Gzebm12037 0

SHOP 12037-xE-GB-0
Shop Manual
HYDRAULIC
EXCAVATOR
PC8000E-6
Serial Number 12037 and up
SHOP MANUAL
SHOP 12037-xE-GB-0
HYDRAULIC EXCAVATOR
PC8000E-6
Machine model
PC8000E-6
Serial number
12037 and up
00 Foreword
PC8000E-6
1.1 CONTENTS OF VOLUME 1 BINDER
1.1
CONTENTS OF VOLUME 1 BINDER
The volume 1 binder contains the Operation and Maintenance

Manual for your KOMATSU Hydraulic Mining Shovel.
Manufacturer of this Product
Komatsu Mining Germany GmbH
Buscherhofstrasse 10
40599 Dsseldorf
Germany
NOTICE
This Operation and Maintenance Manual is the Original

Edition issued in February 2010.
1.1.1
SPECIFICATION AND SERIAL NUMBER PLATE
The specification and serial number plate is located on the outside of the Operators cab near the door.
Product Identification Number

The Product Identification Number (PIN-Code) is printed in the
space provided on the specification and serial number plate, illustration Z25844.
INTRODUCTION
INTRODUCTION
1.2
1.2 CONTENTS OF VOLUME 2 BINDER
CONTENTS OF VOLUME 2 BINDER
The volume 2 binder is being delivered with the Shovel. This

Binder contains the General Assembly Procedure Manual for the
Shovel, Specification Booklet, Service Literature for the Power
Unit (Diesel Engine or Electric Motor) and for Special Equipment.
The Electrical- and Hydraulic Diagrams are attached in the pocket
of the front cover.
Refer to the -TABLE OF CONTENTS VOLUME 2 BINDERfor details.
Read the Manuals before You Start the Engines.

Before operating the machine, familiarize yourself with its instruments and controls.
Observe the instructions in these manuals for:
your Personal SAFETY
Operating SAFETY, and
READY and EFFICIENT PERFORMANCE of your

KOMATSU Hydraulic Mining Shovel.
Periodic preventive inspections and maintenance are the surest

means of keeping the machine in proper working order. Prompt
detection and correction of minor irregularities, and immediate
replacement of worn out or broken parts will prevent failures and
avoid expenses.
Replace damaged graphics and symbols.
Observe safety precautions to prevent injury and damage.
If you have any questions concerning this literature please contact
Service Information
Department 8151.30
P.O. Box 18 03 61
D - 40570 Dsseldorf
GERMANY
1.3 DESIGNATED USE OF THE SHOVEL
1.3
DESIGNATED USE OF THE SHOVEL
This machine has been manufactured in accordance with

advanced and up-to-date technology standards including recognized safety rules. Nevertheless, its use may constitute a risk to
life and limb of the user or of third parties, or cause damage to the
machine and to other material property.
The machine must only be used in technically perfect condition in
accordance with its designated use and the instructions set out in
the operation manual. Only trained safety-conscious operators
who are fully aware of the risks involved should operate the
machine. Any functional disorders, especially those affecting the
safety of the machine, should, therefore, be rectified immediately.
The hydraulic Shovel is designed exclusively for excavating, i.e.
excavation of bulk material and natural soil structure (e.g. earth,
clay, sand and stones ashore and off-shore). Observe local and
national safety regulations. Special conditions at the worksite
require additional safe working precautions, follow your company's safety instructions. Short traveling distances for changing
the working site are considered as part of the designated use of
the Shovel.
Using the Shovel for purposes other than those mentioned above
(such as object handling, use as a transport vehicle and towing of
other machinery) is considered contrary to its designated use.
The manufacturer/supplier cannot be held liable for any damage
resulting from such use. The risk of such misuse lies entirely with
the user.
WARNING
Special use of the Shovel beyond its designated use, e.g.
object handling operations, require written agreement from
the manufacturer and retrofitment of the Shovel with respective safety related equipment before such special applications are permitted.
INTRODUCTION
INTRODUCTION
1.4
1.4 DELIVERY OF THE SHOVEL
DELIVERY OF THE SHOVEL
The Shovel is being delivered disassembled into its main components.

For assembling the Shovel refer to the separate Manual
General Assembly Procedure in Volume 2 Binder:
WARNING
Personnel entrusted with work on the machine must have
read the Assembly Manual, the Operation,- Lubrication- and
Maintenance Manual and in particular the section on safety
before beginning work. Reading the instructions after work
has begun is too late.
If there are any questions concerning the assembling procedure,

contact your local Service Center.
Prior to first operation, inspect the Shovel thoroughly with the Service Engineer responsible for the erection of the machine. Check
all fluid levels according to the Lubrication and Maintenance
Schedule.
Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee.
NOTICE
If the Shovel is equipped with a fire suppression system,
make sure that the system is ready for operation.
SPARE PARTS
For your spare part orders refer to the Parts Catalogue.
The use of genuine Komatsu spare parts is recommended to
assure safe mounting and operation of the machine.
The use of any part other than the genuine part releases the
KOMATSU MINING GERMANY GmbH from any guarantee.
SERVICE
For all questions related to your Shovel please contact your local
Service Center.
In all your written or phoned inquiries please indicate the model
and serial number of your Shovel.
1.5 EXPLANATION OF ABBREVIATIONS
1.5
EXPLANATION OF ABBREVIATIONS
ABB.
Definition
Ampere
AC
Alternating Current
API
American Petroleum Institute
cSt
Centistoke
Degree Celsius
CENSE
Engine Monitoring System
CLS
Central Lubrication System
DC
Direct Current
DIN
German Institute for Standardization
EBL
Electronic Bucket Levelling System
ECM
Electronic Control Module (Engine)
FGPS
Front Guard Protective Structure
FOPS
Falling-Object Protective Structure
GL
Gear Lubricant
hours of operation
HPF
High Pressure Filter (Hydraulic Oil)
HT
High Tension
LED
Light Emitting Diode
LT
Low Tension
Newton
Nm
Newton meter
QUANTUM
Electronic Control System (Engine)
QSK
Type of Engine Fuel System
PLC
Programmable Logic Controller
PM
Planned Maintenance
ppm
parts per million
PTO
Power Take-Off
(Pump Distributor Gear)
SLS
Swing circle pinion Lubrication System
Volt
VHMS
Vehicle Health Monitoring System
1/min
Revolutions Per Minute (RPM)
INTRODUCTION
SAFETY
2 SAFETY
IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS

INJURY OR DEATH.
Please read and make sure that you fully understand the precautions described in this section and the
safety labels on the machine. When operating or servicing the machine, always follow these precaution
strictly.
2 -1
SAFETY
CONTENTS
2.1
SAFETY INFORMATION ................................................................................................................... 2-3
2.2
OVERVIEW.........................................................................................................................................
2.2.1 NORMAL OPERATIONS .......................................................................................................
2.2.2 REGULAR MAINTENANCE...................................................................................................
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR .......................................................
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND
TRANSPORTATION OF THE EXCAVATOR.........................................................................
2-4
2-4
2-4
2-4
2-4
2.3
SOUND PRESSURE LEVEL IN THE OPERATORS CAB. .............................................................. 2-5
2.4
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................... 2-6

2.4.1 UNDERSTANDING THE MACHINE ...................................................................................... 2-6
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................... 2-6
2.4.2.1 ENSURING SAFE OPERATION............................................................................ 2-6
2.4.3 PREPARATIONS FOR SAFE OPERATION.......................................................................... 2-6
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT........................ 2-6
2.4.3.2 INSPECTING THE MACHINE................................................................................ 2-6
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.................. 2-7
2.4.3.4 KEEP MACHINE CLEAN ....................................................................................... 2-7
2.4.3.5 PRECAUTIONS INSIDE OPERATORS COMPARTMENT ................................... 2-7
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ........................................ 2-8
2.4.3.7 IF A PROBLEM IS FOUND .................................................................................... 2-8
2.4.4 FIRE PREVENTION............................................................................................................... 2-8
2.4.4.1 PRECAUTIONS TO PREVENT FIRE .................................................................... 2-8
2.4.4.2 ACTION IF FIRE OCCURS.................................................................................... 2-9
2.4.4.3 EMERGENCY EXIT FROM OPERATORS CAB................................................. 2-10
2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 2-10
2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ....................................... 2-10
2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE
MACHINE............................................................................................................. 2-10
2.4.6.2 NO JUMPING ON OR OFF THE MACHINE ........................................................ 2-10
2.4.6.3 NO PEOPLE ON THE ATTACHMENT ................................................................ 2-10
2.4.6.4 WORKING IN HIGH PLACES .............................................................................. 2-10
2.4.6.5 LEAVING OPERATORS SEAT WITH LOCK ...................................................... 2-11
2.4.6.6 LEAVING THE MACHINE .................................................................................... 2-11
2.4.7 BURN PREVENTION........................................................................................................... 2-11
2.4.7.1 HOT COOLANT .................................................................................................. 2-11
2.4.7.2 HOT OIL .............................................................................................................. 2-12
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .......................................... 2-12
2.4.8.1 UNAUTHORIZED MODIFICATION...................................................................... 2-12
2.4.9 PRECAUTIONS AT JOBSITE.............................................................................................. 2-14
2.4.9.1 VISIBILITY FROM OPERATORS SEAT ............................................................. 2-15
2.4.9.2 CAMERA SYSTEM WITH MONITORS................................................................ 2-15
2.4.9.3 ENSURE GOOD VISIBILITY................................................................................ 2-15
2.4.9.4 CHECKING SIGNS AND SIGNALMANS SIGNALS............................................ 2-15
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.................................... 2-16
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES .......................................... 2-16
2.4.9.7 WORKING ON LOOSE GROUND ....................................................................... 2-17
2.4.9.8 GAS, DUST, STEAM AND SMOKE ..................................................................... 2-17
2.4.9.9 VENTILATION OF ENCLOSED AREAS.............................................................. 2-18
2 -2
SAFETY
2.5
2.6
2.4.10 STARTING ENGINE ............................................................................................................

2.4.10.1 WARNING TAG ...................................................................................................
2.4.10.2 CHECKS BEFORE STARTING ENGINE ............................................................
2.4.10.3 PRECAUTION WHEN STARTING ENGINE........................................................
2.4.10.4 PRECAUTION IN COLD AREAS .........................................................................
2.4.11 OPERATION........................................................................................................................
2.4.11.1 CHECKS BEFORE OPERATION ........................................................................
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE ...............
2.4.11.3 PRECAUTIONS WHEN TRAVELLING ................................................................
2.4.11.4 TRAVELLING ON SLOPES .................................................................................
2.4.11.5 OPERATIONS ON SLOPES................................................................................
2.4.11.6 PROHIBITED OPERATIONS...............................................................................
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES.......................
2.4.11.8 PARKING THE MACHINE ...................................................................................
2.4.11.9 TRANSPORTATION ............................................................................................
2-19
2-19
2-19
2-19
2-20
2-20
2-20
2-21
2-22
2-23
2-24
2-24
2-25
2-25
2-25
PRECAUTION FOR MAINTENANCE..............................................................................................

2.5.1 GENERAL PRECAUTIONS .................................................................................................
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC
RESPONSIBILITIES ............................................................................................
2.5.1.2 STOP ENGINE FOR MAINTENANCE .................................................................
2.5.1.3 WARNING TAG ...................................................................................................
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY .............................................................
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS .....................................
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS
RUNNING ............................................................................................................
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS ...............................
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR
EQUIPMENT........................................................................................................
2.5.1.9 NOISE ..................................................................................................................
2.5.1.10 WHEN USING A HAMMER .................................................................................
2.5.1.11 PROPER TOOLS.................................................................................................
2.5.1.12 ACCUMULATOR .................................................................................................
2.5.1.13 PERSONNEL .......................................................................................................
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................
2.5.2.1 PRECAUTION WHEN WELDING ........................................................................
2.5.2.2 BATTERY HANDLING .........................................................................................
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID...............................................................
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE ................................................
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES ..........................................
2.5.3.3 REPLACEMENT OF HOSE LINES......................................................................
2.5.3.4 INSPECTION OF HOSE LINES...........................................................................
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ............................
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE...............................................................
2.5.3.7 AIR CONDITIONING MAINTENANCE ................................................................
2.5.3.8 COMPRESSED AIR.............................................................................................
2.5.3.9 WASTE MATERIALS ...........................................................................................
2-26
2-26
2-27
2-28
2-28
2-29
2-30
2-30
2-30
2-31
2-31
2-31
2-32
2-32
2-32
2-32
2-32
2-33
2-34
2-34
2-34
2-34
2-35
2-35
2-36
2-36
2-36
2-37
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND

ADJUSTMENTS............................................................................................................................... 2-38
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ................................................................... 2-38
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING
2 -3
SAFETY
2.6.3
2.7
2 -4
ADJUSTMENTS................................................................................................................... 2-38
AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 2-38
SPECIAL SAFETY EQUIPMENT.....................................................................................................

2.7.1 FRONT GUARD PROTECTIVE STRUCTUR FOPS FOR OPERATORS CAB ................
2.7.2 OBJECT HANDLING ...........................................................................................................
2.7.3 LIGHTING ............................................................................................................................
2.7.4 WARNING BEACON............................................................................................................
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ...........
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361
(EUROPEAN STANDARD) ..................................................................................
2.7.5.2 INSTRUCTIONS FOR USE .................................................................................
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL .........................
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), ....................................
2.7.5.5 INSTRUCTIONS FOR USE .................................................................................
2-40
2-41
2-41
2-41
2-41
2-41
2-41
2-43
2-45
2-45
2-47
SAFETY
2.1
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
To identify important safety messages in the manual and on the machine labels, the following signal
words are used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
DANGER
This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING
This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
NOTICE
This signal word is used to alert you to information that must be followed to avoid damage to the machine.
This precaution is given where the machine may be damaged or the service life reduced if the precaution
is not followed.
2 -5
OVERVIEW
2.2
SAFETY
OVERVIEW
The appropriate safety information for specific working modes on the excavator can be found in the following:-
2.2.1
NORMAL OPERATIONS
For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.
For operational safety information, refer to section 2.4 on page 3-8.
For on site safety information, refer to section 2.4.9 on page 3-16.
2.2.2
REGULAR MAINTENANCE
For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section
of the Operation and Maintenance Manual.
For maintenance safety information, refer to section 2.5 on page 3-28.
2.2.3
TROUBLESHOOTING, ADJUSTMENTS AND REPAIR
For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 3-40.
For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through
Komatsu Mining Germany.
For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through
Komatsu Mining Germany.
2.2.4
ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING,

DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR
Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional
safety precautions given in the ASSEMBLY PROCEDURE MANUAL.
2 -6
SAFETY
2.3
SOUND PRESSURE LEVEL IN THE OPERATORS CAB.
SOUND PRESSURE LEVEL IN THE OPERATORS

CAB.
Fig. 3-1
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. 3-1.
2 -7
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.4
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION

ON THE EXCAVATOR
WARNING
WHEN MISUSED, THESE MACHINES ARE DANGEROUS.
Mistakes in operation, inspection, or maintenance may result in personal injury or death.
Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels
on the machine carefully and obey the warnings.
2.4.1
UNDERSTANDING THE MACHINE
Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.
2.4.2
PRECAUTIONS BEFORE STARTING OPERATION ON THE

EXCAVATOR
2.4.2.1 ENSURING SAFE OPERATION
Only trained and authorized personnel can operate and maintain the machine.
During operations, personnel are not allowed outside of the 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 operation beforehand and use pre-determined signals when carrying out these operations.
2.4.3
PREPARATIONS FOR SAFE OPERATION
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT
Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired
immediately if they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.
2.4.3.2 INSPECTING THE MACHINE

Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.
2 -8
SAFETY
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT
Do not wear loose clothing and accessories. If these catch on

the control levers or moving parts, there is a danger that it
may cause the machine to move unexpectedly.
Always wear a hard hat and safety shoes when working on

the machine outside of the cabin. If the nature of the work
requires it, wear safety glasses, mask, gloves, ear plugs and
a safety belt when operating or maintaining the machine (Fig.
3-2).
If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine, so
tie your hair up and be careful not to let it get caught.
Check that all protective equipment functions properly before

using it.
Fig. 3-2
2.4.3.4 KEEP MACHINE CLEAN
If you get on or off the machine or carry out inspection or

maintenance when the machine is dirty with mud or oil, there
is a hazard that you will slip and fall. Wipe off any mud or oil
from the machine. Always keep the machines clean.
If water gets into the electrical system (Fig. 3-3), there is a

hazard that it will cause malfunctions or a misoperation. If
there is any misoperation, there is a danger that the machine
may move unexpectedly and cause serious personal injury or
death. When washing the machine with water or steam, do
not allow the water or steam to come into direct contact with
electrical components.
Fig. 3-3
2.4.3.5 PRECAUTIONS INSIDE 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.
2 -9
SAFETY
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any
injury or fire should occur.
Be sure that fire extinguishers have been provided and read

the labels to ensure that you know how to use them in emergencies.
Carry out periodic inspection and maintenance to ensure that

the fire extinguisher can always be used.
Provide a first aid kit. Carry out periodic checks and add to
the contents if necessary (Fig. 3-4).
Fig. 3-4
2.4.3.7 IF A PROBLEM IS FOUND

If you find any problems in the machine during operation and maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil, leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.
2.4.4
FIRE PREVENTION
2.4.4.1 PRECAUTIONS TO PREVENT FIRE

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

that contain flammable liquids.
Determine well ventilated areas for storing oil and fuel.
Keep the oil and fuel in the determined place and do not
allow unauthorised persons to enter.
REMARKS: Before carrying out grinding or welding work on the machine, remove any flammable materials.
2 - 10
SAFETY
Fire caused by accumulation of flammable material.

Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
affixed around the engines, exhaust manifold, muffler or battery, or inside the undercovers.
Fire coming from electrical wiring

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

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

When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications.
When taking the electrical power for the lighting from the machine itself, follow the instructions of this manual.
2.4.4.2 ACTION IF FIRE OCCURS
Activate the STOP switch to stop the engine.
Use the access ladders and steps to get off the machine.
If it is impossible to escape from the rear of the cab, use the

rope ladder provided for emergency escape to escape from
the side of the cab. (Fig. 3-6.)
Fig. 3-6
After escaping with the emergency escape ladder, activate

the engine stop chains (1 on Fig. 3-7) to shut down the engine
if they are equipped on your shovel.
Fig. 3-7
2 - 11
SAFETY
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 CLEANING CAB GLASS
Always keep the cab glass clean to ensure good visibility when operating.
Use an ethyl alcohol based washer liquid. Methyl alcohol based liquid may irritate your eyes, so do not use it.
If the cab glass on the work equipment side is broken, there is a hazard that the intruding objects may contact the
operator's body directly. Stop operation immediately and replace the glass.
2.4.6
PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE
To prevent personal injury caused by slipping or falling off the machine, always do as follows.
Always use the handrails and steps when getting on or off the
machine.
To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands
and one foot - see Fig. 3-8). with the handrails and steps to
ensure that you support yourself.
When walking around the machine, where possible, move

only in areas that have non-slip padded walkways and nonslip gratings. Extra care is to be taken when moving around
outside of these areas.
Before getting on or off the machine, check the handrails and

steps. If there is any oil, grease, or mud on the handrails or
steps, wipe it off immediately. Always keep these parts clean.
Repair any damage and tighten any loose bolts.
Fig. 3-8
2.4.6.2 NO JUMPING ON OR OFF THE MACHINE
Never jump on or off the machine. Never get on or off a moving machine.
If the machine starts to move when there is no operator on the machine, do not jump onto the machine and try
to stop it.
2.4.6.3 NO PEOPLE ON THE ATTACHMENT

Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment.
There is danger of falling and suffering serious personal injury. For further information refer to section 2.7 on page
3-42.
2.4.6.4 WORKING IN HIGH PLACES

When working in high places, use safety harness and fall absorber to ensure that the work can be carried out
safely. For further information refer to section 2.7 on page 3-42.
2 - 12
SAFETY
2.4.6.5 LEAVING OPERATORS SEAT WITH LOCK
Before standing up from the operator's seat in order to adjust

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

completely to the ground, turn off the engine, relieve the pressure in the hydraulic system and set lock lever (1) securely to
the LOCK position (L), then stop the engine. Use the key to
lock all the equipment. Always remove the key, take it with
you, and keep it in the specified place (Fig. 3-10). For information on relieving the pressure in the hydraulic system, refer
to chapter RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM in the OPERATION part of this manual.
Fig. 3-10
2.4.7
BURN PREVENTION
2.4.7.1 HOT COOLANT
To prevent burns from hot water or steam spurting out when

checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap
(Fig. 3-11 and Fig. 3-12) by hand before starting the operation. Even when the coolant has cooled down, loosen the cap
slowly to relieve the pressure inside the radiator before
removing the cap.
Fig. 3-11
2 - 13
SAFETY
2.4.7.2 HOT OIL
To prevent burns from hot oil spurting out when checking or

draining the oil, wait for the oil to cool to a temperature where
it is possible to touch the cap or plug by hand before starting
the operation (Fig. 3-12). Even when the oil has cooled down,
loosen the cap or plug slowly to relieve the internal pressure
before removing the cap or plug.
Fig. 3-12
2.4.8
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
On jobsites where there is a hazard that falling objects (Fig. 3-13),

flying objects (Fig. 3-14), or intruding objects may hit or enter the
operator's cab, consider the operating conditions and install the
necessary guards to protect the operator.
When carrying out operations in mines or quarries where

there is danger of falling or flying rocks, order/use the optionally available front guard.
When carrying out the above operations, always ensure that

bystanders are a safe distance away and are not in hazard
from falling or flying objects.
The above recommendations assume that the conditions are Fig. 3-13
for standard operations, but it may be necessary to add additional guards according to the operating conditions on the jobsite. Always contact your Komatsu distributor for advice.
Fig. 3-14
2.4.8.1 UNAUTHORIZED MODIFICATION
Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting
in modifications made without authorisation from Komatsu.
Any modifications made without authorisation from Komatsu can create hazards. Before making a modification, consult your komatsu distributor.
Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
2 - 14
SAFETY
Please continue reading on the next page.
2 - 15
2.4.9
Fig. 3-15
2 - 16
PRECAUTIONS AT JOBSITE
SAFETY
SAFETY
2.4.9.1 VISIBILITY FROM OPERATORS SEAT
WARNING
THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGEROUS!
Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of
man and equipment is always ensured.
Fig. 3-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels.
The grey shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operators
seat, and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from
outside surface of the shovel. Please be fully aware that there are places that can not seen when operating the
machine.
REMARKS: The blind areas (A) differ depending on the machine type, attachment and position of attachment.
The International Standard ISO 5006 defines criteria for Operators visibility. This standard is not met
and does not apply to large hydraulic mining shovels.
2.4.9.2 CAMERA SYSTEM WITH MONITORS

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

When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side
or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator
may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the
following items strictly.
If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful
attention to the signs and follow the instructions of the flagman.
The signals should be given only by one flagman.
When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set
up additional lighting in the area.
Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.
Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view
to ensure good visibility.
In areas where it is impossible to confirm the area around the machine and observation cameras have been
set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of
the machine.
2.4.9.4 CHECKING SIGNS AND SIGNALMANS SIGNALS
Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.
2 - 17
SAFETY
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS

On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting operations, always check the following to confirm there are no dangers on the jobsite.
When carrying out operations near combustible materials,

there is a hazard of fire, so be careful when operating.
Check the terrain and condition of the ground at the worksite,

and determine the safest method of operation. Do not operate
where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may be

buried under the worksite, contact each utility and identify
their locations. Be careful not to sever or damage any of
these lines (Fig. 3-16).
Take necessary measures to prevent any unauthorized person from entering the operating area.
If there is a fire near the machine, there is danger of sparks

being sucked in and causing a fire on the machine.
When travelling or operating in shallow water or on soft

ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting operations.
Maintain the travel path on the jobsite so that there is no

obstruction to travel operations.
Fig. 3-16
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES
DANGER
HIGH VOLTAGE!
Do not travel or operate the machine near electric cables
(Fig. 3-17). There is a hazard of electric shock, which may
cause serious injury or property damage. Even going close
to high-voltage cables can cause an electric shock, which
may cause serious burns or even death.
Fig. 3-17
2 - 18
SAFETY
On jobsites where the machine may go close to electric cables,

always do as follows.
Before starting work near electric cables, inform the local

power company of the work to be performed, and ask them to
take the necessary action.
Always maintain a safe distance (see the table on the right)

between the machine and the electric cable. Check with the
local power company about safe operating procedure before
starting operations.
To prepare for any possible emergencies, wear rubber shoes

and gloves. Lay a rubber sheet on top of the seat, and be
careful not to touch the chassis with any exposed part of your
body.
Use a signalman to give warning if the machine approaches

too close to the electric cables.
When carrying out operations near high voltage cables, do

not let anyone near the machine.
If the machine should come too close or touch the electric

cable, to prevent electric shock, the operator should not leave
the operator's compartment until it has been confirmed that
the electricity has been shut off. Also, do not let anyone near
the machine.
Voltage of Cables
100 V - 200 V
6,600 V
22,000 V
66,000 V
154,000 V
187,000 V
275,000 V
500,000 V
Safety Distance
Over 2 m (7 ft)
Over 2 m (7 ft)
Over 3 m (10 ft)
Over 4 m (14 ft)
Over 5 m (17 ft)
Over 6 m (20 ft)
Over 7 m (23 ft)
Over 11 m (36 ft)
2.4.9.7 WORKING ON LOOSE GROUND
Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.
2.4.9.8 GAS, DUST, STEAM AND SMOKE
WARNING
RISK OF EXPOLSION AND FIRE!
Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which
may result in serious injury or death.
All relevent safety measures must be followed and only under expressly obtained authorization.
Special care must be taken before welding, flame-cutting and grinding operations are carried out on the
counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight.
These gases must be expelled before welding, flame-cutting and grinding operations are carried out on
the counterweight.
Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases from the
counterweight chambers. (See Volume 2 binder)
2 - 19
SAFETY
WARNING
RISK OF EXPLOSION!
Substances and objects igniting can lead to fire or explosion resulting in serious injury or death.
Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated as there is a risk of explosion.
2.4.9.9 VENTILATION OF ENCLOSED AREAS
WARNING
POISONOUS FUMES!
Unventilated areas where poisonous fumes can accumulate can kill.
Always ensure adequate ventilation.
Operate internal combustion engines and fuel operated heating systems only on adequately ventilated premises. Before
starting the machine on enclosed premises, make sure that
there is sufficient ventilation (Fig. 3-18).
Observe the regulations in force at the respective site.
If it is necessary to start the engine within an enclosed area,

or when handling fuel, flushing oil, or paint, open the doors
and windows to ensure that adequate ventilation is provided
to prevent gas poisoning.
Fig. 3-18
2 - 20
SAFETY
2.4.10 STARTING ENGINE

