings according to the instructions on page 4-134.
1. Place boom (1) on wooden blocks (2). Ensure that there is enough space to install boom and stick cylinders.
2. Thoroughly clean the pins and bushings of boom and cylinders. These parts should be completely free of the
protective coating.
3. Center the seal rings (8 and 10) within their grooves of the bearing bushings. Use multi-purpose grease from
the Central Lube System to keep the seal rings centered in place.
4. Apply grease to the bearing bushings.
5. Apply the Aluminum Anti-Seize paste to the pin fixing points.
6. Lift the boom cylinders (3) and align them according to their bearings (A-A).
7. Make sure seal rings (8) are in centered position.
8. Install pins (5) and secure the pins with locking parts (4, 6 and 7).
9. Fasten boom cylinders (3) to the boom using chain hoists (14). To prevent damage to the bearing bushings
place edge protections on each bushing.
10. Prepare pin seals (10) of the boom bearing bushings for the stick cylinders (9).
11. Apply grease to the bearing bushings on the boom.
12. Apply the Aluminum Anti-Seize paste to the fixing points on the forked cylinder bearings for pins (11).
13. Lift the stick cylinders (9) and align them according to their bearings (B-B).
15. Install pins (11) and secure the pins with locking parts (12 and 13).
16. Fasten stick cylinders (9) to the boom using chain hoists (14). To prevent damage to the bearing bushings
place edge protections on each bushing.
4.9.4 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME
Fig. 4-92
CAUTION
Before removing fastenings (7) Fig. 4-92 support the boom cylinders by means of fork lifts equipped with
clamping jaws or similar equipment which ensures safe handling of the cylinders. Take measures to pre-
vent a moving out of the piston rods.
REMARKS: For installation of pins (3 and 8) use only the push rod delivered with the machine. The use of ham-
mers or other pushing tools could damage the pin seals.
Treat the pins, seal rings and bushings according to the instructions on page 4-134.
1. Prepare pin seal rings of the boom bearing bushings.
3. Apply the Aluminum Anti-Seize paste to the pin fixing points on A-frame and boom cylinder foot bearings.
4. Lift the boom (1) with boom and stick cylinders attached.
5. Align the boom with the boom pivot bearings (2) of the A-frame.
6. Lower the boom so that the bores of the boom and the boom pivot bearings are aligned.
7. Make sure pin seal rings of the boom bearing bushings are in centered position.
8. Insert the two pins (3) and secure with the retainers (4), washers (5) and bolts (6), bolt size M36 x 85.
9. Tighten bolts (6) with 3100 Nm.
10. Lower the boom cylinder until the bore of the cylinder and the superstructure bearings are aligned.
11. Make sure pin seal rings of the bearing bushings are in centered position.
12. Insert the pin (8) and secure with the retainers (4), washers (5) and bolts (6).Tighten bolts with 3100 Nm.
13. Attach the grease collecting boxes (9 and 10) on inside and outside of both A-frames.
14. Use washers (11) and bolts (12) for fastening the grease boxes.
Weights Pin boom / superstructure A-frame: 200 kg.
Pin boom cylinder / superstructure: 100 kg.
PRE-ASSEMBLY OF BACKHOE BOOM ASSEMBLY SEQUENCE
4.10 PRE-ASSEMBLY OF BACKHOE BOOM
Fig. 4-93
ASSEMBLY SEQUENCE PRE-ASSEMBLY OF BACKHOE BOOM
Installation of Boom Ladder and Railings
Legend for Fig. 4-93.
With boom safely resting on the ground install railings with rungs.
(1) Railing with rungs
(2) Lower pipe clamps
(4) Locking plate. Use the locking plates for securing the bolt connections (3).
(5) Upper pipe clamps
(8) Plate
(9) Washer
4.10.1 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE
BOOM
Fig. 4-94
WARNING
Two cranes and four chain hoists.
Weights Boom with attached stick and boom cylinders: 46000 kg.
Boom cylinder: 4400 kg
Stick cylinder: 3300 kg
Pin boom cylinder / boom: 102 kg.
Pin stick cylinder / boom: 124 kg
(1) Boom
(2) Boom cylinders
(3) Sling hoists for securing boom cylinders to the boom
(4) Boom cylinder pins
(5) Rotation locks
(6) Shackles
(7) Locking plates
(8) Bolts
(9) Stick cylinders
(10) Stick cylinder pins
(11) Rotation locks
(12) Shackles
(13) Locking plates
(14) Bolts
Fig. 4-95
Attach Backhoe Boom Cylinders and Stick Cylinders to the Boom (continued)
WARNING
Inadvertent movement of piston rods may cause serious injury or death.
Always secure piston rods in retracted position by means of suitable lashing straps.
1. Place boom (1) on the ground. Use blocks and supports to secure the boom. Ensure that there is enough
space to install the boom cylinders.
2. Thoroughly clean the pins and bushings of boom and cylinders. These parts should be completely free of the
protective coating.
3. Center the pin seal rings of boom and cylinder bushings within their grooves. Use multi-purpose grease from
the Central Lube System to keep the seal rings centered in place.
4. Apply grease to all the bearing bushings.
5. Apply the Aluminum Anti-Seize paste to all non-movable pin bearing points on the attachment and cylinders
that are without bushings.
6. Lift the boom cylinders (2) and align them according to their bearings.
7. Make sure the pin seal rings are in centered position.
8. Install pins (4) and secure the pins with locking parts (5, 6, 7 and 8).
9. Fasten boom cylinders (3) to the boom using sling hoists (3).
10. Lift the stick cylinders (9) and align them according to their bearings.
11. Make sure the pin seal rings are in centered position.
12. Install pins (10) and secure the pins with locking parts (11, 12, 13 and 14).
4.10.2 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME
Fig. 4-96
CAUTION
Before removing fastenings (7) Fig. 4-96 support the boom cylinders by means of fork lifts equipped with
clamping jaws or similar equipment which ensures safe handling of the cylinders. Take measures to pre-
vent a moving out of the piston rods.
REMARKS: For installation of pins (3 and 8) use only the push rod delivered with the machine. The use of ham-
mers or other pushing tools could damage the pin seals.
Treat the pins, seal rings and bushings according to the instructions on page 4-134.
1. Prepare pin seal rings of the boom bearing bushings.
3. Apply the Aluminum Anti-Seize paste to the pin fixing points on A-frame and boom cylinder foot bearings.
4. Lift the boom (1) with boom and stick cylinders attached.
5. Align the boom with the boom pivot bearings (2) of the A-frame.
6. Lower the boom so that the bores of the boom and the boom pivot bearings are aligned.
7. Make sure pin seal rings of the boom bearing bushings are in centered position.
8. Insert the two pins (3) and secure with the retainers (4), washers (5) and bolts (6), bolt size M36 x 85.
9. Tighten bolts (6) with 3100 Nm.
10. Lower the boom cylinder until the bore of the cylinder and the superstructure bearings are aligned.
11. Make sure pin seal rings of the bearing bushings are in centered position.
12. Insert the pin (8) and secure with the retainers (4), washers (5) and bolts (6).Tighten bolts with 3100 Nm.
13. Attach the grease collecting boxes (9 and 10) on inside and outside of both A-frames (if so equipped).
14. Use washers (11) and bolts (12) for fastening the grease boxes.
Weights Pin boom / superstructure A-frame: 200 kg.
Pin boom cylinder / superstructure: 100 kg.
MOUNTING OF COUNTERWEIGHT ASSEMBLY SEQUENCE
4.11 MOUNTING OF COUNTERWEIGHT
Fig. 4-97
ASSEMBLY SEQUENCE MOUNTING OF COUNTERWEIGHT
Fig. 4-97
WARNING
RISK OF EXPLOSION!
Failure to properly expel the gases from the counterweight chambers can result in an explosion with seri-
ous personal injury or death.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 car-
ried out on the counterweight it is vital to expel these gases from the counterweight chambers.
REMARKS: Follow the instructions given in Parts & Service News No. AH04518 last edition for expelling the
gases from the counterweight chambers.
Guideline for transportation and lifting of the counterweight
1. Thoroughly clean the contact surfaces of counterweight and platform.
2. Prepare all mounting bolts (2) and washers. Lubricate the threads of the bolts with grease as used in the cen-
tral lubrication system. Apply same grease to the washers.
REMARKS: DO NOT use the special grease used for the mounting bolts of the slew ring since such a use would
cause loss of the bolt strength due to overtightening.
3. Lift the counterweight as shown in the illustration.
4. Align the bores in counterweight and platform.
5. Carefully lower counterweight onto the bearing surfaces of the platform.
6. Install bolts (2) with washers.
7. Tighten the bolts with the specified torque.
Qty Tightening
torque Nm
(1) Counterweight. Weight: 37000 kg
(2) Mounting bolts M42 x 520 mm, Grade 10.9 16 4950
Washers 16
(3) Instruction label
(4) A1, A2 and A3 fastening points for horizontal transport and for loading of the counterweight with
three symmetrical ropes
(5) A1 and A2 fastening points for lifting the counterweight with two symmetrical ropes
(6) A1 and A2 fastening points for raising up the counterweight with two symmetrical ropes
MOUNTING OF THE FUEL TANK ASSEMBLY SEQUENCE
4.12 MOUNTING OF THE FUEL TANK
Fig. 4-98
ASSEMBLY SEQUENCE MOUNTING OF THE FUEL TANK
1. Thoroughly clean the contact surfaces of fuel tank and superstructure platform.
2. Attach fuel tank to the crane. Use the lifting points shown in the illustration.
REMARKS: Use appropriate slings and lifting gear for handling of the fuel tank.
3. Align the fuel tank to the superstructure platform and lower the fuel tank onto the platform in such a way, that
the embossed hooks of the fuel tank and platform will firmly engage.
4. Lubricate the threads and the head surface of the bolts (1 and 4) with grease as used in the central lubrication
system. Apply same grease to the resilient sleeves (3) and washers (2). DO NOT use the special grease used
for the mounting bolts of the slew ring since such a use would cause loss of the bolt strength due to overtight-
ening.
5. Insert bolts (1) with washers (2).
6. Tighten bolts (1) with the specified torque.
7. Insert bolts (4) with resilient sleeves (3).
Qty Tightening
torque Nm
(2) Washers 4
(3) Resilient sleeves 4
Weight of fuel tank: 3500 kg (empty)
4.12.1 CONNECTING FUEL SYSTEM HOSE LINES
WARNING
Fuel is flammable. When inspecting or performing service or repair on the fuel system, to reduce the pos-
sibility of fire and resulting severe personal injury, death or property damage, never smoke or allow
sparks or flames (such as pilot lights, electrical switches, or welding equipment) in the work area.
NOTICE
Cleanliness is vital when working on the fuel system. Even smallest foreign matter in the fuel system can
cause malfunction of internal parts that could result in severe damage to other engine components.
Fig. 4-99
Fig. 4-100
Fig. 4-101
Legend for Fig. 4-99, Fig. 4-100 and Fig. 4-101.
Connect fuel lines according to Fig. 4-99 to Fig. 4-101
REMARKS: All fuel lines and their connectors are provided with identification tags. Remove the sealing plugs
from fuel lines and connectors only just before the lines are ready for connection. Make certain lines,
unions and fittings are clean and all fuel line protection hoses are in place and securely fastened.
1. Connect fuel refilling hose (1) to elbow (2) and install bracket (3).
2. Connect fuel supply line (4) from first stage fuel filters (5) to fuel shut-off solenoid valve (6).
3. Connect fuel return lines (15 and 17) to the fuel tank.
4. Install fuel tank breather filters (18) with breather hoses (19).
5. Connect the electrical cables to the fuel shut-off solenoid valve (6) and pressure transducer (21).
6. Check all fuel lines and connectors for tightness, good condition and proper fastening.
(1) Fuel refilling hose from service arm, fixed on superstructure platform. Connect to elbow (2).
(2) Elbow
(3) Hose clamp bracket
(4) Supply line from fuel shut-off solenoid valve (31Q599) to the first stage fuel filters (5)
(5) First stage fuel filters with water separators
(6) Fuel shut-off solenoid valve (31Q599)
(7) Shut-off cock
(8) Receiver valve of Wiggins refuelling system
(9) Jet sensor hoses
(10) Jet sensor of Wiggins refuelling system
(11) Line from first stage filters to fuel lift pump on the engine
(12) Line from fuel lift pump to second stage filters
(13) Second stage fuel filters
(14) Line from second stage filters to engine fuel pump
(15) Fuel return line to connector plate on fuel tank
(16) Connector plate on fuel tank
(17) Fuel return line
(18) Breather valves with filter of Wiggins refuelling system
(19) Breather lines
(20) Fuel shut-off cock
(21) Pressure transducer for fuel level indication (31B063)
(22) Fuel tank bottom flaps
(23) Captive bolts
(24) Drain coupling
ATTACHING THE CAB BASE ASSEMBLY SEQUENCE
4.13 ATTACHING THE CAB BASE
Fig. 4-102
ASSEMBLY SEQUENCE ATTACHING THE CAB BASE
1. Thoroughly clean the contact surfaces of cab base and superstructure platform.
2. Attach cab base to the crane. Use the lifting points shown in Fig. 4-102.
REMARKS: Use appropriate slings and lifting gear for handling of the cab base.
3. Align the cab base to the superstructure platform and lower the cab base onto the platform in such a way, that
the embossed hooks of the cab base and platform will firmly engage.
4. Lubricate the threads and the head surface of the bolts (1 and 4) with grease as used in the central lubrication
system. Apply same grease to the washers (2 and 3). DO NOT use the special grease used for the mounting
bolts of the slew ring since such a use would cause loss of the bolt strength due to overtightening.
Qty Tightening
torque Nm
(2) Washers 4
(3) Washers 4
Weight of cab base: 3800 kg
4.13.1 MAKING OF ELECTRICAL CABLE CONNECTIONS
Fig. 4-103
Connect cables from machinery house to cab base
REMARKS: In order to prevent too great sagging of cables (1) below the cab base equalize the cable length
between the cable brackets and leave a loop at the machinery house (starting point of laying).
1. Connect the cables (1) from machinery house to the plug sockets on bulkhead (2). Cable connectors and bulk-
head sockets have the same designation marks.
REMARKS: Tighten the jam nuts of the Deutsch plugs DT18 and DT24 on the CAN-Bus cables with 12.5 Nm.
2. Connect the heater supply and return hoses to the adapter plate (3), see Fig. 4-104.
3. Connect the pneumatic actuation hose for the pressure switch of the fire suppression system to the connec-
tion bore M25.
4. Connect the cables to the terminals on the low voltage switch board. The cable connections inside the cab
base are already prepared ex works.
5. Remove bulkhead (3) and connect cables (4) from Operators cab after installation of the cab.
6. Check to make sure that the gasket of bulkhead (3) is correctly placed and not damaged. Attach bulkhead to
base ceiling.
7. Tighten the fastening nuts (5) of bulkhead (3) with 15 Nm.
8. Check ground cables (6) for correct connection to the welded stud (7).
-A- Cab base viewed from below
-B- Cab base bottom
-C- Cab base ceiling
(1) Cables coming from machinery house
(2) Cable bulkhead
(3) Cable bulkhead
(4) Cables coming from cab
(5) Bulkhead mounting nuts. Tightening torque 15 Nm.
(6) Ground cables
(7) Welded ground stud
4.13.2 CONNECT CAB HEATER HOSES TO CAB BASE
Fig. 4-104
Connect Heater Hoses
Legend for Fig. 4-104.
1. Connect hose (1) from intermediate plate to pipe socket on plate (3).
2. Connect hose (2) from intermediate plate to pipe socket on plate (3).
3. Connect hoses (4 and 5) from cab to pipe sockets on plate (6).
(1) Supply line from hot coolant channel on the engine
(2) Coolant return line to radiator manifold
(3) Adapter plate on cab base bottom
(4) Supply line coming from cab
(5) Return line coming from cab
(6) Adapter plate on cab base ceiling
ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE ASSEMBLY SEQUENCE
4.14 ATTACHING THE CAB WITH SUPPORT FRAME TO
THE CAB BASE
Fig. 4-105
ASSEMBLY SEQUENCE ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE
REMARKS: Cable connections to remote terminal boxes and lighting equipment will be made after installation of
all railings, catwalks and steps.
Sealing compound [Epple 28], part of the tool box.
Locking compound [Loctite 222], part of the tool box.
Weight of cab with
attached support frame
5200 kg
Qty Tightening
torque Nm
1. Carefully clean the mating surfaces of cab base and support frame.
2. Apply sealing compound [Epple 28] onto the whole contact surfaces (A) of the cab base.
3. Attach the cab to the crane. Use the lifting points shown in the illustration and lift the cab.
4. Position the cab so that the cables from the cab can be connected to the plug sockets of
the bulkhead (3) on the cab base roof, see Fig. 4-103.
5. Align the cab support frame (B) with the cab base contact surfaces (A). Carefully lower the
cab so fare, that the heater hoses can be connected to the unions on the cab base roof,
see Fig. 4-104 for details. Connect the refrigerant supply and return hoses to the air condi-
tioner unit, see Fig. 4-106. Connect the condensation drain hose of the air conditioner unit.
6. Lower the cab support frame completely onto cab base.
7. Apply locking compound [Loctite 222] onto the thread of all 21 mounting bolts (C) and fas-
ten the cab support frame (B) with bolts (1) and resilient sleeves (2) onto the cab base.
Tighten bolts (1) with the specified torque.
8. Connect the cables to the bulkhead (3) Fig. 4-103. All cables and plug sockets on bulkhead
(3) have identification marks.
9. Connect the remaining electric cables, refer to the electrical diagram of your machine for
more information.
10. Make certain the ground cables (6) Fig. 4-103 are securely connected to the welded stud
(7).
4.14.1 CONNECTING THE AIR CONDITIONER HOSES OF THE CAB
Fig. 4-106
Connect air conditioner hoses of the Operators cab
Fig. 4-107
(HP) High Pressure service valve of the refrigerant compressor
(LP) Low Pressure service valve of the refrigerant compressor
(1) High pressure hoses, nominal width 12
(2) Low pressure hoses, nominal width 16
(3) Pipe connectors for refrigerant hoses on air conditioner unit
(4) Air conditioner condensation drain line
4.14.2 INSTALL ORBCOMM ANTENNA
Fig. 4-108
Install ORBCOMM Antenna
(Special equipment)
1. Attach bracket (1) with antenna to cab roof and fasten with bolts (2) and resilient sleeves (3).
Observe the minimum bending radius of the antenna cable (53 mm).
2. Connect angle plug (8) to the plug socket provided on the cab wall.
REMARKS: Connection of the antenna cable to the ORBCOMM controller is made via the bulkhead in the cab
base.
(1) Bracket
(2) Mounting bolt M6 x 35, Qty 4.
(3) Resilient sleeve
(4) Antenna
(5) Antenna cable
(6) Connector
(7) Cable protection hose
(8) Angle plug
CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE AND SUPERSTRUCTURE ASSEMBLY SEQUENCE
4.15 CONNECTING HYDRAULIC LINES BETWEEN
MACHINERY HOUSE AND SUPERSTRUCTURE
Fig. 4-109
ASSEMBLY SEQUENCE CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE AND SUPERSTRUCTURE
Connecting hydraulic lines between machinery house and superstructure
REMARKS: The numbers 1 to 15 are stamped on interface bracket (20). The number 16 (not encircled) is also
stamped on the line connecting plate. The corresponding matching parts of the superstructure have
the same numbering.
Connection points, Fig. 4-109
P1 Pressure line main pump 1
1 Return oil line from valve cartridge bank
2 Pressure line swing gear brake
3 Pressure line remote control units
4 Return oil line from radiator fan motor
5 Return oil line from radiator fan drive pressure control valve (31.2), see hydraulic diagram.
6 Pressure line travel brake
7 Pressure line swing gear
8 Pressure line grease pump
9 Leakage oil line from radiator fan motor
10 Refilling line central lubrication system
11 Return oil line PTO cooling
12 Return line from oil cooler fan drive pressure control valve (31.1), see hydraulic diagram.
13 Supply oil line PTO cooling
14 Hydraulic oil refilling line
15 Refilling line swing circle toothing lubrication system
16 Pressure line oil cooler fan motor
20 Interface bracket
21 Intermediate pipe on suction oil reservoir
22 Leakage oil line to main oil reservoir
23 Transfer pump suction line
CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE AND SUPERSTRUCTURE ASSEMBLY SEQUENCE
4.15.1 CONNECTING HIGH PRESSURE LINES OF THE MAIN PUMPS
Fig. 4-110
ASSEMBLY SEQUENCE CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE AND SUPERSTRUCTURE
REMARKS: For correct tightening torque of the flange bolts (7) refer to the Torque Charts for Flange Joints on
page 3-67.
Connect the four high pressure hose lines to the pipes (5). Take care the O-rings (6) are properly seated in the
flange grooves.
P1 - P4 Main pump hose lines
(5) Pipes fixed on superstructure platform
(6) O-rings
(7) Flange bolts M20 x 120. Quality grade 8.8.
(8) Nuts
ATTACHING THE HYDRAULIC OIL RESERVOIR ASSEMBLY SEQUENCE
4.16 ATTACHING THE HYDRAULIC OIL RESERVOIR
Fig. 4-111
ASSEMBLY SEQUENCE ATTACHING THE HYDRAULIC OIL RESERVOIR
1. Remove self locking nuts (3), these nuts are only slightly tightened ex works to preserve their clamping force.
2. Remove the standard mounting nuts of plate (2).
3. Remove the blanking plate (2). Take care that no dirt enters the opening of the compensator.
4. Attach the reservoir to the crane. Use the lifting points shown in the illustration. Use appropriate slings and lift-
ing gear for handling of the reservoir.
5. Align the hydraulic oil reservoir to the superstructure platform and lower the reservoir onto the platform in such
a way, that the embossed hooks of the reservoir and platform will firmly engage and the flanges of compensa-
tor (1) and intermediate pipe (8), Fig. 4-112 are in line. If necessary move the oil reservoir slightly until the mat-
ing surfaces of compensator and intermediate pipe are in contact.
6. Insert bolts (4) with washers (5), Fig. 4-111 and tighten the bolts with the specified torque.
7. Insert bolts (6) with washers (7) and tighten the bolts with the specified torque.
8. Connect compensator (1) to pipe (8), Fig. 4-112 using bolts (9) and self locking nuts (3). Tighten self locking
nuts (3) with 70 Nm. DO NOT overtighten otherwise the sealing flange of compensator (1) could be damaged.
9. Check the bolted connections of main shut-off valve (10) to the pipe on the oil reservoir and of intermediate
pipe (8) to the suction oil reservoir for good condition and security.
Qty Tightening
torque Nm
(1) Compensator
(2) Blanking plate
(3) Self locking nuts, observe special torque. (8) 70
Weight of hydraulic oil reservoir: 3500 kg
Fig. 4-112
ATTACHING THE HYDRAULIC OIL COOLER ASSEMBLY SEQUENCE
4.17 ATTACHING THE HYDRAULIC OIL COOLER
Fig. 4-113
ASSEMBLY SEQUENCE ATTACHING THE HYDRAULIC OIL COOLER
1. Attach the cooler to the crane. Use the lifting points shown in the illustration. Use appropriate slings and lifting
gear for handling of the cooler.
2. Align the hydraulic oil cooler to the superstructure platform and lower the cooler onto the platform in such a