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

Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur
with the operation of the machine, and there is the danger that this could lead to serious personal injury or death.
Remove all dirt from the surface of the window glass to

ensure a good view.
Completely remove all flammable materials accumulated

around the engine and battery, and remove any dirt from the
windows, mirrors, handrails, access ladder and steps.
Check the coolant levels, fuel levels, and oil levels, and check
for damage to the electric wiring.
Adjust the operator's seat to a position where it is easy to

carry out operations, check the camera system functions and
check that there is no damage or wear to the seat belt or
mounting clamps.
Check the operation of the instruments and gauges, check

the angle of the mirror, and check that the control levers are
all at the Neutral position.
Before starting the engine, check that lock lever (Fig. 3-20) is
in LOCK position (L).
Adjust the mirrors so that the rear of the machine can be seen
clearly from the operator's seat.
Check that there are no persons or obstacles above, below,

or in the area around the machine.
Fig. 3-20
2.4.10.3 PRECAUTION WHEN STARTING ENGINE
Start and operate the machine only while seated.
Do not short circuit the starting motor circuit to start the engine. Short circuiting can cause fire.
When starting the engine, sound the horn as a warning.
2 - 21
SAFETY
Do not let any person on the machine other than the operator and the operator's assistant (1 person). For
demonstration purposes or during training, more than two people can be present in the 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.
2.4.10.4 PRECAUTION IN COLD AREAS
Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers or control pedals are operated, the reaction of the machine will be slow or the machine may move in a
way not expected by the operator. Particularly in cold weather, be sure to carry out the warming-up operation
thoroughly.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery and cause the battery to explode.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.
2.4.11 OPERATION
2.4.11.1 CHECKS BEFORE OPERATION
If the checks before starting are not carried out properly, the machine will be unable to display its full performance,
and there is also danger that it may lead to serious personal injury or death.
When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
Always fasten your seat belt.
Check that the movement of the machine matches the display on the control pattern label in the cabin. If it
does not match, replace it immediately with the correct control pattern label.
Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel
system and swing system.
Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is
no leakage of oil or fuel.
If any problem is found, carry out repairs immediately.
2 - 22
SAFETY
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE
Before travelling, set the machine so that sprocket (1) is

behind the operator's seat (Fig. 3-21).
If sprocket (1) is in front of the operator's cab, the machine

moves in the opposite direction from the operation of the pedals (front and rear travel is reversed, left and right steering is
reversed). Be extremely careful when operating the machine
in this situation.
Fig. 3-21
Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles (Fig. 3-22).
Before travelling, sound the horn to warn people in the area.
Always operate the machine only when seated.
Do not allow anyone apart from the operator to ride on the

machine.
Check that the travel alarm works properly.
Secure the cab door when it is both open and closed.
Always keep the cab door closed when operating the

machine.
Fig. 3-22
If there is an area to the rear of the machine which cannot be

seen, position a signal person. Take special care not to hit
other machines, objects or people when turning or swinging
the machine (Fig. 3-23)
Fig. 3-23
NOTE!
Always be sure to carry out the above precautions even when the machine is equipped with mirrors
or camera systems.
2 - 23
2.4.11.3 PRECAUTIONS WHEN TRAVELLING
When travelling on flat ground, keep the work equipment 100

to 150 cm (39 to 59 in) high above the ground (Fig. 3-24).
If the view to the right side is poor, raise the boom to ensure
better visibility.
When travelling on rough ground, travel at low speed and do

not operate the steering suddenly. There is danger that the
machine may turn over. The work equipment may hit the
ground surface and cause the machine to lose its balance, or
may damage the machine or structures in the area.
Fig. 3-24
Avoid travelling over obstacles when possible. If the machine

has to travel over an obstacle, keep the work equipment close
to the ground and travel at low speed. Never travel over
obstacles which make the machine tilt strongly to one side
(Fig. 3-25).
When travelling or carrying out operations, always keep a

safe distance from people, structures or other machines to
avoid coming into contact with them.
Fig. 3-25
2 - 24
SAFETY
SAFETY
2.4.11.4 TRAVELLING ON SLOPES

To prevent the machine from tipping over or slipping to the side,
always do as follows.
Keep the work equipment 100 - 150 cm (39 - 59 in) above the
ground surface so that the work equipment can be lowered to
the ground immediately to stop the machine in emergencies
(Fig. 3-26).
When travel up slopes, set the operator's cab facing uphill,

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

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

neutral position, and travel at low speed.
Always travel straight up or down a slope. travelling at an

angle or across the slope is extremely dangerous.
Do not turn on slopes or travel across slopes. Always go

down to a flat place to change the position of the machine,
then travel on to the slope again (Fig. 3-28).
Travel on slippery ground with low speed. Even with slight

slopes there is a hazard that the machine may slip
Fig. 3-28
2 - 25
2.4.11.5 OPERATIONS ON SLOPES
When working on slopes, there is a hazard that the machine

may lose its balance and turn over when the swing or work
equipment are operated. This may lead to serious injury or
property damage, so always provide a stable place when carrying out these operations, and operate carefully.
Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous, and may cause the machine to tip over.
If the machine has to be used on a slope, pile the soil to make

a platform (A on Fig. 3-29) that will keep the machine as horizontal as possible.
Fig. 3-29
2.4.11.6 PROHIBITED OPERATIONS
Never dig the work face under an overhang. There is a hazard that rocks may fall or that the overhang may collapse and
fall on top of the machine (Fig. 3-30).
Fig. 3-30
Do not excavate too deeply under the front of the machine.

The ground under the machine may collapse and cause the
machine to fall (Fig. 3-31).
Fig. 3-31
2 - 26
SAFETY
SAFETY
To make it easier to escape if there is any problem, set the

tracks at right angles to the road shoulder or cliff with the
sprocket at the rear when carrying out operations (Fig. 3-32).
Generally speaking, the machine is more liable to overturn

when the work equipment is at the side than when it is at the
front or rear.
Do not suddenly lower, swing, or stop the work equipment.
Do not suddenly extend or retract the boom cylinder.
There is a hazard that impact will cause the machine to tip
over.
Do not pass the bucket over the head of other workers or over
the operator's seat of dump trucks or other hauling equipment. The load may spill or the bucket may hit the dump truck
and cause serious injury or property damage.
Fig. 3-32
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES
Snow-covered or frozen surfaces are slippery, so be extremely careful when travelling or operating the
machine, and do not operate the pedals suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.
With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful not to leave the road shoulder or to get trapped in a snow drift.
When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations carefully.
2.4.11.8 PARKING THE MACHINE
Park the machine on firm, level ground. Select a place where

there is no hazard of falling rocks or landslides, or of flooding
if the land is low.
Lower the work equipment completely to the ground.
When leaving the machine, set lock lever (1) to the LOCK
position (L), then stop the engine (Fig. 3-33).
Always close the operator's cab door, and use the key to lock
all the equipment in order to prevent any unauthorized person
from moving the machine. Always remove the key, take it with
you, and leave it in the specified place.
If it is necessary to park the machine on a slope, always set

the bucket on the downhill side, then dig it into the ground.
Fig. 3-33
2.4.11.9 TRANSPORTATION
This machine must be disassembled for transportation. When transporting the machine, please consult your
Komatsu distributor.
Use only appropriate means of transport and lifting gear of adequate capacity.
The recommissioning procedure must be strictly in accordance with the General Assembly Procedure Manual.
2 - 27
PRECAUTION FOR MAINTENANCE
2.5
2.5.1
GENERAL PRECAUTIONS
SAFETY
Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation,- Lubrication and Maintenance Manual, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.
Brief operating personnel before beginning special operations and maintenance work, and appoint a person to
supervise the activities.
In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices
or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the Operation,- Lubrication and Maintenance Manual and the information on maintenance
work.
Ensure that the maintenance area is adequately secured.
If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by:
locking the principal control elements and removing the ignition key and/or
attaching a warning tag to the main switch or control levers.
setting the maintenance safety switch to the 0 position and securing it with a padlock
Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has
been secured against inadvertent movement and buckling.
To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes
should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear
and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.
The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only.
The marshaller giving the instructions must be within sight or sound of the operator.
For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders
and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out
maintenance work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.
Always tighten any screwed connections that have been loosened during maintenance and repair.
Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work.
Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental
impact.
Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 3-1.
Park the Excavator at a safe place on level ground. Proceed according to the instructions Parking the
Shovel. Lower the attachment flat onto the ground. Move all control levers to neutral position.
Stop the engines and move all control levers through their shift positions to relieve the pressure in the hydraulic system. Refer to Stopping the Engines for detailed description of the stopping procedure.
Before any maintenance work is started, set the maintenance safety switch to 0 position.
Find to the location of the maintenance safety switch refer to section 2.5.1.3 on page 3-30. In the 0 position the
engines can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten
padlocks can be attached to the holes provided.
A warning plate Caution Machine Maintenance must be fixed in the Operators cab before any lubrication or
maintenance work is started.
Block the machine to prevent machine movement
2 - 28
SAFETY
Always use safety devices to block hydraulic cylinders. Never rely on the machine hydraulic system to hold
when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidently
strike the control levers causing the loader to fall.
Relieve all pressure in the hydraulic system before servicing the hydraulic system.For information on relieving
the pressure in the hydraulic system, refer to chapter Relieving The Pressure In The Hydraulic System in the
Operation part of this manual.
Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting
maintenance work.
Switch-off battery main switch and remove key, before working on the electrical system.
Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this
necessary. Observe the local safety rules.
Never allow unauthorized persons access to the machine during lubrication and maintenance work.
After servicing, remove oily cloth, inflammable material and all tools from the machine.
Clean the Excavator with a steam jet, especially after servicing the hydraulic system and fuel system.
WARNING
BEWARE OF STEAM!
Hot steam can cause serious personal injury. When using a steam cleaner, wear safety glasses and protective clothing.
For cleaning the Excavator and its components use only fresh water with a salt content of less than 0.05%.
DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid
valves, sensors, cable connections and bearings.
Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine.
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES
Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits
must be observed.
Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for
operation, set-up, maintenance and repair.
All personnel must be aware of the appropriate safety measures when working on or around the machine.
Make sure that only authorized personnel works on or with the machine.
Define the machine 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 electrical engineering rules and regulations.
Work on the chassis, brake and steering systems must be performed only by skilled personnel who have been
specifically trained for such work.
Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of
hydraulic equipment.
2 - 29
SAFETY
2.5.1.2 STOP ENGINE FOR MAINTENANCE
Stop the machine (Fig. 3-34) on firm, level ground.
Select a place where there is no hazard of falling rocks or

landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground and stop

the engine.
Fig. 3-34
Turn the main key switch to the ON position. Operate the

work equipment control lever back and forth, left and right at
the full stroke 2 to 3 times to eliminate the remaining internal
pressure in the hydraulic circuit, and then push up lock lever
(1) to the LOCK position (Fig. 3-35).
Check that the battery main switch is off and main power is
not conducted. (Wait for approx. one minute after activating
the engine STOP switch and press the horn switch. If the
horn does not sound, it is not activated.)
Fig. 3-35
2.5.1.3 WARNING TAG
Always attach the DO NOT OPERATE warning tag (Fig. 336) to the work equipment control lever in the operator's cab
to alert others that you are performing service or maintenance
on the machine. Attach additional warning tags around the
machine if necessary.
Keep this warning tag in the tool box while it is not used. If
there is not the tool box, keep the tag in the operation manual
pocket.
If any other person starts the engine, or touches or operates

the control levers or control pedals while you are performing
service or maintenance, you may suffer serious injury.
Fig. 3-36
2 - 30
SAFETY
Before entering the machinery house, switch off maintenance

safety switch (Fig. 3-37)
The maintenance safety switch is located in the machinery

house, next to the entrance door (Pos. 1 on Fig. 3-38).
Before beginning maintenance operations, set the safety

switch to "0" to prevent a starting of the engines. Secure this
position by inserting a padlock into the holes of the safety
switch. Up to ten padlocks can be attached.
Fig. 3-37
Fig. 3-38
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY
CAUTION
HAZARD OF ACCIDENTS!
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure
yourself.
Observe the following points.
Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out operations safely.
Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying
2 - 31
SAFETY
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING
To prevent injury, do not perform maintenance or adjustments

while the engine runs. If work must be carried out with the
engine running, carry out the operation with at least two workers and do as follows:
One worker must always sit in the operator's seat and be
ready to stop the engine at any time. All workers must
maintain contact with each other and be fully aware of all
relevant safety measures.
For safety information when working with high pressure oil in

the hydraulic system, refer to section 2.6 on page 3-40.
When carrying out operations near rotating parts, there is a

hazard of being caught in the parts, so be careful not to come
close (Fig. 3-39).
Fig. 3-39
Do not touch any control levers or pedals. If they must be

operated, always give a signal to other workers to warn them
to move to a safe place.
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS
Appoint a leader before starting removal or installation operations for attachments.
Place attachments that have been removed from the machine

in a stable condition so that they do not fall (Fig. 3-40). And
take steps to prevent unauthorized persons from entering the
storage area.
Fig. 3-40
2 - 32
SAFETY
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT
If it is necessary to go under the work equipment or the

machine to carry out service and maintenance (Fig. 3-41),
support the work equipment and machine securely with
blocks and stands strong enough to support the weight of the
work equipment and machine.
It is extremely dangerous to work under the machine if the

track shoes are lifted off the ground and the machine is supported only with the work equipment. If any of the control
levers are touched by accident, or there is damage to the
hydraulic piping, the work equipment or the machine will suddenly drop. This is extremely dangerous. Never work under
the work equipment or the machine.
Fig. 3-41
2.5.1.9 NOISE
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent
hearing problems.
2.5.1.10 WHEN USING A HAMMER

When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury.
Always do as follows.
If hard metal parts such as pins, bucket teeth, cutting edges,

or bearings are hit with a hammer, there is a hazard that
pieces might be scattered and cause injury. Always wear
safety glasses and gloves (Fig. 3-42).
When hitting pins or bucket teeth, there is a hazard that broken pieces might be sent flying and injure people in the surrounding area. Always check that there is no one in the
surrounding area.
There is a hazard that the pin hit with strong force may fly out
and injure people in the surrounding area.
Fig. 3-42
2 - 33
SAFETY
2.5.1.11 PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools
or improper use of the tools could cause serious personal
injury (Fig. 3-43).
Fig. 3-43
2.5.1.12 ACCUMULATOR
The accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless procedure may cause
an explosion which could lead to serious injury or property damage (Fig. 3-44). For this reason, always observe the following
precautions.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it, weld it, or use a cutting torch.
Do not hit or roll the accumulator, or subject it to any impact.
When disposing of the accumulator, the gas must be

released. Please contact your Komatsu distributor to have
this work performed.
Fig. 3-44
2.5.1.13 PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
2.5.2
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
2.5.2.1 PRECAUTION WHEN WELDING
WARNING
RISK OF EXPOLSION AND FIRE!
Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which
may result in serious injury or death.
All relevent safety measures must be followed and only under expressly obtained authorization.
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.
2 - 34
SAFETY
2.5.2.2 BATTERY HANDLING
WARNING
RISK OF EXPLOSION AND FIRE!
Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may
explode. Wrong handling can lead to serious injury or fire. For this reason, always observe the following
precautions.
Do not use or charge the battery if the battery electrolyte level

is below the LOWER LEVEL line. This may cause an explosion. Check the battery electrolyte level periodically and add
distilled water to bring the electrolyte level to the UPPER
LEVEL line.
When working with batteries, always wear safety glasses and

rubber gloves.
Never smoke or use any flame near the battery (Fig. 3-45).
Fig. 3-45
If you spill acid on your clothes or skin, immediately flush the

area with large amount of water.
If acid gets into your eyes (Fig. 3-46), flush them immediately
with large amount of water and seek medical attention.
Before working with batteries, activate the STOP switch and

remove battery main switch key.
Fig. 3-46
As there is a hazard that sparks will be generated, always do as follows.
Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
When disconnecting the battery terminals, wait for approx. one minute after activating the engine STOP switch
and be sure to disconnect the grounding terminal
(negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then
the grounding (-) terminal. Make sure that all the terminals are connected securely.
Attach the battery terminal securely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
Tighten the battery caps securely.
Install the battery securely to the determined place.

2 - 35
2.5.3
SAFETY
PRECAUTIONS WITH HIGH PRESSURE FLUID
WARNING
FLUID UNDER HIGH PRESSURE!
The hydraulic system is always under internal pressure and can lead to serious injury when leaking.
When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has
been released.
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE
For details of the method of releasing the pressure, see the

latest version of the Operation and Maintenance Manual. If
the circuit is still under pressure, do not carry out any inspection or replacement operation.
If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and
hoses and for swelling in the hoses.
When carrying out inspections, wear full-face protection and

penetration resistant clothing and gloves (leather).
There is a hazard that high-pressure oil leaking from small

holes may penetrate your skin or cause blindness if it contacts your eyes directly (Fig. 3-47). If you are hit by a jet of
high-pressure oil and suffer injury to your skin or eyes, wash
the place with clean water, and consult a doctor immediately
for medical attention.
Fig. 3-47
High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection
or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before starting inspection or maintenance.
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES
If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are
found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
Damaged or leaking hydraulic fitting.
Frayed or cut covering or exposed reinforcement wire layer.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.
2.5.3.3 REPLACEMENT OF HOSE LINES

Hydraulic hoses are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years.
NOTICE
The maximum permissible storage time of hydraulic hoses must be observed.
2 - 36
SAFETY
This storage period is part of the usable lifetime and must be considered when installing a new hose line. If, for
example, a hose line with a one year storage time is to be installed, the remaining service life of the hose line
must be considered. All hose lines are marked with the date of production.
Hose lines considered as Safety Critical Parts have to be replaced earlier. Refer to the chapter "Lubrication
and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for further information.
All hydraulic hoses of the Shovel have to be replaced when their service life has expired, even if there is no visible
damage. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the
Operation and Maintenance Manual for further information.
NOTICE
Repairs on hydraulic hoses are not allowed. Use ONLY GENUINE Komatsu Mining Germany replacement
hose lines.
2.5.3.4 INSPECTION OF HOSE LINES
WARNING
FLUID UNDER HIGH PRESSURE!
The hydraulic system is always under internal pressure and can lead to serious injury when leaking.
When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has
been released.
Inspect all hoses, hose lines and fittings carefully during the course of the daily walk-around inspection. Check for
leaks and damages. Beware of pinhole leakages. Replace damaged parts without delay.
Some examples of faults on hydraulic hoses requiring replacement of the concerned part:
Damage to the outer layer (e.g. chafed spots, cuts or scratches).
Brittle top layers. Flaws on the hose material
Distortion of the hose line (strong deviation from the original shape) under pressurized and pressureless conditions or when kinked or crushed, e.g. disintegration of hose layers or blistering.
Leaks.
Detachment of hose and fitting. Damaged hose fitting.
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating the machine, the user of the machine must always carry out periodic
maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts
given in the table. These parts are particularly closely connected to safety and fire prevention.
With these parts, the material changes as time passes, or they easily wear or deteriorate. However, it is difficult to
judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed
time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function
completely. However, if these parts show any abnormality before the replacement interval has passed, they should
be repaired or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time
as the hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
2 - 37
SAFETY
Ask your Komatsu distributor to replace safety critical parts.
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE
DANGER
HIGH VOLTAGE!
High voltage appliances cause serious injury or death.
Authorized staff only.
When the engine is running and immediately after it is stopped, high voltage is generated inside the engine
controller and the engine injector.
The headlights also operates using high voltage. Never perform maintenance on the headlights.
If it is necessary to touch the inside of the controller or the engine injector portion, or the headlight electrics
please contact your Komatsu distributor.
The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff
only.
2.5.3.7 AIR CONDITIONING MAINTENANCE
WARNING
AIR CONDITIONING REFRIGERANT IS HARMFUL!
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may
cause frostbite.
Never touch refrigerant.
2.5.3.8 COMPRESSED AIR
WARNING
COMPRESSED AIR IS HAZARDOUS!
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
Wear protective clothing.
When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves,
and other protective equipment.
Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.
2 - 38
SAFETY
2.5.3.9 WASTE MATERIALS

Operation
Avoid engine idling over long periods. Long periods of idling

(more than 10 minutes), will not only waste fuel, but is also
harmful to the engine.
Avoid operation against the main relief valves of the hydraulic

system. Move control lever to neutral position before the
loader attachment stalls due to overload.
Position trucks in such a way, that loading operation can be

carried out in a safe and economic manner. Avoid swing
angles over 90.
Maintenance
Preserve our environment. To prevent environmental pollution, pay careful attention to the method of disposing waste
materials.
Always drain fluids from your machine into containers. Never

drain fluids onto the ground or dump it into the sewage system, rivers, the sea or lakes. (Fig. 3-48).
Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in accordance with local environmental regulations and laws.
Fig. 3-48
2 - 39
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
2.6
ADDITIONAL SAFETY INFORMATION

FOR TROUBLESHOOTING AND ADJUSTMENTS
2.6.1
INSPECTION OF THE HYDRAULIC SYSTEM
SAFETY
A hands-on approach to inspecting the hoses and pipes of the hydraulic system can only be made when the excavator is shut down and there is no oil pressure in the hydraulic system.
Do not use your hands during inspection or move in the vicinity of the hydraulic 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 3-9, full face protection and penetration resistant clothing and gloves must be worn.
Troubleshooting and adjustments may only be performed by personnel trained by Komatsu Mining Germany in
safe and correct hydraulic handling procedures.
Before troubleshooting or adjustments, the inspection of areas of potential dangers for damages, leaks or
loose connections on the pressure lines and hydraulic components must be carried out visually only when the
engine is shutdown and when there is no hydraulic pressure in the system.
When the machine is running, the areas of potential danger can only be entered when no leakages or other
irregularities have been noticed when the high pressure oil circulation has been brought up to maximum pressure from a safe distance (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.
An operator that has been trained on the machine he is operating, must always sit in the operator's seat and be ready to
stop the engine at any time. All workers must maintain contact with the other workers and be fully aware of all relevant
safety measures.
When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts,
so be careful not to come close (Fig. 3-49).
Do not touch any control levers or control pedals. If any control levers or control pedals must be operated, always give a
signal to the other workers to warn them to move to a safe
place.
Fig. 3-49
2.6.3
AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR
General safety rules for working on the excavator
Only trained personnel who are aware of all dangers are allowed to work on the hydraulic system
Visually inspect all potential danger areas for leakages before pressure build up.
Do not remain on or around the excavator for longer than is absolutely necessary in order to perform your
tasks.
2 - 40
SAFETY
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
Please continue reading on the next page.
2 - 41
SPECIAL SAFETY EQUIPMENT
2.7
Fig. 3-50
2 - 42
SAFETY
SAFETY
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 applications where there is a risk of hitting objects from the front.
2.7.2
OBJECT HANDLING
Object handling operations are not allowed.
2.7.3
LIGHTING
The Shovel must only be operated when the operator has sufficient visibility in relation to the work area.
Disturbing shady areas or dazzling effects must be avoided.
If necessary, the Shovel must be retrofitted with additional lighting equipment (working lights) in order to ensure
sufficient visibility conditions.
2.7.4
WARNING BEACON
The Shovel can be retrofitted with a warning beacon which is fitted on the cab roof by means of a magnetic
bracket.
REMARKS: The above-mentioned special safety devices can be ordered as accessories together with the
Shovel.
They are also available as a field package for installation through our service organization.
2.7.5
SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN

STANDARD)
The safety harness should only be used together with connectors according to
EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360.
See the following pages for further information.
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
WARNING
RISK OF FALLING!
Injuries can occur when working in high areas. Always use a Safety Harness (1) in conjunction with a
strap type Fall Absorber (2), illust. (Fig. 3-50) before boarding the loader attachment or other unsecured
areas on the Shovel.
The Safety Harness is located in the Cabinet in the Operators Cab.
The illustration (Fig. 3-50) shows the standard use of the safety harness with a strap type fall absorber.
2 - 43
2 - 44
SAFETY
SAFETY
Legend for Fig. 3-50

(1)
Safety Harness according to EN 361
(2)
Strap-Type Fall Absorber according to DIN EN 355
(3)
Railings (attachment points)
(4)
Walkway on the boom
(A)
Shoulder Strap
(B)
Back Plate
(C)
Catching Hook
(D)
Shoulder-Strap Fixing
(E)
Belly Strap
(F)
Holding Hook
(G)
Hold-Back Hook
(H)
Pelvis Strap
(J)
Leg Strap
2.7.5.2 INSTRUCTIONS FOR USE

Open the lock, lift the harness by the catch hook (C), ensuring the leg straps hang below (J). Pull the harness over
the shoulders as you would a jacket. Insert the end of the belly strap (E) through the buckle and tighten securely,
as shown in the illustration (Fig. 3-50).
Prevent the shoulder straps from slipping by fastening the breast strap. Pull the leg straps (J) between the legs
and securely buckle them at the front as illustrated. Adjust the harness so that it snugly fits the body ensuring that
the catching hook (C) is in the center of the back.
The safety harness is a personal accessory and should only belong to its owner.
The safety harness should only be used together with connectors acc. to EN 354, and fall arrest acc. to EN 355, or
fall protection devices acc. to EN 360.
The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attachment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795.
2 - 45
2 - 46
SAFETY
SAFETY
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL
Carry out a visual check of the system or component; correct functioning and perfect working order have to be
assured.
Make sure that the recommendations for use with other components of the system be observed in conformity
with the instructions for use.
The system or component must no longer be used, if there are any doubts in respect of its safe condition. The
equipment has to be inspected by the manufacturer or by a qualified person.
It is essential for safety reasons that a fall protection system or system component which has already been subjected to fall be removed from service and sent back to the manufacturer or an authorized qualified repair shop for
maintenance and renewed testing.
Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned
against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharpedged objects.
Should the harness have become wet during use or cleaning, do not dry near a fire or other sources of heat, but
rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up.
When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest Systems" have to be observed for protection against danger.
At least every 12 months, the safety harness and its components have to be inspected by a competent person
authorized by the manufacturer and maintained, if the manufacturer considers it necessary.
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK

HOOKS OF THE SAFETY HARNESS (1),
During the holding function, the connectors may only be placed around a mast or other construction between the
two holding hooks, so that free fall is limited to max. 0.5 m.
It should be strictly seen to it that the connector be not slung around constructions with too small diameter or sharp
edges.
With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs).
The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be
reached.
2 - 47
2 - 48
SAFETY
SAFETY

Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD)
Use
Within a fall-arrest system, the strap-type fall absorber (2) has to be used in conjunction with a safety harness (1)
acc. to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a
rope-shortening device has to be applied in addition.
Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the
safety harness. The attachment point should be above the wearer and its minimum carrying capacity should be 10
KN, acc. to DIN EN 795.
The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull
them over sharp edges nor get them burnt by welding sparks.
Storing and maintenance
The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be ex-posed to acids, caustic
chemicals, nor to an aggressive atmosphere, and contact with oils has to be avoided. If the strap-type fall absorber
is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or
other sources of heat). Protect it from sharp-edged objects.
Inspection
Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall
absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed
from service immediately. The strap-type fall absorber must not be changed in any way.
2 - 49
2 - 50
SAFETY
HYDRAULIC MINING EXCAVATOR

PC8000E-6
Machine model
Serial numbers
PC8000E-6
12037 and up
01 Specification
Copyright 2010 KOMATSU MINING GERMANY GmbH
PC8000E-6
OPERATING WEIGHT
700-720 ton 1,540,000-1,590,000 lb
42
m3
SHOVEL CAPACITY
55 yd3 SAE 2:1 heaped
BACKHOE CAPACITY
42 m3 55 yd3 SAE 1:1 heaped
PC 8000
PC
8000
SUPER SHOVEL
PC 8000
S UPER S HOVEL
WALK-AROUND
Building on the technology and expertise
Komatsu has accumulated since
establishment, GALEO presents customers
worldwide with a strong, distinctive image
of technological innovation and value.
Designed for high productivity, safety and
environmental considerations,
GALEO machines reflect Komatsus
commitment to contributing to the creation
of a better world.
Genuine Answers for Land and

Environment Optimization
Quality management ISO 9001 certified.
Environmental Management
ISO 14001 certified.
High consistent quality through continuous
investment in personnel, design and manufacturing systems and processes.
Advanced Hydraulics
Extended reliability and precise control
Comprehensive monitored filtration.
Simple open circuit hydraulic system with
high efficency swing out oil coolers.
Powerful Diesel Engine

Two Komatsu SDA16V160 engines
Rated (each) 1500 kW 2010 HP, at 1800 rpm.
Electonic engine management.
Low engine emission levels meet EPA
regulations.
Time saving oil management system
fitted as standard; Centinel Engine Oil
Management, Reserve Engine Oil Supply
and Eliminator Oil Filter systems.
Reliability and Durability

Designed for lower operating costs
Robust structural design developed from field
experience and finite element analaysis.
Extended life undercarriage wear parts;
Big diameter rollers, idlers and sprockets.
Large surface area and extensive precision hardening.
Hardened track link pin bores.
SUPER SHOVEL
PC 8000
MATCHED FOR TRUCKS
240 ST AND LARGER
Large Comfortable Cab

Full shift comfort
Komatsu low noise cab on multiple viscous mounts for
reduced noise and vibration.
Large volume cab with deep wide front window.
Comprehensive climate control with pressurised filtered air
ventilation and air conditioning.
High specification multi-adjustable air suspension seat.
Well elevated operator position giving good all round view.
SHOVEL BUCKET
42 m3 55 yd3 SAE 2:1 heaped
CROWD/BREAKOUT FORCE
2320 kN 521,500 lb
MAIN DRIVE
DIESEL:
2 x 1500 kW 2 x 2010 HP
ELECTRIC:
2 x 1450 kW
Sustained High Production

Designed for more tons per hour
Powerful digging forces.
Ease of bucket filling.
Proven attachment design.
All cylinders mounted under the shovel
attachment for protection.
Buckets and Wear Packages to suit all
material densities and mining conditions.
Easy Maintenance
Simple, common-sense design gives quick safe
access to all major components
Generous access to all major service points from
machinery house floor level.
Enclosed, internally lit machinery house with firewall separating engine from pump area.
Automatic central lubrication.
ECS electronic monitoring system providing real
time information about the operating status of the
machine.
Ground-level access to hydraulically powered swing
down service arm with Wiggins connections.
Worldwide Experience
The PC8000 is the worlds largest
series built hydraulic mining shovel
and proven in key mining areas.
Each shovel symbol represents one
or several machines in operation.
PC 8000
S UPER S HOVEL
SPECIFICATIONS
DIESEL DRIVE
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x Komatsu SDA16V160
Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection
Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rated power. . . . . . . . . . . . . . . . 2x 1500 kW 2010 HP @ 1800 rpm
(SAE 1995/J1349)
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronic

The integrated engine oil and filter system extends service
intervals. This combines the oil stabilising systems Reserve and
Centinel with the Eliminator self cleaning oil filter to extend, with oil
analysis, the oil change interval to 4000 hours.
The high capacity engine radiators are each cooled by a
hydraulically driven fan for superior cooling efficiency and requiring
little maintenance.
ELECTRIC DRIVE
Type................................................2 x Squirrel-cage induction motor
Power output ....................................................................2x 1450 kW
Voltage .....................................................................................6600 V*
Amperage (approximate) ......................................................2 x 155 A
Frequency (standard) .............................................50 Hz @ 1500 rpm
Optional frequency.................................................60 Hz @ 1800 rpm
*Other voltages available on request
ELECTRIC SYSTEM (Electric Version)

System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Batteries (series/parallel). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 12 V
Standard working lights . . . . . . . . . . . . . . . . . . . . . . . 8 Xenon lights
Standard service lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 lights
Optional lighting upon request
ELECTRIC SYSTEM (Diesel Version)

System ..........................................................................................24 V
Batteries (series/parallel).........................................................8 x 12 V
Alternator ..............................................................................2 x 100 A
Standard working lights...............................................8 Xenon Lights
Standard service lights...........................................................15 lights
*Optional lighting upon request
UNDERCARRIAGE
Undercarriage consists of one center carbody and two track
frames, each attached by four large diameter hardened pins.
Center frame .............................................................................H-type
Track frame ..............................................................Steel box-section
CRAWLER ASSEMBLY
Track adjustment .........................................Automatic hydraulic type
Number of track shoes....................................................48 each side
Number of top rollers ........................................................3 each side
Number of bottom rollers ..................................................8 each side
TRAVEL AND BRAKE SYSTEMS

Travel control...................................................................2 foot pedals
Gradeability ........................................................................Up to 50%
Travel speed (maximum) .........................................2.4 km/h 1.5 mph
Service brake ..............................................................Hydraulic brake
Parking brake ..........................................................Wet, multiple-disc
HYDRAULIC SYSTEM
The power train consists of two main drives. Diesel engines or
electric motors can be supplied. Each of the two gearboxes drives
four identical pumps which draw hydraulic oil from an unpressurized
hydraulic tank. Open circuit hydraulics provide maximum cooling
and filtering efficiency.
Rated flow (total output) ...............................8280 ltr/min .. 2190 gpm
Relief valve setting ...............................................310 bar.... 4,495 psi
Swing flow rate .............................................2070 ltr/min ... 547 gpm
High pressure in line filters...............................................200 microns
one per pump located at the valve blocks
Full flow return line filters (8 double elements) ..................10 microns

at head of hydraulic tank
Case drain/by-pass return line filters ..................................3 microns

The four-circuit system features a load-limiting governor with oil
delivery summation to the working circuits and incorporates
pressure cut-off control. Hydropilot prioritizes hydraulic flow giving
smooth hydraulic response, simple hydraulic system layout, and a
reduced number of components. The hydraulic system includes six
large swing-out vertical air-to-oil hydraulic coolers with temperatureregulated hydraulically driven fans.
AUTOMATIC CENTRALISED
LUBRICATION
Two hydraulically powered Lincoln Single Line automatic lubrication
systems are provided as standard, complete with time and volume
variable controls. Activity and malfunction events are linked to the
ECS. The central lubrication and open gear lubricant are supplied by
identical pump assemblies from a refillable twin container which has
a capacity of 2 x 300 litres (2 x 80 gal.). Replenishment of the
containers is through the Wiggins connections on the service arm.
SWING SYSTEM
Hydraulic motors and drives..............................................................3
Swing brake, service ..................................................Hydraulic brake
Swing brake, parking ..............................................Wet, multiple-disc
Swing ring teeth ......................................................................External
Swing speed (maximum) .........................................................2.7 rpm
SERVICE CAPACITIES
Hydraulic oil tank . . . . . . . . . . . . . . . . . .83500 ltr 2,205 U.S. gal
Hydraulic system . . . . . . . . . . . . . . . . . .11500 ltr 3,040 U.S. gal
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .13500 ltr 3,564 U.S. gal
Engine coolant . . . . . . . . . . . . . . . . . . .2x 475 ltr 2x 125 U.S. gal
Engine oil . . . . . . . . . . . . . . . . . . . . . . .2x 290 ltr 2x 77 U.S. gal
Centinel engine oil make up tank . . . . .2x 670 ltr 2x 180 U.S. gal
PC 8000
SUPER SHOVEL
CAB
The large welded steel safety cab is mounted with 18 viscous
damping pads and sound insulated.
It is equipped with automatic climate control and is pressurised.
The operators seat is fully adjustable, air suspended, electrically
heated and has a lap seat belt. There is a trainers seat.
Low effort joy stick controls are electric over hydraulic and foot
controls are for front shovel clam, crawler and swing brake.
Full instrumentation and ECS are provided. Space in the console
is provided for an additional monitor. AM/FM radio is fitted. The
windshield wash wiper has two speed and intermittent operation.
(Water reservoir 7 litres 1.8 gal.) Amenities include a wash basin
with running water, water reservoir, (50 litres 13 gal.), refrigerator
and storage cabinets. Powered mirrors are adjusted from inside
the cab.
There are left and right hand sliding windows. All windows
are tinted parsol green. External metal louvres are provided on the
cab side windows.
Cab engineering standards are;

ISO 3449 Falling Objects Protection Structure
ISO 6396 Noise in operators cab is 76 dB(A)
ISO 2631-1/ 5349-1 Vibration and Shock
Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . .10kW 34120 Btu
Heater/Demister (Diesel version) . . . . . . . . . . . . .10kW 34120 Btu
Heater/Demister (Electric version) . . . . . . . . . . . .12kW 40940 Btu
CS
HEALTH MONITORING SYSTEM

The ECS digital diagnostic system, mounted in the operators
console, provides a text display of real time and stored information
about the status of the operating machine. Non serious and critical
faults are immediately announced, and for major malfunctions the
engines are also shut down. The integrated digital storage provides
full event history, which can be down loaded with a laptop computer.
The ability to electronically record service events provides precise
service information to assist in reducing downtime.
OPERATING WEIGHTS
PC 8000 Backhoe:
PC 8000 Front Shovel:
Operating weight including 11,500 mm 379 boom, 5500 mm 180 stick, 38 m3 50.0 yd3
backhoe bucket, operator, lubricant, coolant, full fuel tank and standard equipment.
Operating weight including 8150 mm 269 boom, 5750 mm 189 stick, 42 m3 55.0 yd3
shovel bucket, operator, lubricant, coolant, full fuel tank and standard equipment.
Shoe Width
Operating Weight
Ground Pressure
Shoe Width
Operating Weight
Ground Pressure
1500 mm
59
710 t
1,565,000 lb
26.7 N/cm2
38.7 psi
1500 mm
59
700 t
1,540,000 lb
26.3 N/cm2
38.1 psi
1900 mm
75
720 t
1,590,000 lb
21.4 N/cm2
31.0 psi
1900 mm
75
710 t
1,565,000 lb
21.2 N/cm2
30.7 psi
10
5
4
3
8
9
7
2
2
10
8
6
Diesel
10
Explanation
1 Cab
2 Diesel Engines
3 Hydraulic Pumps
4 Hydraulic Tank
5 Hydraulic Coolers
6
7
8
9
10
SKZ 8006-64
Fuel Tank
Valve Blocks
Swing Motors
Counterweight
Secondary Egress
Electric
Variation for Electric
Drive Version
2 Electric Motors
6 High Voltage
Electric Cabinet
SKZ 8006-65
Lower-Level
Walkways
Upper-Level
PC 8000
S UPER S HOVEL
PRODUCTIVITY-FEATURES
8006057
DIGGING FORCES
Break-out force
Tear-out force
2000 kN
1800 kN
449,500 lb
404,600 lb
Maximum reach at ground level . . . . . . . . . .19900 mm 654

Maximum digging depth . . . . . . . . . . . . . . . .8400 mm 277
BACKHOE BUCKET, STICK AND BOOM COMBINATION

Bucket
Capacity
Width
Teeth
SAE
Heaped 1 : 1
Boom Length
11500 mm 37 9
including Wear package

WP-1
WP-2
Stick Length
5500 mm 18 0
38 m3 50 yd3
4830 mm
1510
45.5 t 100,300 lb
Material weight to 1.8 t/m3 3000 lb/yd3
42 m3 55 yd3
4780 mm
158
40.3 t 88,900 lb
Alternative buckets / wear packages are available
Weight
SUPER SHOVEL
PC 8000
8006058
DIGGING FORCES
Break-out force
Crowd force
2320 kN
2320 kN
521,500 lb
521,500 lb
Level crowd at ground level . . . . . . . . . . . . .5900 mm

Maximum dumping height . . . . . . . . . . . . .13900 mm
194
457
SHOVEL BUCKET, STICK AND BOOM COMBINATION

Bucket Capacity
SAE / CECE
Heaped 2 : 1
Heaped 1 : 1
42 m3 55 yd3
48 m3 63 yd3
Width
5630 mm 186
Teeth
Weight
Boom Length
8150 mm 26 9
including
Wear package-3
Stick Length
5750 mm 18 9
67.2 t 148,000 lb

Alternative buckets / wear packages are available
STANDARD EQUIPMENT
Hydraulic Mining Shovel will comprise:
FRONT SHOVEL ATTACHMENT
8.15 m 26'9" boom and 5.75 m 18'9" stick
complete with cylinders. 42 m3 55 yd3 (SAE
2:1) shovel bucket with mechanical teeth and
lip system.
OR
BACKHOE ATTACHMENT
11.5 m 37'9" boom and 5.5 m 18'0" stick
with 38 m3 50 yd3 (SAE 1:1) bucket with
mechanical teeth and lip system.
CRAWLER UNDERCARRIAGE
Heavy-duty shovel type undercarriage
consisting of a center carbody and 2 heavy
box-type track frames, each having 8
bottom rollers, 3 top rollers, and 1500 mm
59" cast steel track shoes.
Hydraulic track adjustment and parking
brake provided.
SUPERSTRUCTURE
A main frame mounted over an externally
toothed swing circle carries the platform
component modules and the counterweight.
AM-FM radio. Washbasin with running water

(reservoir 50 ltr 13 gal). Refrigerator and
storage cabinets. Left and right hand sliding
windows, external metal sunblinds.
All windows tinted parsol green.
LIGHTING
8 Xenon high performance lights.
15 service lights throughout platform.
LUBRICATION
LINCOLN central lubrication for basic machine,
attachment, and bucket. 300 ltr 80 gal
refillable container.
LINCOLN automatic pinion lubrication system
for swing circle teeth with 300 ltr 80 gal
refillable container.
Service point (diesel version only as standard)
on hydraulic arm carrying WIGGINS fluid
receiving connectors for filling of fuel, engine
oil and coolant, hydraulic oil, grease, cab
water and the evacuation of coolant, and
hydraulic and engine oils.
ACCESSORIES
Acoustic travel alarm
Hydraulically actuated ground access ladder
Electric air horn
Engine oil management package
(Centinel, Reserve & Eliminator systems)
Diesel version
Fuel tank module.
Drive module:
Two Komatsu SDA16V160 diesel engines,
each driving 4 identical hydraulic pumps.
Electric version
Electrical cabinet module.
Drive module:
2 Squirrel cage induction motors, each
with soft start and mounted with 4
identical main hydraulic pumps per motor.
Hydraulic tank module.
Oil cooler module.
Cab base module:
Includes the low tension electrical cabinet.
OPERATORS CAB
Fully enclosed steel cab which incorporates
the ISO 3449 standard FOPS structure and
CARRIER STRAK air-conditioning unit.
Mounted on viscous pads. GRAMMER full
suspended seat with lap-belt. Fold-away
auxiliary seat. Full selection of controls,
switches, and ECS (Electronic Control
System). Joystick and pedal-operated
controls are electric over hydraulic.
Windshield wash wiper with two-speed and
intermittent operation (reservoir 7 ltr 1.8 gal).
OPTIONAL EQUIPMENT
1900 mm 75" trackshoes
Extra or alternative, lighting
Fire suppression system
Electric drive
Cable reel (Electric version)
Service crane
Low temperature package

(incl. KIM hot start)
Auxiliary diesel generator
DIMENSIONS
BASIC MACHINE WITH COUNTERWEIGHT

OR
O
A
1500mm
B
1900mm
CA 8150mm
CB 8550mm
D
2830mm
E
3970mm
F
7945mm
G 10515mm
H
3470mm
59"
75"
26'9"
28'1"
9'3"
13'00"
26'00"
34'6"
11'5"
I
3550mm
J
8780mm
K
9500mm
LA
4550mm
LB
5530mm
M
3750mm
N 10000mm
O
8410mm
OR 8710mm
11'8"
28'10"
31'2"
14'11"
18'1"
12'4"
32'10"
27'7"
28'7"
I
J
H
D
A
B
E
F
G
CA
CB
Ground Clearance: 1144mm 3'9"
QESS0086 01
LB
LA
8006_63
8006_62
2006 Komatsu Printed in Germany
KOMATSU MINING GERMANY GMBH

BUSCHERHOFSTRASSE 10
D-40599 DSSELDORF
PHONE +49 (0) 211/ 71 09-0
FAX
+49 (0) 211/ 71 58 22
www.komatsumining.com
Materials and specifications are subject to change without notice.

is a trademark of Komatsu Ltd. Japan.
SHOP MANUAL
SHOP 12037-xE-GB-0
HYDRAULIC EXCAVATOR
PC8000E-6
Machine model
PC8000E-6
Serial number
12037 and up
10 Structure, Function
PC8000E-6
PC8000-6-E_#12048_Contents and 00_Foreword_rev1.doc
CONTENTS
TABLE OF CONTENTS
00
01
02
Safety - Foreword
Technical DATA (Leaflet)
Assembly PROCEDURE (Brochure)
Section
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Main assembly groups

Drive
Hydraulic oil tank
Hydraulic oil cooling
Controlling
Components
Main hydraulic pumps and pump regulation
Operating hydraulic
Hydraulic track tensioning system
Hydraulic operated access ladder
Cable drum
Hints for the hydraulic circuit diagram
Hints for the electric circuit diagram
ECS-T
Lubrication System
APPENDIX
Each section includes a detailed table of contents.
02.09.09
PC8000-6-E_#12048_Contents and 00_Foreword_rev1.doc
02.09.09
SAFTEY
SAFTEY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
The following Symbols are used in this Manual to designate Instructions of
particular Importance.
WARNING -
Serious personal injury or extensive property damage can

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

the shovel can be damaged if the caution instructions are not
followed.
NOTE -
Refers to special information
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE
MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
continued
00-1
SAFTEY
SAFTEY NOTICE
Cont'd:
GENERAL PRECAUTIONS
3. If welding repairs are needed, always have a trained, experienced welder carry out the
work. When carrying out welding work, always wear welding gloves, apron, glasses, cap
and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the
operating procedure before starting. Always inform your fellow workers before starting
any step of the operation. Before starting work, hang UNDER REPAIR signs on the
controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the
tools and parts in their correct places. Always keep the work area clean and make sure
that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making repairs, park the machine on hard, level ground, and block
the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower bucket, hammer or any other work equipment to the ground.
If this is not possible, insert the safety pin or use blocks to prevent the work equipment
from falling. In addition, be sure to lock all the control levers and hang warning signs on
them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands
before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine.
Always use the handrails, ladders or steps when getting on or off the machine. Never
jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs,
loosen
them
slowly
to
prevent
the
oil
from
spurting
out.
Before disconnecting or removing components of the oil, water or air circuits, first
remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to
get burned.
Wait for the oil and water to cool before carrying out work on the oil or water circuits.
continued
00-2
SAFTEY
SAFTEY NOTICE
Cont'd:
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from
the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly
to prevent the component from hitting any other part. Do not work with any part still
raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring,
always leave two bolts in position on opposite sides. Slowly release the pressure, then
slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring, Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to
the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to wash parts.
19. Be sure to assemble all parts again in their original places. Replace any damaged part
with new parts.
When installing hoses and wires, be sure that they will not be damaged by contact with
other parts when the machine is being operated.
20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes
are dangerous, so be extremely careful when installing tubes for high pressure circuits.
Also check that connecting parts are correctly installed.
21. When assembling or installing parts, always use the specified tightening torques. When
installing protective parts such as guards, or parts which vibrate violently or rotate at high
speed, be particularly careful to check that they are installed correctly.
22. When aligning two holes, never insert your fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled
before taking any measurements.
24. Take care when removing or installing the tracks of track-type machines. When removing
the track, the track separates suddenly, so never let anyone stand at either end of the track.
00-3
ENVIRONMENT PROTECTION
Environment NOTICE
RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION

AND MAINTENANCE OF HYDRAULIC MINING SHOVELS
OPERATION
Avoid operation against the main relief valves of the hydraulic system. Move control
lever to neutral position before the loader attachment stalls due to overload.
Position trucks in such a way, that loading operation can be carried out in a safe and
economic manner. Avoid swing angles over 90.
MAINTENANCE
Preserve our environment. To prevent environmental pollution, pay careful attention to

the method of disposing waste materials.
Always drain fluids from your machine into containers. Never drain fluids onto the
ground or dump it into the sewage system, rivers, the sea or lakes.
Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in
accordance with environmental regulations and laws.
FOREWORD
FOREWORD
GENERAL
With this SERVICE MANUAL KOMATSU provides you with the
description of the construction and the function of the major systems of the
Hydraulic Excavator PC8000-6-E.
We describe for you all functions and how to carry out the inspections and
adjustments.
How do you find "your" desired information?
In the table of CONTENT all the functions and components are shown in
their sequence of the description.
If after reading this SERVICE MANUAL you can give us suggestions and
comments for improvements - please do not hesitate to contact us.
- Service Training Postfach 180361
40570 Dsseldorf
Tel.:0211 / 7109 - 206
Fax.:0211 / 74 33 07
The editorial staff will be pleased about your co-operation.
- FROM THE PRACTICE - FOR THE PRACTICE -
This service manual corresponds to the state of development of the

machine at the time the manual was produced.
Variations based on special customers request and special equipment
are not included in this manual
00-4
FOREWORD
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted with a hoist etc.
If a part cannot be smoothly removed from the machine by hoisting,

the following checks should be made:
1. Check for removal of all bolts fastening the part to the relative
parts.
2. Check for existence of another part causing interface with the part
to be removed.
WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter
[mm]
10,0
11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0
Allowable
load [tons]
1,0
1,4
1,6
2,2
2,8
3,6
4,4
5,6
10,0 18,0 28,0 40,0
The allowable load value is estimated to be 1/6 or 1/7 of the breaking

strength of the rope used.
2. Sling wire ropes from the middle portion of the hook. Slinging near the edge
of the hook may cause the rope to slip off the hook during hoisting, and a
serious accident can result. Hooks have maximum strength at the middle
portion.
continued
Cont'd:
00-5
FOREWORD
WIRE ROPES
3. Do not sling a heavy load with one rope alone, but sling with two or more
ropes symmetrically wound on to the load.
Slinging with one rope may cause turning of the load during hoisting,
untwisting of the rope, or slipping of the rope from its original
winding position on the load, which can result in a dangerous
accident.
4. Do not sling a heavy load with ropes forming a wide hanging angle from the
hook. When hoisting a load with two or more ropes, the force subjected to
each rope will increase with the hanging angles. The table below shows the
variation of allowable load (kg) when hoisting is made with two ropes, each of
which is allowed to sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of total weight can be
suspended. This weight becomes 1000 kg when two ropes make a 120
hanging angle. On the other hand, two ropes are subject to an excessive force
as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.
00-6
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm)

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
Bolt
dia.
Wrench
size [mm]
Tightening torque
[Nm]
Quality grades
8.8
10.9
12.9
M 8
13
21
31
36
M 10
17
43
63
73
M 12
19
10
74
108
127
M 14
22
12
118
173
202
M 16
24
14
179
265
310
M 18
27
14
255
360
425
M 20
30
17
360
510
600
M 22
32
17
485
690
810
M 24
36
19
620
880
1030
M 27
41
19
920
1310
1530
M 30
46
22
1250
1770
2080
M 33
50
24
1690
2400
2800
M 36
55
27
2170
3100
3600
M 39
60
2800
4000
4700
M 42
65
3500
4950
5800
M 45
70
4350
6200
7200
M 48
75
5200
7500
8700
M 52
80
6700
9600
11200
M 56
85
8400
12000
14000
M 60
90
10400
14800
17400
M 64
95
12600
17900
20900
M 68
100
15200
21600
25500
32
35
41
46
Insert all bolts lubricated with MPG, KP2K
00-7
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of
figures. For details of the method of using the Conversion Table, see the example
given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
(a) Locate the number 5 in the vertical column at the left side, take this as (A),
then draw a horizontal line from (A).
(b) Locate the number 5 in the row across the top, take this as (B), then draw a
perpendicular line down from (B).
(c) Take the point where the two lines cross as (C). This point (C) gives the
value
when
converting
from
millimeters
to
inches.
Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.
(a) The number 550 does not appear in the table, so divide by 10 (move the
decimal one place to the left) to convert it to 55 mm.
(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(c) The original value (550 mm) was divided by 10, so multiply 2.165 inches
by 10 (move the decimal one place to the right) to return to the original
value. This gives 550 mm = 21.65 inches.
00-8
FOREWORD
00-9
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-10
FOREWORD
00-11
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-12
FOREWORD
CONVERSION TABLE
Basic Values in Ohm according to DIN 43 76

For Measuring Resistor PT100
-0
-1
-2
-3
-4
-5
-6
-7
-8
-9
-50
80,31
79,91
79,51
79,11
78,72
78,32
77,92
77,52
77,13
76,73
-40
84,27
83,88
83,48
83,08
82,69
82,29
81,89
81,50
81,10
80,70
-30
88,22
87,83
87,43
87,04
86,64
86,25
85,85
85,46
85,06
84,67
-20
92,16
91,77
91,37
90,98
90,59
90,19
89,80
89,40
89,01
88,62
-10
96,09
95,69
95,30
94,91
94,52
94,12
93,73
93,34
92,95
92,55
100,00
99,61
99,22
98,83
98,44
98,04
97,65
97,26
96,87
96,48
100,00
100,39
100,78
101,17
101,56
101,95
102,34
102,73
103,12
103,51
10
103,90
104,29
104,68
105,07
105,46
105,85
106,24
106,63
107,02
107,40
20
107,79
108,18
108,57
108,96
109,35
109,73
110,12
110,51
110,90
111,28
30
111,67
112,06
112,45
112,83
113,22
113,61
113,99
114,38
114,77
115,15
40
115,54
115,93
116,31
116,70
117,08
117,47
117,85
118,24
118,62
119,01
50
119,40
119,78
120,16
120,55
120,93
121,32
121,70
122,09
122,47
122,86
60
123,24
123,62 124,01, 124,39
124,77
125,16
125,54
125,92
126,31
126,69
70
127,07
127,45
127,84
128,22
128,60
128,98
129,37
129,75
130,13
130,51
80
130,89
131,27
131,66
132,04
132,42
132,80
133,18
133,56
133,94
134,32
90
134,70
135,08
135,46
135,84
136,22
136,60
136,98
137,36
137,47
138,12
100
138,50
138,88
139,26
139,64
140,02
140,39
140,77
141,15
141,53
141,91
110
142,29
142,66
143,04
143,42
143,80
144,17
144,55
144,93
145,31
145,68
120
146,06
146,44
146,81
147,19
147,57
147,94
148,32
148,70
149,07
149,45
130
149,82
150,20
150,57
150,95
151,33
151,70
152,08
152,45
152,83
153,20
140
153,58
153,95
154,32
154,70
155,07
155,45
155,82
156,19
156,57
156,94
150
157,31
157,69
158,06
158,43
158,81
159,18
159,55
159,93
160,30
16067
00-13
FOREWORD
CONVERSION TABLE
TEMPERATURE
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit
temperature reading into a Centigrade temperature reading or vise versa is to enter
the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the
center column as a table of Fahrenheit temperatures and read the corresponding
Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the
center column as a table of Centigrade values, and read the corresponding
Fahrenheit temperature on the right.
00-14
FOREWORD
CONVERSION TABLE
00-14
Main Assembly Groups
Section 1.0
Page 1
Table of contents section 1.0