way, that the embossed hooks of the cooler and platform will firmly engage.
3. Insert bolts (1) with resilient sleeves (2) and tighten the bolts with the specified torque.
4. Insert bolts (3) with washers (4) and tighten the bolts with the specified torque.
5. Check to make sure that sealing strip (6) is not damaged and correctly placed between frame and oil cooler.
Qty Tightening
torque Nm
(4) Washers 4
(5) Oil cooler
(6) Sealing strip affixed on plate (7)
(7) Plate
Weight of hydraulic oil cooler: 5800 kg
Fig. 4-114
4.17.1 CONNECTING THE HYDRAULIC HOSE LINES OF THE OIL
COOLER CIRCUIT
Fig. 4-115
REMARKS: For correct tightening torque of the flange bolts refer to the Torque Charts for Flange Joints on
page 3-67.
REMARKS: All hydraulic lines have matching marks ex works. Observe these markings when connecting hydrau-
lic lines.
1. Remove the blanking plates from the flanges on the hydraulic hoses (1) and on the back-pressur pipe (3).
2. Connect hose lines (1).
3. Remove the blanking plates from the flanges on the upper hydraulic hoses (4) and on the main oil reservoir fil-
ter chamber.
4. Connect hose lines (4).
(1) Intake hose lines to coolers (hot oil)
(2) Unions
(3) Back-pressure pipe
(4) Return hose lines to hydraulic oil reservoir (cooled oil)
(5) O-ring
(6) Flange bolt M12 x 35, quality grade 8.8.
4.17.2 CONNECTING THE HOSE LINES OF OIL COOLER FAN MOTORS
Fig. 4-116
lic lines.
1. Connect pressure hose lines (1) with union (2) to pipe connector (3).
2. Connect return oil line (4) to union (5) on back-pressure pipe (6).
3. Connect leakage hose lines (7) to the leakage filter chamber of main oil reservoir.
(1) Pressure line from hydraulic pump
(2) Reducing union
(3) Pipe connector
(4) Return hose lines to back-pressure pipe
(5) Union
(7) Leakage oil line
16 Line lead-through on suction tank. The number 16 (not encircled) is also stamped on the line lead-
through plate. See also Fig. 4-109.
4.17.3 CONNECTING THE HOSE LINES OF PTO OIL COOLING CIRCUIT
Fig. 4-117
REMARKS: Observe the matching marks when connecting hydraulic lines.
1 Connector on distributor block (12) for supply oil line 13. Connect the supply line to interface
bracket (20) connector 13, see also Fig. 4-109.
10 Connector on distributor block (12) for return oil line 11. Connect the return line to interface
bracket (20) connector 11.
(12) Distributor block
(20) Interface bracket, see also Fig. 4-109.
4.17.4 CONNECTING THE RETURN OIL HOSE LINE OF RADIATOR FAN
MOTOR
Fig. 4-118
page 3-67.
lic lines.
1. Connect return oil hose line (1) Fig. 4-118 from back-pressure pipe (2) to fitting 4 on interface bracket (20).
2. Connect leakage oil hose line (3) from leakage oil filter chamber (5) to fitting 9 on interface bracket (20).
(1) Return oil hose line
(3) Leakage oil hose line
(5) Leakage oil filter chamber
(20) Interface bracket, see also Fig. 4-109.
4.17.5 CONNECTING THE HOSE LINES FROM RETURN OIL MANIFOLD
TO BACK-PRESSURE PIPE
Fig. 4-119
page 3-67.
(1) Return oil hose lines
(2) Return oil manifold
(6) Nut
CONNECTING SWING GEAR HYDRAULIC LINES ASSEMBLY SEQUENCE
4.18 CONNECTING SWING GEAR HYDRAULIC LINES
Fig. 4-120
ASSEMBLY SEQUENCE CONNECTING SWING GEAR HYDRAULIC LINES
4.18.1 CONNECTING THE RETURN AND LEAKAGE OIL HOSE LINES
lic lines.
(1) Return oil hose line from RH swing gear to back-pressure pipe (2)
(3) Return oil hose line from LH swing gear to return oil manifold (4)
(5) Leakage oil hose lines from swing motors to leakage oil filter chamber (6)
(6) Leakage oil filter chamber
(7) Leakage oil hose lines from valve blocks to leakage oil filter chamber (6)
CONNECTING SWING GEAR HYDRAULIC LINES ASSEMBLY SEQUENCE
4.18.2 CONNECTING THE SWING BRAKE PRESSURE HOSES AND
PILOT OIL HOSES
Fig. 4-121
ASSEMBLY SEQUENCE CONNECTING SWING GEAR HYDRAULIC LINES
The hydraulic hoses between valve block (256) and interface bracket (20) are connected ex works.
(1) Swing brake pressure hose, connect from T-union (3) to interface bracket (20) connector 2, see
also Fig. 4-109.
(3) T-union
(4) Swing brake pilot oil hose, connect from T-union (5) to interface bracket (20) connector 7.
(5) T-union
(20) Interface bracket, viewed from inside machinery house.
CONNECTING THE RETURN AND PRESSURE OIL HOSES FROM VALVE BLOCK ASSEMBLY SEQUENCE
4.19 CONNECTING THE RETURN AND PRESSURE OIL
HOSES FROM VALVE BLOCK
Fig. 4-122
ASSEMBLY SEQUENCE CONNECTING THE RETURN AND PRESSURE OIL HOSES FROM VALVE BLOCK
Connect the hydraulic hoses 1, 5 and 12 between interface bracket (20) and hydraulic oil reservoir.
1 Leakage oil line from valve block
5 Return oil line from radiator fan drive pressure control valve (31.2), see hydraulic diagram.
12 Return line from oil cooler fan drive pressure control valve (31.1), see hydraulic diagram.
(19) Valve block
Fig. 4-123
1. Connect the pressure hose 3 between interface bracket (20) and remote control units (24).
2. Connect leakage oil line (25) to leakage oil filter chamber.
3. Connect leakage oil line (26) to T-union of line (25).
3 Pressure hose
(19) Valve block
(24) Remote control units
(26) Leakage oil line from central lubrication pump station
Fig. 4-124
1. Connect the pressure hose 8 between interface bracket (20) and T-union (27).
2. Connect the leakage oil lines (28) to the leakage oil filter chamber.
8 Pressure oil hose for grease pump drive of Central Lubrication System (CLS) and Slew ring
toothing Lubrication System (SLS).
(19) Valve block
(20) Interface bracket
(27) T-union
(28) Leakage oil lines from grease pumps
CONNECTING THE HOSE LINES OF THE TRANSFER PUMP ASSEMBLY SEQUENCE
4.20 CONNECTING THE HOSE LINES OF THE TRANS-
FER PUMP
Fig. 4-125
ASSEMBLY SEQUENCE CONNECTING THE HOSE LINES OF THE TRANSFER PUMP
1. Connect the hose line (7) to suction oil reservoir (11).
2. Connect the hose line (8) to back-pressure valve pipe (13).
3. Connect the hose line (9) to return oil manifold (12).
(1) Cock for suction oil reservoir (11)
(2) Cock for back-pressure valve pipe (13)
(3) Cock for return oil manifold (12)
C - Closed
O - Open
(4) Electric motor of the transfer pump
(5) Transfer pump
(6) Operating switch (40S035) for transfer pump (4)
(7) Suction line to connector on suction oil reservoir (11).
(8) Suction line to back-pressure valve pipe (13)
(9) Suction line to return oil manifold (12)
(10) Hand wheel of main shut-off valve
To OPEN the valve turn hand wheel (10) CCW to the stop.
To CLOSE the valve turn hand wheel (10) CW to the stop.
A proximity switch located on the gearbox of the shut-off valve monitors the valve position.
With the valve not fully open a corresponding message will be displayed on the screen in the
Operators cab.
NOTICE
Before starting the engine make sure the shut-off valve is completely open by turning
hand wheel (10) fully to the left (CCW).
(11) Suction oil reservoir
(13) Back-pressure valve pipe
(14) Back-pressure valve
CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT ASSEMBLY SEQUENCE
4.21 CONNECTING HYDRAULIC LINES TO THE
ROTARY JOINT
Fig. 4-126
ASSEMBLY SEQUENCE CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT
page 3-67.
REMARKS: Observe the matching marks on the rotary joint when connecting the hydraulic lines.
1. Connect the hose lines (1) to pipes (2) of main control valve -II-.
2. Connect the hose lines (3) to pipes (4) of main control valve -IV-.
(1) Hose lines for LH travel motor
(2) Pipe lines on main control valve -II-
(3) Hose lines for RH travel motor
(4) Pipe lines on main control valve -IV-
(6) Nut
CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT ASSEMBLY SEQUENCE
4.21.1 CONNECTING THE PILOT OIL LINE, RETURN OIL LINE AND
LEAKAGE OIL LINE TO THE ROTARY JOINT
Fig. 4-127
ASSEMBLY SEQUENCE CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT
REMARKS: Observe the matching marks on the rotary joint when connecting the hydraulic lines.
1. Connect the pressure hose (1) from T-union (2) to connector 6 on interface bracket (20).
2. Connect the return oil line (3) from T-union (4) to the return oil chamber of the oil reservoir.
3. Connect the leakage oil line (5) to the leakage oil filter chamber of the oil reservoir.
6 Connector on interface bracket for pilot oil line (1)
(1) Pilot oil line pressure oil to travel brake
(2) T-union
(3) Return oil line
(4) T-union
(19) Valve block
Fig. 4-128
ATTACHING THE HANDRAILS, CATWALKS AND STEPS ASSEMBLY SEQUENCE
4.22 ATTACHING THE HANDRAILS, CATWALKS AND
STEPS
Fig. 4-129
ASSEMBLY SEQUENCE ATTACHING THE HANDRAILS, CATWALKS AND STEPS
WARNING
Falling from high places can cause serious injury or death. Always wear the safety harness in connection
with the strap type fall absorber when working on unsecured places of the shovel.
Install the railings, catwalks and steps according to Fig. 4-129 and Fig. 4-130. For the correct specifications of the
mounting bolts and types of bolted connections refer to the parts book of your machine.
Required accessories Safety Harness with strap type fall absorber according to DIN EN
361, refer to the Operation and Maintenance Manual for more infor-
mation.
One crane
Fig. 4-130
MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES ASSEMBLY SEQUENCE
4.23 MOUNTING OF THE FIRE EXTINGUISHING TANK
ASSEMBLIES
Fig. 4-131
ASSEMBLY SEQUENCE MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES
4.23.0.1 MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES
NOTICE
All work on the Fire Detection, Actuation and Suppression System has to be carried out by well trained
specialists having the manufacturers certificate for working on such systems.
The local rules and directives regarding the installation procedure of the Fire Detection, Actuation and
Suppression Systems have to be observed.
REMARKS: Ex-works, all LT-A-101 extinguishing tanks (2) with hose lines are mounted on the brackets (1).
1. Attach the bracket assemblies (1) to counterweight and fasten with bolts (4) and resilient sleeves (5).
2. Attach liquid agent tank (6) of the LVS fire suppression system to the base plate and fasten with bolts (7) and
resilient sleeves (8).
3. Connect nitrogen expellant gas hose (9) from time delay unit (10) to expellant gas cartridge (11).
4. Connect the extinguishing hose (12) of the LVS extinguishing tank (6) to the union (13) on machinery house
roof. Observe matching marks.
A Nitrogen expellant gas supply from the actuators, see hose lines (17 and 18), Fig. 4-132.
B Nitrogen expellant gas supply to dry chemical agent tanks of the LT-A-101 fire suppression system
C Nitrogen expellant gas supply to the time delay unit (10) for LVS system
D Nitrogen expellant gas supply from time delay unit (10) to the expellant gas cartridge (11) on the
LVS tank
(1) Brackets mounted on LH and RH side of the counterweight with pre-assembled dry chemical agent
tanks of the LT-A-101 fire suppression system
(2) Dry chemical agent tanks of the LT-A-101 fire suppression system
(3) Nitrogen expellant gas cartridge of the LT-A-101 fire suppression system
(4) Mounting bolts of LH and RH bracket assemblies (1). Size M16 x 90, Tightening torque 265 Nm.
QTY 16.
(6) Liquid agent tank of the LVS fire suppression system
(7) Mounting bolts of LVS tank (6). Size inch - 13 UNC. Tightening torque 95 Nm. QTY 6.
(9) Nitrogen expellant gas hose of the LVS fire suppression system
(10) Time delay unit for LVS system, pneumatically actuated.
(11) Nitrogen expellant gas cartridge on the LVS tank
(12) Extinguishing hose of the LVS fire suppression system
(13) Connection point of the LVS extinguishing hose on machinery house roof
(14) Extinguishing hose inside machinery house with nozzle assemblies, installed ex works.
(15) Safety relief valve of the expellant gas circuit (manually operated)
MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES ASSEMBLY SEQUENCE
Fig. 4-132
ASSEMBLY SEQUENCE MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES
Mounting of Fire Extinguishing Tank Assemblies (continued)
5. Connect the extinguishing hoses of the LT-A-101 extinguishing tanks (2) Fig. 4-131 to the unions on machin-
ery house roof. Observe matching marks.
6. Check all hoses to make certain they are securely fastened and not cut or showing signs of abrasion.
7. Make certain all hose fittings are tight.
8. Check to make sure that the blow-off caps on all nozzles are properly installed.
A Nitrogen expellant gas supply from the actuators of the fire suppression system
(16) Connection point of the expellant gas hose on machinery house roof
(17) Nitrogen expellant gas hose
(20) Manual actuator located on the radiator door for manual actuation of the LT-A-101 and LVS fire sup-
pression system.
(21) Manual actuator located on the rear machinery house door for manual actuation of the LT-A-101
and LVS fire suppression system.
(22) Manual/automatic actuator in the operators cab for actuation of the LT-A-101 and LVS fire suppres-
sion system.
(23) Pressure switch DPST (Double-Pole, Single-Throw) located in the cab base
(24) Expellant gas cartridges (LT-10-R filled with Nitrogen). Install after all testing has been successfully
completed. Refer to "PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SER-
VICE" for testing procedure.
CENTRAL REFILLING SYSTEM ASSEMBLY SEQUENCE
4.24 CENTRAL REFILLING SYSTEM
Fig. 4-133
ASSEMBLY SEQUENCE CENTRAL REFILLING SYSTEM
4.24.1 CONNECTING THE REFILLING LINES
1. Connect fuel refilling line (2) to elbow (2.1) and to Wiggins fast fill receiver, see Fig. 4-99 for more information.
2. Connect grease refilling line (3) for swing circle pinion lubrication system (SLS) to connector 15 on interface
bracket (20).
3. Connect grease refilling line (4) for central lubrication system (CLS) to connector 10 on interface bracket (20).
4. Connect hydraulic oil evacuation and refilling line (5) to connector 14 on interface bracket (20).
5. Connect the refilling lines from interface bracket (20) to the final users, see Fig. 4-134.
(1) Connecting plate on service arm
(2) Fuel line to Wiggins fast fill receiver, see Fig. 4-99 for more information.
(2.1) Elbow mounted on the connecting plate
(2.2) Flange bolt M16 x 40, quality grade 8.8.
REMARKS: For correct tightening torque of the flange bolts refer to the Torque Charts for Flange
Joints on page 3-67.
(3) Grease refilling line to swing circle pinion lubrication system (SLS)
(4) Grease refilling line to central lubrication system (CLS)
(5) Hydraulic oil evacuation and refilling line
(6) Coolant evacuation and refilling line to the radiator
(6.1) Connector for coolant evacuation and refilling line on the radiator
Fig. 4-134
4.24.1.1 CONNECTING THE REFILLING LINES (CONTINUED)
1. Connect grease refilling line (3) from grease filter (3.1) to the connector 15 on interface bracket (20).
2. Connect grease refilling line (4) from grease filter (4.1) to the connector 10 on interface bracket (20).
3. Connect hydraulic oil evacuation and refilling line (5) from union (5.1) to the connector 14 on interface bracket
(20).
(3) Grease refilling line to the grease filter of the swing circle pinion lubrication system (SLS)
(3.1) Grease filter of the swing circle pinion lubrication system (SLS)
(3.2) Grease refilling line to the grease container of the swing circle pinion lubrication system (SLS)
(4) Grease refilling line to the grease filter of the central lubrication system (CLS)
(4.1) Grease filter of the central lubrication system (CLS)
(4.2) Grease refilling line to the grease container of the central lubrication system (CLS)
(5) Hydraulic oil evacuation and refilling line
(5.1) Union on hydraulic oil reservoir
Fig. 4-135
4.24.1.2 CONNECTING THE REFILLING LINES (CONTINUED)
4. Connect the engine oil evacuation and refilling lines to the engine oil pan and to the engine oil reserve tank.
5. Connect the hydraulic lines for the lift cylinder (16).
6. Check clearance (B) of proximity switch (15) and adjust if necessary.
7. Connect the electrical cables. All cables have identification tags for indicating their connection points. For
more information refer also to the electrical diagram of your machine.
8. Connect the service arm actuation chain to pull switch (55S087). Length of the chain 1800 mm.
REMARKS: The function of proximity switch (15) will be checked during the final inspection.
(11) Service arm
(12) Engine oil evacuation and refilling lines
(13) Bracket on service arm carrier for proximity switch (15)
(14) Reference face on service arm for proximity switch (15)
(15) Proximity switch (55B023) monitors service arm position. This switch cuts-off the pilot control when
the service arm is not fully lifted in its home position.
(16) Service arm lift cylinder
CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS ASSEMBLY SEQUENCE
4.25 CONNECTING THE GREASE LINES OF THE AUTO-
MATIC LUBRICATION SYSTEMS
Fig. 4-136
ASSEMBLY SEQUENCE CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS
(3.1) Grease filter of the swing circle pinion lubrication system (SLS)
(3.2) Grease refilling line to the grease container of the swing circle pinion lubrication system (SLS)
(4.1) Grease filter of the central lubrication system (CLS)
(4.2) Grease refilling line to the grease container of the central lubrication system (CLS)
(5) Grease supply line from the injector bank on the platform to the boom.
MOUNTING THE CAN-NODE BOXES ONTO THE MACHINERY HOUSE ROOF ASSEMBLY SEQUENCE
4.26 MOUNTING THE CAN-NODE BOXES ONTO THE
MACHINERY HOUSE ROOF
Fig. 4-137
ASSEMBLY SEQUENCE MOUNTING THE CAN-NODE BOXES ONTO THE MACHINERY HOUSE ROOF
4.26.1 CONNECTING THE CABLES TO THE CAN-NODES
Weight of the CAN-Node box with mounting bracket approximately: 150 kg.
1. Assemble the three CAN-Node boxes with mounting brackets and connector plates.
2. Mount the CAN-Node boxes to the locations (A, B and C) using mounting parts (2, 3 and 4).
3. Connect the cables to the CAN-Node connector plates (5, 6 and 7).
REMARKS: All connectors on the cables and CAN-Nodes have identification tags.
A CAN-Node box on main hydraulic oil reservoir, Location 40.
B CAN-Node box on pump compartment roof, Location 56.
C CAN-Node box on engine room roof, Location 51.
(1) CAN-Node box with mounting bracket
(2) Mounting bolts M10 x 70, quality grade 10.9. (five for each CAN-Node box).
(3) Lock washers
(5) Cable connector plate on CAN-Node box (A)
(6) Cable connector plate on CAN-Node box (B), seen from inside pump compartment.
(7) Cable connector plate on CAN-Node box (C), seen from inside engine room.
PRE-CHECKS PRIOR TO INITIAL START UP ASSEMBLY SEQUENCE
4.27 PRE-CHECKS PRIOR TO INITIAL START UP
CAUTION
Observe the local safety rules and regulations for operating large mining equipment.
The Operator must have read and understood the Operation and Maintenance Manual of this machine.
Carry out the pre-checks in the following order:
1. Make sure that all hand rails, catwalks, steps and emergency escape systems are correctly installed.
2. Make sure that all protective devices such as fan guards, drive belt guards on alternators and air conditioning
compressor are in place and securely fastened.
3. Check the heat protections for correct installation.
4. Make sure that all safety decals are correctly placed and readable.
5. Make sure fire extinguisher and first aid kit are securely in place.
6. Make sure that all hoses and electrical connections are correctly established. All disconnected hose lines and
electrical cables are marked with identification numbers ex works. Refer to the applying electrical and hydrau-
lic diagrams for additional information.
REMARKS: Disconnect the cable plug on the magnetic clutch of the air conditioning compressor. This is neces-
sary to prevent the compressor from running up against the closed system. Reconnect the cable
plug when the air conditioning is ready for operation.
7. Check fluid levels in PTO gear, travel gears, final drives, swing gears, brake housings and motor adapter
housings. Refer to the Operation and Maintenance Manual for checking procedure and fluid specifications.
8. Check fluid levels in bottom rollers, carrier rollers and guide wheels. Be sure the rollers and guide wheels are
in the correct checking position as described in section -ASSEMBLING OF UNDERCARRIAGE- on page 4-80.
Although the rollers and guide wheels are basically maintenance free, it is vital to have the oil levels in these
parts checked prior to initial start up. This is especially important for pressure balancing on machines working
on high altitudes.
9. Check oil level in the flexible coupling between Engine and PTO. Refer to the Operation and Maintenance
Manual for checking procedure and fluid specifications.
10. Make sure that the hoses for the clam cylinders are covered with sealing plates.
11. Make sure that the shut off valve between the main- and the suction oil tank is completely open.
12. Check to make sure that the pressure relief cocks for the hydraulic track tensioning system are CLOSED and
the shut-off cocks in the crawler carriers are OPEN.
13. Fill the fuel tank with approved Diesel fuel. Use the Central Refilling System for filling procedure.
Refer to the Operation and Maintenance Manual of your machine for correct handling of the refilling system.
14. Bleed the fuel system. Refer to the Engine Operation and Maintenance Manual for more information.
15. Fill the engine oil pan and reserve tank with the specified engine oil. Use the Central Refilling System for filling
procedure. Refer to the Operation and Maintenance Manual of your machine for correct handling of the refill-
ing system.
ASSEMBLY SEQUENCE PRE-CHECKS PRIOR TO INITIAL START UP
Pre-Checks Prior to Initial Start Up
16. Check coolant level and concentration of Supplemental Coolant Additives (SCA) and Antifreeze in the radiator
of the engine. Refer to the Operation and Maintenance Manual of your machine and to the engine manual for
more information.
17. Carry out all functional checks in accordance with the Commissioning Check List.
REMARKS: The Commissioning Check List is part of the documentation delivered with the machine.
Execute all items marked with -S- in the Execution column on each page of the Commissioning
Check List. Verify each item by entering your signature and date of inspection into the column
Inspector / Date.
18. Fill and bleed the hydraulic system according to the procedures shown in section FILLING AND BLEEDING
THE HYDRAULIC SYSTEM on page 222.
FILLING AND BLEEDING THE HYDRAULIC SYSTEM ASSEMBLY SEQUENCE
4.28 FILLING AND BLEEDING THE HYDRAULIC
SYSTEM
Fig. 4-138
ASSEMBLY SEQUENCE FILLING AND BLEEDING THE HYDRAULIC SYSTEM
4.28.1 FILLING THE HYDRAULIC SYSTEM
1. Make sure main shut-off valve is in open position and all connections are securely tightened.
REMARKS: Select hydraulic oil viscosity grade according to ambient temperatures. If the hydraulic oil has a dif-
ferent viscosity grade compared with the hydraulic oil used for final test in the factory, it is necessary
to enter the new viscosity grade into the VHMS/KOMTRAX Plus Service Menu. Refer to the Service
Manual for more information.
2. On machines equipped with Central Refilling System fill main hydraulic oil reservoir according to section
-Central Refilling System- in the Operation Manual.