Section
1.0
Page
Main assembly groups
General lay out
1.1
Superstructure
1.1.1
Machine house
1.1.2
Hydraulic Oil Reservoir
1.1.3
Hydraulic Oil Cooler
1.1.4
High Voltage Switch Cabinet
1.1.5
Counter weight
1.1.6
Cab support (with Medium Voltage Switch Cabinet)
1.1.7
Operators cab
10
1.1.8
Main pumps and Control blocks
11
1.1.9
Swing gears
12
1.2
Under carriage
1.3
Attachment
13
1.3.1.
Backhoe Attachment (BHA)
14
1.3.2.
Front Shovel Attachment (FSA)
15
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2
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1.0
Section 1.0
Page 2
General lay out

Legend for illustration (Z 22388):
(1)
Superstructure
(2)
Under carriage
(3)
(4)
Backhoe Attachment (BHA)
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3
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1.1
Section 1.0
Page 3
Superstructure
(1)
Operators Cab with integrated FOP system
(2)
Cab support
(contains the electrical switch board for low- and medium-voltage)
(3)
Swing ring connection
(4)
High-Voltage cabinet
(5)
Main entrance to the motor and pump compartment.
(6)
Hydraulic ladder
(7)
Counter weight
(8)
Hydraulic oil cooler with hydraulic driven fans
(9)
Hydraulic oil reservoir
(10)
(11)
(12)
(13)
Electric motor No 1
Flexible coupling, rubber type
PTO gear with all hydraulic pumps
Main hydraulic pumps 1 4
(14)
(15)
(16)
(17)
(18)
(19)
Electric motor No 2
PTO gear with all hydraulic pumps
Main hydraulic pumps 5 8
Control blocks with high pressure filters
Swing gears
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1.1
Section 1.0
Page 4
Superstructure
1.1.1
Machine house

(A)
Motor cooling air inlet
(B)
Motor cooling air outlet
(1)
Electric motor No 1
(2)
Electric motor No 2
(3)
(4)
Protecting cover
(5)
PTO gear box
(6)
High tension terminal box
(7)
Cooling fan housing
(8)
Air duct
(9)
Air to air heat exchanger
(10)
Air outlet duct
(11)
Hydraulic pump for the hydraulic oil cooler fan drive
(12)
Main hydraulic pumps
(13)
Auxiliary pumps, installed at the drive through shaft of the main
hydraulic pumps (piggyback pumps)
(14)
Suction oil reservoir
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1.1
Section 1.0
Page 5
Superstructure
1.1.2

(1)
Breather filter
(2)
Temperature controlled back pressure valve
(3)
Transfer pump
(4)
Return oil filter
(5)
Case drain (leak oil) filter
(6)
Main shut-off valve (Gate valve) with compensator
(7)
Return oil collector tube
(8)
Strainer
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Section 1.0
Page 6
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1.1
Section 1.0
Page 6
Superstructure
1.1.3
Hydraulic Oil Cooler
Legend for illustration (Z 22781a):

(1)
Hydraulic oil cooler assembly with swing out facility
(2)
(3)
(4)
Lower radiator set (2 identical cooler elements 106.3 and 106.4)

Lower fan
Hydraulic motor of lower fan (driven by prime mover 1)
(5)
(6)
(7)
Upper radiator set (2 identical cooler elements 106.1 and 106.2)

Upper fan
Hydraulic motor of upper fan (driven by prime mover 2)
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1.1
Section 1.0
Page 7
Superstructure
1.1.4
High Voltage Switch Cabinet
Access to the high voltage area for authorized personnel only.

The local safety regulations must be observed.
Before opening the door of the high voltage switch cabinet, make sure
that the main power supply from the power station is interrupted.
(1)
Door, high voltage switch cabinet
(2)
Door, medium voltage switch cabinet (cab base)
(3)
Key for load cut-off switch actuator. Keep in the switch cabinet
(4)
Flap lockable for load cut-off switch
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Load cut-off switch

Fuses
Air conditioner including electric heaters for high voltage switch
cabinet. The control panel for operating the air conditioner is located in
the Medium Voltage Switch Cabinet.
Compressor for air conditioner in high voltage switch cabinet.
Thermoswitch (6B1) for monitoring temperature in high voltage switch
cabinet. If temperature exceeds a fixed value the thermoswitch sends an
error signal to the fault detection systems.
Electric heater (3R23). The control panel for temperature adjustment is
located in the Medium Voltage Switch Cabinet.
Electric heater (3R21). The control panel for temperature adjustment is
located in the Medium Voltage Switch Cabinet.
Make sure to lock up door (1) and flap (4) with padlocks to prevent
unauthorized access to the high voltage area.
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8
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Section 1.0
Page 8
1.1
Superstructure
1.1.5
Counter weight
Legend for illustration (Z 22674b):

(1)
Counter weight
Total weight
~ 53000 kg
(2)
Mounting bolts
Quantity
16
Bolt size
(mm)
Grade
SW*
(mm)
M 48
10.9
75
SW = Wrench size
(3)
Washers
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Tightening
torque (Nm)
7500
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9
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1.1
Section 1.0
Page 9
Superstructure
1.1.6
Cab support (with Medium Voltage Switch Cabinet)
Legend for illustration (Z 22782c):

(1)
Air conditioner for cab base, located at the outside of rear cab
base wall.
(2)
Signal horn and compressor
(3)
Entrance door of cab base
(4)
Light switch
(5)
Switch board no. 3 at the back wall of cab base (socket outlets)
(6)
Switch board medium voltage.
(7)
Monitor and control panel.
(8)
Switch board for air conditioner in cab base
(9)
Switch board (X2). See page 227 for more information
1U2 + 1U4
Battery charger for main batteries.
1U4
Battery charger for emergency lighting system.
3R25 + 3R26
Electric heater, controlled by the air conditioner in cab base.
2M3
Compressor for air conditioner in operators cab (including

crankcase heater).
2M2
Compressor for air conditioner in cab base (including crankcase

heater).
1U1
Inverted rectifier. The inverted rectifier is protected by one

1.6AT fuse at the (+) terminal and one 10A circuit breaker at
the terminal no. (11). The controls and monitors of the rectifier
are located on panel (6).
REMARK:
The units 1U1, 2M2, and 2M3 are located below the floor
plates in the cab base.
Refer to the operation and maintenance manual, for further

information.
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10
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1.1
Section 1.0
Page 10
Superstructure
1.1.7
Operators cab

(1)
(2)
(3)
(E19)
Monitor panel
Switch panel
Operators seat
Control lever
EURO Control
KMG Control
(E20)
Control lever
EURO Control
KMG Control
(E21a)
Control pedal
A - forward
Left track
B - reverse
(E21b)
Control pedal
A - forward
Right track
B - reverse
(E22)
(E23)
(E24)
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Control pedal Control pedal Control pedal -
Swing brake
Bucket closing
Bucket opening
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11
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1.1
Section 1.0
Page 11
Superstructure
1.1.8
Main pumps and Control blocks

(1)
Main pumps (prime mover 1)
(2)
Main pumps (prime mover 2)
(3)
High pressure filter
(4)
Main control blocks
(5)
Remote control valves
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12
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1.1
Section 1.0
Page 12
Superstructure
1.1.9
Swing gears

(1)
Oil level gauge
(2)
Oil filler plug
(3)
Breather filter
(4)
Oil level gauge and filler tube.
(5)
Breather filter
(6)
Oil drain plug
(7)
Drain plug
(8)
Pinion
(20.1 20.3) Swing motors
(49.1 49.3) Swing brake valve blocks
(50.1 50.3) Swing gear boxes with integrated spring loaded multi disk brakes
(Released by oil pressure)
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13
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1.2
Section 1.0
Page 13
Under carriage
(1)
Undercarriage center body
(2)
Crawler carrier
(3)
Connecting pins, center body to crawler carriers
(4)
Crawler tracks
(5)
Rotary distributor
(6)
Brake valves
(7)
Travel motors
(8)
Parking brakes, spring loaded disk type brakes
(9)
Travel gear
(10) Sprocket
(11) Track rollers
(12) Carrier rollers
(13) Valve block of the hydraulic track tensioning system
(14) Pressure accumulators of the hydraulic track tensioning system
(15) Hydraulic track tensioning cylinders
(16) Guide wheel (Idler)
(17) Slip ring unit
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14
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1.3
Section 1.0
Page 14
Attachment
1.3.1
Backhoe attachment (BHA)

(1)
Boom
(2)
Boom Cylinders
(3)
Stick
(4)
Stick Cylinders
(5)
Bucket
(6)
Bucket Cylinders
(7)
Control arm
(8)
Linkage
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15
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1.3
Section 1.0
Page 15
Attachment
1.3.2

(1)
Boom
(2)
Boom Cylinders
(3)
Stick
(4)
Stick Cylinders
(5)
Bucket backwall
(6)
Bucket Cylinders
(7)
Bullclam
(8)
Bucket Clam cylinders
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Drive
Section 2.0
Page 1

Section
2.0
Page
Prime drive assembly
General
2.1
Flexible coupling
2.2
Pump distributor gearbox (PTO)
2.3
Pump spline shaft lubrication
2.4
PTO Lubrication and cooling - Function
2.5
PTO Lubrication and cooling Adjustments
2.6
Hydraulic pumps location, drive speed and flow rates
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2
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Drive
2.0
Section 2.0
Page 2
Prime drive assembly

(1)
Electric Motor 1
(2)
Electric Motor 2
(3)
Cooling air intake
(4)
Cooling air exhaust
(5)
Alignment shims
(6)
Alignment supports
(7)
Motor frame
(8)
Coupling
(9)
Pump distributor gear (PTO)
General
The two electric motors are solid bolted to the motor frame (7).
The thickness of alignment shims (5) has to be selected according to the
results of the alignment procedure, refer to Parts & Service News AH01523,
last edition for more information.
The alignment procedure must also be carried out when replacing the
electric motor and/or the PTO.
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3
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Section 2.0
Page 3
Drive
2.1
Flexible coupling
(1)
Housing (Rubber support ring)
(2)
Input drive hub (Motor side)
(3)
Output drive hub (PTO side)
(4)
Output drive flange
(5)
Rubber element (Motor side)
(6)
Bolt
Quantity Bolt size (mm)
16
(7)
(8)
(9)
M 27 x 60
Grade
10.9
SW* (mm)
41
Tightening torque (Nm)

960.0 +110.0
Motor drive shaft

Rubber element (PTO side)
Bolt
16
(10)
M 27 x 60
22
M 16 x 310
41

960.0 +110.0
Grade
10.9
SW* (mm)
24

250.0 +30.0
Washer
Nut
Bolt
1
(14)
10.9
SW* (mm)
Bolt
(11)
(12)
(13)
Grade
M 36 x 60
Grade
8.8
SW* (mm)
55

2170.0
Bolt
10
M 18 x 40
Grade
10.9
SW* (mm)
27

360.0
Design:
VULASTIC-L coupling type are provided with two flexible rubber
elements (5 + 8). The flexible ring connect the input drive hub (2) via input
drive flange (4) with the output drive hub (3) of the coupling.
Function:
The high flexible LULASTICL coupling transfers the torque without any
rotational gap. They are wear-resisting and maintenance free. Because of
symmetrical arrangement of the flexible rings, there are no returning forces
either by the torque transfer or the centrifugal forces.
VULASTIC-L couplings dampen rotating vibrations, reducing same by
partial storing of the shock energy and damp noises.
The coupling allows in an acceptable range axial, radial and angular
misalignment of the shafts.
Repair and replacement have to be carried out according to Parts &

Service News AH01523, last edition.
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2.2
Section 2.0
Page 4
Pump distributor gearbox (PTO)

(1)
Oil level gauge
(2)
Oil filler plug
(3)
Breather filter
(4)
Oil level sight gauge
(5)
Flange for heater studs
(6)
Main pump drive shaft housings
(7)
Oil level plug of pump drive shaft housing
(8)
Oil filler plug with breather pipe of pump drive shaft housing
(9)
Oil drain plug of pump drive shaft housing
(10)
Oil drain plug of PTO gear
(11)
Suction line connection for gear oil cooling
(12)
Gear oil temperature probe mounting bore
(13)
Thermostat switch mounting bore cover plate
(14)
Return line connection from gear oil cooler
(15)
Return line connection from cooling system relief valve
(C)
Power take off for hydraulic oil cooler fan drive pump
(D)
Drive flange
(M)
Power take off for main pumps
Detail S.
The arrows at detail S indicates the spray direction of the jet borings.
Pay attention when disassembling / assembling.
Description
The pump distribution gear (PTO gear) is of a spur gear design and driven by
an electric motor.
The PTO gear runs in antifriction bearings and has been provided with a splash
lubrication system. The oil supply of the bearings and tooth contacts takes
place by an injection. The gearwheels are of case-hardened steel.
The hydraulic pumps are directly attached to the gearbox. O-rings included in
the supply enable the unit to be reliably sealed statically.
The gearbox housing is of one-piece design and made of grey cast iron. Gearbox
design allows a direct attachment to the drive motor via connection flange.
The gearbox has been provided with connections for a separate cooling system
resp. for heating rods. For more information refer to the REPAIR MANUAL
Description for the lubrication see next pages.
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2.3
Section 2.0
Page 5
Pump spline shaft lubrication

Drive shaft housings
(1)
Oil filler plug with breather pipe of pump drive shaft housing
(2)
(3)
(A)
Configuration, main pump drives
(B)
Configuration, auxiliary pump drives
All drive shaft housings are filled with the same gear oil as the pump
distributor gear.
This is done for two reasons:
1. To lubricate the multi-spline connections, to prevent wear and corrosion.
2. It makes it easier to determine a sealring leak at one of the drive shaft
connections.
Function:
If the oil level increases the oil drops out of the breather pipe (1).
If this oil is gear oil it indicates a possible leak at the gearbox side.
If the oil is a mixture of gear oil and hydraulic oil it shows a possible
leak at the pump side.
If at an oil level check a loss of oil is found it may be due to worn or
defective radial seal rings.
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6
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2.4
Section 2.0
Page 6
PTO Lubrication and cooling

The machine is equipped with two motors and gearboxes. The motor to the front
is called motor 1 and the motor close to the counter weight is called motor 2. The
extension of the component designation shows the mounted position. Example:
Pressure filter (69.1) is the pressure filter for the PTO lubrication of motor 1 and
(69.2) for motor 2.
(1)
Line to the cooler (hot gear oil)
(2)
Return line from valve (74.1 74.2)
(3)
Case drain line from valve (74.1 74.2)
(4)
Return line from the cooler (cooled gear oil)
(5)
Pressure line to hydraulic fan drive motor
(6)
Hydraulic fan drive motor
(7)
Return line to hydraulic tank
(9.2 + 9.4)
Gear pump PTO-gearbox lubrication
(69.1+69.2)
Pressure filter - PTO gear lubrication
(74.1+74.2)
Pressure relief valve, 7.5 bar
(96)
Hydraulic oil tank
(114.1+114.2)
Pressure reducing valve (fan speed)
(116.1+116.2)
Check valve (anti cavitation valve for fan drive motor)
(117.1+117.2)
Gear Oil cooler unit (incl. hydraulic fan motor)
(B17-1+B17-2)
Pressure switch, 0,5 bar
(B27-1+B27-2)
Maintenance switch, 5 bar
(B49-1+B49-2)
Temperature sensor
(M21-1+M21-2)
Pressure check point (fan speed)
(P)
Pressure port
(Y201-1+Y201-2) Solenoid valve
Function:
Pump (9.2)/(9.4) forces the gear oil from the gear oil pan through filter
(69.1)/(69.2) to pressure relief valve (74.1)/(74.2). This pressure relief valve acts
as a back pressure valve causing that most of the oil passes through the gear oil
coolers (117.1)/(117.2).
The gear oil coolers are assemblies consisting of frame, cooler element, hydraulic
motor with intake air fan and fan guard. The units are located below the catwalk
in front of the PTOs.
From the coolers the oil flows to the port (P) of the gear and internally via a
system of pipes to the several spray nozzles. The spray nozzles in the gear case
ensure proper and adequate distribution of the lube oil. The circuit is monitored
by the pressure switches (B17-1)/(B17-2). At too low lube oil pressure (0.5 bar), a
fault message will be displayed on the monitor at the dash board.
The gear oil temperature is monitored by the sensor unit (B49-1) (B49-2). At too
high oil temperature a fault message will be displayed on the monitor at the dash
board.
During the warm up period solenoid valve (Y201-1) / (Y201-2) is de-energized so
that the oil flow through the cooler is interrupted, which causes that the oil gets
quicker its optimum operating temperature.
At normal operating temperature solenoid valve (Y201-1/Y201-2) is energized and
opens the oil flow through the oil coolers.
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2.5
Section 2.0
Page 7
PTO Lubrication and cooling Adjustments

(1)
(2)
(3)
(4)
(5)
(6) Port for pressure check stud

(7) Jet bore
(8) Valve spring
(9) Seal rings
(A) Pressure port
(T) Return from valve
(74.1+74.2)
Pressure relief valve, 7.5 bar
(114.1+114.2)
Pressure reducing valve (fan speed)
(117.1+117.2)
Gear Oil cooler unit (incl. hydraulic fan motor)
(M8-1+M8-2)
PTO lubrication pressure
(M21-1+M21-2)
(Y6a/b-1 / Y6a/b-2) Solenoid valve Hydr. oil cooler fan speed (max. pressure if
de-energized)
Pilot operated relief valve

Plug screw
Valve piston
Port for pressure switch B17-1/-2
"Y"- port (external return to tank)
The adjustment of the maximum permissible PTO lube pressure,

has to be carried out with warm oil.
Setting the pressure relief valve (74.x)

1.
Connect a pressure gauge to check point (M8-1 / M8-2)
2.
Start the respective motor
3.
Required pressure: 7,5 bar.
If adjustment is required:
4.
Remove protection cap (1a).
5.
Loosen lock nut (1b).
6.
Set the pressure with set screw (1c).
7.
Tighten lock nut (1b) and re-install protection cap (1a)
If the pressure of 7,5 bar cannot be adj. 100 %, adj. to the lowest
visible pressure.
Adjustment of the PTO cooler fan drive speed

1.
Connect a pressure gauge to check point (M21-1 / M21-2)
2.
Disconnect plug of solenoid valve Y6a/b-1 / Y6a/b-2
3.
Start the respective motor
4.
Check the fan speed with a non-contact rev counter
Required fan speed: 2200 min-1 at about 100 bar
5.
Correct the speed at pressure reducing valve 114.1 /114.2 if necessary
6.
Reconnect plug of solenoid valve Y6a/b-1 / Y6a/b-2
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Section 2.0
Page 8
Drive
2.6
Hydraulic pumps location, drive speed and flow rates

(1 - 8)
Axial piston pump (swash plate type)
pump volume
Vg
theoretical flow rate, each
Qmax
Drive speed*
n
for all working motions
(9.1 + 9.3)
(9.2 + 9.4)
Gear pump
pump volume
theoretical flow rate
Drive speed*
for pilot pressure supply
Vg
Qmax
n
= 110.8 cm/rev
= 152 Liter/min
= 1378 min-1
Gear pump
pump volume
Drive speed*
for PTO gear lubrication
Vg
Qmax
n
= 110.8 cm/rev
= 152 Liter/min
= 1378 min-1
(10.1 10.4) Axial piston pump

pump volume
Drive speed* for
Hydr. oil cooler fan drive
PTO cooler fan drive
(13)
Gear pump
pump volume
Drive speed*
for flushing the travel motors
= 750 cm/rev
= 1034 Liter/min
= 1378 min-1
Vg
Qmax
n
Vg
Qmax
n
= 108 - 160 cm
= 188 - 278 Liter/min
= 1741 min-1
= 58,7 cm/rev
= 82,2 Liter/min
= 1378 min-1
* at 1800 min-1 input drive speed (60 Hz) and
1500 min-1 input drive speed (50 Hz)
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Section 3.0
Page 1

Section
3.0
Page
General lay out
3.1
Main oil tank, location of switches, sensors etc.
3.2
Suction oil tank with strainers
3.3
Return oil collector tube with strainer
3.4
Back pressure valve
3.5
Transfer pump
3.6
Return and Leak Oil Filter
3.7
Breather Filter
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Section 3.0
Page 2
General lay out

(1)
Filter cover retainer
(2)
Filter cover
(3)
Filter element
(51.1 51.7) - Return oil filter - 10 m
(66)
- Case drain filter - 3 m
(4)
Man hole cover
(26)
Back pressure valve
(40)
Suction oil tank
(54)
Shut off valve with S31 (Gate valve)
(55)
Compensator
(55a)
Intermediate pipe with inspection cover for strainer (56)
(56)
Suction oil strainer
(51.1 51.7)
Return oil filter
(57.1 57.3)
Breather filter
(58.1 58.3)
Oil drain, quick release coupling
(66)
Case drain filter
(95)
Strainer oil cooler
(96)
Main oil reservoir
(97)
Hydraulic oil level gauge
(98)
Filler screen
(M13)
Leak oil filter chamber pressure check point
(M14)
Return oil filter chamber pressure check point
(M15)
Back pressure check point
The hydraulic oil tank is a welded sheet-metal construction.
The capacity is about 7750 litres. The tank contains seven return oil filters (51.1
51.7) and one case drain filter (66).
The breather filter (57.1 57.3) cleans the air that streams into the tank.
The back pressure valve (26) and the pressure check point (M15) are located at
the collector tube for return oil.
The connection to the suction tank can be closed with the shut- off valve (54) to
prevent oil flow during repairs on the hydraulic pumps. This unit is monitored by
the switch S31, to make sure that the a motor will not start with a closed shut-off
valve. Fault message Start blocked because of main Shut-Off (gate) valve is
displayed at the operators dash board.
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Section 3.0
Page 3
Main oil tank, location of switches, sensors etc.

(B4)
Oil level sensor Hydraulic oil level too low
(B15)
Hydraulic oil temperature probe
(B24)
Breather filter pressure switch
(B25)
Pressure switch Pressure leak oil chamber
(B26)
Pressure switch Pressure return oil chamber
(B32)
Hydraulic oil temperature probe Temp. gauge cabin
(B42)
Oil level sensor Oil level maximum
(B50)
Oil level sensor Hydraulic oil refill level
(B68)
Oil level switch Turns off transfer pump when return oil
filter chamber is empty
(B165)
Differential pressure switch (2 bar) Monitoring of
strainer oil cooler
(M8)
Electric motor of transfer pump
(S31)
Proximity switch Gate valve monitoring
(S35)
Switch transfer pump ON / OFF
(Y101)
Solenoid valve Back pressure reduction
(1B7)
Thermostat switch for pre-heating
(1B15 1B21)
Thermostat switches for heater elements
(1R15 1R21)
Pre-Heating elements
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Section 3.0
Page 4
Suction oil tank with strainers

(1)
Suction hose
(2)
Suction hose connection pipe
(3)
Gaskets
(40)
(54)
Shut off valve (Gate valve)
(55)
Compensator
(55a)
Intermediate pipe with inspection cover for strainer (56)
(56)
Main suction oil strainer
(75.1 75.8)
Suction strainer one for each main pump
(96)
Main oil reservoir
(1B14)
Thermostat switch for pre-heating
(1R12 1R14)
Pre-Heating elements
The suction oil tank (40) is a welded sheet-metal construction.