3. On machine without central refilling system fill main oil reservoir (1) through opening (4). The new oil flows
through the return oil filter chamber into the main oil reservoir. During filling up observe the filter chamber oil
level through the filler opening. The oil can overflow due to filter flow resistance.
4. Depending on type of attachment and the present oil temperature, select the applying oil level range on plate
(3) and fill up to the MAX level. Be sure to use the correct markings.
5. Bleed the hydraulic system according to the instructions on next page.
(1) Main hydraulic oil reservoir
(2) Hydraulic oil level sight gauge
(3) Oil level plate
(4) Oil filler plug
4.28.2 BLEEDING THE HYDRAULIC SYSTEM
Fig. 4-139
BLEEDING THE HYDRAULIC SYSTEM
REMARKS: Make sure the main shut-off valve is in open position and the main hydraulic oil reservoir is filled up
to the correct level shown on the oil level plate.
WARNING
Be careful when opening bleeder plugs, system pressure can cause a splashing out of an oil/air mixture.
Use suitable receptacles to catch outflowing oil.
Bleed the hydraulic system as follows:
Loosen bleeder plug (A1) of suction oil reservoir (5). Retighten bleeder plug (A1) when the outflowing oil is free of
air bubbles.
6. Loosen bleeder plug (A2) of suction oil reservoir (5). Retighten bleeder plug (A2) when the outflowing oil is free
of air bubbles.
7. Bleed the lower main pumps (2 and 3) by opening first bleeder plugs (B) at the suction pipes (10). When the
outflowing oil is free of air bubbles close bleeder plugs (B). Open bleeder valves (C) on top of the main pumps
(2 and 3). Retighten the bleeder valves (C) when the outflowing oil is free of air bubbles.
8. Bleed oil cooler fan drive pump (6) and radiator fan drive pump (7) by opening first bleeder plugs (D and E) on
the suction flanges. Retighten bleeder plugs (D and E) when the outflowing oil is free of air bubbles. Open
bleeder valves (C) on top of the pumps (6 and 7). Retighten the bleeder valves (C) when the outflowing oil is
free of air bubbles.
9. Bleed the upper main pumps (1 and 4) by opening first bleeder plugs (B) at the suction pipes (10). When the
outflowing oil is free of air bubbles close bleeder plugs (B). Open bleeder valves (C) on top of the main pumps
(1 and 4). Retighten the bleeder valves (C) when the outflowing oil is free of air bubbles.
(1 - 4) Main hydraulic pumps
(5) Suction oil reservoir
(6) Hydraulic pump for hydraulic oil cooler fan drive
(7) Hydraulic pump for engine coolant radiator fan drive
(8) Gear pump for pump regulation and pilot oil circuit
(9) Gear pump for PTO gear lubrication
(10) Suction flange of the four main pumps
(A1 and A2)) Vent plugs on suction oil reservoir
(B) Vent plugs on the suction flange of the four main pumps
(C) Bleeder valves on top of the main pumps
(D) Bleeder plug on suction flange of the hydraulic oil cooler fan drive pump
(E) Bleeder plug on suction flange of the radiator fan drive pump
(F) Bleeder plug on suction flange of the gear pump for pump regulation and pilot oil circuit
(G) Bleeder plug on suction flange of the gear pump for PTO gear lubrication
Fig. 4-140
BLEEDING THE HYDRAULIC SYSTEM (continued)
10. Bleed the gear pump (8) for pump regulation and pilot oil circuit by loosening bleeder plug (F) at the suction
line flange. Retighten bleeder plug (F) when the outflowing oil is free of air bubbles.
11. Check hydraulic oil level and, if necessary, add hydraulic oil up to the applying mark on the oil level plate at the
main hydraulic oil reservoir.
NOTICE
It is likely that air is still present in the hydraulic system. To remedy this, start the engine and run at low
idle speed for a short period to allow the oil to circulate through the system. Stop the engine.
12. Repeat steps 3, 4, 5 and 6 until the system is free of air and no more air bubbles are visible in the oil level sight
glass and when opening the bleeder plugs.
4.28.3 BLEEDING THE GEAR PUMP FOR PTO GEAR LUBRICATION
Bleed the gear pump (9) as follows:
1. Open bleeder plug (G) on the pump suction flange of gear pump (9).
2. As soon as bubble free gear oil flows out, tighten the bleeder plug (G).
ASSEMBLY FACE SHOVEL ATTACHMENT ASSEMBLY SEQUENCE
4.29 ASSEMBLY FACE SHOVEL ATTACHMENT
Fig. 4-141
ASSEMBLY SEQUENCE ASSEMBLY FACE SHOVEL ATTACHMENT
4.29.1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM
REMARKS: Use only slings for lifting the mounting pins of the bucket cylinders. Do not use wire ropes or chains
as such metallic parts would damage the machined surface of the pins.
WARNING
Falling from high places can lead to serious injury or death.
REMARKS: For installation of pins (4) Fig. 4-141 use only the push rod delivered with the machine. The use of
hammers or other pushing tools could damage the pin seals.
1. Thoroughly clean the pins and bushings of boom and bucket cylinders. These parts should be completely free
of the protective coating.
2. Center the seal rings (3) within their grooves of the bearing bushings (2). Use multi-purpose grease from the
Central Lube System to keep the seal rings centered in place.
3. Apply grease to the bearing bushings (2).
4. Apply the Aluminum Anti-Seize paste to the pin fixing points on boom.
5. Lift the bucket cylinders in such away that the piston rod side shows approx. 45 up to the bearings of the
boom. Make sure the hose connector of the piston rod points to the outside and the embossed face (A) points
to the front.
6. Align the eyes of the piston rod (1) with the boom bores.
8. Install pin (4) and secure with stirrups (5).
9. Attach ring (6) with cover (7) and fasten with bolts (8).
10. Secure bolts (8) with locking plates (9).
One crane.
Weights Bucket cylinder: 2750 kg
Pin bucket cylinder / boom: 108 kg.
Pin bucket cylinder / bucket: 125 kg.
Fig. 4-142
4.29.2 ATTACHING THE STICK TO THE BOOM
REMARKS: Make sure that the crane and lifting gear are of sufficient capacity for lifting the stick.
Use only slings for lifting the mounting pins of the stick and cylinders. Do not use wire ropes or
WARNING
REMARKS: For installation of pins (4) Fig. 4-142 use only the push rod delivered with the machine. The use of
hammers or other pushing tools could damage the pin seals.
1. Thoroughly clean the pins and bushings of the stick. These parts should be completely free of the protective
coating.
4. Apply the Aluminum Anti-Seize paste to the pin fixing points on boom.
5. Lift the stick (1) above the bearing position stick to boom.
6. Lower the stick until stick to boom bores are aligned.
8. Install pin (4) and secure with stirrups (5).
9. Attach ring (6) with cover (7) and fasten with bolts (8).
10. Secure bolts (8) with locking plates (9).
11. Lower front of stick and support with wooden blocks.
12. Unhook stick from the crane.
One crane and two chain hoists.
Weights Stick: 14900 kg.
Pin stick / boom: 212 kg.
Pin stick cylinder / stick: 52 kg
4.29.3 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO
BOOM
page 3-67.
1. Lift the pre-assembled hose line group (1) with clamp rails (4), Fig. 4-143 above the boom.
2. Remove the blind plugs from the fittings and connect the hoses from manifold (2) to the boom pipes (3).
3. Take care that the O-rings are properly seated into their grooves.
4. Connect the grease hose of the central lubrication system to the grease pipe on the boom. Connect grease
lines to all pivot bearings. Connect the cable of the end-line pressure switch to the connector on the boom.
4.29.4 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS
1. Connect hose lines (1), Fig. 4-144 from boom pipes (2) to boom cylinders (3).
3. Connect grease lines to the pivot bearings of the boom cylinders.
Fig. 4-143
Fig. 4-144
Fig. 4-145
4.29.5 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS
page 3-67.
1. Connect hose lines (1), Fig. 4-145 from boom pipes (2) to stick cylinders (3).
2. Lift the pre-assembled hose line group (4) with clamp rails (5) above the boom and connect the hoses for
bucket and clam cylinders to the boom piping (6).
3. Connect the hoses (7) for bucket cylinder piston side to the pipe fittings on the stick, see Fig. 4-146 on next
page for details.
4. Connect the hoses (8) for bucket cylinder rod side to the pipe fittings on the stick.
5. Connect hose (9) for clam cylinder piston side to the fitting on the stick.
6. Connect hose (10) for clam cylinder rod side to the fitting on the stick.
8. Connect the grease hose of the central lubrication system to the grease pipe on the stick.
9. Connect grease lines to the pivot bearings of the stick and stick cylinders.
10. Connect grease lines to the pivot bearings of the bucket cylinders.
11. Connect the cable of the end-line pressure switch to the connector on the stick.
Fig. 4-146
4.29.6 CONNECTING HOSE LINES FROM STICK TO BUCKET
CYLINDERS
page 3-67.
1. Connect the hose lines (7), Fig. 4-146 from stick pipes (2) to bucket cylinders piston side (3).
2. Connect the hose lines (8) from stick pipes (5) to bucket cylinders rod side (6).
REMARKS: In order to prevent chafing of the hose lines (8) against cylinder barrels (6) when the attachment is in
motion, take care that there is enough space between hose lines (8) and bucket cylinders (6) when
connecting the hose lines.
If necessary loosen flange bolts (9) of flange (10) and slightly turn the hose flange (11) to obtain the
required space. Do not use force for turning the hose flange. Retighten flange bolts (9).
4.29.7 CONNECTING STICK CYLINDERS TO THE STICK
Fig. 4-147
Connecting the stick cylinders to the stick
WARNING
REMARKS: For removal and installation of pins (1) Fig. 4-147 use only the push rod delivered with the machine.
The use of hammers or other pushing tools could damage the pin seals.
1. Lower the stick cylinders rod side (5) by means of the chain pulls to the level of the connecting bores on the
stick.
2. Remove retainer plate (2) and push out connecting pin (1) from piston rod eyes only so far, that the forked pis-
ton rod eyes can pass the bearing plate on the stick.
3. Thoroughly clean the pins (1) and bushings (6) of the stick. These parts should be completely free of the pro-
tective coating.
6. Apply the Aluminum Anti-Seize paste to the pin fixing points on the forked piston rod.
7. Start the engine and carefully move the stick control lever in the stick cylinder extending position only so far,
that the piston rods of the stick cylinders move slowly to the final connecting position.
CAUTION
Keep clear of the moving cylinders and high pressure hoses while the engine is running.
8. Stop the engine.
10. Push in the connecting pin (1) and attach retainer plate (2).
11. Secure retainer plate (2) with washers (3) and bolts (4).
12. Check hydraulic oil level and refill hydraulic oil as necessary.
BLEEDING HYDRAULIC CIRCUITS ASSEMBLY SEQUENCE
4.30 BLEEDING HYDRAULIC CIRCUITS
Fig. 4-148
ASSEMBLY SEQUENCE BLEEDING HYDRAULIC CIRCUITS
4.30.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT
REMARKS: Before attaching the bucket back wall to the stick it is essential to have the hydraulic circuits bled
since the mounting procedure of the back wall requires several movements of the attachment cylin-
ders and travel circuits.
1. Check hydraulic oil level in the main reservoir. If necessary add hydraulic oil up to the correct level.
2. Check to make sure that the main shut off valve between main and suction oil reservoir is in completely open
position.
3. Start the engine.
REMARKS: Due to the high volume of oil circulated through the hydraulic system at the first start-up of the
engine, the oil level in the main reservoir may rapidly drop below the MIN level. Therefore check the
oil level immediately after run-up of the engine. If refilling is necessary, stop the engine and add
hydraulic oil up to the correct level. Again start the engine.
4. Place a suitable receptacle below union nut (2), Fig. 4-148 in order to catch outflowing oil.
5. Loosen union nut (2) on brake housing (1). With the engine running it can take up to ten minutes until a steady
stream of bubble free oil flows out. When it is ensured that all the air is removed from the brake circuit, tighten
union nut (2).
6. Repeat steps 4 and 5 on the second brake housing.
4.30.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT
7. Place a suitable receptacle below brake housing (3), Fig. 4-148 in order to catch outflowing oil.
8. Loosen the pilot oil line on the union (4) of the brake housing (3) on both travel gears. With the engine running
it can take up to ten minutes until a steady stream of bubble free oil flows out. When it is ensured that all the air
is removed from the brake circuit, re-connect the pilot oil line to union (4) on both travel gears.
9. Stop the engine.
Fig. 4-149
4.30.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT
REMARKS: The valve position (open or closed) does not depend on the lever position.
For the real status of the valve look at the groove on the square head (4) of the valve (below the lever).
Check to make sure that the cock (1) is closed and cocks (3) in both side frames are in open position.
position.
3. Connect a test hose (without pressure gauge) to the test connectors (5 and 6) on the track tensioning cylin-
ders and place the open end of the hoses into a receptacle in order to catch outflowing oil.
5. With the engine running it can take up to ten minutes until a steady stream of bubble free oil flows out on the
test hoses. When it is ensured that all the air is removed from the track tensioning circuit, remove test hoses
from connectors (5 and 6) and attach protection caps onto the test connectors.
6. Repeat steps 3 and 5 on the track tensioning cylinders of the opposite side frame.
7. Stop the engine.
8. Check low stage track tensioning pressure by connecting a pressure gauge (60 bar range) to test connector
(5). Required pressure 35 bar. If necessary adjust the low and high stage pressure on the pressure increasing
valve. Refer to the Service Manual for adjustment procedure.
tensioning system
Ex-works
Working position
Closed
Closed
(not used on this machine)
Ex-works
Working position
Closed
Open
Working position
Closed
Open
valve position
O Open
C closed
(5) Test connector on outer tensioning cyl-
inder
(6) Test connector on inner tensioning cylin-
der
4.30.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER
WARNING
People within moving range of the access ladder could suffer serious injury.
Before operating the hydraulic access ladder make sure that no one is in the moving range of the ladder.
Raise and lower the ladder ten times over the full moving range using ladder control switch.
4.30.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS
REMARKS: Due to the large amount of air in the attachment cylinders they may not respond immediately when
actuated for the first time. Cylinder movement can be delayed by up to ten seconds. Do not operate
the control levers to their end of stroke to overcome this delay.
2. Extend and retract the piston rod of each attachment cylinder four to five times for a short travel only. Do not
move the control levers over their full range. Reverse cylinder movement approximately 150 mm before the
end of stroke in both directions.
CAUTION
REMARKS: Due to the large amount of oil used for filling the cylinders, the oil level in the main reservoir may rap-
idly drop below the MIN level. Therefore stop the engine and check the oil level.
3. Add hydraulic oil up to the correct level.
4. Wait until all air pockets are separated from the hydraulic oil. This process may take several hours. Therefore
it is advisable to carry out the first bleeding cycle at the end of the shift and continue on the following day. Con-
tinuing the bleeding procedure directly after refilling of the oil reservoir could led to main pump failure (cavita-
tion) caused through air pockets in the oil.
5. At the beginning of the next shift start the engine and continue bleeding of the attachment cylinders.
6. Extend and retract the piston rod of each cylinder 10 to 15 times. Be sure to reverse the moving direction of
the piston rod approx. 150 mm before the end of stroke.
7. After all attachment cylinders have been bled according to item 6 check hydraulic oil level and add oil as nec-
essary.
8. Check the attachment cylinder circuits for leak tightness by running the piston rods for a short-time against the
mechanical stops in both directions.
4.30.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS
WARNING
People within moving range of the superstructure could suffer serious injury.
Before slewing the superstructure make sure that no one is in the slewing range of the superstructure.
1. Slew the superstructure 5 to 6 full rotations in both directions.
2. Check hydraulic oil level and add oil as necessary.
ATTACHING FACE SHOVEL TO THE STICK ASSEMBLY SEQUENCE
4.31 ATTACHING FACE SHOVEL TO THE STICK
Fig. 4-150
ASSEMBLY SEQUENCE ATTACHING FACE SHOVEL TO THE STICK
4.31.1 ATTACHING BUCKET BACK WALL TO THE STICK
X - Mounting position of stick to back wall.
Y - Mounting position of bucket cylinders to back wall.
1. Lift the attachment and retract the stick cylinders until the stick is in a vertical position, Fig. 4-150.
2. Place the back wall (1) on the ground below the connection points of the stick (2) and of the bucket cylinders
(14) as shown in the illustration.
3. Apply grease onto seal rings (3) and place the rings onto the collar of bushings (4), see detail -X-.
4. Align the bores of the stick (2) with the bores of the bucket wall (1).
5. Push the pins (5) from (A) to (B) so far in so that the axle stirrups (6) can be installed.
6. Fill the grooves of the seal fixing rings (7) with grease and place the ring halves (7) over the seals (3).
7. Tighten bolts (8).
8. Attach retainer plate (9) and fasten with lock washers (10) and bolts (11).
9. Apply grease onto seal rings (12) and place the rings onto the collar of bushings (13), see detail -Y-.
10. By moving and extending the bucket cylinders (14) align the cylinder eyes with the bores of the bucket wall
plates (15).
11. Now push pins (16) from outside to inside so far in so that axle stirrups (17) can be installed.
12. Fill the grooves of the seal fixing rings (18) with grease and place the ring halves (18) over the seals (12).
13. Tighten bolt (19).
14. Attach retainer plate (20) and fasten with lock washers (21) and bolts (22).
Fig. 4-151
4.31.2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM
CYLINDERS
page 3-67.
1. Connect the hose line (9), Fig. 4-151 for clam cylinder piston side from stick pipe (1) to the lower distributor
block (4A).
2. Connect the hose line (10) for clam cylinder rod side from stick pipe (1) to the upper distributor block (4B).
3. Connect the hose lines (5) from upper distributor block (4B) to clam cylinder rod side (6). The hose lines (7) for
clam cylinder piston side are already connected ex works.
5. Connect the grease hose of the central lubrication system from the stick to the grease distributor block on the
bucket back wall.
Fig. 4-152
4.31.3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL
1. Place the clam shell (42) into the position as shown.
2. Align the back wall bores with the clam bores by moving boom, stick and bucket cylinders. Make sure pin seal
rings (47) are centered in the bushing grooves. Install pins (50) with spacer rings (32) and stirrups (68). Insert
catch (66) into protective frame (64) and secure with bolt (70).
3. Remove the transportation lock rods for the clam cylinders using a grinder. Smoothen the spots where the
rods had been welded and apply paint. Support the clam cylinders so that the piston rod eye (43) is in line with
the clam bores. Extend clam cylinder as necessary to align the rod eye (43) with the bores in the clam.
4. Make sure pin seal rings are centered in the grooves of the clam cylinder piston rod bushings.
5. Install pins (49) and lock them with stirrups (52) and plate (53). Insert bolts (63) with lock washer (62) and
tighten the bolts. Continue with connection of the grease lines.
(16) Cover
(18) Lock washer
(19) Bolt
(32) Spacer ring
(34) Plate
(35) Threaded pin
(36) Lock washer
(37) Nut
(41) Bucket back wall
(42) Clam shell
(43) Clam cylinder
(47) Pin seal rings
(49) Pin with plate
(50) Pin with plate
(52) Stirrup
(53) Plate
(62) Lock washer
(63) Bolt
(64) Protective frame (welded)
(66) Catch
(68) Stirrup
(70) Bolt
Fig. 4-153
4.31.4 CONNECTING GREASE LINES OF THE FACE SHOVEL
ATTACHMENT
1. In order to ensure that the main grease supply lines are filled with grease disconnect these lines straight on
the injector banks and set the grease pump of the lubrication system into operation.
2. As soon as a steady grease flow appears reconnect the grease lines.
3. Pre-lubricate all attachment bearings manually. To do this, remove protection cap (10), Fig. 4-153 and apply a
grease gun to the grease fitting (9). Press in grease until a grease collar appears on the connected bearing.
Attach protection cap (10) and tighten with 14 Nm.
4. Repeat the pre-lubrication procedure on all injectors until all pivot bearings of the attachment and cylinders are
lubricated.
5. Connect grease lines on the bucket, see next page for more information.
NOTICE
When tightening a fitting (9, 10, 11, 12 or 13) take care not to overtighten these fittings. The proper tighten-
ing torque is 14 Nm. Too high tightening torque would block the movement of the injector piston resulting
in interruption of grease supply to the connected bearing.
REMARKS: For operational checks and adjustments of the central lubrication system refer to section Final
Checks and Adjustments on page 5-309.
(1) Lube cycle indicator stem of the grease injectors
(2) Grease output adjusting screws
(3) Boom
(4) Stick
(5) Bucket
(6) Injector banks on boom
(7) Injectors on bucket, see next page for details.
(8) Injector banks on stick
(9) Grease fitting
(10) Protection cap
(11) Grease outlet fitting
(12) Grease inlet fitting (on combined injectors only)
(14) Grease supply line to bearing
Fig. 4-154
4.31.5 CONNECTING GREASE LINES ON THE BUCKET
1. Connect the grease line from stick to the junction block (1).
2. Connect grease lines from injectors to clam cylinder piston rod eyes (2).
3. Connect grease lines from injectors to clam pivot bearings (3).
4. Pre-lubricate all pivot bearings of bucket clam and clam cylinders. Use same procedure as used for pre-lubri-
cation of the attachment.
NOTICE
When tightening a grease fitting (6) or grease outlet fitting (7) take care not to overtighten these fittings.
The proper tightening torque is 14 Nm. Too high tightening torque would block the movement of the injec-
tor piston resulting in interruption of grease supply to the connected bearing.
4.31.6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS
1. Open and close the bucket clam 10 to 15 times. Be sure to reverse the moving direction of the cylinders
approx. 150 mm before the end of stroke.
3. Check the clam cylinder circuit for leak tightness by running the piston rods for a short-time against the
(1) Junction block for grease supply line from stick