The capacity is 520 liters.
The suction lines of all hydraulic pumps are connected to the suction tank.
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Section 3.0
Page 5
3.3
Return oil collector tube with strainer

(1)
Return oil collector tube - Part 1 (2)
Strainer
(5)
Bolt
Quantity
8
(6)
M 20 x 70
Grade
SW*
(mm)
10.9
30
Grade
SW*
(mm)
10.9
30
Tightening
torque (Nm)
510
Bolt
Quantity
8
(7)
(8)
(86)
(93)
*
Bolt size
(mm)
Bolt size
(mm)
M 20 x 90
Tightening
torque (Nm)
510
Self locking nut

Gasket
Pressure switch (B165)
Pulsation damper
SW = Wrench size
Task:
The strainer (monitored by differential pressure switch B165) is installed to
prevent the hydraulic oil coolers from getting clogged up in case of
contamination in the main return circuit oil.
Excessive increase of the hydraulic oil temperature can be an indication for a
restricted strainer, i.e. bad cooling performance due to insufficient oil flow
through the coolers.
In case that main components such as cylinders or motors are internal
fragmentary damaged, the strainer should be inspected for metal chips.
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3.4
Section 3.0
Page 6
Back pressure valve

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

refer to Section 4.0 this Manual.
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Section 3.0
Page 7
Transfer pump
(1)
Shut-off valve for return oil compartment and leakage oil filter chamber
(2)
Shut-off valve for return oil collector pipe
(3)
Shut-off valve suction oil reservoir
C - Closed
O - Open
(4)
Operating switch for pump (5)
(5)
Transfer pump
(6)
Return oil compartment
(7)
Main oil reservoir
(8)
Vent plug, remove before transfusing oil from return oil compartment
and leakage oil filter chamber into the main reservoir
(9)
Return oil collector pipe
(10)
Hand wheel of the main shut-off valve between main- and suction oil
reservoir
(11)
Vent plug on top of the main oil reservoir, remove before transfusing
oil from return oil compartment and leakage oil filter chamber into
the main reservoir
(12)
Leakage oil filter
(13)
Return oil filters
(14)
Breather filters
Functions of the Transfer Pump:
1 - Transfusing the oil from the return oil compartment and leakage oil
filter chamber into the main oil reservoir.
Necessary for filter service and for hydraulic oil change.
2 - Transfusing oil from return oil collector tube and back-pressure valve
pipe into main oil reservoir. Necessary when changing the hydraulic oil
and prior to servicing the high pressure filters, the main control valves,
or hydraulic oil cooler (oil return system).
3 - Transfusing oil from the suction oil reservoir into the main oil reservoir.
Necessary for evacuation of the suction oil reservoir, when changing
the hydraulic oil. Prior servicing the main hydraulic pumps it is
advisable to empty the suction oil reservoir partially.
During normal operation the valves (1, 2 and 3) must be in closed

position C.
Refer to the operation and maintenance manual, for further
information.
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3.6
Section 3.0
Page 8
Return and Leak Oil Filter

(1)
Filter cover retainer
(2)
Filter cover with o-ring
(3)
Pre-tensioning spring
(4)
Retainer
(5)
Filter assembly
(6)
Filter pot with machined cover
(7)
Main filter element, 10 micron absolute for return oil
3 micron absolute for leak oil
(8)
Safety filter element (200 micron strainer) same for return and leak oil
(9)
By pass-valve, 2.3bar
(9.1)
Valve cone
(9.2)
Valve spring
(9.3)
O-ring
(10)
Profile gasket
(11)
Seal ring
(12)
Self locking nut
(13)
Self locking nut
Function:
The returning oil flows into the filter chamber (A) of the hydraulic tank. (The
sketch shows one section only).
The chamber is split into two sections; one section with 4 filter elements for the
return oil (10 micron) and another section with one filter element for the leak oil
(3 micron). But the structure of the five filter assemblies is basically the same.
The hydraulic oil enters the filter at the top and passes then on its way to the
entire tank the filter-element (7). "Inside to outside filtration."
The filter element condition is monitored by a pressure switch (B25, 0.5 bar for
the leak oil filter) and (B26, 2 bar for the return oil filter).
As soon as the pressure inside the filter chamber reaches the set pressure of those
switches due to the restriction of the filter-element which is caused by foreign
matters, the fault message Return oil filter restricted" or Leak oil filter
restricted is displayed at the operator's dash board The filter elements must be
replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As
the filter chamber pressure increases the by-pass valve opens at 2.3 bar and
protects the element from bursting.
But the oil flows not totally unfiltered into the tank because it must flow through
the strainer (8).
The switch point of the pressure switch for the leak oil has been
chosen so low with best intention to protect first of all the radial seal
rings of the hydraulic motors.
Refer to the maintenance manual, for further information
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Section 3.0
Page 9
Breather filter
(1)
Nut
(2)
Cover
(3)
Filter element
(4)
Filter pot
(B24) Vacuum type pressure switch
A breather filter is installed to clean the air that streams into the tank any time
the oil level decreases while extending attachment cylinders
The filter element condition is monitored by a vacuum type pressure switch
(B24, 80mbar).
Refer to the maintenance manual, for further information
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Hydraulic Oil Cooling
Section 4.0
Page 1

Section
4.0
Page
Hydraulic oil cooling
4.1
General
4.2
Function of the hydraulic oil cooling circuit
4.3
4.4
4.5
4.2.1 Standard hydraulic oil cooling circuit
4.2.2 Additional hydraulic oil cooling circuit
Back Pressure Valve

4.3.1 Adjustment of the Back Pressure Valve
4.3.2 Qmax adjustment
6+7
Fan drive of standard cooler

4.4.1 Two stage cooler fan RPM control
4.4.2 Pressure relief valves and solenoid valves
9 + 10
4.4.3 Fixed Displacement Pump, with variable setting
11
4.4.4 Adjustment of the cooler fan drive speed
12 + 13 + 14
4.4.5 Function check of fan speed control
15
4.4.6 Switch points cooler fan speed (PLC controlled)
15
Fan drive of additional cooler

4.5.1 Function of the cooler fan RPM control
16
16
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4.1
Section 4.0
Page 2
General
The hydraulic oil cooling system maintains the hydraulic oil at a normal
operating temperature.
Legend for illustration (Z 22797)
(1)
Standard cooler assembly with swing out facility
(2)
Additional oil cooler assembly with swing out facility
(3)
Hydraulic motor of upper fan (driven by prime mover 2)
(4)
Upper fan
(5)
Upper cooler set (4 identical cooler elements 106.1 to 106.4)
(6)
Hydraulic motor of lower fan (driven by prime mover 1)
(7)
Lower fan
(8)
Lower cooler set (4 identical cooler elements 106.5 to 106.8)
(9)
Hydraulic motor of additional fan (driven by prime mover 1)
(10)
Hydraulic motor of additional fan (driven by prime mover 2)
(11)
Additional cooler set (2 identical cooler elements 151.1 and 151.2)
(12)
Drive shaft
(13)
Shaft protecting Sleeve
(14)
Drive shaft seal
(15)
Ball bearings
(16)
Seeger clip ring
(17)
Breather filter
(18)
Oil level plug
(19)
Bearing group housing
(20)
Bearing group carrier
Design:
The hydraulic oil cooler, installed in front of the hydraulic tank is divided in
two parts:
A. The standard cooler assembly (1) with eight cooler elements mounted
in one frame. The air stream needed for the cooling is produced by
hydraulically driven fans. The air flows from inside to outside through
the coolers.
For easy cleaning, the coolers can be opened. ("Swing out cooler")
The bearing group housing is filled with oil to lubricate the bearings.
B. Additional oil cooler assembly (2) with two cooler elements mounted in
one frame on top of the standard cooler assembly. The air stream needed
for the cooling is produced by hydraulically driven fans. The air flows
from inside to outside through the coolers.
For easy cleaning, the coolers can be opened. ("Swing out cooler")
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Section 4.0
Page 3
4.2.1 Function of the hydraulic oil cooling circuit

Standard circuit
(26)
Back pressure valve
(93)
Accumulator (Pulsation damper)
(96)
Main oil reservoir
(106.1 106.8) Hydraulic oil cooler elements
(107.1 107.4) Restrictor, shock absorbers for the hydraulic oil cooler
(L20 L22)
Supply line for the anticavitation circuit of the swing motors
(L23 L27)
Return line from control blocks
(L28 L32)
Supply line for the anticavitation circuit of attachment cylinders
(M15)
Pressure check point
(Y101)
Solenoid valve 4/2-directional control valve
(H)
Lines to cooler (hot oil)
(C)
Lines to tank (cold oil)
Function:
The returning oil from the system flows via the lines into the collector tube.
On the top of it is the Back Pressure Valve (26) installed.
The back pressure valve (26) causes a back pressure which forces most of the
relative hot oil through the lines (H) to the cooler (106.1 106.8).
The hydraulic oil passes first the restrictors (107.1 107.4) before it gets
cooled in the cooler elements and flows than through and the lines (C) into
the filter chamber of the main oil reservoir (96).
The restrictors are acting like shock absorbers and prevent together with the
pulsation damper (93) cooler cracking at pressure peaks.
Besides the back pressure valve acts as an oil flow control valve as far as the
oil temperature has not reached its steady temperature.
During the warm up period (1/2 Qmax) the back pressure valve (26) is wide
open, because solenoid valve Y101 is energized, which results in less oil flow
through the cooler which causes that the oil gets quicker its optimum
operating temperature.
With increasing oil temperature the oil gets thinner, so that the main pumps
can be shifted to Qmax position and simultaneously solenoid valve Y101 will
be de-energized, so that the valve piston will be more closed by the force of
the spring thus that more oil passes the cooler.
(See sectional drawing on page 5.)
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Section 4.0
Page 4
4.2.2 Function of the hydraulic oil cooling circuit

Additional circuit
(10.1 + 10.3)
Fan drive pumps (fixed displacement pump, with variable setting)
(23.1 + 23.2)
Fan drive motors (standard cooler)
(68.2 + 68.4)
Pressure filter with pressure differential switch
(96)
Main oil reservoir
(151.1 + 151.2) Additional oil cooler elements
(152.1 + 152.2) Fan drive motors (additional cooler)
(H)
(C)
Function:
Oil delivery of both fan drive pumps (10.1+10.3) is directed to the additional cooler
elements (151.1+151.2) after leaving the four fan drive motors (103.3+103.4 and
152.1+152.2) and flows back into the filter chamber of the main oil reservoir (96).
This ensures that a constant oil volume circulates through the additional cooler,
independent of the main return oil flow.
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Section 4.0
Page 5
4.3 Back Pressure Valve

4.3.1 Adjustment of the Back Pressure Valve
Checks and settings only at normal operating temperature of the hydraulic oil,
main pumps in maximum flow position and "Idle Time" control eliminated.
1.
Connect a pressure gauge to check point (M15).
2.
Disconnect plug connector (13) of solenoid valve Y101.
3.
Actuate service switch S155 in to position Qmax.
4.
Start both motors
5.
Required pressure: 10 0,5 bar
a) Take off protective cap (12).
b) Loosen lock nut (5).
c) Alter the pressure with the set screw (6).
d) Tighten lock nut (5) and refit protective cap (12).
6.
Disconnect the pressure gauge, reconnect solenoid valve Y101 and
switch back service switch S155 in to automatic mode (center
position).
(1)
Control oil port
(2)
"Y"- port (external return to tank)
(2a)
"X"- port (external return to tank via solenoid valve Y101)
(3)
Poppet
(4)
Valve spring
(5)
Lock nut
(6)
Set screw
(7)
Jet bore (large)
(8)
Valve spring
(9)
Valve piston
(10)
Jet bore (small)
(11)
Plug screw
(12)
Protective cap
(13)
Plug connector
(A)
Return to tank (Filter chamber)
(Z)
Pressure oil to valve
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4.3.2
Section 4.0
Page 6
Qmax adjustment
For efficient hydraulic oil cooling during idle time all pumps are automatically in
Qmax position reducing the circulating oil volume so that oil flows only
through the oil coolers. If all pumps would stay in Qmax position during idle time
a high amount of the circulating oil would pass the back pressure valve before
returning in the oil tank this would waste energy and create adverse high oil
temperatures.
Before Qmax adjustment is made the back pressure valve must be
correct adjusted with all pumps in Qmax position and hydraulic oil
at operating temperature.
All main pumps must be correctly adjusted i.e. start of de-stroking
and Qmax stop bolt setting. See section 7 in this Service Manual for
adjustment procedure.
Precondition
The actual PLC software with Qmax idle control must run on the PLC.
Make sure that the filled in hydraulic oil viscosity is selected at the PLC.
See Operation and Maintenance Manual to select the oil viscosity.
Procedure:
1.
2.
3.
4.
5.
6.
7.
Connect a pressure gauge to back pressure check point (M15).

Connect a pressure gauges to the X3 pressure check point (M36).
Start both motors (both diesel engines must run at high idle)
Warm up hydraulic oil so that the hydraulic oil cooler fans run with
maximum speed, controlled by the PLC (oil temperature above T3).
With all controls in neutral position the pumps should move in Qmax
position, because of the de-energised solenoid valve Y17a.
Unplug solenoid valve Y17a to keep the valve de-energised.
Check the X3 pressure at test point M36 in the Qmax position of the
pumps. The pressure indicated on the gauge should be 155 bar.
continued
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Section 4.0
Page 7
4.3.2 Qmax adjustment

Contd.
8.
Check back pressure at test point M15.

if the pressure is lower as the required normal back pressure of 10bar
continue with next item Nr.9.
if the pressure shows the required normal back pressure of 10bar
decrease the X3 pressure setting with pressure reducing valve (244.4)
until the back pressure drop to a lower pressure as 10bar.
a) Loosen lock nut.
b) Correct the pressure with the set screw.
- turn clock wise (cw) to increase the pressure
- turn counter clock wise (ccw) to decrease the pressure
c) Tighten lock nut.
9.
Increase pump delivery by increasing the X3 pressure setting of pressure

reducing valve (255.4) which in turn increases the back pressure. As
soon as the gauge (M15) shows 10 bar (equal to back pressure valve
setting) stop adjustment.
Check the resulting X3 pressure at test point M36 and record it for later
checks, the values must be distinctly lower as the max X3 pressure (45
bar).
Check the back pressure after activating a control lever or activate Qmax
switch S155. The pumps change now to Qmax but the back pressure
must stay constant at 10 bar (check point M15).
Turn switch S155 back to normal operating position (center position) and
remove all gauges.
10.
11.
12.
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8
13.
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Section 4.0
Page 8
4.4.1 Two stage cooler fan RPM control

(10.1 + 10.3)
(23.1 + 23.2)
(45.1 + 45.2)
Pressure relief valve (maximum fan speed)
(48.1 + 48.2)
Pressure relief valve (medium fan speed)
(103.3 + 103.4) Check valve (Anti cavitation valve for fan drive motor)
(68.2 + 68.4)
Pressure filter with pressure differential switch
(Y6a/b-1 / -2)
Solenoid valve
(M6-1 / -2)
Function:
From pump (10.1 + 10.3) flows the oil through the filter (68.2 + 68.4) to the fan
motors (23.1 + 23.2) and then back to the tank. (or through additional cooler if
installed)
The check valve (103.3 + 103.4) act as an anti cavitation valve and is installed,
because the fan motor -driven by inertial force- is running for a short period after the
oil flow is inerrupted by solenoid valve (Y6a/b-1 / -2), or if the motor has been
switched off.
The hydraulic circuit "Fan drive" is protected by the pilot controlled pressure relief
valves (45.1 + 45.2) and (48.1 + 48.2).
These valves are working together with the solenoid valve (Y6a/b-1 / -2), controlled
by the ECS - system, depending on the hydraulic oil temperature:
With de-energized solenoids Y6a and Y6b the relief valve (45.1 + 45.2) is
functioning and the fans are running with max. adjusted speed (1250 RPM)
With solenoid Y6a energized the relief valve (45.1 + 45.2) is not functioning
and the fans are running with a very low speed caused by the flow resistance
only.
With solenoid Y6b energized the relief valve (48.1 + 48.2) is controlling the
relief valve (45.1 + 45.2) and the fans are running with 1000 RPM only.
(See also description on next page)
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Section 4.0
Page 9
4.4.2 Pressure relief valves and solenoid valve

Pressure relief valve (45.1 + 45.2)
Legend for illustration (Z 21598b)
(1)
Valve cartridge
(2)
Spring
(3)
Spring chamber
(4)
"X" port
(5)
Jet bore, Pilot poppet
(6)
Jet bore, Main piston
(7)
Main piston
(8)
Valve housing
(9)
Pilot poppet
(Y)
External leak oil port
(A)
Pressure port
(B)
Return oil port
Function:
Pressure in line A affects the main piston (7). At the same time there is pressure
via the jet bore (6) on the spring-loaded side of the main piston and via jet bore (5)
at the pilot poppet (9) of the relief valve cartridge (1).
If system pressure in line A exceeds the value set at the spring (2), pilot poppet (9)
opens. The signal for this comes from line A via the jet bores (6) and (5).
The oil on the spring-loaded side of the main piston (7) now flows via the jet bore
(5) and poppet (9) into the spring chamber (3).
From here it is fed internally by means of the control line (Y) to tank (port B).
Due to the state of equilibrium at the main piston (7), oil flows from line A to line
B, while the set operating pressure is maintained.
The pressure relief valve (45.1 + 45.2) can be unloaded (Remote controlled) by
means of the port "X" and the combined function of solenoid valve Y6a/b-1 / -2
with pressure relief valve 48.1 + 48.2 .( Function see next page)
continued
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Section 4.0
Page 10
4.4.2 Pressure relief valves and solenoid valve, illustration (Z 21599c)

Contd.
Function:
With de-energized solenoids (Y6a and Y6b), the spool (3) keeps the "X"
connection of valve (45.1 + 45.2) and port B to port P closed. The pressure relief
valve (45.1 + 45.2) operates normal.
The energized solenoid Y6b, operate the spool (3) and a connection is made
between port P and port B and port "X" of valve (45.1 + 45.2).
The system pressure now opens the main piston (7) of valve (45.1 + 45.2), because
via solenoid Y6b (P to B) the oil from the rear side of piston (7) flows from the "X"port to the P connection of valve (48.1 + 48.2). The normal valve function is now
remote controlled by the pressure adjusted at valve (48.1 + 48.2).
The energized solenoid Y6a, operate the spool (3) and a connection is made
between port P and port A and port "X" of relief valve (45.1 + 45.2).
The system pressure now opens the main piston (7) of valve (45.1 + 45.2) because
via the "X"-port the oil from the rear side of piston (7) flows to tank. The normal
relief valve function is eliminated.
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Section 4.0
Page 11
4.4.3 Fixed Displacement Pump, with variable setting

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

cavitation and over-speeding the hydraulic motor!
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Section 4.0
Page 12

Basic Adjustment Maximum Speed
(a)
Dust cap
(b)
Lock nut
(c)
Set screw
(6)
Qmin stop bolt
(6.1)
Lock nut
(7)
Qmax stop bolt
(7.1)
Lock nut
(10)
Positioning pin (mover)
(L1)
Measurement of Qmin stop bolt
(L2)
Measurement of Qmax stop bolt
(10.1 + 10.3)
(23.1 + 23.2)
(45.1 + 45.2)
Pressure relief valve (maximum fan speed)
(Y6a/b-1 / -2)
Solenoid valve
(M6-1 / -2)
Basic adjustment has to be carried out whenever one of the following

components has been replaced:
- pump
- relief valve
- hydraulic motor
1. Reduce the output flow of pump (10.1 and/or 10.2), by adjusting the
minimum possible swivel angle, to avoid over speeding the fan:
To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)
and turn in bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts.
2. Remove protection cap (a) from relief valve (45.1 and/or 45.2), loosen lock
nut (b) and turn set screw (c) fully clockwise and then a half turn counter
clockwise.
3. Isolate the function of solenoid valve (Y6a/b-1 and/or Y6a/b-2), by
disconnecting both plug connectors, to ensure that the full flow of pump
10.1 and/or 10.2 will be delivered to the fan motor.
continued
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Section 4.0
Page 13
4.4.4 Adjustment of the cooler fan drive speed, illustration Z22802

Cont'd
Basic Adjustment Maximum Speed
4. Connect a pressure gauge to check point (M6-1 and/or M6-2).
5. Start the respective motor.
6. Check the fan speed with a non-contact rev counter
Required fan speed: 1250 min-1
Be careful not to get caught in the fan or other rotating parts
7. Increase the output flow of pump (10.1 and/or 10.2), by adjusting the
swivel angle, until the fan speed will be 20 min-1 higher than required:
To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6)
and turn out bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts (6.1 + 7.1).
Do not exceed the maximum permissible operating pressure of 230bar.
Note down the lengths L1 and L2 as reference measurements.
8. Loosen lock nut (b) of the relief valve (45.1 and/or 45.2), and decrease
the pressure with set screw (c) until the correct fan speed is obtained.
9. Tighten lock nut (b) and fix protection cap (a).
continued
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Section 4.0
Page 14
4.4.4 Adjustment of the cooler fan drive speed, illustration Z22804

Cont'd
Basic Adjustment Medium Speed
10. Activate the function of pressure relief valve (48.1 and/or 48.2), by
connecting the plug connector of solenoid valve Y6a/b-1 and/or Y6a/b-2.
11. In order to ensure a proper function of solenoid valve Y6b during the
adjustment, energize the valve by using the manual control Digital Outputs
of the ECS-System ( refer to section 5 of the operation manual), or
activate Y6b, by connecting the solenoid plug to permanent 24 V. Use the
24V socket at the PTO *)
12. Loosen lock nut (e) of the relief valve (124), and turn set screw (f) fully
counter clockwise and then clockwise until the correct fan speed is obtained.
Required fan speed: 1000 min-1
13. Tighten lock nut (e) and fix protection cap (d).
14. Note down the pressure as reference value (expected ~ 150 bar)
15. Disconnect the pressure gauge from check point (M6).
16. Connect the plug connector of solenoid valve Y6a.
*) Prepare a test wire with a plug ET-No. 891 039 40, and a plug ET-No. 440
305 99. Connect terminal 1 to positive (+) (center off plug 440 305 99) and
terminal 2 to ground (-).
4.4.5 Function check of fan speed control
Switch manually the output signals to Y6a/b and check the fan speed:
Y6a
Y6b
0
0
Y6a
Y6b
0
1
Y6a
Y6b
1
0
nmaximum 1250 min-1
nmedium 1000 min-1
nminimum 0 - 50 min-1
For operating instructions of the ECS system refer to section 3.4 of the
operation manual
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Section 4.0
Page 15
4.4.6 Switch points of cooler fan speed (PLC controlled)

Switch points with hysteresis:
30C
39C
48C
56C
65C
VG22:
VG32:
VG46:
VG68:
VG100:
46C
57C
67C
73C
73C
Switch point: Speed decrease
Fan speed
Maximum
Medium
Minimum
Temperature
Switch point: Speed increase
PC8000-6-E_Sec_4-0_#12044_rev2.doc
67C
58C
50C
41C
32C
VG100:
VG68:
VG46:
VG32:
VG22:
75C
75C
69C
59C
48C
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4.5
Section 4.0
Page 16
Fan drive of additional cooler

(10.1 + 10.3)
(23.1 + 23.2)
(103.3 + 103.4) Check valve (Anti cavitation valve for fan drive motor)
(152.1 + 152.2) Fan drive motors (additional cooler)
(154.1 + 154.2) Pressure reducing valves Fan drive additional oil cooler
(Y6a/b-1 / -2)
Solenoid valve
(M21-3 / -4)
4.5.1
Function of the cooler fan RPM control

Since the oil delivery of the fan drive pumps (10.1 + 10.3) is used for the standard
fan motors 23.1 + 23.2 and for the additional fan motors 152.1 + 152.2, the speed
of the additional fans depends on the speed control of the standard fans.
Therefore only the maximum speed of the additional fans can be adjusted with the
cooler standard fans running at maximum speed.
The maximum speed adjustment of the additional fans must be carried out to
ensure the intended cooling performance of the system.
4.5.2
Adjustment of the cooler fan drive speed

Precondition for this adjustment is the correct setting of the standard
cooler fan drive.
Procedure:
1.
Connect a pressure gauge to check point (M21-3 and/or M21-4).
2.
Unplug solenoid valve (Y6a/b-1 and/or Y6a/b-2). to ensure max.
speed of the standard fan drive.
3.
Start the respective motor.
4.
Adjust* at valve (154.1 and/or 154.2.3) a fan speed of approx. 1550 rpm.
5.
Re-plug solenoid valve (Y6.1 and/or Y6.2).
Be careful not to get caught in the fan or other rotating parts!
How to change the valve adjustment:

Remove dust cap (a).
Loosen lock nut (b).
Adjust the pressure with set screw (c).
Tighten lock nut and install dust cap.
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Section 5.0
Page 1
Controlling

Section
5.0
Page
Controlling
General lay out
5.1
Control and filter panel location of components

(valves, switches, sensors etc.)
3+4+5
5.2
Pilot Pressure Supply and Adjustments
6+7+8
5.3
Remote control valves arrangement
5.4
Function principle of the

Electro-Hydraulic- Proportional Control
10 + 11
5.5
Potentiometer Control (Lever, Joy Stick)
12
5.6
Potentiometer Control (Pedal)
13
5.7
Proportional amplifier module, Type A

(for swing brake only)
14
5.8
Proportional amplifier module, Type B

(for Boom, Stick, Bucket, Swing and Travel)
15
5.9
Ramp Time Module

(Analogue command value module for Boom,
Stick, Travel and Swing function)
16
5.10
Adjustments of Amplifier Modules (General)
17
5.11
Adjusting the Amplifiers Type B
18 + 19
5.12
Adjusting the Amplifiers Type A
20 + 21
5.13
Adjusting the Ramp Time Modules
22 + 23 + 24
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5.0
Section 5.0
Page 2
General lay out

(E19) Electro proportional joy stick control
(E20) Electro proportional joy stick control
(E21a) Electro proportional pedal control, travel left crawler
(E21b) Electro proportional pedal control, travel right crawler
(E22) Electro proportional pedal control, swing brake
(E23) Electro proportional pedal control, bucket closed
(E24) Electro proportional pedal control, bucket open
(9.1)
Gear pump for Pilot pressure (Motor 1)
(9.3)
Gear pump for Pilot pressure (Motor 2)
(36)
Central control and filter panel
(37.1) Control and filter panel (PTO - and Hydraulic oil cooling) Motor 1
(37.2) Control and filter panel (PTO - and Hydraulic oil cooling) Motor 2
(68.1) Pressure filter of pilot pressure pump with pressure differential
switch B22-1 (Motor 1)
(68.7) Pressure filter of pilot pressure pump with pressure differential
switch B22-2 (Motor 2)
(85)
Pressure accumulator (Bladder Accumulator 10 Liter, 10 bar precharge pressure)
(102) Remote control valve blocks
General
The controlling includes the pilot pressure system and the pump regulation
system.
The pumps (9.1 / 9.3) forcing the oil through the filters (68.1 / 68.7) to all
involved valves.
The pressure accumulator (85) ensures that under any circumstances enough
pilot pressure oil is available. The accumulator (85) is also functioning as a
hydraulic battery for a certain time when the engine was shut down or to
pressure relieve the system for repair works.
When the operator is using his controls an electrical signal causes energizing
of the selected solenoid valve of the remote control valves(102).
By the function of the remote control valves pilot pressure oil is send to the
relevant control block spools which in turn allows operating hydraulic oil to
the users.
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5.1
Section 5.0
Page 3

Solenoid valves
(Y5)
Swing parking brake operating pressure
(Y16)
Travel parking brake operating pressure
(Y17)
Idle time control, (Pump control system)
(Y17a)
Q-max (reduced oil flow at too cold oil)
(Y61-1)
X1 pressure, pumps 1 4 (Motor 1)
(Y61-2)
X1 pressure, pumps 5 8 (motor 2)
(Y100)
Reserve
(Y120)
Hydraulic swing brake, maximum operating pressure
(Y123a)
Hydraulic access ladder raise
(Y123b)
Hydraulic access ladder lower
(Y125)
Hydraulic access ladder fast movement
(Y127)
Proportional pressure to hydraulic swing brake
(Y200)
Hydraulic flow heating for attachment (pressure increasing valve boom)
Filter:
(68.1)
(68.7)
Pressure filter of pilot pressure pump 9.1 (Motor 1)

Pressure filter of pilot pressure pump 9.3 (Motor 2)
Pressure switches:
(B16)
Swing parking brake operating pressure
(B22-1)
Pilot pressure pump 9.1 (Motor 1) - Filter element monitoring
(B22-2)
Pilot pressure pump 9.3 (Motor 2) - Filter element monitoring
(B48)
Travel parking brake operating pressure
(B85-1)
Pressure transducer X1 pressure (Motor 1)
(B85-2)
Pressure transducer X1 pressure (Motor 2)
(B86)
Pressure transducer X2 pressure
continued
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5.1
Section 5.0
Page 4

Cont'd:
Miscellaneous:
(85)
Pressure accumulator (10 Liter, 10 bar pre-charge pressure)
(147)
Pressure reducing valve Track tensioning system (35bar)
(252.1)
Pressure reducing valve for pilot pressure X2 (45bar)
(252.2)
Pressure relief valve for pump support pressure X4 (60bar)
(252.3
Check valve (pilot oil from pump 9.1 motor1)
(252.4)
Check valve (pilot oil from pump 9.3 motor2)
(253.1)
Change over valve Electronic pump regulation or hydraulic. constant
regulation Motor 1
(253.2)
Pressure reducing valve hydraulic constant regulation (Motor 1)
(254.1)
Change over valve Electronic pump regulation or hydraulic constant
regulation Motor 2
(254.2)
Pressure reducing valve hydraulic constant regulation (Motor 2)
(255.4)
Pressure reducing valve Qmax (~ 15 bar)
(257.1)
Pressure relief valve Safety valve for Travel brake / Track tensioning
system (55 bar)
(258.3)
Pressure relief valve Hydraulic access ladder (70 bar)
Pressure check points:
(M1.1)
X4, Pump support pressure, Pump bearing lubrication (60bar)
(M1.2)
X2 pressure, pilot pressure (45bar)
(M2)
Bladder Accumulator, pilot pressure (45bar)
(M3.1)
X1 pressure, hydraulic constant regulation Motor 1
(M3.2)
X1 pressure, hydraulic constant regulation Motor 2
(M5.1)
X1 pressure general Motor 1
(M5.2)
X1 pressure general Motor 2
(M9.1)
Travel parking brake operating pressure (45 bar)
(M9.2)
Travel parking brake supply pressure (35 bar)
(M10)
Swing parking brake operating pressure (45 bar)
(M12)
Option operating pressure: fast motion for travel not used
(M30.1)
X4, (60bar) of pump 9.1 only (Motor1)
(M30.2)
X4, (60bar) of pump 9.3 only (Motor2)
(M33)
Reduced X3 pressure to pump No 1 Qmax (~ 15 bar)
(M34)
not used
(M36)
X3 pressure pumps No 2 to No 8
(M37.1)
Hydraulic cylinder access ladder piston side
(M37.2)
Hydraulic cylinder access ladder rod side
(M39)
Proportional pressure to hydraulic swing brake
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5.1
Section 5.0
Page 5

(37.1) Control and filter Panel mounted on front PTO for motor 1 circuit
(37.2) Control and filter Panel mounted on rear PTO for motor 2 circuit
Solenoid valves
(Y6a-1)
Cooler fan RPM control minimum speed (Motor 1)
(Y6a-2)
Cooler fan RPM control minimum speed (Motor 2)
(Y6b-1)
Cooler fan RPM control medium speed (Motor 1)
(Y6b-2)
Cooler fan RPM control medium speed (Motor 2)
Filter:
(67)
Oil filter for flushing circuits of travel motors.
(68.2)
Pressure filter of Oil cooler fan drive pump 10.1 (Motor 1)
(68.3)
(68.4)
(68.5)
(69.1)
Pressure filter PTO 1 gear lubrication pump 9.2 (Motor 1)
(69.2)
Pressure filter PTO 2 gear lubrication pump 9.4 (Motor 2)
Pressure switches:
(B17-1)
Monitoring the PTO 1 gear lubrication pressure (lowest permissible pressure)
(B17-2)
Monitoring the PTO 2 gear lubrication pressure (lowest permissible pressure)
(B21-1)
Filter element monitoring Oil cooler fan drive pump 10.2 (Motor 1)
(B21-2)
(B27-1)
Filter element monitoring PTO 1 gear lubrication pump 9.2 (Motor 1)
(B27-2)
Filter element monitoring PTO 2 gear lubrication pump 9.4 (Motor 2)
(B28-1)
(B28-2)
(B200)
Filter element monitoring (13) for flushing circuit pump. (Motor 2)
Miscellaneous:
(45.1+45.3) Pressure relief valve Max. operating pressure cooler fan drive (Motor 1)
(45.2+45.4) Pressure relief valve Max. operating pressure cooler fan drive (Motor 2)
(48.1)
Pressure relief valve Medium speed cooler fan (Motor 1)
(48.2)
Pressure relief valve Medium speed cooler fan (Motor 2)
(74.1)
Pressure relief valve PTO 1 gear lubrication - oil cooler
(74.2)
Pressure relief valve PTO 2 gear lubrication - oil cooler
(114.1)
Pressure reducing valve Operating pressure fan drive PTO 1 oil cooler
(114.2)
Pressure reducing valve Operating pressure fan drive PTO 2 oil cooler
(M6.1)
Fan drive pressure hydraulic oil cooler (Motor 1)
(M6.2)
Fan drive pressure hydraulic oil cooler (Motor 2)
(M8.1)
PTO 1 gear lubrication pressure
(M8.2)
PTO 2 gear lubrication pressure
(M21.1)
Fan drive pressure PTO 1 cooler (Motor 1)
(M21.2)
Fan drive pressure PTO 2 cooler (Motor 2)
(M30)
Flushing circuit pressure for travel motors.
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5.2
Section 5.0
Page 6

Pilot Pressure Circuit, illustration (Z 22747)
The pilot pressure oil is used for the following functions.
To move the control block spools, to supply the main pump regulation system, to
lubricate the main pump bearings, to release the travel- and swing gear house
brakes (spring loaded multi disk brakes), to operate the hydraulic access ladder, to
drive the grease pumps and to supply the hydraulic track tensioning system.
Function: Study together with the hydraulic circuit diagram

The pumps (9.1 + 9.3) are delivering the oil through the filters (68.1 + 68.7) and
via check valves (252.3 + 252.4) to port A of pressure relief valve (252.2).
The pressure relief valve (252.2) maintains the adjusted pressure of 60 bar, called
X4-pressure.
X4 - pressure: Pump support pressure
Pump bearing lubrication
Actuation of refilling arm and ladder
Lubrication system
The pressure reducing valve (252.1) maintains the adjusted pressure of 45 bar,
called X2-pressure.
X2 pressure: Pilot pressure system
Pump regulation system
Travel- and Swing parking brakes (spring loaded multi -disk
brakes)
The pressure accumulator (85) holds an amount of oil under pressure to provide
sufficient pilot pressure during normal operation and to ensure a limited number
of lowering operations with the main drive motor at standstill.
The check valve (256.6) prevents return flow of the pilot pressure oil.
continued
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5.2
Section 5.0
Page 7

Cont'd:
Pilot Pressure Circuit
(85)
Bladder Accumulator (10 Liter, 10 bar pre-charge pressure)
(96)
(PX2)
(LX2)
Main oil reservoir

Pilot pressure line
Leak / return oil line from the remote control blocks
Function:
The pilot pressure oil flows via line (PX2) to port (P) of each remote control
block and is present via a gallery at all proportional and directional solenoid
valves.
These solenoid valves are energized by the function of the Electro
proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to
the respective spools of the main control blocks with a variable pilot pressure
proportional to the deflection of the controls.
For the location and designation of the proportional and directional

solenoid valves of the remote control blocks refer to page 9 in this
section.
continued
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5.2
Section 5.0
Page 8

Cont'd:
Checks and Adjustment of Pilot Pressure
(85)
Bladder Accumulator 10 liter, 10bar pre-charge pressure
(252.1) Pressure reducing valve for pilot pressure X2 (45bar)
(252.2) Pressure relief valve for pump support pressure X4 (60bar)
(M1.1) Pressure check point X4, pump support pressure (60bar)
(M1.2) Pressure check point X2 pressure, pilot pressure (45bar)
(M2) Pressure check point for accumulator
Since the X2 and the X4 pressure are influencing each other it is

always necessary to adjust both valves 252.1 + 252.2 alternately.
60 bar pressure X4, valve 252.2:
1.
Connect pressure gauge to check point (M1.1)
2.
Start both motors.
3.
Read pressure, required = 60-2 bar
If readjustment is required proceed as follow:
a) Loosen lock nut (1).
b) Set pressure with set screw (2).
c) Tighten lock nut (1).
45 bar pressure X2, valve 252.1:
1.
Connect pressure gauge to check point (M1.2)
2.
Start both motors.
3.
Read pressure, required = 45+3 bar
Checking of Accumulator Function
1.
Connect pressure gauge to check point (M2).
2.
Start both motors.
3.
After build-up of pressure stop the drive motors, but do not turn the
key switch to zero position.
4.
Watch pressure gauge. Pressure should remain constant for at
least 5 minutes.
If the pressure droops the system must be checked for leakages.

To check the accumulator charging pressure refer to PARTS &
SERVICE NEWS AH01531a latest edition.
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Page 9
Controlling
5.3
Remote control valves arrangement

Legend for illustration (Z 21636c)
Remote control unit
Schematic code
(102.1)
(102.2)
(102.3)
(102.4)
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Directional
solenoid
Proportional
solenoid
Y20a
Y20b
Y21a
Y21b
Y22a
Y22b
Y23a
Y23b
Y20
Y24a
Y24b
Y25a
Y25b
Y26a
Y26b
Y27a
Y27b
Y24
Y28a
Y28b
Y29a
Y29b
Y30a
Y30b
Y31a
Y31b
Y28
Y32a
Y32b
Y33a
Y33b
Y34a
Y34b
Y35a
Y35b
Y32
Y21
Y22
Y23
Y25
Y26
Y27
Y29
Y30
Y31
Y33
Y34
Y35
Function
BHA
FSA
L.H. Crawler reverse
L.H. Crawler forward
Stick extending
Stick retracting
Bucket filling (curl)
Bucket emptying (dump)
Boom raising
Boom lowering
R.H. swing
L.H. swing
not used
Boom lowering
Stick extending
Stick retracting
R.H. Crawler reverse
R.H. Crawler forward
Boom raising
Boom lowering
Stick extending
Stick retracting
Clam opening
Clam closing
Boom raising Stick extending
Boom lowering Stick retracting
Stick retracting Boom raising
Stick extending Boom lowering
not used
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5.4
Section 5.0
Page 10
Function principle of the Electro-Hydraulic- Proportional Control

(1)
Pump
(2)
Filter
(3)
Pressure relief valve
(4)
Check valve
(5)
Pressure Accumulator
(6)
Directional Solenoid valve, a side
(7)
Directional Solenoid valve, b side
(8)
Proportional Solenoid valve
(9)
Control valve block
(10)
Battery
(11)
Electronic units with amplifiers etc.
(12)
Control lever (Potentiometer control)
Function:
The electric-hydraulic control system is used to control the direction and
volume of oil flow to the operating cylinders and motors via the control valve
blocks.
Hydraulically:
The oil volume of pump (1) flows through filter (2) into the pilot pressure
system. The pressure is limited by the pressure relief valve (3).
With the pressurized oil stored in accumulator (5), a limited number of spool
movements can be carried out with the main drive motor at standstill.
When a lever (or pedal) is actuated, proportional solenoid valve (8) and one
of the directional solenoid valves (either 6 or 7) are energized, and allows the
pilot pressure oil to flow to the spools of the control blocks.
Electrical
Whenever a lever or a pedal is moved out of its neutral position, an amplifier
will created a current between 0 and 1000 mA. (For detailed information refer
to page 10 in this section)
Depending on the lever direction, simultaneously one of the directional
solenoid valves (either 6 or 7) is energized.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full
stroke position.
continued
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5.4
Section 5.0
Page 11
Function principle of the Electro-Hydraulic- Proportional Control

Cont'd:
(Exemplary illustration of the function of two axis with one Amplifier only)
Legend for illustration (Z 21638c)
(1)
Control lever (joystick)
(2)
Capacitor-Module
(3)
Ramp time module
(4)
Proportional-Amplifier-Module
(5)
Relay (Supply Voltage)
(6)
Proportional solenoid valve-(Pressure-Reducing Valve)
(7)
Directional solenoid valve
(8)
Control block spool
General Function
Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts
and with 24 VDC capacitor supported to create the signal voltage.
When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives
at relay (5) and energizes the Proportional Amplifier (4) with capacitor
supported 24 VDC via terminal 1.
Depending on the function of the control lever, 1 to 4 Amplifiers can be involved
for the Y-axis (forward/ backwards direction) and 1 to 4 Amplifiers for the Xaxis (left/right direction.)
The polarity of the Output Signal from joystick (1), either positive or negative,
between 0 and 10 VDC indicates the direction of the lever movement and is
proportional to the lever deflection. This is the Input Signal to the ramp time
module (3) at terminal 5 which will arrive after the adjusted ramp time delay via
terminal 7 to the proportional amplifier (4) at terminal 5.
This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal
between 0 to 1000 mA and is send via terminal 7 (negative) or terminal 8
(positive) to the Proportional Solenoid valve (6) . Simultaneous a 24V signal is
send to the Directional solenoid valve (7) via terminal 3 (negative) or terminal 9
(positive) to the a or b-side.
The proportional Solenoid valve (6) alters the pilot pressure (X2) of 45 bar to a
value proportional to the Current Signal.
This pressure controls the movement of the control block spool (8) between
neutral and full stroke position.
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5.5
Section 5.0
Page 12
Potentiometer Control (Lever, Joy Stick)

Legend for illustration (Z 21639b)
(1)
Push button *
(2)
Toggle switch *
(3)
Inductive linear transmitter
(4)
Universal joint
(5)
Electronics
(6)
Push pin
(7)
Shaft seal
(8)
Reset spring
(9)
Coil core
(10)
Coil
* Alternative application
The non-contacting lever control (inductive linear transmitter) contains both
the electronic and mechanical components which converts the lever
movement into a proportional electrical voltage. The lever can be operate in
two axes:
Axis "Y", splitted into the half axis Y- and Y + (backward and forward)
Axis "X", splitted into the half axis X- and X + (left and right)
Of course the lever can be moved in any other direction (Joy stick function)
In order to be able to monitor the direction of the lever movement and the
neutral position, the electronics (8) sends a 24V signal as soon as the lever
gets moved out of its neutral position.
For one axis are used two inductive linear transmitter (3). The motion of the
coil core (9) connected to the push pin (6) causes a variation of the induction
in the coils (10). The electronics convert this inductive signal into a
proportional output signal of 10...0...+10 V for the amplifiers.
The electronic part of the lever is equipped with a internal fault detector. In
case of a internal electronic fault the electronic send a 24V signal to the test
output. The test input is used for a lever system check before engine start.
The inductive system is designed as a redundant system with two separate
coils.
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5.6
Section 5.0
Page 13
Potentiometer Control (Pedal)

Legend for illustration (Z 21300a)
(1)
Potentiometer Control Unit
(2)
Pedal
(3)
Standard cable
(4)
Connection cable for combined operation
(5)
Push pin
(5.1)
Coil
(6)
Switch actuator
(7)
Direction monitoring
(7.1)
Directional contacts
(8)
Neutral position monitoring
(8.1)
Neutral position contacts
(9)
Electronic
Application for:
(A)
Swing foot brake
(B)
Clam Opening/closing
(C)
Travelling
The Potentiometer Control (inductive, linear travel transmitter) contains both
the electronic and mechanical components which converts the pedal movement
into a proportional electrical voltage.
In order to be able to electrically monitor the pedal (2) action a neutral position
switch is fitted.
This switch closes when the pedal is moved out of the rest position.
When using the double unit (B) (combined operation) only the signal output from
one unit is used for the Clam Operation.
Due to the cross lined connection via the connection cable (4) the signal is once
positive and once negative (inverted), depending on the Pedal used.
In order to be able to monitor the direction of the pedal movement and the neutral
position of travel unit (C), two switches (5 and 6) are fitted; which are actuated by
the actuator (4) as soon as the lever gets moved out of its neutral position.
For the Output Signal generation are used two coils (3.1), in series connected. The
push pin motion causes a variation of the induction and this in turn causes a signal
variation at the AC voltage bridge. The AC voltage gets rectified and becomes the
DC-Signal Voltage for the amplifiers.
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5.7
Section 5.0
Page 14
Proportional Amplifier Module, Type A

Type A (for swing brake only)
(LED) LED for Solenoid A or B
(P)
Set Potentiometer
R1 for the lowest current value
R2 for the highest current value
The amplifier module contains the necessary electronics for the control of
two proportional solenoids. Depending on the input polarity, either solenoid
A or solenoid B is operated.
The solenoid current (solenoid A - solenoid B) is measured and compared
with the external input value. Differences between feed-back and input
values, for example caused by changes in solenoid temperature or supply
voltage, are compensated.
The module also generates a direction-dependent voltage signal (solenoid A solenoid B) as soon as the solenoid current reaches the lowest set value.
The lowest and highest values are set externally via the potentiometer R1 + R2.
The brightness of the LED's changes with the current.
This function should not be used for setting.
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5.8
Section 5.0
Page 15
Proportional Amplifier Module, Type B

Type B (for Boom, Stick, Bucket, Clam, Swing and Travel)
(LED)
(P) Set Potentiometer:
AX: Proportional output AX active
- 10% for the lowest current value
AS: Switched output AS active
- J2 for the highest current value
BX: Proportional output BX active (Pt) Set Potentiometer for the Ramp
BS: Switched output BS active
Time
Power: Internal supply voltage
Fault: Fault indication
The amplifier module contains the necessary electronics for the control of
two proportional solenoids and two directional solenoids. The amplifier
outputs for proportional solenoids Ax and Bx and the switched outputs As
and Bs are activated by connecting a minimum of approx. 10% signal voltage
at the amplifier input.
A positive signal voltage controls outputs A, a negative signal voltage
controls output B.
A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the
amplifier, produces a stepped output voltage. The height of this 10% jump
may be set separately for proportional outputs Ax and Bx via external
potentiometer. As the signal voltage rises the solenoid current for the
proportional outputs increases linearly.
A further step in output current occurs at approx. 90% signal voltage.
The maximum current or the 90% jump may be set separately for outputs Ax
and Bx via external potentiometers and hence the gradient of the output curve
may be influenced.
LED`s indicate the current output to each proportional and switched output,
whereby the brightness is approx. proportional to the solenoid current in Ax
and Bx. This function should not be used for setting.
A Ramp Time function is included in the amplifier which may be externally
changed by a set potentiometer. The setting range for the ramp time is
approx. from 80ms to 1s. The time setting applies to both up and down ramps
and to both proportional solenoids.
A fault is indicated by the LED Fault.
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5.9
Section 5.0
Page 16
Ramp Time Module

(Analogue command value module for Boom, Stick, Travel and Swing function)
Potentiometer:
"t1" to "t5"
Ramp times
"w1" to "w4" Command value call-ups
"G"
Zero point matching
"Z"
Amplitude attenuation for the differential input
LED displays:
(1)
green Operational power
(2)
"4-Q" Quadrant recognition
(3)
"INV" Inversion active
(4)
(5)
(6)
yellow display for potentiometer t1 to t4

yellow display for potentiometer w1 to w4
Measurement sockets: "t" Actual ramp time
"w" Internal adjustment variable
"" Reference potential / GND
General
The Ramp Time Module is snapped onto mounting rails inside the X2-box.
The electrical connection is done via screw terminals.
The module is operated with 24 VDC. A power supply provides the internally
required positive and negative supply voltages.
As soon as the power supply is in operation the green LED (power) lights up.
Internal command values
The internal command value signal is generated from the external command
value signal which is being applied to the differential input, a called-up signal
and an offset signal (zero point potentiometer "Z").
The external command value signal can, via potentiometer "G", changed from
0% to approx. 110%.
Command value call-ups
The call-up signals w1 to w4 also have an adjustment range of 0% to 110%.
No settings required. (factory set to 100%).
Ramp time call up
If the quadrant recognition is not activated, then each command value call-up
"w1" to "w4" is allocated its own ramp time "t1" to "t4".
As long as there is a signal change, the LED allocated to the actual ramp time
is alight.
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Page 17
Controlling
5.10 Adjustments of Amplifier Modules (General)

(1)
Potentiometer control
(2)
Terminal with a separating possibility
(3)
Ramp time module
(4)
Amplifier
(5)
Solenoid valve
(6)
Service module
Introduction:
The illustration shows simplified the route of the signal voltage from
Potentiometer Control (1) to Solenoid-Valve (5):
A.
With ramp time module,
i.e. Boom,- Stick,- Travel,- and Swing Function.
B.
Without ramp time module,
i.e. Bucket,- Clam,- and Swing Brake Function.
The ramp time modules (3) and the amplifiers (4) are adjustable.
Adjustments are required:
Ramp time modules
When commissioning the machine
When replacing a module
Amplifiers
When replacing a solenoid valve
When replacing an amplifier
For Checking and Setting the Signal Current at the Proportional-Amplifier (4),
both separating terminal (2) before and behind the Amplifier (4) must be opened.
For the setting procedure the signal voltage from the potentiometer control (1) can
be simulated with the potentiometer of Service-Module (6),which is installed on
the X2-panel.
Accessories required for the adjustments:
a) A multimeter, good readable for
values between 0 and 1000 mA.
b) More convenient is a second meter
for reading voltage simultaneously.
c) A simple wire, 1m length, or better
a prepared test lead same length
d) Four test leads, 1m length, with
banana type connectors on each
end.
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"a"
"b"
mA
VDC
"c" "d"
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Section 5.0
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5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)

Procedure applicable for all amplifiers except the one for the swing
brake:
(Do not start the motor, turn only the key switch in ON position.)
1.
Open* the respective separating terminal (T1) between the lever unit and
the amplifier module to be set.
2.
Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3.
Disconnect the wire from terminal five.
4.
Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5.
Attach a multimeter for voltage reading to the service module, using test
lead (3).
6.
Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test leads (3).
7.
Move the lever of the Potentiometer Control into its final position; or
override manual the relay which allows 24 V operating voltage to the
amplifier module; thus the amplifier gets 24 V operating voltage. The
power LED and simultaneously LED A(+) or B(-) lights up, depending on
the polarity.
8.
Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC (it may be either positive or negative); the multimeter for the
current reading will show a value which should correspond to the value
giving in the circuit diagram e.g. 330 mA. (The first step (10 %) value)
If necessary correct the value with potentiometer (R1).
9.
Turn the potentiometer (P) of the Service-Module further until the
multimeter shows 9 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 660 mA. (The second step (90 %) value).
10. Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
* How to open and close the terminal:

Push the yellow stud (1) down with a screw driver and turn it 90 to the left to
open or to the right to close the terminal. A spring pushes then the stud
outwards and the contacts are either open or closed.
continued
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Section 5.0
Page 19

Cont'd:
11.
12.
13.
If the setting with either positive or negative potential was successful, turn
the potentiometer (P) of the service module into the opposite direction and
check the settings with the other polarity i.e. if the first setting was done
with positive potential then turn the pot into negative direction; otherwise
vice versa.
Repeat the setting as described under item 7 to 10.
Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.
Adjusting the Ramp Time

1.
2.
Turn potentiometer (Rt) 30 revolutions counter clockwise, to guarantee the

correct start position at the complete left side.
Turn potentiometer (Rt) so many revolutions clockwise as shown in the
table below (part of the electrical circuit diagram).

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Section 5.0
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The amplifiers for the crawler foot pedals are adjustable in the same way as
the amplifiers for the joy sticks.(refer to page 17 and 18 in this section)
The amplifier for the swing foot brake is similar.
Procedure for the swing foot brake:
1.
Open* the respective separating terminal (T1) between the pedal unit and
the amplifier module to be set.
2.
Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3.
Disconnect the wire from terminal five.
4.
Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5.
Attach a multimeter for voltage reading to the service module, using test
lead (3).
6.
Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test lead (3).
7.
Press the pedal fully down ; or manual override the relay which allows 24 V
operating voltage to the amplifier module; thus the amplifier gets 24 V
operating voltage.
8.
Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC ; the multimeter for the current reading will show a value
which should correspond to the value giving in the circuit diagram e.g. 10
mA. (10 % value)

continued
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Section 5.0
Page 21

Cont'd:
9.
)
10.
11.
Turn the potentiometer (P) of the Service-Module further until the

multimeter shows 10 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 500 mA. (100 % value).
It is important that the pilot pressure for the pressure increasing valve
is 24 +/- 1 bar.
For more information refer to section 8.2 Swing Circuit
Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.

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Section 5.0
Page 22
5.13 Adjusting the Ramp Time Module

(2) Capacitor-Module
(3) Ramp time module
(6) Service module
(P) Potentiometer
The following adjustments have to be done when commissioning the

machine and whenever the Ramp Time Module has been replaced.
Do not start the motor, turn only the key switch in ON position.
Basic Adjustment:
1.
2.
Connect 0VDC with a test lead from the red positive terminal of the service module
(6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot Z" a value of 0
VDC measured at terminal 7. Disconnect the test lead after the setting is done.
Connect +10VDC with a test lead from the red positive terminal of the service
module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot G" a
value of 10 VDC measured at terminal 7. Check the negative voltage as well(- 10
VDC). Disconnect the test lead after the setting is done.
Repeat settings of item 1 and 2 until both values are stabilized, because
"Pot Z" and "Pot G" influence each other.
The factory setting of potentiometer "w1" to "w4" for the command
value call-ups must not be adjusted.
continued
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Section 5.0
Page 23

Cont'd:
(1) Control lever (joystick)
(2) Capacitor-Module
(3) Ramp time module
(4) Proportional-Amplifier-Module
(5) Relay (Supply Voltage)
Ramp time adjustment in relation to the operating movements:
3.
Disconnect the cables at terminal 3 and terminal 5 of the respective module.