(2) Grease line connection point on the clam cylinder piston rod eyes
(3) Grease line connection point on the clam pivot bearings
(4) Grease line connection point on the clam cylinder foot bearings. This line is already connected ex
works.
(5) Injector banks
(6) Grease fitting
(8) Lock nut
(9) Grease output adjusting screw
(10) Lube cycle indicator stem
ASSEMBLY BACKHOE ATTACHMENT ASSEMBLY SEQUENCE
4.32 ASSEMBLY BACKHOE ATTACHMENT
Fig. 4-155
ASSEMBLY SEQUENCE ASSEMBLY BACKHOE ATTACHMENT
4.32.1 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO
BOOM
page 3-67.
1. Lift the pre-assembled hose line group (1) with clamp rails (4), Fig. 4-155 above the boom and distributor man-
ifold.
2. Remove the blind plugs from the fittings and connect the hoses to manifold (2) and to the boom pipes (3).
4. Connect the grease hose of the central lubrication system to the grease pipe on the boom. Connect grease
lines to all pivot bearings. Connect the cable of the end-line pressure switch to the connector on the boom.
4.32.2 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS
page 3-67.
1. Connect hose lines (1), Fig. 4-156 from boom pipes (2) to boom cylinder piston side (3).
2. Connect hose lines (4) from boom pipes (2) to boom cylinder rod side (5).
4. Connect grease lines to the pivot bearings of the boom cylinders.
NOTICE
Check to make certain that both protection shields (6) are securely fastened on the pipes (2).
Fig. 4-156
4.32.3 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS
page 3-67.
1. Connect the hose lines (1), Fig. 4-157 from boom pipes to stick cylinder piston side [A].
2. Connect hose lines (2) from boom pipes to stick cylinder rod side [C].
Fig. 4-157
Fig. 4-158
4.32.4 ATTACHING THE STICK TO THE BOOM
REMARKS: Make sure that the crane and lifting gear are of sufficient capacity for lifting the stick with attached
bucket cylinders. Use only slings for lifting the mounting pins of the stick. Do not use wire ropes or
WARNING
Working in high places unsecured can lead to serious injury or death.
REMARKS: For removal and installation of pin (4) Fig. 4-158 use only the push rod delivered with the machine.
The use of hammers or other pushing tools could damage the pin seals.
1. Place the stick in a secure mounting position. See Fig. 4-159 for examples of stick mounting positions.
2. Thoroughly clean the pins and bushings of stick and stick cylinders. These parts should be completely free of
the protective coating.
3. Center the seal rings of stick pivot bearings within their grooves. Use multi-purpose grease from the Central
Lube System to keep the seal rings centered in place.
4. Apply grease to the bearing bushings of the stick.
5. Apply the Aluminum Anti-Seize paste to the pin fixing points on the forked piston rod of the stick cylinders and
to the boom bearings for pin (4).
6. Attach the thread protection sleeve (3) to the pin (4) and insert pin (4).
7. Remove protection sleeve (3).
8. Install a hook-on whirl (5), M20 thread in nut (6).
9. Lift the pin locking cap (7) with a crane, tilt it and screw it on the pin (4) by using nut (8), M30 thread.
10. Secure locking cap (7) with bolt (9) and secure bolt (9) by inserting cotter pin (10) into hole (11).
11. Connect the stick cylinders to the stick.
12. Connect hydraulic hose lines to the bucket cylinders (12), see Fig. 4-158.
Weights Stick with bucket cylinders, steering arm and linkage: 26000 kg.
Pin stick / boom: 1119 kg.
Pin stick cylinder / stick: 86 kg
Locking cap stick / boom pin: 36 kg
Fig. 4-159
4.32.4.1 STICK MOUNTING POSITIONS
Example -E1- Fig. 4-159:
Prepare an open pit as shown in example -E1-.
Place the stick into the pit.
Align boom and stick bores.
Install the stick connecting pin according to the instructions on page 4-261.
Example -E2- Fig. 4-159:
Align the stick bores with the boom bores.
Install the stick connecting pin according to the instructions on page 4-261.
Fig. 4-160
Attaching the Stick to the Boom (continued)
CAUTION
HIGH FLUID PRESSURE!
High pressure fluid when inadvertently released may cause injuries.
There may be some pressure in the system. Therefore be careful when opening the hoses.
13. Unhook stick from the crane.
14. Connect the main grease supply hose of the central lubrication system to the hose connector on the stick.
15. Connect grease lines to the pivot bearings of the stick, stick cylinders and steering rods.
16. Connect the cable of the end-line pressure switch to the connector on the stick.
4.32.5 CONNECTING HOSE LINES FROM BOOM TO BUCKET
CYLINDERS
page 3-67.
1. Connect hose lines (1), Fig. 4-161 from boom pipes (3) to bucket cylinder rod side.
2. Connect hose lines (2) from boom pipes (3) to stick cylinder piston side.
Fig. 4-161
4.33 BLEEDING HYDRAULIC CIRCUITS
Fig. 4-162
4.33.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT
REMARKS: Before attaching the bucket back wall to the stick it is essential to have the hydraulic circuits bled
since the mounting procedure of the back wall requires several movements of the attachment cylin-
ders and travel circuits.
position.
REMARKS: Due to the high volume of oil circulated through the hydraulic system at the first start-up of the
engine, the oil level in the main reservoir may rapidly drop below the MIN level. Therefore check the
oil level immediately after run-up of the engine. If refilling is necessary, stop the engine and add
hydraulic oil up to the correct level. Again start the engine.
4. Place a suitable receptacle below union nut (2), Fig. 4-162 in order to catch outflowing oil.
5. Loosen union nut (2) on brake housing (1). With the engine running it can take up to ten minutes until a steady
stream of bubble free oil flows out. When it is ensured that all the air is removed from the brake circuit, tighten
union nut (2).
6. Repeat steps 4 and 5 on the second brake housing.
4.33.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT
7. Place a suitable receptacle below brake housing (3), Fig. 4-162 in order to catch outflowing oil.
8. Loosen the pilot oil line on the union (4) of the brake housing (3) on both travel gears. With the engine running
it can take up to ten minutes until a steady stream of bubble free oil flows out. When it is ensured that all the air
is removed from the brake circuit, re-connect the pilot oil line to union (4) on both travel gears.
9. Stop the engine.
Fig. 4-163
4.33.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT
REMARKS: The valve position (open or closed) does not depend on the lever position.
For the real status of the valve look at the groove on the square head (4) of the valve (below the lever).
Check to make sure that the cock (1) is closed and cocks (3) in both side frames are in open position.
position.
3. Connect a test hose (without pressure gauge) to the test connectors (5 and 6) on the track tensioning cylin-
ders and place the open end of the hoses into a receptacle in order to catch outflowing oil.
5. With the engine running it can take up to ten minutes until a steady stream of bubble free oil flows out on the
test hoses. When it is ensured that all the air is removed from the track tensioning circuit, remove test hoses
from connectors (5 and 6) and attach protection caps onto the test connectors.
6. Repeat steps 3 and 5 on the track tensioning cylinders of the opposite side frame.
7. Stop the engine.
8. Check low stage track tensioning pressure by connecting a pressure gauge (60 bar range) to test connector
(5). Required pressure 35 bar. If necessary adjust the low and high stage pressure on the pressure increasing
valve. Refer to the Service Manual for adjustment procedure.
tensioning system
Ex-works
Working position
Closed
Closed
(not used on this machine)
Ex-works
Working position
Closed
Open
Working position
Closed
Open
valve position
O Open
C closed
(5) Test connector on outer tensioning cyl-
inder
(6) Test connector on inner tensioning cylin-
der
4.33.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER
WARNING
People within moving range of the access ladder could suffer serious injury.
Before operating the hydraulic access ladder make sure that no one is in the moving range of the ladder.
Raise and lower the ladder ten times over the full moving range using ladder control switch.
4.33.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS
REMARKS: Due to the large amount of air in the attachment cylinders they may not respond immediately when
actuated for the first time. Cylinder movement can be delayed by up to ten seconds. Do not operate
the control levers to their end of stroke to overcome this delay.
2. Extend and retract the piston rod of each attachment cylinder four to five times for a short travel only. Do not
move the control levers over their full range. Reverse cylinder movement approximately 150 mm before the
end of stroke in both directions.
CAUTION
REMARKS: Due to the large amount of oil used for filling the cylinders, the oil level in the main reservoir may rap-
idly drop below the MIN level. Therefore stop the engine and check the oil level.
3. Add hydraulic oil up to the correct level.
4. Wait until all air pockets are separated from the hydraulic oil. This process may take several hours. Therefore
it is advisable to carry out the first bleeding cycle at the end of the shift and continue on the following day. Con-
tinuing the bleeding procedure directly after refilling of the oil reservoir could led to main pump failure (cavita-
tion) caused through air pockets in the oil.
5. At the beginning of the next shift start the engine and continue bleeding of the attachment cylinders.
6. Extend and retract the piston rod of each cylinder 10 to 15 times. Be sure to reverse the moving direction of
the piston rod approx. 150 mm before the end of stroke.
7. After all attachment cylinders have been bled according to item 6 check hydraulic oil level and add oil as nec-
essary.
8. Check the attachment cylinder circuits for leak tightness by running the piston rods for a short-time against the
4.33.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS
WARNING
People within moving range of the superstructure could suffer serious injury.
Before slewing the superstructure make sure that no one is in the slewing range of the superstructure.
1. Slew the superstructure 5 to 6 full rotations in both directions.
ATTACHING BACKHOE BUCKET TO THE STICK ASSEMBLY SEQUENCE
4.34 ATTACHING BACKHOE BUCKET TO THE STICK
Fig. 4-164
ASSEMBLY SEQUENCE ATTACHING BACKHOE BUCKET TO THE STICK
REMARKS: Make sure that the crane and lifting gear are of sufficient capacity for lifting the bucket. Use only
slings for lifting the mounting pins of the bucket. Do not use wire ropes or chains as such metallic
parts would damage the machined surface of the pins.
WARNING
Working in high places is hazardous and may result in serious injury or death.
1. Place bucket (1) on level ground as shown in Fig. 4-164. Observe lifting points and make sure that the lifting
ropes have a minimum length (A) of 1870 mm.
2. Fill the cavity (F) of stick (5) completely with grease.
3. Remove pin (2) from bucket.
4. Apply grease onto seal (3) and place the seal onto the ring (4) on left and right bucket bearings.
5. Use the excavator hydraulic to align the bores of the stick (5) with the bores of the bucket (1).
9. Install a hook-on whirl (7), M20 thread in nut (8).
11. Secure locking cap (9) with bolt (11).
12. Secure bolt (11) by inserting cotter pin (12) into hole (13).
Weights Bucket with pins: 24000 kg.
Pin bucket / stick: 738 kg.
Pin bucket / link: 514 kg
Locking cap bucket pins: 35 kg
Fig. 4-165
Attaching the Backhoe Bucket to the Stick (continued)
13. Remove pin (14) from bucket.
14. Fill the cavity (F) of link (17) completely with grease.
REMARKS: In order to prevent seizing on pins and bushings it is essential that the cavities (F) of stick (5) and link
(17) are completely filled with grease before the seals and pins are installed. The cavities of link (17)
can be filled by applying a grease gun to the inch bores (21) shown in Fig. 4-166. Required grease
amount approximately 50 kg.
15. Apply grease onto seal (15) and place the seal onto the collar of bushings (16) on left and right bucket bear-
ings.
16. Operate bucket cylinders (18) to align the bores of the link (17) with the bores of the bucket (1).
20. Install a hook-on whirl (7) with M20 thread in nut (8).
22. Secure locking cap (9) with bolt (11).
23. Secure bolt (11) by inserting cotter pin (12) into hole (13).
24. Fill the grooves of the four seal fixing rings (19) with grease and place the ring halves (19) over the seals (3)
on both sides of stick pin (2) and over the seals (15) on both sides of the link pin (14).
25. Tighten bolts (20).
Fig. 4-166
Fig. 4-167
4.34.1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT
1. Make sure that the main grease supply line (3), Fig. 4-167 on boom and stick are connected.
2. In order to ensure that the main grease supply lines are filled with grease disconnect these lines straight on
the injector banks and set the grease pump of the lubrication system into operation.
3. As soon as a steady grease flow appears reconnect the grease lines.
4. Pre-lubricate all attachment bearings manually. To do this, remove protection cap (10) and apply a grease gun
to the grease fitting (9). Press in grease until a grease collar appears on the connected bearing. Attach protec-
tion cap (10) and tighten with 14 Nm.
5. Repeat the pre-lubrication procedure on all injectors until all pivot bearings of the attachment and cylinders are
lubricated.
NOTICE
When tightening a fitting (9, 10, 11, 12 or 13) take care not to overtighten these fittings. The proper tighten-
ing torque is 14 Nm. Too high tightening torque would block the movement of the injector piston resulting
in interruption of grease supply to the connected bearing.
(1) Lube cycle indicator stem of the grease injectors
(2) Grease output adjusting screws
(3) Main grease supply line
(4) Rear injector banks on stick
(5) Front injectors on stick
(6) Cover for injectors (5)
(7) Injectors on bucket link
(8) Lower cover for injectors (7)
(9) Grease fitting
(10) Protection cap
(14) Grease supply line to bearings
BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS ASSEMBLY SEQUENCE
4.35 BLEEDING HYDRAULIC CIRCUITS OF THE
TRAVEL MOTORS
1. Swing the attachment over the left crawler track and lift the track off the ground.
2. Run the track approx. 10 sprocket revolutions forward and backward.
3. Lower the track onto the ground.
4. Swing the attachment over the right crawler track and lift the track off the ground.
5. Run the track approx. 10 sprocket revolutions forward and backward.
6. Lower the track onto the ground.
7. Place the attachment in the correct parking position, see oil level plate on the hydraulic oil reservoir.
8. Stop the engine.
279
5 FINAL CHECKS AND
ADJUSTMENTS
FINAL CHECKS AND ADJUSTMENTS
Fig. 5-168
5.0.1 COMMISSIONING CHECK LIST
The Commissioning Check List is part of the documentation delivered with the machine. Execute all items marked
in the Field Service column on each page of the Commissioning Check List. Verify each item by entering your sig-
nature and date of inspection into the column Inspector / Date.
Send a copy of the completed Commissioning Check List to the KMG Service Department.
5.0.2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS
Setting of Pause Time and Grease Injector Output
SL-1 Medium size grease injector
SL-11 Large size grease injector
Two sizes of grease injectors are used on the machine. Depending on the demand of grease
quantity for the single bearing versions, SL-1 or SL-11 injectors are utilized.
(A) Grease inlet
(B) Grease outlet
(1) Adjusting screw for injector output. For reducing the grease output from maximum setting ex
works, turn the adjusting screw clockwise into the injector. On SL-1 injectors each turn will reduce
the output approx. 0.15 cm (0.009 in). Minimum output is reached after 8 turns.
On SL-11 injectors each turn will reduce the output approx. 0.70 cm (0.043 in). Minimum output
is reached after 12-3/4 turns. When adjusting the output on the SL-11 injector to any setting below
1/2 output, the output should be verified.
(2) Indicator stem for visual indication of injector operation. The indicator stem must move in and out
once a complete lubrication cycle.
(3) Lock nut
(4) Injector piston
(5) Spring
(6) Slide valve
(7) Grease fitting or second grease outlet for combined injectors.
(8) Discharge chamber
(9) Passage
(10) Grease fitting
(11) Protection cap
(15) Grease supply line to bearing
Fig. 5-169
Setting of Pause Time and Grease Injector Output (continued)
REMARKS: Ex works the pause time of the automatic lubrication systems is set to the shortest adjustable time
and all grease injectors are set to maximum output:
SL-1 injectors to 1.3 cm (0.08 in) per cycle.
SL-11 injectors to 8.2 cm (0.5 in) per cycle.
These settings are used for the initial 40 operating hours in order to ensure proper lubrication of the
new machine. For further adjustments after that period refer to the SERVICE MANUAL of your
machine. Normally the output of the injectors can be reduced and the pause time can be extended
after the running-in period.
Functional Tests of the Automatic Lubrication Systems
The electrical and hydraulic functions of the Central Lubrication System (CLS) and of the Slew ring open gear
Lubrication System (SLS) have been tested during the execution of the guidelines given in the Commissioning
Check List.
NOTICE
When tightening a fitting (10, 11, 12, 13 or 14), Fig. 5-169 take care not to overtighten these fittings. The
proper tightening torque is 14 Nm. Too high tightening torque would block the movement of the injector
piston resulting in interruption of grease supply to the connected bearing.
5.0.3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE
MINE SITE
If the operating site of the machine is more than 1000 Meter above sea level, adjustment of main pump displace-
ment has to be carried out. Refer to Parts & Service News No. AH06542, latest edition for more information.
5.0.4 PRESSURE COMPENSATION OF SEALED COMPONENTS
If the operating site of the machine is more than 1000 Meter above sea level, pressure compensation of the follow-
ing components is necessary in order to prevent leakages caused through failing seals:
CAUTION
Always wear safety glasses and protective gloves when opening a sealed component.
Flexible Coupling (Non-closed version only)
Use the barring device of the engine to bring the oil level gauge of the flexible coupling in the oil level checking
position (12 oclock). Remove level gauge for pressure compensation. Check also the oil level. If necessary add
the specified engine oil. Install level gauge with packing ring.
Track Rollers and guide wheels
With all bottom rollers, top rollers and guide wheels in the correct oil level checking position i.e. filler plugs posi-
tioned between 2:30 and 3:0 oclock, remove protection plugs and filler plugs with packing rings for pressure com-
pensation. Check also the oil levels and correct as necessary. Use synthetic gear oil such as Shell Omala HD 220
if refilling is necessary. Install all filler plugs with packing rings. Install all protection plugs.
REMARKS: Bottom rollers and guide wheels have screwed filler plugs with packing rings and protection plugs.
Top rollers have screwed filler plugs only.
5.0.5 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN
SERVICE
Fig. 5-170
5.0.5.1 GENERAL
The mining shovel is equipped with the following systems:
CHECKFIRE SC-N ELECTRIC DETECTION AND ACTUATION SYSTEM
DRY CHEMICAL FIRE SUPPRESSION SYSTEM LT-A-101
LIQUID AGENT FIRE SUPPRESSION SYSTEM LVS
The CHECKFIRE SC-N system provides automatic fire detection and automatic or manual actuation of the fire
suppression systems. If the CHECKFIRE SC-N system detects a fire it will automatically actuate the suppression
systems in two steps. First the DRY CHEMICAL FIRE SUPPRESSION SYSTEM LT-A-101 will be actuated and
after a 20 second delay the LIQUID AGENT FIRE SUPPRESSION SYSTEM LVS will be actuated.
The dry chemical portion of the twin agent system is primarily responsible for the suppression. Although the LVS
wet chemical solution is primarily intended for cooling, it can also aid in suppression by two means:
The water content of the solution cools the fuel and the surroundings surface areas. Cooling the surrounding
surface areas minimizes the change for reflash.
Forming a film over the fuel, which aids in securing against reflash.
NOTICE
All work on the Fire Detection, Actuation and Suppression System has to be carried out by well trained
specialists having the manufacturers certificate for working on such systems.
The local rules and directives regarding the installation procedure of the Fire Detection, Actuation and
Suppression Systems have to be observed.
CAUTION
Do not install the expellant gas cartridges (7), Fig. 5-170 before all testing has been successfully com-
pleted. Otherwise inadvertent discharge of the fire suppression system can occur.
Location of Components:
A In Operators cab
B On radiator door
C On hydraulic oil reservoir
D In cab base
E On machinery house roof
F In machinery house
G On cab base
(1) Control module (technical designation 20K351).
(2) Linear fire detection wire (technical designation 50B353) routed through the machinery house and
pump compartment with 4,7 k Ohm end-of-line resistor (technical designation 50R352).
(3) Cable assembly. This cable will be connected to manual/automatic actuator (5) after all testing has
been successfully completed.
Fig. 5-171
General (continued)
5.0.5.2 CONNECT THE PNEUMATIC ACTUATION LINES ACCORDING TO Fig. 5-171.
(4) Terminal housing. Connection point of cable assembly (3) with the lead wires of the Protracting
Actuation Device (PAD) in the manual/automatic actuator (5). The PAD device is not yet installed.
(5) Manual/automatic actuator in the operators cab for actuation of the LT-A-101 and LVS fire suppres-
sion systems.
(6) CHECKFIRE release circuit test module
(7) Expellant gas cartridges (LT-10-R filled with Nitrogen). Install after all testing has been successfully
completed.
(8) Check valves
(9) Pneumatic actuation line. Connect this line to the union on pressure switch (18) and to line (17) in
the cab base.
(10) Manual actuator located on the radiator door for manual actuation of the LT-A-101and LVS fire sup-
pression systems.
(11) Pneumatic actuation line. Connect this line to the T-union (13) in the machinery house.
(13) T-union in the machinery house
(14) T-union in the machinery house
(15) Manual actuator on the hydraulic oil reservoir for actuation of the LT-A-101and LVS fire suppression
systems.
(17) Pneumatic actuation line. Connect this line to the union on pressure switch (18) in cab base.
(18) This pressure switch is a DPST (Double-Pole, Single-Throw) pneumatically operated, resettable
switch used as an interface to shut down the prime mover when the checkfire release circuit
detects a fire (technical designation 10B350). Refer to page 5-297 for functional description
(19) Pneumatic actuation line. Connect this line to T-union (20) on machinery house roof.
(20) T-union on machinery house roof
(21) Pneumatic actuation line. Connect this line to the starting expellant gas cartridge (22) on LH side of
the machinery house roof.
(22) Expellant gas cartridge
(23) End-of-line resistor 4,7 k Ohm (technical designation 50R352)
(24) Extinguishing nozzles with blow-off caps (red LT-A-101 dry chemical agent, blue LVS liquid agent).
(26) Remote high level alarm will sound when the system detects a fire (technical designation 60P351).
(27) Pneumatic actuation line. Connect this line to the starting expellant gas cartridge (28) on RH side of
the machinery house roof.
(28) Expellant gas cartridge
(35) Fire wire signal cable to low voltage board in cab base
Fig. 5-172
5.0.5.3 ARRANGEMENT OF EXTINGUISHING TANKS AND EXPELLANT GAS
CARTRIDGES ON MACHINERY HOUSE ROOF
REMARKS: Observe matching marks on your machine when connecting the extinguishing hoses. Fig. 5-172
shows a typical configuration of extinguishing tanks and hoses.
A Nitrogen expellant gas supply from the actuators
B Nitrogen expellant gas supply to dry chemical agent tanks of the LT-A-101 fire suppression
system
C Nitrogen expellant gas supply to the time delay unit (10) for LVS system
D Nitrogen expellant gas supply from time delay unit (10) to the expellant gas cartridge (11) on
the LVS tank
(1) Brackets mounted on LH and RH side of the counterweight with pre-assembled dry chemical
agent tanks of the LT-A-101 fire suppression system
(2) Dry chemical agent tanks of the LT-A-101 fire suppression system
(4) Mounting bolts of LH and RH bracket assemblies (1). Size M16 x 90, Tightening torque 265
Nm. QTY 16.
(6) Liquid agent tank of the LVS fire suppression system
(7) Mounting bolts of LVS tank (6). Size inch - 13 UNC. Tightening torque 95 Nm. QTY 6.
(9) Nitrogen expellant gas hose of the LVS fire suppression system
(10) Time delay unit for LVS system, pneumatically actuated.
(11) Nitrogen expellant gas cartridge on the LVS tank
(12) Extinguishing hose of the LVS fire suppression system
(13) Connection point of the LVS extinguishing hose on machinery house roof
(14) Extinguishing hose inside machinery house with nozzle assemblies, installed ex works.
(15) Safety relief valve of the expellant gas circuit (manually operated)
5.0.5.4 PROTRACTING ACTUATION DEVICE (PAD)
NOTICE
The Protracting Actuation Device (28) with connected lead wires (27), Fig. 5-173 is being delivered in a
separate box. Install the Protracting Actuation Device (PAD) into manual/automatic actuator (5) after all
testing has successfully completed. Refer to page 5-299 for installation procedure.
WARNING
On electrical actuation, the Protracting Actuation Device (28) Fig. 5-173 operates very quickly. A small
brass septum is ejected from the actuating end of the device which presents a hazard to unprotected
eyes. When handling the Protracting Actuation Device, always point the actuating end of the device away
from you. Physical damage may also result from contact with the moving piston. The Protracting Actua-
tion Device (28) has to be replaced after actuation.
Fig. 5-173
5.0.5.5 MAKING OF ELECTRICAL CIRCUIT CONNECTIONS
1. Remove front cover of control module (1), Fig. 5-174 and check for correct connections of detection circuit wir-
ing.
REMARKS: If necessary, refer to the manufacturers Maintenance Manual CHECKFIRE SC-N ELECTRIC
DETECTION & ACTUATION SYSTEM for more information.
2. After verifying correct connections, reinstall the front cover of module (1). Make certain the cover seal is cor-
rectly in place and not twisted.
3. Connect fire wire signal cable (35) to the terminals on low voltage board in the cab base and then from low
voltage board to the control module connector in the cab.
4. Check linear fire detection wire (2) and end-of-line resistor (23) for damage, loose or interrupted connections.
If any irregularities are found, corrective action must be taken.
5. Make certain pressure switch (18), alarm (26) and fuel shut-off solenoid valve (29) are correctly connected.
Refer to the electrical diagram of your machine for terminal designation.
Fig. 5-174
Fig. 5-175
Fig. 5-176
5.0.5.6 TESTING AND TROUBLE SHOOTING OF THE CHECKFIRE RELEASE
CIRCUIT
WARNING
Before carrying out any inspection or trouble shooting on a system already in service remove all expellant
gas cartridges (7) Fig. 5-171 and disconnect the lead wires (27) Fig. 5-173 of the Protracting Actuation
Device (28). To do this, remove terminal housing (4) and carefully pull-off the lead wire connector. If these
measures are not carried out, inadvertent discharge of the fire suppression system can occur.
Make sure that the Protracting Actuation Device (PAD) and the Expellant gas cartridges are not installed.
Testing the Checkfire Release Circuit of the Machinery House Fire Detection and Suppression System
A - Simulate an open circuit in the Release Circuit of Machinery House
REMARKS: Refer to the applying electrical diagram of your machine for the correct terminal designation. The dia-
grams shown in this section are for example only.
1. Open the dashboard and disconnect fire wire from pin (4), see arrow in Fig. 5-176. Under this condition the
yellow LED -DETECTION- on control module (1), Fig. 5-175 must pulse once every 10 seconds and the
sounder must give audio signal indicating that an open circuit is present in the release circuit. If the -DETEC-
TION- LED and sounder give no signal, corrective action must be taken. For more information refer also to the
ANSUL Manual CHECKFIRE SC-N DETECTION & ACTUATION SYSTEM.
2. Reconnect fire wire to pin (4).
3. Reset control module (1) by pressing the reset button.
B - Simulate a Fire Situation in the Machinery House
1. Connect the control module actuator cable (3), Fig. 5-175 to the terminal housing (4).
2. Connect the cable of CHECKFIRE release circuit test module (6) to control module actuator cable (3) in termi-
nal housing (4) using adapter cable (31).
3. Set the slide switch (32) on test module (6) to SQUIB position and press the RESET button. This will illuminate
the READY LED.
4. Start the prime mover.
5. With test module (6) connected as shown in Fig. 5-175, open the dashboard and place a bridge (33) between
fire wire pins (3 and 4), see Fig. 5-176. This creates continuity of the conductors. Under this condition the LED
-PASS- on test module (6) must illuminate, indicating that the release circuit has detected a fire situation and,
the prime mover must shutdown. If the -FAIL- LED is illuminated or the prime mover does not shutdown, cor-
rective action must be taken. For more information refer also to the Trouble Shooting Chart in the ANSUL
Manual CHECKFIRE SC-N DETECTION & ACTUATION SYSTEM.
6. Remove bridge (33) from the terminal pins.
7. Reset control module (1) by pressing the reset button. Reset test module (6), Fig. 5-175 by pressing the reset
button.
8. Set slide switch (32) to OFF position and remove adapter cable (31) from terminal box (6).
9. Push in the reset plunger of the pressure switch in the cab base, see on page 5-297 for more information.
Fig. 5-177
5.0.5.7 FIRE WIRE ROUTING IN MACHINERY HOUSE
1. Check linear fire detection wire (2), end-of-line resistor (23), signal cable (35), extinguishing nozzles (24) and
mounting brackets for damage, loose or missing mounting parts. If any irregularities are found, corrective
action must be taken.
2. Test the function of the pressure switch (10B350) according to the instructions on page 5-297.
(2) Fire detection wire
(23) End-of-line resistor 4,7 kOhm
(24) Extinguishing nozzles with blow-off caps (red LT-A-101 dry chemical agent, blue LVS liquid
agent).
(34) Toggle switch, shown with front cover removed. Switch in normal operating position.
(35) Fire wire signal cable routed to low voltage board in cab base
(10B350) Pressure switch (typical arrangement of pressure switch and controllers)
(10K300) KOMTRAX-Plus controller
(10T058) ORBComm controller
Fig. 5-178
5.0.5.8 TESTING THE PRESSURE SWITCH
The pressure switch, Fig. 5-178 is a DPST (Double-Pole, Single-Throw) pneumatically operated, resettable switch
used as an interface to shut down the prime mover when the checkfire release circuit detects a fire.
Pneumatic Function of the Pressure Switch
In case of fire, the Nitrogen pneumatic actuation system actuates the toggle switch (5) via hose (8) and in turn
forces the plunger (1) to move up to position (B). A simultaneous shutting down of the prime mover is initiated via
the electric release circuit.
Check electrical Function of the Pressure Switch
1. Start the prime mover.
2. Remove front cover (4), Fig. 5-178 with plunger assembly, see also Fig. 5-177 on previous page.
3. Manually move up toggle switch (5). The prime mover should shut down immediately. If the prime mover does
not shut down, check the electrical circuit between pressure switch, the control module in the cab and the
shutdown relay.
4. Reset toggle switch (5) to normal operating position.
5. Attach cover (4), Be sure plunger (1) is in normal position (A).
(1) Reset plunger
A - Normal operating position
B - Fire suppression system actuated, shutdown position.
(2) Moisture proof joint
(3) Gasket nut
(4) Front cover
(5) Toggle switch
(6) Piston
(7) Piston O-ring gasket
(8) Pneumatic actuation hose
(9) Union inch
(10) Electrical conduit
(11) Terminals (to power)
(12) Terminals (to electrical circuit)
Fig. 5-179
5.0.5.9 INSTALL THE PROTRACTING ACTUATION DEVICE (PAD) IN THE MANUAL/
AUTOMATIC ACTUATOR
Installation Procedure, Fig. 5-179
1. Unscrew the upper portion (1) of the actuator body to expose the bore (2) in the top of the puncture pin, see
detail -A-.
2. Before inserting the Protracting Actuation Device (3) into the bore (2), route the PAD connector (4) from the
inside of the actuator to the outside through the port in the actuator body. Then, as the connector is being
pulled through the port, insert the PAD (3) into the bore (2), see detail -B-.
3. When the PAD (3) is fully seated inside the bore (2), carefully pull on the lead wires (5), detail -C- to take up
the remaining slack in the lead wires. DO NOT pull on the connector (4).
4. Position the upper body (1) so that the slot (6) in the stem base straddles the lead wires (5), see detail -C-.
5. Thread the upper actuator body (1) back in the lower body, see detail -D-.
REMARKS: Before connecting the PAD lead wires (5) to the control cable (7) make certain there are no alarms
present.
6. Connect the connector (4) to the connector of the control cable (7) located inside the terminal housing (8).
Attach terminal housing (8) and cable assembly to the actuator body, using the captive screws (9),
see detail -D-.
7. Push RESET button on the control module to reset the systems. Depress the button for at least 3 seconds.
WARNING
Make certain the expellant gas cartridge is not installed at this time. The fire suppression system will dis-
charge if the cartridge is installed when operating the strike button (10), see detail -D-.
8. Push strike button (10) on manual/automatic actuator several times to ensure smooth movement.
9. Make sure puncture pin (11) is fully retracted, see detail -E- and insert ring pin through actuator body into
puncture pin shaft.
REMARKS: The tip of the puncture pin (11) should be retracted a distance slightly less than 3.2 mm (1/8 inch)
above the bottom of the actuator, see (Z) in detail -E-.
10. Remove shipping cap from the expellant gas cartridge and weigh the cartridge before installing. Replace if
weight is 7.1 gram (1/4 ounce) or more below the weight stamped on the cartridge.
11. Screw cartridge into actuator and hand tighten.
12. Repeat steps 8. to 11. on the remote manual actuators (10 and 15), see Fig. 5-171.
REMARKS: Make sure the fire detection, actuation and suppression system is in an operational condition before
handing over the machine to the customer.
5.0.5.10 CONTROL MODULE - LED INDICATIONS
*) For more information refer to the ANSUL CHECKFIRE SC-N MANUAL.
Fig. 5-180
(1) Sounder, gives audio indication for all alarm and trouble conditions. The sounder will pulse at the same
rate as the corresponding LED. *)
(2) Battery trouble (yellow). The LED pulses once every 10 seconds when indicating battery trouble. *)
(3) Alarm (red). The LED will flash if an alarm condition exists. An alarm condition is caused by detection cir-
cuit activation and manual or automatic actuation of the fire suppression system. *)
(4) Detection trouble (yellow). The LED and the sounder pulse once every 10 seconds when the control
module detects a trouble in the detection circuit. *)
(5) Release trouble (yellow). The LED and the sounder pulse once every 10 seconds when a trouble condi-
tion is detected in the release circuit. *)
(6) Power normal (green). The LED pulses once every 3 seconds when indicating normal power. *)
(7) Delay button. Pushing the delay button during the first time delay cycle (alarm condition) will restart the
time delay cycle which will delay discharge of the fire suppression system by 10 seconds. If the second
time delay cycle (shutdown of prime mover) has already started, the delay button will have no effect.
Manual Actuation will bypass all alarm and time delay functions. *)
(8) Reset button used to re-initialize the control module and to test LED and sounder function. *)
5.0.5.11 MAINTENANCE SCHEDULE
NOTICE
Maintenance should be performed by an authorized ANSUL distributor or someone who has been trained
and authorized by ANSUL to perform maintenance checks.
Service Interval Service Point Service
Daily Inspections Control Module Check LED indication. See ANSUL Manual
-CHECKFIRE SC-N ELECTRIC DETECTION &
ACTUATION SYSTEM-
Every 50 Operating
hours or weekly (which-
ever comes first)
Pneumatic actuation
lines, linear fire detec-
tion wire, extinguishing
nozzles and mounting
brackets
Check for damage, loose or missing mounting
parts. If any irregularities are found, corrective
action must be taken. Contact your local
ANSUL Service.
Every 3000 Operating
hours or every 6 month
(whichever comes first)
Fire Detection and Actu-
ation System
Expellant gas cartridges
(LT-10-R)
LT-A-101 and LVS Fire
Suppression Systems
Check the complete system according to the
instructions in the ANSUL Manual. -CHECK-
FIRE SC-N ELECTRIC DETECTION & ACTUA-
TION SYSTEM-
Check weight. Weight is stamped on the car-
tridge. Replace the cartridge if the weight is
1/4 oz. (7.1 g) or more below the weight
stamped on the cartridge.
Check the complete systems for mechanical
damage or corrosion. Check that all compo-
nents are securely fastened and all hose fittings
are tight. Check filling level of extinguishing
agent tanks. See ANSUL Manuals LT-A-101
and LVS for detailed description of the checking
procedures. If any irregularities are found, cor-
rective action must be taken. Contact your local
ANSUL Service.
Every 6000 Operating
hours or yearly (which-
ever comes first)
Control Module Replace Lithium Battery, see ANSUL Manual
-CHECKFIRE SC-N ELECTRIC DETECTION &
ACTUATION SYSTEM-
Every 5 Years Actuation System Replace Protracting Actuation Device (PAD).
This Device replaces also the Squib Assembly
used on former systems. Check fire detection
wire and end of line resistance
See ANSUL Manual -CHECKFIRE SC-N ELEC-
TRIC DETECTION & ACTUATION SYSTEM-
10-Year Maintenance
Examination
LVS System Pressure test of expellant gas cartridges.
See ANSUL Manual -LVS SYSTEM-
12-Year Maintenance
Examination
LT-A-101 and LVS
System
Pressure test of all extinguishing agent tanks
and all actuating hoses. Replacement of all
expellant gas cartridges.
See ANSUL Manuals LT-A-101 System and
LVS SYSTEM.
5.0.6 COMMISSIONING OF THE AIR CONDITIONING
WARNING
When working on the Air Conditioning Systems observe the Safety Precautions listed below.
Refrigerant must be handled with care to avoid serious personal injury.
Wear safety goggles to prevent refrigerant from contacting your eyes. Refrigerant can cause serious frost bite
or blindness because of its low boiling temperature. In case of eye contact, flush with plenty of water for at
least 15 minutes. Call a Physician. Wash skin with soap and water.
Do not overheat the refrigerant container. Temperatures above 40C will cause excessive container pressures
which can cause the container to burst.
When it is necessary to heat service cans for charging in cold weather, use warm water at a temperature
below 40C.
Do not smoke or discharge refrigerant near an open flame. When refrigerant vapor contacts an open flame,
poisonous gas is produced.
When removing refrigerant from the system, use a recovery process that minimizes refrigerant loss to the
atmosphere.
Use caution with a refrigeration system in a closed or confined area with a limited air supply. Refrigerant dis-
places air and can cause oxygen depletion, resulting in suffocation and possible death.
If refrigerant was inhaled, move victim to fresh air and use cardiopulmonary resuscitation or mouth to mouth
ventilation, if necessary. Stay with victim until arrival of emergency medical personnel.
All work on the air conditioning should be carried out by well trained refrigeration specialists only.
General Instructions regarding Commissioning of the Air Conditioning
Absolute cleanliness must be ensured when working on the air conditioning system, as practically all the faults that
arise can be traced back to the presence of dirt. As a refrigeration system is a closed system, any foreign bodies
remain in the system until they cause a problem or even serious damage, which can then usually only be repaired
at a great deal of trouble and expense. The system may nevertheless appear to start up and work perfectly nor-
mally. Damage caused by foreign bodies and dirt may not manifest itself for many month.
The continued proper functioning of the system depends on thorough and professional standards of work right
from the outset. This entails proper storage and keeping all components closed and/or covered, through profes-
sional installation and assembly. In repair situations as well, right up to the scrupulous checking for leaks, cleaning,
filling and commissioning of the system.
Professional and careful handling of tools, vacuum pumps, gauge manifold, etc. will provide many years of reliable
system operation.
Checking for leaks
Following commissioning every air conditioning system must be checked for leaks. Leaks not only means loss of
refrigerant and hence reduced cooling capacity, they can also result in the ingress of moisture, which will eventu-
ally cause problems in the system. A pressure test must first be performed when a new system has been installed.
Dry nitrogen 4.6 or 5.0 at 20 to max. 25 bar is used for the pressure test. This has the advantage that serious leaks
or loose connections can be detected without the loss of any expensive refrigerant. In addition, the use of nitrogen
purges (and hence cleans) the system as part of the pressure test. Do not add any kind of additives or contrast
substances to the refrigerant oil and/or refrigerant. If the pressure in a closed system does not fall, it can be
assumed that there is no leakage in the system.
Commissioning of the Air Conditioning (continued)
REMARKS: The air conditioning system will be delivered ex works completely filled with refrigerant and oil.
Technical Data
Refrigerant
R 134a
Refrigerant Oil
Compressor oil POE
Carrier Strak SE 55
Fuchs Reniso E 68
ICI RL 68 S
Mobil EAL Arctic 68
Refrigerant Charge (for empty systems)
Operators Cab: 6.000 gram
at an ambient temperature of 22 Celsius
Pressure Switches
Working pressure (Gauge reading)
High pressure switch:
Cut-off point 23.5 bar
Switch-on point 16.6 bar
Low pressure switch:
Cut-off point 0.35 bar
Switch-on point 2.10 bar
Pressure figures at various outside and inside temperatures for R 134a refrigerant
On the high pressure side should be a pressure (gauge reading) of 12.2 to 20.2 bar under normal conditions.
On the low pressure side should be a pressure (gauge reading) of 1.9 bar under normal conditions.
Outside temperature
in C
Gauge indication in bar
(high pressure)
25 10.6 - 13.9
30 12.2 - 15.8
35 13.9 - 17.9
40 15.8 - 20.2
45 17.9 - 22.6
Inside temperature
in C
Gauge indication in bar
(low pressure)
20 1.0 - 1.9
25 1.4 - 2.5
30 1.9 - 3.1
35 2.5 - 3.9
Fig. 5-181
5.0.6.1 AIR CONDITIONING FOR OPERATORS CAB
Connect the high and low pressure refrigerant lines from compressor (2) to the air conditioner unit (1) and open
service valves (15 and 16) Fig. 5-181. Reconnect cable plug (18) for the magnetic clutch (17).
Check refrigerant level.
Switch on air conditioning equipment and run at maximum capacity for approx. 5 minutes. Observe inspection
glass (3). A refrigerant flow loaded with bubbles or foam indicates a lack of refrigerant. In this case add the missing
quantity of refrigerant.
(1) Air conditioner unit
(2) Refrigerant compressor. The Maintenance Manual for the compressor is part of the
Operation and Maintenance Manual Volume 2 Binder.
(3) Sight glass for checking refrigerant filling
(4) Shut-off valve on dryer cartridge
(5) Dryer cartridge
(6) Refrigerant collector reservoir
(7) Condenser
(8) Condenser blower
(9) Low pressure switch
(10) High pressure switch
(11) Expansion valves
(12) Evaporator blower
(13) Evaporator
(14) Cool air outlets
(15) High pressure service valve
(16) Low pressure service valve
(17) Magnetic clutch
(18) Cable plug for the magnetic clutch
PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC MANUAL FINAL CHECKS AND ADJUST-
5.1 PERFORM THE PM-CLINIC PROCEDURE
ACCORDING TO THE PM-CLINIC MANUAL
Exemplary page of a PM-CLINIC PROCEDURE MANUAL.
PM-CLINIC GUIDE
REMARKS: All items in the PM-CLINIC PROCEDURE MANUAL marked with the letter C have to be carried out
during commissioning.
Example: Checking function of the Central Lubrication System (CLS).
Note mark Explanation
B Bench test
C Field assembly / Commissioning
FT Final Test Factory
PM PM-CLINIC every 2000 hours
Item no. of data sheet Note Action required
27. Central
Lubrication
System (CLS)
FT
C
1. Unplug the solenoid valve 62Q507a (vent valve) at the
CLS pump station.
2. Start the engine ? high idle.
3. Activate the manual CLS lubrication at the dash board
1 time with switch 20S124 in order to start the CLS pump.
(Remove the plastic tab to see the grease pump cylinder
movement. For details refer to the SERVICE MANUAL.)
4. Count the number of double strokes of the CLS
lubrication pump and note it at item 27a. If adjustment is
required, adjust the speed with the left valve at the pump
cylinder support. Refer to the SERVICE MANUAL.
5. Re-connect valve 62Q507a.
6. Again activate the manual CLS lubrication 1 time at the
dash board with switch 20S124 in order to start the CLS
pump.
7. Note the maximum pressure until the CLS pump stops
(item 27b). If adjustment is required open the cover at the
pressure end line switch and adjust it with the set screw.
Refer to the SERVICE MANUAL.
8. If necessary adjust the pause time (item 27c) at the
display. For the first adjustment refer to the SERVICE
MANUAL.