Connect 24Volt with a test lead to terminal 9, 10, 11 and 12 one after another and
adjust with the respective "Pot t1, t2, t3 and t4" the values giving in the table on the
next page. (Measure the voltage only at the Measurement socket "t" of the ramp
time module)
4.
To check the adjustments under operating conditions reconnect terminal 3 and

terminal 5 and measure the ramp time with a stopwatch.
5.
If the above mentioned values are not suitable for the local working conditions, for
example due to, different Attachments or different operation feeling of the operator,
the ramp time can be changed according to the NOTE on illustration
Z 21645, to ensure smooth and efficient working cycles.
continued
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Section 5.0
Page 24

Cont'd:
E48 Stick
24 Volt at
Joy stick Signal
Pot
Value to be measured at socket "t"
Terminal 9
Neutral Stick out
0V to +10V
t1
0,10 Volt = 1000ms
Terminal 10
Stick out Neutral
+10V to 0V
t2
5,00 Volt = 20ms
Terminal 11
Neutral Stick in
0V to -10V
t3
0,10 Volt = 1000ms
Terminal 12
Stick in Neutral
-10V to 0V
t4
5,00 Volt = 20ms
Pot
E49 Boom
24 Volt at
Joy stick Signal
Terminal 9
Neutral Lower
0V to +10V
t1
0,10 Volt = 1000ms
Terminal 10
Lower Neutral
+10V to 0V
t2
5,00 Volt = 20ms
Terminal 11
Neutral Lift
0V to -10V
t3
0,10 Volt = 1000ms
Terminal 12
Lift Neutral
-10V to 0V
t4
5,00 Volt = 20ms
Pot
E50 Swing
24 Volt at
Joy stick Signal
Terminal 9
Neutral Swing R
0V to +10V
t1
0,20 Volt = 500ms
Terminal 10
Swing R Neutral
+10V to 0V
t2
0,10 Volt = 1000ms
Terminal 11
Neutral Swing L
0V to -10V
t3
0,20 Volt = 500ms
Terminal 12
Swing L Neutral
-10V to 0V
t4
0,10 Volt = 1000ms
Pot
E50b Swing brake

24 Volt at
Joy stick Signal
Terminal 9
Neutral Swing R
0V to +10V
t1
0,10 Volt = 1000ms
Terminal 10
Swing R Neutral
+10V to 0V
t2
5,00 Volt = 20ms
Terminal 11
Neutral Swing L
0V to -10V
t3
0,10 Volt = 1000ms
Terminal 12
Swing L Neutral
-10V to 0V
t4
5,00 Volt = 20ms
E51 Left crawler

24 Volt at
Pot
Terminal 9
t1
0,10 Volt = 1000ms
Terminal 10
t2
0,10 Volt = 1000ms
Terminal 11
t3
0,10 Volt = 1000ms
Terminal 12
t4
0,10 Volt = 1000ms
E52 Right crawler

24 Volt at
Pot
Terminal 9
t1
0,10 Volt = 1000ms
Terminal 10
t2
0,10 Volt = 1000ms
Terminal 11
t3
0,10 Volt = 1000ms
Terminal 12
t4
0,10 Volt = 1000ms
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Components
Section 6.0
Page 1

Section
6.0
Page
Components
6.1
Hydraulic
6.1.1
Main Control Blocks and High Pressure Filter
6.1.2
Distributor Manifold Location of Restrictor blocks
6.1.3
Restrictor Block with Pressure Relief Valve (Type 131)
6.1.4
Restrictor Block with Pressure Relief Valve (Type 132)
6.1.5
Anti Cavitation Valve Block (Type 109)
6.1.6
Anti Cavitation Valve Block (Type 142 - 145)
6.1.7
Remote Control Valves
6.1.8
Directional Solenoid Valves (Three positions / 4-ways)
6.1.9
Proportional Solenoid Valves
10
6.1.10
High Pressure Filter
11
6.1.11
Control Blocks and Valves
6.1.12
Travel Brake Valve
17
6.1.13
Pressure Reducing Valve
18
6.1.14
Directional Solenoid Valves (Two positions / 4-ways)
19
6.1.15
Pressure Increasing Valve
20
6.1.16
Hydraulic Cylinder
21
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Components
Section 6.0
Page 2
6.1.1 Main Control Blocks and High Pressure Filter

Legend for illustration (Z 22727d):
Circuit No. I
(14 / I)
Main Control block (Travel L.H. / Stick / Bucket / Boom)
(18.2)
High pressure filters for main pumps 2 + 6 (double unit), with
differential pressure switches B6-1 and B6-2.
(32.1+32.2) Anti Cavitation Valve (ACV) Travel motors
(32.3)
ACV Stick cylinder piston side
(32.4)
ACV Bucket cylinder rod side
(32.5)
ACV Bucket cylinder piston side
(33.1)
Service-line Relief Valve (SRV) Stick cylinder rod side
(33.2)
Service-line Relief Valve (SRV) Bucket cylinder rod side
Circuit No. II
(15 / II)
Main Control block (Swing / Boom / Stick / Bucket)
(18.1)
(32.6)
(32.7)
(32.8)
(33.3)
Service-line Relief Valve (SRV) Bucket cylinder rod side
Circuit No. III
(16 / III)
Main Control block (Travel R.H. / Boom / Bucket / Stick)
(18.3)
(32.9+32.10) Anti Cavitation Valve (ACV) Travel motors
(32.11)
(32.12)
(262)
SRV (pressure increasing valve) Boom cylinder rod side
Circuit No. IV
(17 / IV)
Main Control block (Clam / Bucket / Stick / Boom)
(18.4)
(32.14)
ACV Clam cylinder piston side
(32.15)
ACV Clam cylinder rod side
(32.16)
(32.17)
(32.18)
(33.6)
SRV Bucket cylinder rod side
(33.7)
SRV Stick cylinder rod side
(33.8)
SRV Boom cylinder rod side
There is one Main Relief Valve in each control block
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Section 6.0
Page 3
6.1.2 Distributor Manifold - Location of restrictor blocks and anti cavitation valves
Front Shovel Attachment
(SB)
Synchronization (Equalization) block
(SL)
Synchronization (Equalization) lines

(73)
Distributor manifold
(142)
cylinder
Section A B,
Anti Cavitation Valve (ACV) Block , Boom
(132.1+.2)
Section B
Restrictor blocks, Boom cylinder piston side

with SRVs and check points M16.1 + M16.2
(131.1)
Section C
Restrictor block, Bucket cylinder piston side

with SRV and pressure check point M17.1
(131.4)
Section E
Restrictor block, Bucket cylinder piston side

(92)
Section F
Valve block SRVs, Clam cylinder piston side

with check points M20.1 + M20.2 + M20.3
(109.2)
Section G
ACV Block, Stick cylinder rod side
(131.5+.6)
Section H
Restrictor blocks, Stick cylinder piston side

(143)
Section H J,
Anti Cavitation Valve (ACV) Block , Stick cylinder
(131.7+.8)
Section K
Restrictor blocks, Stick cylinder piston side

(131.9)
Section L
Restrictor block, Clam cylinder rod side

(144)
Section M N, Anti Cavitation Valve (ACV) Block, Bucket cylinder
(131.11+.12) Section N
Restrictor blocks, Bucket cylinder piston side

(132.3+.4)
Section P
Restrictor blocks, Boom cylinder piston side

(145)
Section P Q,
Anti Cavitation Valve (ACV) Block, Boom cylinder
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Section 6.0
Page 4
6.1.3 Restrictor Block with Pressure Relief Valve

(Type 131.1 131.13 of the hydraulic circuit diagram)
A restrictor block is used for limiting cylinder lowering speeds.

A Service Line Relief Valve is installed to limit the maximum system
pressure due to external forces.

(1)
(2 + 3)
(4)
(5 + 6)
(7)
(8)
(9)
(10)
(11
(12)
(13)
(14)
(15)
(16)
A+B
M
Y
T
Adjustment spindle
O-ring with back-up ring
Retainer
Spring
Spring cup
Throttle sleeve
O-ring
Housing
Return line port, T
Allen bolt
Clip ring
Lock nut
Line ports
Control oil drain port
Return line port
Function:
Setting of the maximum permissible cylinder speed (flow B to A) is carried
out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in
the valve poppet (9) will be partially opened to achieve the required throttling
of the oil flow.
The extra holes (fixed throttle 9.2) prevents the valve from becoming
completely closed.
For the lifting operation (flow A to B), the valve poppet (9), which is guided
by the spindle (1), is pressed against spring (7) so that the valve will be
completely open.
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Section 6.0
Page 5
6.1.4 Restrictor Block with Pressure Relief Valve

(Type 132.1 132.4 of the hydraulic circuit diagram)
A restrictor block is used for limiting cylinder lowering speeds.

A Service Line Relief Valve is installed to limit the maximum system
pressure due to external forces.

(1)
Adjustment spindle
(2 + 3)
(4)
(5 + 6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15 + 16)

Flange
Spring
Spring cup
Throttle sleeve
Lock nut
Housing
Clip ring
Allen bolt
Jet bore, 1 mm
(17 + 17.1) Pressure relief valve, pilot

operated
(18)
Jet bore, 1.2 mm
(19)
Flange
(20)
Allen bolt
(21
Correction shim(s)
(22)
Valve housing
(23)
Valve spring
24 + 25)
(26)
O-ring
A+B
Line ports
T
Return line port
M
Y
Function:
Setting of the maximum permissible cylinder speed (flow B to A) is carried
out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in
the valve poppet (9) will be partially opened to achieve the required throttling
of the oil flow.
The extra holes (fixed throttle 9.2) prevents the valve from becoming
completely closed.
For the lifting operation (flow A to B), the valve poppet (9), which is guided
by the spindle (1), is pressed against spring (7) so that the valve will be
completely open.
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Section 6.0
Page 6
6.1.5 Anti Cavitation Valve Block

(Type 109.1 + 109.2 of the hydraulic circuit diagram)
ACVs are installed to avoid cavitation damages on users (hydraulic

cylinders), by compensating a possible lack of oil, when the SRV at the
opposite side of the cylinder opens (see circuit diagram).

(1)
(2)
(3)
(4)
(5)
(6)
S
A and B
Housing
Valve cone
Spring
O-ring
Control and leak oil bore
Cap screw (torque 900 Nm)
Supply line
(Return oil pressurized to approximately 10 bar by
back pressure valve)
Line connections
Function:
The circuit pressure in the line A and B hold the valve cone (2) closed. The
pressure of the supply line S forces onto the valve cone.
The valve cone opens, whenever the pressure at the A and B side is lower
than the back pressure at return oil port S, to allow necessary oil supply into
the circuit.
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Section 6.0
Page 7
6.1.6 Anti Cavitation Valve Block

(Type 142 -145 of the hydraulic circuit diagram)
ACVs are installed to avoid cavitation damages on users (hydraulic

cylinders), by compensating a possible lack of oil, when the SRV at the
opposite side of the cylinder opens (see circuit diagram).

(1)
(2)
(3)
(4)
(5)
(6)
(7)
S
A and B
Housing
Valve cone
Spring
O-ring
Support ring
Control and leak oil bore
Supply line
(Return oil pressurized to approximately 10 bar by
back pressure valve)
Line connections
Function:
The circuit pressure in the line A and B hold the valve cone (2) closed. The
pressure of the supply line S forces onto the valve cone.
The valve cone opens, whenever the pressure at the A and B side is lower
than the back pressure at return oil port S, to allow necessary oil supply into
the circuit.
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Section 6.0
Page 8
6.1.7 Remote control valves
Remote control valves are part of the electric-hydraulic control system

(1 - 8)
(9)
(10)
(11)
(12)
(13)
(14)
Pilot pressure lines to the control block

Pilot pressure supply port
Return to tank port
Manifold block
Double directional solenoid valve
Single proportional solenoid valve
Plug-in orifice for A / B ports
Function:
The electric-hydraulic control system is used to control the direction and
volume of oil flow to the operating cylinders and motors via the main control
valve blocks.
When a lever (or pedal) is actuated, a proportional solenoid valve (13) and
one of the directional solenoid valves (12 either a or b) are energized, and
allows the pilot pressure oil to flow to the spools of the main control blocks.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full
stroke position.
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Section 6.0
Page 9
6.1.8 Directional Solenoid Valves (Three positions / 4-ways)
This solenoid operated directional spool valves are installed to control

the start, stop and direction of an oil flow.

(1)
(2)
(3)
(4)
(5)
(6)
(7)
Housing
Solenoids
Control spool
Reset springs
Plunger
End cover
Plug-in orifice
Function:
In un-operated condition the control spool (3) is held in the neutral or
starting position by the reset springs (4). Operation of the control spool is by
means of oil immersed solenoids (2).
The force of the solenoid (2) acts via the plunger (5) on the control spool (3)
and pushes its from its resting position into the required end position. This
results in the required free flow from P to A and B to T or from P to B and
A to T.
When the solenoid (2) is de-energised, the control spool (3) is returned to its
original position by the reset springs (4).
Where necessary restriction orifices are installed into the valve ports, to
reduce the oil flow.
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Section 6.0
Page 10
6.1.9 Proportional Solenoid Valve
This valves are responsible for the creation of a variable control

pressure proportional to the electrical signal output of an amplifier.

(1)
(2)
(3)
(4)
Proportional solenoid
Control piston
Valve housing
Pressure measuring spool
(5)
(6)
(7)
(8)
Pressure measuring spool

Connection plug
Return spring
Bleed screw
Function:
In unoperated condition the control spool (2) is held in the neutral or starting
position by reset springs.
The control spool (2) is directly operated by the proportional solenoid (1).
If the solenoid is energized, it produces a force to operate the control spool (2) via
the pressure measuring spool (4) and moves the spool to the left. Oil flows from P
to A. As pressure in A increases, it passes via the radial borings in the control
spool (2) to the inner end of the pressure measuring spool (2).
The force generated by the pressure now works against the solenoid force and
pushes the control spool (2) to the right (closing direction) until a balance is
achieved between the two forces. In order to achieve this, the pressure measuring
spool (2) moves to the left until it is supported by the pin (5).
When the force balance is achieved, the connection between P and A is
interrupted and the pressure in line A is held constant.
Any reduction in the solenoid force leads to the pressure force exceeding the
solenoid force on the control spool (2). The control spool is then moved to the
right causing a connection from A to T allowing the pressure to fall until a
balance is re-established at a lower level.
At rest, when the solenoid is de-energized, ports A and B are open to tank, whilst
port P is blocked from both ports A and B.
In order to achieve optimum functioning of the valve, it must be bleed
when commissioning:
- Supply pressure to the valve
- Remove plug 8
- When no more air bubbles appear screw in plug 8.
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Section 6.0
Page 11
6.1.10 High Pressure Filter
There is one filter in each pump line installed.

(1)
(2)
(3)
(4)
(5)
(6)
Filter housing
Drain plug
O-ring
Back-up ring
Filter element
O-ring
(7)
(8)
(9)
(10)
(11)
P1
P2
a
b
c
d
e
Higher static pressure

Lower static pressure
Electrical connection
REED contact
Permanent magnet piston
Spring
Plug screw
Spring
Differential pressure switch
O-ring
Allen bolt
Lock washer
Function:
High-pressure in-line filters prevent contamination from entering the
hydraulic circuits. The spin-on filters are installed between the main
hydraulic pumps and multi-valve control blocks. All hydraulic components,
behind the pumps, are effectively protected from damage and undue wear.
Each filter is equipped with a differential pressure switch to monitor the filter
flow restriction. If the pressure reaches an unsafe difference of 8.5 bar, a
message appears on the display in the cab.
Example:
Fault No. 674:
(677)
Help:
$h:
High pressure filter #5 or pump #5
restricted. Stop Motor 2
Differential pressure switch B5-2 not closed.
- Clean or replace filter element.
- Check pump
or
Fault No. 644:
(647)
Help:
PC8000-6-E_Sec_6-0_#12048_rev0.doc
$h:
Start of motor 2 blocked due to
contamination of pump #5
Differential pressure switch B5-2 not closed.
- Check cables to differential pressure switch B5-2.
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Section 6.0
Page 12
6.1.11 Control Blocks and Valves
This is a principle drawing, showing valve block I to IV.

(1)
(2)
(3)
(4)
(5)
(6)
(7)
Control block housing

Cab ("A side)
Cap ("B" side)
Spool
"B" side service line ports
Centering springs
MRV, main relief valve
(8)
(9)
(10)
(11)
(12)
(13)
Port B, to cylinder/motor
Port A, to cylinder / motor
Fine controlling grooves
Port P, from pumps
Port T, to tank
Load holding valves
Control blocks with "Open Center and Closed Ports".

Control blocks I, II, III and IV are 4-spool blocks and V is a 1-spool block.
See hydraulic circuit diagram for spool details.
Each spool is provided with "Fine Controlling Grooves" and ring grooves for
hydraulically centering of the spool.
Between 8 and 19 bar pilot pressure the spools are moved in their fine control
range.
The 4-spool blocks are equipped with different spools, depending on function
and priority.
a2 / a3
Spools without a symbol (standard) are connecting the rod side of the cylinders
with the pump supply line and the piston side with the tank.
Spools with #-symbol are connecting the piston side of the cylinders with the tank
only. (lowering with free pump circulation, i.e. the pressure channel is connected
to the center channel, so that pump flow is available for other functions.)
Spools with $-symbol (floating) are connecting the piston side of the cylinders
with the rod side and also with the tank.
The Load Holding Valves are installed inside of the spool, for each port to
the cylinder or motor one valve. The hydraulic diagram shows only one.
The MRV is a pilot operated pressure relief valve.
continued
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Section 6.0
Page 13

Cont'd:
(1)
(2)
(3)
(4)
Main relief valve (MRV)Control block housing

Check valve (Load holding valve)
Anti cavitation valve (ACV)
Service line relief valve (SRV)
Explanation of the schematic drawing of the control block:

The hydraulic oil flows through the control block from port P to T, if all
spools are in neutral position ("pressure-less circuit" or Free circulation).
(A) 4-spool valve block
Example 1: Spool #1 moves up when pilot pressure is build up in the control pipe
line a1. (Imagine the upper symbol box moves to the center position.)
Now pump oil flows through check valve (2) to the user port A1 (travel motors)
because the free flow circulation to the hydraulic reservoir is closed. The main
relief valve (1) limits the maximum operation pressure in this circuit. Via port B1
the return oil from the travel motors is flowing back to the hydraulic oil reservoir.
During down hill travel motion and stopping procedure the ACVs (3) prevents
cavitation on the hydraulic motors. Because during these short periods of time the
hydraulic motor needs a higher oil supply than the pump can deliver.
Example 2: Spool #2 moves up when pilot pressure is build up in the control pipe
line a2. (Imagine the upper symbol box moves to the center position.)
Now pump oil flows through check valve (2) to the user port A2 (stick cylinder
rod side) because the free flow circulation to the hydraulic reservoir is closed. The
main relief valve (1) limits the maximum operation pressure in this circuit. Via
port B2 the return oil from the stick cylinder piston side is flowing back to the
hydraulic oil reservoir.
SRV (4) is installed to limit maximum possible pressure peaks in the service line..
Shortly high pressure closes check valve (2) which secures the hydraulic pump
from pressure peaks.
The check valves (2) have also the function of load holding valves because during
the fine controlling period all lines are connected together (negative overlapping). The load pressure is for a moment higher than the pump pressure.
(B) 1-spool valve block
The "C" port is used for combined operation with a second pump circuit if the
swing function is not used. (see circuit diagram).
continued
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Components
Section 6.0
Page 14

Cont'd:
(1)
(2)
(3)
Spool
Centering springs
Load holding valve
Function:
Reset springs (2) moves the spool (1) in neutral position.
Fine control grooves provide for sensitive controlling, because a motion is
started always while the pressure oil and the return oil first passes this fine
control grooves before spool (1) is inter connecting the entire groove to the
user channel.
Upper picture:
In neutral position of spool (1) the pump oil is flowing back via port PU to the
tank.
Lower picture:
Example. The spool is moved by pilot pressure on the left spool side to right
position: Port PU is closed and the connection through the holding valve (3) to
the user (port A) is open. Also the connection from the other user side (port B
return) is connected to the port T (return line to tank).
continued
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Section 6.0
Page 15

Cont'd:
(01)
(02)
(03)
(04)
(5)
(6)
(7)
(8)
Service -Line Relief Valve

Anti Cavitation Valve
Main Relief Valve
Closing plate
Plug screw
Spring
Valve cone
Dust cap
(9)
(10
(11)
(12)
(13) + 16)
(14)
(15)
(17)
Set screw
Lock nut
Spring, pilot part
Poppet
Jet bore
Spring, main cone
Main valve cone
Pilot oil dump line to tank
MRVs and SRVs are pilot operated relief valves. The MRV limits the max.
Pump supply line pressure. The SRV limits the max. possible pressure peak in
the service-line.
The valves have an opening characteristic. That means, that in case of
contamination after the response procedure no further pressure increasing is
possible and damages are avoided.
Function:
The circuit pressure P forces with the force F1 on the piston surface A of the
main valve cone (15). Because there is via the jet bore (16) the same pressure on
the back side of the main cone, this results together with the spring (14) force in
a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit
pressure is in front of the poppet (12). Exceeds the circuit pressure the setting
value of the spring (11), the poppet opens against the force of the spring (11).
This causes that the force F2 decreases and there is no more balance condition
between F1 and F2. Valve cone (15) is moved upwards by the greater force F1.
That means there is now a direct connection from port P to T (tank).
ACVs serve for compensation possible lack of feed when the SRV at the
opposite port is actuated (see circuit diagram) and for avoiding cavitation
damages. In addition, to supply a user in case it is continuously moved by
acceleration forces at zero position of the control spool.
Function:
The circuit pressure inside the spring chamber closes the valve cone (7).
The back pressure of the return line acts on the surface of the valve cone (7).
Whenever the pressure in the service-line is lower than the springs force the
valve cone opens by the force of the back pressure and hydraulic oil is additional
supplied.
continued
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Section 6.0
Page 16

Cont'd:
Load Holding Valve
((1)
(2)
(3)
Spool
Centering springs
Load holding valve
Control Blocks I to IV (4-spool blocks)

Two load holding valves are fitted into each spool of the control blocks, one
valve for each port (A and B).
They have three tasks:
1.
When circuit pressure due to attachment weight is higher than pump
pressure these valves prevent dropping of the attachment, within their
sensitive (fine controlling) range.
2.
Due suddenly pressure peaks in the service lines the valves also protect
the pump.
3.
When two pumps flows are used for one user they ensure that at least
the flow of one pump reaches the user in case one MRV is defect or not
more correct adjusted.
That means: Up to the max. Pressure of the defective valve both load holding
valves are open allowing the flow of both pumps to the user, then one valve will
be closed by the higher pressure and the flow of one pump only flows to the
user.
Function:
In neutral position (upper picture) of the spool (1) both valve cones (3) are
closed by the springs (2).
In switched position (lower picture) forces the circuit pressure onto the front
area of the valve piston (3).
This force moves the piston against spring (2) and allows the oil to flow from
the pump supply port (P) to the user port (A) and from port B to the return oil
passage (T).
If due to an external force the pressure directed to the pump overcomes the
pressure in the pump line; this pressure (force) closes the valve
(direction P to A).
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17
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Components
Section 6.0
Page 17
6.1.12 Travel Brake Valve

Illustration Z 21695
Task:
Travel brake valves control the oil flow from the hydraulic motor to the tank
depending on operating pressure. This braking action prevents the motors from
overspeeding.
Function:
Spring force keeps the spool in the lowest flow position. with increasing
operating pressure the opening for the return oil flow becomes larger.
On its way to the hydraulic motor the oil flows from A to A1 respectively from
B to B1 depending on the selected travel motion.
Example:
Operating pressure at port A moves spool (1) against the force of the spring (2)
and opens the way for the return oil (B1 to B).
Check valve (3) prevents a direct oil flow from B1 to B.
If the operating pressure decreases to such an extend that the spring force
overcomes the pressure, the flow to the tank becomes restricted, resulting in
braking of the machine.
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18
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Components
Section 6.0
Page 18
6.1.13 Pressure Reducing Valve
Pressure reducing valves are installed to reduce the common 45 bar

pilot pressure to a lower pressure for other systems, e.g. the hydraulic
track tensioning system.

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Set screw
Spool
Compression spring
Threaded sleeve
Non return valve
Boring
Spring chamber
Control land
Function:
Pressure reducing valves type DR & DP are direct operated valves of 3 way
design, e.g. with a pressure relief function on the reduced pressure side.
At rest, the valve is normally open, and fluid can flow unhindered from port P
to A. Pressure in port A is also present on the end of the spool (2), via control
line (6), opposing the compression spring (3). When the pressure in port A
reaches the pressure level set at spring (3), spool (2) moves to the control
position and holds the pressure in port A constant.
Fluid to control the valve is taken from port A via the boring (6).
If the pressure in port A rises still further due to external forces, the spool (2)
is moved still further towards the compression spring (3).
This causes a flow path to be opened over control land (8) in the control spool (2)
to tank. Sufficient fluid then flows to tank to prevent any further rise in pressure.
An optional non return valve (5) is available to allow free flow from A to P.
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19
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Components
Section 6.0
Page 19
6.1.14 Directional Solenoid Valves (Two positions / 4-ways)
This solenoid operated directional spool valves are installed to control

the start, stop and direction of an oil flow.

(1)
(2)
(3)
(4)
(5)
(6)
Housing
Solenoid
Control spool
Return spring
Plunger
Dust cap with stem for manual operation
Function:
When there is no flow through the valve, control spool (3) is held in neutral
or output position by means of the return springs (4). The control spool (3) is
operated by means of oil immersed solenoid (2).
The force of the solenoid (2) effects control spool (3) by means of the plunger
(5) and pushes it from its resting position to the required end position.
This results in free flow from or P to B and A to T.
When solenoid (2) is de-energized, control spool (3) is moved back to its
resting position by means of return springs (4).
An optional hand emergency (6) allows movement of the control spool (3)
without energizing the solenoid.
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Components
Section 6.0
Page 20
6.1.15 Pressure Increasing Valve
The pressure increasing valve is a remote controlled pressure relief

valve, actuated by hydraulic pressure. The individual pressure is in
such a way determined by the pilot pressure.