FINAL CHECKS AND ADJUSTMENTS PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC MAN-
5.1.1 VISUAL INSPECTION
1. Check the painting of the machine. Repaint areas that have paint damage with the paint delivered with the
machine.
2. Check for leakages. Take corrective action if necessary.
3. Check hydraulic hoses of the attachment for free movement by carrying out several complete working cycles.
Take corrective action as necessary. For repositioning of bucket cylinder hoses, refer to Fig. 4-146.
5.1.2 TRAVELLING INSTRUCTIONS
The maximal permissible operating temperature of traveling gear components is 80C.
In order to prevent overheating of travelling gear components when travelling with the machine over extended dis-
tances above 500 m, observe the following precautions.
1. After a 500 m travelling distance, stop the machine and check the temperature of the following components:
Bottom rollers
Guide wheels
Top rollers
Travel parking brake housings
2. If the temperature of the components is within the permissible range, continue travelling the next 500 m.
3. Stop the machine and check the temperature again. Consider the tendency of temperature development. If the
temperature of one of the components is near maximum, cool down to a temperature of at least 20C below
80C. If the temperature of the components is within the permissible range, continue travelling the next 500 m.
4. Repeat the 500 m stops and temperature measurements.
5. If the temperature of one of the listed components is higher than 80C, park the machine for at least 10 min-
utes and cool down the components by applying water.
6. When the final destination of the machine is reached, shut down the machine and check the components for
leakages and irregularities.
7. Take corrective action as necessary.
REMARKS: It is good practice to keep the attachment near to the machine (center of gravity) and to make sta-
tionary turns instead of travelling a continuous curve. This practice reduces the strain on the travel-
ling gear components.
HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING FINAL CHECKS AND ADJUSTMENTS
5.2 HANDLING OF DOCUMENTATION AFTER ASSEM-
BLY AND COMMISSIONING
REMARKS: Refer to the SERVICE POLICY AND PROCEDURE MANUAL (SPPM) for detailed instructions
regarding Handling of Documentation after Assembly and Commissioning. The latest version of the
SPPM Manual is available in the SMAP. Follow the instructions given in section 4 REPORTING of
the SPPM Manual. A summary of the reporting items is shown below.
1. Delivery Report
Fill out the Delivery Report and have the Report undersigned by Customer or by authorized representative. Send
the original of the completed Delivery Report to the KMG Service Department. A copy of the report remains at the
Customer.
2. Commissioning Check List
The Commissioning Check List is part of the documentation delivered with the machine. Execute all items marked
in the Field Service column -S- on each page of the Commissioning Check List. Verify each item by entering your
signature and date of inspection into the column Inspector / Date. Send a copy of the completed Commissioning
Check List to the KMG Service Department. Another copy should be kept in the distributors file.
3. PM-CLINIC Procedure Manual
Perform the PM-CLINIC Procedure according to the PM-CLINIC Procedure Manual. Handle the completed PM-
CLINC Data Sheets as stated in the PM-CLINIC Procedure Manual under chapter INTRODUCTION.
4. EC Declaration of Conformity for Machines delivered into EU Member States
In order to meet the requirements of the EU Machinery Directive 2006/42/EC the EC Declaration of Conformity
Document has to be signed by the person in charge of supervising the assembling of the machine. With the signa-
ture on the document it is verified that the machine complies with the aforementioned Machinery Directive. The
original of the EC Declaration of Conformity Document remains at the Customer. A copy of the document has to be
sent to KMG Sales Department.
5. Problem List of Field Assembly
Use this form sheet for reporting any problem to KMG Service Department which may have occurred during
assembly of the machine.
DISASSEMBLY OF THE MACHINE
Disassembly 6 - 309
6 DISASSEMBLY OF THE
MACHINE
6 - 310 Disassembly
6.0.1 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES
Fig. 6-182
Disassembly 6 - 311
6.0.2 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE
WARNING
Relieve all pressure in the attachment hydraulic system and in the track tensioning system.
Isolate the batteries.
Provide adequate cranes and lifting gears.
Always use tools that are in good condition. Make sure you understand how to use the tools before performing
any disassembly work.
Make sure the stability of the excavator is always ensured during disassembling. Follow the steps shown on
the following pages.
Disassembly Sequence under Consideration of the Machines Stability
NOTICE
In order to maintain the stability of the machine throughout the single disassembly stages, follow the
sequence shown in Fig. 6-182. Any other assembly sequence will impair the stability and can cause the
machine to turn over.
The numbering in Fig. 6-182 is the guideline for the disassembly steps.
(1) Bucket
(2) Stick
(3) Counterweight
(4) Boom
(7) Operators cab
(8) Fuel tank
(9) Cab base
(10) Machinery house
(12) Cable drum or cable guide (electric machines only)
(13) Side frame RH
(14) Side frame LH
REMARKS: Disassembly of the machine is basically the reverse order of the assembly procedure. Fig. 6-182
shows the removal of main components only. For more information regarding disconnection of
hydraulic and electrical components, refer to the applying sections in part ASSEMBLY SEQUENCE.
Apply matching marks on electrical and hydraulic lines before disconnection. This makes it easier to
establish the correct connections when reassembling the machine.
6 - 312 Disassembly
6.0.3 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES
Fig. 6-183
Disassembly 6 - 313
6.0.4 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE
WARNING
Relieve all pressure in the attachment hydraulic system and in the track tensioning system.
Isolate the batteries.
Provide adequate cranes and lifting gears.
Always use tools that are in good condition. Make sure you understand how to use the tools before performing
any disassembly work.
Make sure the stability of the excavator is always ensured during disassembling. Follow the steps shown on
the following pages.
Disassembly Sequence under Consideration of the Machines Stability
NOTICE
In order to maintain the stability of the machine throughout the single disassembly stages, follow the
sequence shown in Fig. 6-183. Any other assembly sequence will impair the stability and can cause the
machine to turn over.
The numbering in Fig. 6-183 is the guideline for the disassembly steps.
(1) Bucket
(2) Stick
(3) Counterweight
(4) Boom
(7) Operators cab
(8) Fuel tank
(9) Cab base
(10) Machinery house
(12) Cable drum or cable guide (electric machines only)
(13) Side frame RH
(14) Side frame LH
REMARKS: Disassembly of the machine is basically the reverse order of the assembly procedure. Fig. 6-183
shows the removal of main components only. For more information regarding disconnection of
hydraulic and electrical components, refer to the applying sections in part ASSEMBLY SEQUENCE.
Apply matching marks on electrical and hydraulic lines before disconnection. This makes it easier to
establish the correct connections when reassembling the machine.
6 - 314 Disassembly
6.0.5 DISPOSAL OF WASTE MATERIAL
Preserve our environment. To prevent environmental pollution, pay careful attention to the method of dispos-
ing 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 local
environmental regulations and laws.

1

HYTORC Seis GmbH Bergstr. 9, 56290 Beltheim, Germany - Phone: +49 (6762) 40950 Fax: +49 (6762) 409540 e- mail: Info@hytorc-seis.de

Hydraulic Torque Wrenches

AVANTI Series

Operating Manual
&
Servicing Manual

2


Contents

1.0. Hytorc Avanti Series 4
1.1. General notes tool checking prior to using the Hytorc system 4
1.2. Readying the tool for operation 4
1.3. Checking the operability of the system 4
1.4. Setting the torque 5
1.5 Placing the torque wrench on the bolted joint 6
1.6. Direction of rotation of the torque wrench 7
1.7. Position of the square drive 7
1.8. Working with the torque wrench 8
1.9. Working with the disc drive 8
2.0. High-pressure hydraulic power pack 10
2.1. Electric high-pressure hydraulic power pack 11
2.2. Pneumatic high-pressure hydraulic power pack 12
2.3. Safety coupling 13
2.4. Servicing 13
2.5. Notes on safety 14
2.6. Service addresses 15
4.0. Self-help troubleshooting 16
5.0. List of spare parts 18

3


AVANTI
prepared today for tomorrow's
demands

The new AVANTI square drive torque wrench from HYTORC sets new standards in speed,
flexibility, and variety of uses. It has been developed for classic torque bolting and torque
rotational angle bolting as well as spreading with the DISC technology and the CLAMP
System. Whether hands-free, overhead assembly or bolting with limited side clearance
without a reaction arm the many practical advantages of the AVANTI are compelling. The
tool housing is now 10% shorter, lighter in weight, and more compact. All torque and
spreading heads are arranged around the drive axle so that it is no longer necessary to twist the
housing since the torques are initiated in the drive axle therefore reducing noticeably the radial
load on the bolt.
Simply do what you want to do! With its new AVANTI wrench, HYTORC provides you a
versatile and rugged tool that not only meets your expectations today but also more than
meets the demands of tomorrow.

4


1.0. Hytorc Avanti Series

1.1. General notes tool checking prior to using the Hytorc system
A HYTORC torque wrench system is comprised of a torque wrench, an electric or
high-pressure hydraulic power pack, and a high-pressure twin hose.

All HYTORC torque wrenches are high quality and technically fully perfected bolting
tools made to the highest technological standards that have currently been achieved.
Proper tool operation and servicing is of tremendous importance in order to maintain the
functional reliability and long-lasting value of the tool.

It is essential that you read and adhere to the instructions in the steps below before
using the tool for the first time.

1.2. Readying the tool for operation

Check the level of oil in the hydraulic power pack. The oil level should appear
in the upper sight glass.
Check the electrical power cable and the high-pressure twin hose for any damage.
Check the direction of motor rotation at the three-phase AC unit.

Connect the HYTORC torque wrench to the high-pressure hydraulic power pack
using the twin hose.
Please note: Always line up and completely close the flanges of the coupling first
before screwing on the toothed sleeve and locking the toothed coupling piece in
place. A proper flow of oil can be ensured only if the couplings and completely
closed.

1.3. Checking the operability of the system

Press the white arrow button (or green button) briefly on the remote control. The
motor of the electric hydraulic power pack should now begin to idle. Extend the
piston by pressing and holding the white arrow button (or green button) (the square
drive turns). The pressure will then be built up in the system.
The square drive of the torque wrench should turn during this process and the torsion
pawl should audibly lock in place in the tool. Now push up the torsion release
button and release the button on the remote control. The square drive should now
retract.

5


1.4. Setting the torque

Refer to your design drawings and/or specifications for information on the required
torque for tensioning the particular bolts. Now look in the torque pressure table
supplied with the torque wrench for the pressure that corresponds to the desired
torque.

Attention! Use only the torque pressure table that corresponds to the
type of tool.

Now press and firmly hold the white arrow button on the remote control. Use the
pressure adjustment valve at the hydraulic power pack to set the required pressure.
Then lock the pressure adjustment valve in place by screwing in the wing nut securely.

6


1.5 Placing the torque wrench on the bolted joint

Select the right power impact socket and lock it in place on the square drive of the
wrench socket. Place the tool on the bolted joint. Find a support for the reaction
arm that is along the same axis as the square drive and at the same level as the
bolting head.

All HYTORC Avanti series torque wrenches are equipped with a torsion release
pawl lever. Due to the built-up of torsion in the threaded bolt during bolting, it is
possible that the maximum torque is reached simultaneously with the piston end
position. The pawl of the wrench engages and the wrench can get stuck on the
bolted joint. If this happens, proceed as follows:

Push up the torsion release pawl lever.
Press the green button on the remote control again. The pressure in the tool will
relieve the tension on the pawl.
Release the button on the remote control and you will be able to easily lift off
the tool.

Attention: Push the torsion release pawl lever back to its original position.

Torsion release pawl
lever in its normal
position

Pushbutton of the
square drive lock

7


1.6. Direction of rotation of the torque wrench

The design of the torque wrench allows it to rotate in only one direction. It will be
necessary to swap the position of the square drive in order to change the direction of
rotation. To reverse the square drive, push in the pushbutton of the square drive lock,
pull the square drive off the tool, and plug it on the other end of the torque wrench.
The position of the square drive lock is also swapped accordingly and locked in place
by pressing the button on the square drive.

When plugging the square drive into the torque wrench, always ensure that the teeth of
the bearing and the square drive are properly aligned.

1.7. Position of the square drive

Tensioning = viewing the tool from the front, the square dive is plugged in on the right
side.

Backup = viewing the tool from the front, the square dive is plugged in on the left side.

8


1.8. Working with the torque wrench

Operate the HYTORC torque wrench by always pushing the white arrow button on
the remote control at regular intervals. Keep pressing the button until the square
drive no longer turns and the torsion pawl locks in place with a click. Releasing the
white arrow button retracts the piston together with the ratchet system back to its
original position. The starting position of the piston is reached when the drive pawl
engages in the highest tooth of the ratchet with an audible click. The white arrow
button can now be pushed again. During the bolt backup process, repeat the
procedure until the drive stops within the piston stroke when the maximum set
pressure is reached. Carry out a test stoke to ensure that the torque has been
reached.

1.9. Working with the disc drive

This type of work involves bolting without a reaction arm. This is done when the
HYTORC DISC applies the reaction torque under the nut to be tensioned.

The wrench is equipped with a special disc drive for tensioning nuts.

In order to work with the disc drive, take the square drive off the wrench and
remove the standard reaction arm by loosening the slug screws and pushing it
down off the gearing.

Mount the reaction gear wheel on the gearing by simply pushing it on the gearing and
then tightening the slug screws to lock it in place.

9


Reaction gear wheel

Slug screw

Plug and lock the square drive onto the power impact nut.

Now insert the whole unit into the sleeve and fasten with the lock screw.

10

2.0. High-pressure hydraulic power pack

All HYTORC heavy-duty hydraulic power packs are delivered ready for use filled
with the required amount of HLP-46-type hydraulic oil. Consult the manufacturer
before filling the power pack with oils of other viscosities. Biodegradable oils may
be used only for new systems.
Residual pressure in the twin hose if the safety coupling cannot be disconnected after
using the torque wrench. Pressing the button of the pressure relief valve relieves the
pressure in the twin hose and the couplings can be effortlessly disconnected.

11


2.1. Electric high-pressure hydraulic power pack

It is essential to ensure that the direction of rotation is correct for 400 V AC power
packs.

Phase inverter

All electrical devices are equipped with automatic motor trip devices, which cut in
20 to 30 seconds after the green button was last pressed and shut down the unit.
Pressing the green button again restarts the unit. The red button on the remote
control is an Emergency Stop button that switches the unit off immediately when
pressed.

Pressure adjustment
valve

Emergency stop
button

Manual operation

Automatic
pushbutton
Red indicator lamp

12


The electrical devices are equipped with double thermal releases. The temperatures
of the motor and oil are monitored. When the maximum set temperature is exceeded,
a red indicator lamp lights at the control box and a bimetallic release switches the unit
off. The remote controls of units equipped with additional automatic functions are
also fitted with a third double arrow button (black).

Pressure relief valve

Pressure
adjustment valve

2.2. Pneumatic high-pressure hydraulic power pack

The working air of pneumatic units is supplied to the air motor by a FRL
(filter/regulator/lubricator) unit and the air is exhausted through a sound absorber after
passing through cooling coils in the hydraulic oil. An FRL unit automatically
dewaters the air and enriches it with 3 4 drops of oil per minute to lubricate the air
motor. Fill the oiler with resin-free oil only. An air delivery rate of approximately
1.8 cubic meters per minute at a pressure of 4 bars is required in order to operate the
pneumatic unit. Air supply systems that remain idle for extended periods should be
blown out prior to use or operated with a separate dewatering unit. The pneumatic
unit is equipped with a remote control fitted with a toggle switch for starting and
stopping the device. Pressing the pushbutton also builds up the pressure in the unit.

13


2.3. Safety coupling

A safety coupling is comprised of a plug and a socket. The plug is fitted with an anti-
rotation lock ring that can be moved only axially. The socket is equipped with a
screw-type lock. Proper coupling is possible only if both coupling flanges are pushed
together exactly by screwing the sleeve of the socket onto the threads of the plug and
engaging in the gearing of the plug. If this not possible, relieve the pressure from all
balls and attempt to connect again. To release the safety coupling, unscrew the sleeve
after first pulling the anti-rotation lock ring back axially and then pulling the couplings
apart.

Screw ring

Safety ring -------- unlock

716-type safety coupling

2.4. Servicing

- Hydraulic oil

Check the level of oil in the unit before beginning work. The oil level should appear
in the upper sight glass. Use clean hydraulic oil only. We recommend HLP 46
hydraulic oils.
Change the hydraulic oil at least once a year. Change the oil immediately if the color
and/or consistency of the hydraulic oil changes (e.g. becomes cloudy).
Use resin-free oil such as Aral Vitam 22 DE for the oiler.

- Quick-release couplings

Before beginning work, check that the coupling plugs, sockets, and the hydraulic
hoses are clean, free of leaks, and screwed together properly. Use the protective caps
to protect the couplings on the unit and the tool. Roll up the hydraulic hoses and
connect the couplings.

14


- Pressure gauge

The pressure gauge is filled with glycerin for damping purposes. Replace the
pressure gauge glass and/or the pressure gauge itself if the level of fluid drops because
of damage. We recommend that the pressure gauge be tested once a year using a
calibrated pressure gauge tester. This includes issuance of a test certificate.

- Air filter (pneumatic power packs only)

Check the cleanliness of the air filter regularly and clean, blow out, or replace as
required.

- Torque wrench

Check for leakage before beginning work. Clean tools and all other components after
use. Lubricate the square drive and the bearing bushings with Molykote paste
regularly. The wrench should be cleaned and completely lubricated least twice a year.
We recommend that the torque wrench be serviced and tested on a test rig once a year
and a test certificate be issued certifying this test.

2.5. Notes on safety

- Use only intact Hytorc wrench sockets or power impact sockets manufactured in
accordance with DIN 3129.
- Replace damaged couplings and hydraulic hoses immediately! Do not attempt to
repair parts of this kind!
- The tool should be operated and handled by only one person.
- Keep hands away from the reaction arm when bolting!
- Ensure that the correct voltage is being supplied and direction of rotation is
correct (for 400 V AC units only). Have defective connecting cables
repaired only by authorized trained personnel.
- Except for the pressure adjustment valve, do not adjust any other valves on the
pump.

15


2.6. Service addresses

HYTORC Seis GmbH
Central Service and Sales
Frankweiler
Bergstrasse 9
56290 Beltheim, Germany
Phone: +49 (6762) 40950
Fax: +49 (6762) 40954

HYTORC Eich
Service and Sales Office Ottfingen
Johannesstrasse 1
57482 Wenden, Germany
Phone: +49 (2762) 60360
Fax: +49 (2762) 8069
Cell phone: +49 (171) 772-4378

HYTORC Pape
Service and Sales
Zum Langerhof 24
47475 Kamp Lintfort, Germany
Phone: +49 (2842) 929-9765
Fax: +49 (2842) 909349
Cell phone: +49 (171) 311-9145

16


4.0. Self-help troubleshooting
Problem Possible cause Remedy
Tool rotating in wrong direction Couplings reversed at the pump unit,
tool, or hose.
Remount the coupling based on the
circuit diagram.
Piston does not advance

Coupling(s) on the high pressure end
not securely connected to the wrench
and/or pump unit

----------------------------------------
Defective coupling at high-pressure
end.

Connect the coupling securely (do not
use pliers) by first pushing them into
each other and then top with a cap nut.
---------------------------------------
Replace

Piston does not retract

See above but low-pressure end.

See above but low-pressure end.

No pressure build-up in cylinder.

Malfunction caused by open or
defective coupling
---------------------------------------
Defective cylinder seal(s)

See last two items.

---------------------------------------
Replace

Square drive retracts at return stroke.

Retention pawl spring no longer
working properly.
-------------------------------------------
Broken retention pawl.

Replace

---------------------------------------
Replace

Ratchet does not advance.

Faulty retention pawl spring.
---------------------------------------
Defective drive pawl.
----------------------------------------
Piston does not advance completely.
----------------------------------------
Defective coupling or not tightened
properly at high-pressure end.

Replace
---------------------------------------
Replace
---------------------------------------
Position wrench, run without load
several times, and reposition.
---------------------------------------
Retighten coupling by hand. Replace
defective couplings.

Wrench cannot be removed from the
nut.

Load on the retention pawl.

Press the pre-stroke button at the
remote control. Pull back the torsion
release pawl.

17

----------------------------------------
Defective coupling or not tightened
properly at low-pressure end.

---------------------------------------
Unscrew the coupling at the low-
pressure end, replace, and tighten by
hand.

Pump unit does not attain the normal
working speed at the tool.

Wrong direction of rotation for 380 V
AC power pack.

----------------------------------------
Insufficient working air pressure
available at air unit.
----------------------------------------
Not enough oil in unit.
----------------------------------------
Defective low-pressure pump.
----------------------------------------
Defective valve in valve block.

Plug of the hydraulic power pack has a
phase inverter. Turn 180 with a
screwdriver.
---------------------------------------
Wait for or get higher working
pressure.
---------------------------------------
Refill.
---------------------------------------
Replace at the factory.
---------------------------------------
Replace at the factory.

Pump unit creates insufficient or no
pressure.

Defective pressure relief valve.
----------------------------------------
Oil temperature too high.
----------------------------------------
Interior leakage.
----------------------------------------
Defective pressure gauge.

Replace
---------------------------------------
Switch off and let cool down.
---------------------------------------
Contact customer service.
---------------------------------------
Replace

Pump unit switches off. Red indicator
lamp lights.

Excessive load caused by too low
outside temperature.

Preheat oil or choose a warmer work
area.

Pump unit motor switches of after 20
30 minutes.

OK. Switching relay triggered switch-
off.

Press pre-stroke button again.

Pump unit motor does not run.

Unit overloaded.
----------------------------------------
Defective remote control.
----------------------------------------
Defective control button.

See above.
---------------------------------------
Replace
---------------------------------------
Replace

18


5.0. List of spare parts

Part No. Description Avanti 01 Avanti 03 Avanti 05 Avanti 08 Avanti 10
1 Housing AV-01-01 AV-03-01 AV-05-01 AV-08-01 AV-10-01
2 Piston, complete See repair set A
3 Cylinder cover AV-01-34 AV-03-34 AV-05-34 AV-08-34 AV-10-34
4 Lever for retention pawl,
R/L
AV-01-15A AV-03-15A AV-05-15A AV-08-15A AV-10-15A
4-A Drag hook for retention
pawl
AV-01-15B AV-03-15B AV-05-15B AV-08-15B AV-10-15B
4-B Resetter spring for detent
latch
AV-01-18 AV-03-18 AV-05-18 AV-08-18 AV-10-18
5 Detent latch See repair set C
6 Resetter bolt for detent latch AV-01-42 AV-03-42 AV-05-42 AV-08-42 AV-10-42
7 Standard square drive See repair set G
8 Ratchet wheel AV-01-06 AV-03-06 AV-05-06 AV-08-06 AV-10-06
9 Drive plate, R/L AV-01-04 AV-03-04 AV-05-04 AV-08-04 AV-10-04
10 Drive pawl See repair set F
11 Cover plate AV-01-31 AV-03-31 AV-05-31 AV-08-31 AV-10-31
12 Hydraulic connection,
complete
See repair set E
13 Piston rod bolt AV-01-19 AV-03-19 AV-05-19 AV-08-19 AV-10-19
14 Square socket lock AV-01-11 AV-03-11 AV-05-11 AV-08-11 AV-10-11
15 Sleeve, square drive AV-01-07 AV-03-07 AV-05-07 AV-08-07 AV-10-07
16 Reaction arm AV-01-03 AV-03-03 AV-05-13 AV-08-13 AV-10-13
17 Cap, hydraulic connection AV-01-001P AV-03-001P AV-05-001P AV-08-001P AV-10-001P
18 Snap ring AV-01-20 AV-03-20 AV-05-20 AV-08-20 AV-10-20
19 Guide ring AV-01-30 AV-03-30 AV-05-30 AV-08-30 AV-10-30
20 Locating screw, square
drive
AV-01-5A AV-03-5A AV-05-5A AV-08-5A AV-10-5A
21 Locating screw, reaction
arm
AV-01-22 AV-03-22 AV-05-22 AV-08-22 AV-10-22
22 Cover screw, hydraulic AV-01-01 AV-03-13 AV-05-13 AV-08-13 AV-10-13

19

connection
23 Roll pin for drive pawl
spring
AV-01-01 AV-03-40 AV-05-40 AV-08-40 AV-10-40
24 Drive pawl spring

AV-01-27 AV-03-27 AV-05-27 AV-08-27 AV-10-27
25 Cover screw, access hole AV-01-02 AV-03-02 AV-05-02 AV-08-02 AV-10-02
26 Cover plate spring AV-01-59 AV-03-59 AV-05-59 AV-08-59 AV-10-59
27 Screw, cover plate spring AV-01-58 AV-03-58 AV-05-58 AV-08-58 AV-10-58
28 Screw for detent latch lever AV-01-39 AV-03-39 AV-05-39 AV-08-39 AV-10-39
29 Cover plate screw AV-01-32 AV-03-32 AV-05-32 AV-08-32 AV-10-32
30 Locating screw, holding bolt AV-01-65 AV-03-65 AV-05-65 AV-08-65 AV-10-65
31 Detent latch, bolt AV-01-43 AV-03-43 AV-05-43 AV-08-43 AV-10-43
32 Male coupling 90155 90155 90155 90155 90155
33 Female coupling 090156-1 90156 90156 90156 90156
34 Nipple 90103 90101 90101 90101 90101

Repair sets
A Piston, complete AV-01-25 AV-03-25 AV-05-25 AV-08-25 AV-10-25
B Set of housing seals AV-01-62 AV-03-62 AV-05-62 AV-08-62 AV-10-62
C Detent latch, complete AV-01-10 AV-03-10 AV-05-10 AV-08-10 AV-10-10
D Lever for detent latch,
complete
AV-01-15 AV-03-15 AV-05-15 AV-08-15 AV-10-15
E Hydraulic connection,
complete
AV-01-001 AV-03-001 AV-05-001 AV-08-001 AV-10-001
E-1 Set of seals for hydraulic
connection
AV-01-00 AV-03-00 AV-05-00 AV-08-00 AV-10-00
F Drive pawl, complete AV-01-63 AV-03-63 AV-05-63 AV-08-63 AV-10-63
G Standard, square drive,
complete
AV-01-05 AV-03-05 AV-05-05 AV-08-05 AV-10-05

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