(1)
(2)
(3)
(4)
(5)
(6)
(7+8)
(9)
(10)
(11+12)
(13+14)
Pilot valve with valve seat

Valve poppet
Compression spring
Main valve with sleeve
Main piston
Closing spring
Set screws
Piston
Pin
Jet bore
Lock nut
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the P
port.
If static pressure increase above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely to tank (T1). This oil generates a pressure
drop in the spring chamber of the main spool, the closing force of the spring
(6) is cancelled, and the main piston (5) opens to allow the pump flow to flow
to tank (T2).
Damped opening and closing is obtained by the throttled volumetric change.
By applying external pressure of Pst max = 45 bar to the main spool (9) via
port X, the pre-tensioning of the pressure spring (3) is increased by the amount
of the piston stroke "S" and system pressure is increased correspondingly.
The possible pressure increase p is 440 bar max. or 440 bar minus the basic
setting.
The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn
of the screw = 150 bar.
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21
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Components
Section 6.0
Page 21
6.1.16 Hydraulic Cylinder

General
(1) Piston rod
(2) Rod eye bushing
(3) Piston
(4) Cylinder tube
(5) Piston fitting key
(6) Piston nut
(7) Piston nut lock (threaded pin)
(8) Foot end eye bushing
B
Flange bushing: Clam cylinder
B1 Scraper ring
B2 BD seal (Dynamic Seal)
A
Flange bushing: Boom-, Stick-, Bucket-Cylinder
A1 Scraper ring
A2 Support bushing
A3 Hard-plastic back-up ring
A4 Back-up ring
A5 Chevrons
A6 Header ring
A7 Scraper retainer ring
A8 Cover
A9 Steel shims (splitted)
C = Piston rings
C1 Piston seal ring
C2 Piston guide rings, hard
C3 Piston guide, soft
C4 O-ring with back-up rings
Explanation of the cylinder

markings
430/290X3150
Piston diameter / Rod diameter X Stroke
430630 40
Cylinder drawing number (identical with part

No.).
11 / 97
Assembling Month and year (final figure).
261
Internal counting number.
DB 55.
Assembling crew personal code
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Main Hydraulic Pumps

and
Pump Regulation System
Section 7.0
Page 1

Section
7.0
Page
Main hydraulic pumps and pump regulation system
General
7.1
7.2
7.3
7.4
Main Pumps
7.1.1
Location of Pumps, drive speed and flow rates
7.1.2
Pump bearing flushing / lubrication
7.1.3
Operating Principles
7.1.4
Checks and Adjustments
Electronic Pump Regulation System
7.2.1
Electronic load limiting control - General
7.2.2
Components:- Electronic Power Module EPM
- Electronic Signal rectifier ESR
- Microcontroller MC7
7.2.3
Checks and adjustments - General
Method A - With 24V supply to terminals
- X1-Pressure
- Demanded power
- PID - Factor
Method B - With the electronic service tool BB-3
- Language selection
- Adjustment mode SET1 and SET2
- Number of motor selection
- X1-pressure (max. current) adjust.
- Demanded power adjustment
- PID Factor adjustment
- Storage new settings
Method C - With a laptop and BODEM software
- Starting the program
- Language selection
- Entering of the password
- Number of Motor selection
- X1-pressure (max. current) adjust.
- Demanded power adjustment
- PID Factor adjustment
Hydraulic Constant Regulation System
7.3.1
General
7.3.2
X1-pressure adjustment (constant-pressure)
Energy efficiency
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25
6
7
8 15
16 20
21
22
23 + 24
25
26
27
28 + 29
30
31 + 32
33
34
35
36
37
38
39 - 40
41
42
43
44
45 + 46 + 47
48
49
50
51
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2
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and
7.0
Section 7.0
Page 2

General lay out (Hydraulic only)

(1 - 8)
(9.1 + 9.3)
Pilot pressure pumps
(68.1 + 68.7) Pilot pressure filter unit
(252.1)
(252.2)
(252.3)
(252.3)
45 bar pressure reducing valve

60 bar pressure relief valve
Check valve
Check valve
(253.1)
(253.2)
hydraulic
Change over valve: "Electronic or Hydraulic regulation" Motor1

Pressure reducing valve: "Pump regulation pressure X1 at
(Y61-1)
(254.1)
(254.2)
hydraulic
(Y61-2)
(255.4)
(Y17)
(Y17a)
(Y100)
PC8000-6-E_Sec_7-0_#12048_rev1.doc
pump regulation" (Hydraulic constant regulation mode) Motor1

Proportional solenoid valve: "Pump regulation pressure X1 at
electronic pump regulation " (Standard operation mode) Motor1
Change over valve: "Electronic or Hydraulic regulation" Motor2
pump regulation" (Hydraulic constant regulation mode) Motor2
electronic pump regulation " (Standard operation mode) Motor2
Pressure reducing valve: "Remote control pressure" Q-max flow
reduction for the warming-up period.
Solenoid valve: "Remote control pressure"
Q-min flow for all main pumps
Solenoid valve: "Remote control pressure"
Q-max flow reduction for all main pumps
Solenoid valve: Option only "Remote control pressure"
Q-max flow reduction for pump #1 only
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and
7.0
Section 7.0
Page 3

Pump regulation system
General
Controlled output flow of the main pumps is necessary:
To utilize the available motor power most efficiently in every operating
mode.
To limit the power consumption of the hydraulic pumps depending on the
load of the motor. (Electronic pump regulation with micro-controller MC7)
For additional functions, such as rotating dependent or temperaturedependent flow reduction.
Function:
X1 pump regulation pressure (0 34 bar):
The power controller of the main pumps can be remotely controlled by
applying an external pilot pressure (X1 ) at port X LR to the spring chamber of
the power control valve. The start of destroking can be varied in proportion to
the applied X1 - pressure.
X2 pilot pressure (45 bar):

Constant pilot pressure to regulate the main pumps at special circumstances,
e.g. to fix the pumps in Q-max position while servicing the machine.
X3 remote control pressure (0 / 15 / 45bar):

Basic setting Q-min (0 bar), the flow rate increases with the
pilot pressure X3 at port Pst, up to Q-max (45 bar).
The hyperbolic power control is superimposed on the pilot pressure
signal and keeps the specified drive power constant. (p x Vg = constant).
The flow rates are:
Q-min.:
X3 = 0 bar
Q-max.: X3 = 15 bar
Q-max.:
X3 = 45 bar
X4 pump support pressure (60 bar):

Constant pilot pressure to support the regulation function at low operating
pressure and to lubricate the main pump bearings.
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and
7.0
Section 7.0
Page 4

Pump regulation system general
Function:
Solenoid valve Y17:
If de-energized pumps #1-8 are in Q-min position.
It gets energized as soon as one of the control levers/pedals has been operated
and stays energized as long as the temperature state is above T3.
It gets de-energized whenever all controls are in neutral position for more
than 20 seconds and a temperature state between T1 and T3.
Solenoid valve Y17a:
The solenoid is de-energized as long as the temperature state is below T2
(depending on the filled in hydraulic oil) shown in the table. ( pumps #1-8 are
in Q-max. position for warm up)
It gets energized at a temperature state between T2 and T4 as soon as one of
the control levers/pedals has been operated and gets de-energized without
delay whenever all controls are in neutral position.
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and
7.0
Section 7.0
Page 5

Pump regulation system general
Function:
Proportional Solenoid valve Y61-1:
This valve, connected to the MC7 micro-controller (electronic pump
regulation), creates a X1-pressure depending on the load of the motor 1.
This X1-pressure is the information to reduce pump delivery, in order to keep
the motor at rated power.
Pressure reducing valve 253.2:
Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic
constant regulation mode) by the function of change over valve (253.1) for
motor 1.
Proportional Solenoid valve Y61-2:
This valve, connected to the MC7 micro-controller (electronic pump
regulation), creates a X1-pressure depending on the load of the motor 2.
This X1-pressure is the information to reduce pump delivery, in order to keep
the motor at rated power.
Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic
constant regulation mode) by the function of change over valve (254.1) for
motor 2.
"Remote control pressure" (X3)
Q-max flow reduction during the warming-up period for all pumps by
the function of solenoid valve Y17a.
Change over valve 253.1 and 254.1:
Change over three way cock valve to select "Electronic or constant regulation
mode", one for each motor.
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and
7.1
Section 7.0
Page 6
Main Pumps
7.1.1. Location of Pumps
(1 8)
Axial piston pump (swash plate type)
theoretical flow rate, each
1033 Liter/min
Drive speed*
n = 1378 min-1
for all working motions
(9.1 + 9.3)
(9.2 + 9.4)
Gear pump
Drive speed*
for pilot pressure supply
152 Liter/min
n = 1378 min-1
Gear pump
Drive speed*
for PTO gear lubrication
152 Liter/min
n = 1378 min-1
(10.1 10.4) Axial piston pump

Drive speed* for
Hydr. oil cooler fan drive
PTO cooler fan drive
188 278 Liter/min

n = 1741 min-1
* at 1800 min-1 input drive speed (60Hz)
1500 min-1 input drive speed (50 Hz)
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7
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and
7.1
Section 7.0
Page 7
Main Pumps
7.1.2. Pump bearing flushing / lubrication
The installed main pumps are provided with an external cooling and lubrication
system for flushing of drive shaft bearing and shaft seal.
Oil supply is provided from the X4-pressure circuit.
To reach the restricted guidance of the coolant for external bearing flushing, the
throttle screw (located behind the union at port U) must be screwed in all the
way.
An information sign is fixed at the pump.
(1 8)
Main pumps
(94.1 94.8) Orifice (one for each main pump)
(68.1 + 68.7) Filter for pilot pressure
(U)
Port for the pump bearing flushing / lubrication
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8
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and
7.1
Section 7.0
Page 8
Main Pumps
7.1.3 Operating Principles
Main hydraulic pump A4VSLO 750 LR3DN / 30L
Type code explanation:
A4VSLO 750 LR 3 D N / 30 L
Rotation
Series
Basic adjustment for minimum displacement
With pressure control
Hydraulic remote adjustment facility
Constant power with hyperbolic curve
Displacement in cm3 at one (1) revolution
Axial piston pump series 4, variable displacement ,swash plate design for open circuits with charge pump
Function and characteristics:

The A4VSLO variable displacement axial piston pump in swash plate
design is intended for drives in open circuit operation.
The flow volume is proportional to the drive speed and the displacement.
By adjusting the swash plate a infinitely variable flow adjustment is
possible.
Pumps of the same nominal size can be built onto the trough drive.
Combinations with gear pumps are also possible.
(1)
Drive shaft
(2)
Cylindrical roller bearing
(3)
Slipper pad
(4)
Swivel angle indicator
(5)
Positioning piston
(6)
Swivel pin
(7)
Cylinder with pistons
(8)
Final connecting plate
(9)
(10)
Impeller (charging pump)
(11)
Splints for the through drive coupling (Aux. pump drive)
(12)
Swivel cradle
(13)
Q-min stop bolt
(14)
Power control valve
(15)
Pressure balance valve
(16)
Power curve correction
(17)
Pressure cut off valve
(18)
Q-max. stop bolt
(19)
Remote control valve
continued
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and
7.1
Section 7.0
Page 9
Main Pumps
Cont'd:
Symbol of main hydraulic pump A4VSLO 750 LR3DN / 30L
(1)
Main pump (swash plate pump, variable displacement)
(2)
Charging pump (impeller type pump)
(3)
Pump bearing group
(4)
Drive shaft
(5)
Non return valves
(6)
(6.1)
Mechanical stroke limitation*
(6.2)
Remote pressure (PST) operated piston for item 6
(6.3)
Mechanical stroke limitation*
(7)
Spool valve (pressure balance valve)
(8)
Nozzle
(9)
Power control valve
(10)
Nozzle
(11)
Pressure cut-off valve
(12)
Auxiliary pump (Gear pump, fixed displacement
(13)
Positioning piston
(14)
Slipper pad piston
(15)
Lever
(16)
Cam
(17)
Through drive shaft
* Factory side adjusted, no field adjustment required
B/B1
S
MB
ML
MST
R
T
P
PST
U
XLR
Pressure port
Oil intake (suction port)
Operating pressure check point
Charging pressure check point
Control pressure check point
Filler and bleeder port
Connection port for chip indicator
Pump support pressure (X4-pressure)
Remote control pressure port (X3-pressure)
Bearing flushing port
Regulating pressure port (X1-pressure)
continued
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and
7.1
Section 7.0
Page 10
Main Pumps
Cont'd:
Sectional drawing of Power Controller LR3DN / 30L
(6)
(6.1)
Mechanical stroke limitation
(6.2)
Remote pressure (PST) operated piston for item 6
(6.3)
Mechanical stroke limitation
(7)
Spool valve (pressure balance valve)
(9)
Power control valve
(11)
(13)
Positioning piston
(14)
Slipper pad piston
(15)
Lever
Refer also to illustration Z 21550 on the previous page.
continued
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11
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02.09.09
7.1
Section 7.0
Page 11
Main Pumps
7.1.3 Operating Principles, illustration (Z 21552)
Cont'd:
Q-min position: (remember Q means volume)
When are the pumps in Q-min position?
A: Motor at standstill
B: Motor running and the controls are not used for 20 sec. or longer
at normal operating temperature
C: Motor running and service switch S155 activated (Qmin-position)
Example C with the following conditions:
Motor running
Pump pressure smaller than X4 = 60 bar (pump support pressure)
X1 = 34 bar (pump regulation pressure), this pressure will not influence
the Q-min position under these conditions.
X3 = 0 bar (remote control pressure); Y17 de-energized (S155 Qmin activated)
for all pumps.
X4 = 60 bar (pump support pressure)
Pump support pressure is present at valve #7, the slipper pad of
piston #14 and the small area side of the positioning piston #13
Response of pump control mechanism:
Valve #7 moves to position "b" because the X4-pressure will overcome the
spring force, since the oil behind nozzle (8) flows through valve #6 (which is
in position "a", due to the missing remote control pressure X3) back to tank.
Pump support pressure X4 passes valve #7 position "b" and flows via power
control valve #9 position "a" to the large area side of positioning piston #13
Because the large area side of positioning piston #13 is approximately three
times larger as the small area side, the pump support pressure X4 of 60 bar
present on both sides, resulting in stronger force at the large area side, keeps
the pump in Q-min position.
The pump remains in Q-min position
continued
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and
7.1
Section 7.0
Page 12
Main Pumps
Cont'd:
Q-max position: (remember Q means volume)
When does the pumps move into Q-max position?
and
and
and
Motor running
hydraulic oil at normal operating temperature (> T2)
the controls frequently used within 20 sec.
(or Service switch S155 activated Qmax-position)
a pump pressure below start of de-stroking.
Example with the following conditions:

Motor running
Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #14 and the small area side of the positioning piston #13
X1 = 34 bar (pump regulation pressure)
X3 = 45 bar (remote control pressure); Y17 and Y17a energized
for all pumps.
X4 = 60 bar (pump support pressure), present at valve #7.
Valve #7 moves to position "a" because the spring force is supported by the
X4-pressure, since the oil flow back to tank is blocked at valve #6 (which is
in position "b", due to the 45 bar remote control pressure X3).
The large area side of positioning piston #13 is connected, via power control
valve (9) position "a" and pressure balance valve (7) position "a", to the
return oil line.
The pump moves into Q-max position, because the pump pressure acts only
at the small area side of positioning piston #13.
The pump moves into Q-max position
continued
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and
7.1
Section 7.0
Page 13
Main Pumps
Cont'd:
Q-max position: (remember Q means volume)
When does the pumps move into half Q-max position?
and
and
or
and
Motor running
hydraulic oil below normal operating temperature (< T2)
the controls frequently used.
the controls not used at a temperature state between T2 and T4
a pump pressure below start of de-stroking.

Motor running
Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #14 and the small area side of the positioning piston #13
X3 = 15 bar (remote control pressure); Y17 energized and Y17a deenergized
for all pumps.
Valve #7 moves to an intermediate position (in-between "a" and "b"), since a
certain amount of oil behind nozzle (8) flows through valve #6 (which is also
in an intermediate position, due to the 15 bar remote control pressure X3)
back to tank.
The large area side of positioning piston #13 is connected, via power control
valve (9) position "a" and pressure balance valve (7), to the return oil line.
The pump moves into Q-max position, because the return oil flow through
pressure balance valve (7) is restricted (due to its intermediate position),
resulting in a pressure at the large area side of the positioning piston (13).
The pump moves into Q-max position
continued
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and
7.1
Section 7.0
Page 14
Main Pumps
Cont'd:
Destroking: (Pump moves from Q-max. into of Q-min. direction)
When does the pumps start to destroke
Motor running
and hydraulic at normal operating temperature (> T2)
and Service switch S155 deactivated
and The hydraulic load is higher than the rated power of the motor
(The electronic pump regulation system will reduce the X1-pressure)

or
With pump pressure above 180 bar (Hydraulic constant regulation)
(Constant X1-pressure of approximately 13 bar)
Motor running
Pump pressure 180 bar adjustable at main relief valves, present at the
slipper pad of piston #14 and the small area side of the positioning piston
#13
X1 = 13 bar (constant regulation pressure adjustable at pressure reducing
valves 253.2 /254.2) Change over valves switched to hydraulic mode
X3 = 45 bar (remote control pressure); Y17 energized and Y17a energized
for all pumps.
Valve #7 moves to position "a" because the spring force is supported by the
X4-pressure, since the oil flow back to tank is blocked at valve #6 (which is
in position "b", due to the 45 bar remote control pressure X3).
The operating pressure (with the value for start of de-stroking) at the slipper
pad of piston #14 moves the power control valve (9) into position "b" (against
the spring force supported by the X1-pressure).
This in turn connects the operating pressure to the large area side of
positioning piston #13.
times larger as the small area side, the operating pressure present on both sides,
resulting in stronger force at the large area side, moving the pump in Q-min
direction.
The pump de-strokes until the forces at positioning piston #13 are
balanced
continued
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and
7.1
Section 7.0
Page 15
Main Pumps
Cont'd:
Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position)
When is the pressure cut-off valve active?
Motor running
and With pump pressure above 300 bar
Motor running
Pump pressure 300 bar
X3 = 45 bar (remote control pressure)
X4 = 60 bar (pump support pressure)
Independent of the position of power control valve #9 the pressure cut-off
valve #11 causes the pump to de-stroke to the pre-adjusted Q-min position.
The operating pressure moves the pressure cut-off valve #11 (at set pressure)
into position "b" and flows to the large area side of positioning piston #13.
times larger as the small area side, the operating pressure present on both
sides, resulting in stronger force at the large area side, moving the pump in Qmin position.
The pump moves into Q-min position
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and
7.1
Section 7.0
Page 16
Main Pumps
7.1.4 Checks / Adjustments
Location of Adjustments
Legend for , illustration (Z21557)
(1)
(2)
Q-min. stop bolt
(3)
Pressure balance valve
(4)
Start of destroking
(5)
Power curve correction
(6)
(7)
Q-max. stop bolt
(8)
Angle indicator
The average length of the measurement "L" is: set crews (bolts )
location
1
2
3
4
5
6
7
length (mm)
13.8
26.9
8.0
8.1
---6.0
34.4
The measurement "L" is an orientation only if the adjustment is

totally out of requirements.
They must not be used for final adjustments.
The detail for (5) shows the position of the housing edge and the edge
of the eccentric set bolt. The example shows them in parallel position
which is mostly not the case. The adjustment should never be altered.
Further information see next pages
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and
7.1
Section 7.0
Page 17
Main Pumps
Pressure balance valve ( P 20bar), illustration (Z21558)
1.
Connect a 60 bar pressure gauge to check point MST.
2.
Eliminate "Idle Time Control" by using the switch S155 of

the X2-panel, if necessary see Operation Manual.
3.
Unplug solenoid valve Y17a (this causes a remote control.

pressure (X3) of approx. 15 bar)
4.
Start the motor.
5.
Gauge reading at MST must be 40 bar (20bar less than the pump
support pressure of 60bar
Loosen lock nut #4 and adjust with the set bolt #5
6.
Plug-on Y17a
Remove the pressure gauge and set S155 for "Idle Time"
elimination into normal position.
continued
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and
7.1
Section 7.0
Page 18
Main Pumps
Cont'd:
Start of destroking(LR valve), illustration (Z21559)
The reason of this check is to make sure, the pump starts destroking at an
operating pressure of 180 bar with a pump regulation pressure X1 of 13 bar.
1.
2.
3.
4.
5.
6.
Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
Connect a suitable pressure gauge (pressure can be 34 bar in
electronic mode) to pressure check point M5-1/2 at the control
and filter panel (X1-pressure).
Move the change over valve into position Hydraulic (constant
regulation mode).
Insert an Allen key into the angle indicator bolt (see illustration)
for better visibility of the start of destroking.
Start the motor and adjust at pressure reducing valve (253.2 motor1
respectively 254.2 motor2) the X1-pressure to 13 bar.
Stall the hydraulic for the pump to be checked and alter the
operating pressure with the MRV up and down between 160 and
200 bar.
Start of destroking should be at an operating pressure of 180 bar,
shown at the gauge connected to the high pressure filter.

a)
Adjust with the MRV an operating pressure of 180 bar.
b)
Loosen lock nut #6 (Power control valve).
c)
Turn set bolt #7, so that the pump is still in Q-max. position,
but just at the beginning of destroking.
d)
Tighten lock nut #6.
7.
Re-adjust the operating pressure at the MRV to 310+10 bar and the X1-
8.
pressure at the pressure reducing valve (253.2 motor1 respectively

254.2 motor2) to approx. 12bar.
(For exact values refer to the final test report.)
Remove Allen key and gauges.
continued
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and
7.1
Section 7.0
Page 19
Main Pumps
Cont'd:
Pressure cut-off valve (DR control valve), illustration (Z21560)
The reason of this check is to make sure that the pump is in Q-min. position
at an operating pressure between 300 bar and 310 bar.
1.
2.
3.
4.
Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
Insert an Allen key into the angle indicator bolt (see illustration) for
better visibility of the start of destroking.
Start the motor, stall the hydraulic for the pump to be checked and
alter the operating pressure with the MRV up and down between 280
and 310 bar.
The angle indicator must indicate Q-min. position at a pressure of
300 bar shown at the gauge connected to the high pressure filter.

a)
Loosen lock nut #8.
b)
Turn set bolt #9, so that the pump is in Q-min. position at
the required value.
c)
Tighten lock nut #8.
5.
Re-adjust the operating pressure at the MRV to 310+10 bar
6.
Remove Allen key and gauges.
continued
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and
7.1
Section 7.0
Page 20
Main Pumps
Cont'd:
Q-max. and Q-min. stop bolt, illustration (Z21561)
1.
2.
3.
Unscrew box nut (10 or 14).

Loosen the lock nut (11 or 13)
Turn the stop (12 or 15) in or out until required length
Length "X" or "Y"
Tighten the lock nut and screw on box nut (12).
5.
Turning the Q-min. stop bolt too much out can cause serious damage
to the pump.
The pump moves over 0 (zero) position into the opposite drive
direction: (suction line becomes pressure line and pressure line
becomes suction line)
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and
7.2
Section 7.0
Page 21
7.2.1 Electronic load limiting control - general, illustration (Z 22407d)

The drive train of the excavator consists of two electric motors, several hydraulic
pumps, which supply cylinders and hydraulic motors.
The load limiting control ensures optimum use of the power required for the excavator
under varying operating conditions and avoiding overload of the motors.
Illustration Z22407d shows the principle of the electronic load limiting control.
The MC7 (E32) processes the following input signals:
Voltage (Pin 47) from electronic signal rectifier (A32)
Current motor 1 (Pin 45) from electronic signal rectifier (A33-1)
Current motor 2 (Pin 46) from electronic signal rectifier (A33-2)
The MC7 (E32) processes the following output signals:
Signal value to control the proportional solenoid valve Y61-1 (Pin 28) Motor 1
Signal value to control the proportional solenoid valve Y61-2 (Pin 30) Motor 2
Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32)
Each electric motor drives four variable displacement pumps by means of a PTOgearbox. Each pump is equipped with a hydraulic power controller (HPC).
This controller limits the input torque of the pump to an adjusted command value (X1pressure, for start of destroking).
The command value (X1-pressure) is present via proportional solenoid valves Y61-1
respectively Y61-2 at the hydraulic power controllers of each pump.
The auxiliary hydraulic pumps and other consumers can be operated

without being directly affected by the load limiting control.
Function:
The ESR-Module (A32) transforms an AC Voltage, which is proportional to the net
voltage, into a proportional DC Voltage and transfers it into the MC7 (E32).
The ESR-Module (A33-1 + A33-2) transforms an AC Voltage, which is proportional to
the respective motor current, into a proportional DC Voltage and transfers it also into
the MC7 (E32).
These input signals are the information about the actual load to the motors and serves
the MC7 (E32).
The control algorithm of the load limiting control (MC7) always compares the actual
required power with the rated power.
With increasing load the motor torque will rise and in turn the required power.
For this reason the electronic load limiting control will be initiated when the required
power is higher than the rated power, i.e. the torque of the main pumps will be lowered
(by reducing the X1-pressure) until the rated power is attained again.
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and
7.2
Section 7.0
Page 22
7.2.2 Electronic Power Module EPM Module , illustration (Z 22624b)

The power Module A31a transforms the 24 VDC battery voltage into
positive/negative 15 VDC and the power Module A31b into positive 5 VDC
which is the supply voltage for the ESR Modules.
Function check:
Measure the supply voltage. (24 VDC; GND = 0 V).
If the supply voltage is not there, check the supply cable and the circuit
breaker. If the circuit breaker always trips there may be a short within the
cables to the Power Module or a short in the unit itself.
If the supply voltage is ok. the Output Voltages have to be checked. Check
pos. 15 VDC, neg. 15 VDC, 5 VDC to GND.
If the supply voltages are not ok. the short circuit monitoring system of the
Power Modules might be activated, therefore disconnect the cables at the
terminals (+15 VDC, -15 VDC and +5 VDC) and repeat the voltage check.
If now (with disconnected cables) the voltages are as they should be there
is either a short within the cables or in the other modules itself. To determine
the fault connect the entire modules in sequence.
If the voltage is not ok., even when the cables are disconnected from the
Power Module, the Module is defect.
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and
7.2
Section 7.0
Page 23
7.2.2 Electronic Signal Rectifier ESR Modules, illustration (Z 22625c)

Function:
The ESR-Module transforms an AC signal-voltage, which is proportional to the
network voltage respectively the motor current, into a proportional DC Voltage and
transfers it into the MC7.
Testing the ESR-Module, A32 + A33.1 + A33.2
Testing the ESR input/output voltage
For a transformer function test the AC-Input Voltage and the
DC-Output Voltage must be tested.
The potentiometer settings are under no circumstances
allowed to be altered, because the setting is possible only with a HFGenerator and an Oscilloscope.
If the potentiometer set-positions have been altered, a new Module,
with sealed potentiometers, must be ordered.
Procedure: Same procedure for all three Modules
1.
Disconnect the wire from terminal 23 of the ESR Module.
2.
Start the motor and let it run without an extra load on it.
3.
Measure the AC-Voltage between the terminals 21 and 41 and record it.
4.
Measure the DC-Voltage between the terminals 23 and 11 and record it.
5.
The measured DC-Voltage must be 1/4 of the AC-Voltage.

Example:
2.5 VDC
----------- = 0,25 (1 % plus/minus is ok)
10 VAC
Small variations are based on amplitude variations of the AC-Input voltage

while measuring the DC-Output voltage.
Greater variations denotes a faulty ESR Module.
continued
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and
7.2
Section 7.0
Page 24
7.2.2 Electronic Signal Rectifier ESR Modules, illustration (Z 22626d)

Cont'd:
The DC-Output Voltage (UaDC ) can be compared with a calculated Voltage
Value. The calculation can be done with the ratios of the intermediate
transformers given in the circuit diagram, and by the Voltmeter and Ammeter
readings of the cab gauges.
The picture shows a schematic design only and not the actual circuit
diagram, the voltage- and current values may vary, therefore they are
exemplary used.
With the below shown formulas the exact Output Voltages UaDC of an ESR
can be calculated.
Small variations are caused by the transformers.
Variations greater than 20% denotes a faulty transformer.
Example for ESR 1:
U
ESR1 ----------------T1 x T2 x T3
6240 V
--------------- = 2,476 VDC
63 x 10 x 4
Voltage
Example for ESR 2:

I
ESR2 ----------------T1 x T2 x T3
150 A
----------------35 x 0.5 x 4
= 2,142 VDC
Current Motor 1
Example for ESR 3:

I
ESR3 ----------------T1 x T2 x T3
100 A
----------------35 x 0.5 x 4
= 1,428 VDC
Current Motor 2
The AC Input Voltage for an ESR-Module can be calculated with the same
formula but without the value for T3.
Example for ESR 2:
I
ESR2 ----------T1 x T2
PC8000-6-E_Sec_7-0_#12048_rev1.doc
150
----------35 x 0.5
= 8,571 VAC
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and
7.2
Section 7.0
Page 25
7.2.2 Microcontroller MC7, illustration (Z 21716)

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

47 micro timer I contacts
MC7 - Block Circuit Diagram
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and
7.2
Section 7.0
Page 26
7.2.3 Checks and adjustments

Microcontroller MC7, illustration (Z 22623)
The adjustment of the X1-pressure can be done with three different methods:
A.
With 24V supply to separating terminals at the X2-switch board
or
B.
With the electronic service tool (EST) BB-3 connected to the serial
interface X13-1 (located in the operators cab)
or
C.
With a laptop, running the BODEM software, connected to the serial
interface X13-1 (located in the operators cab)
Procedure B and C should only be carried out by authorized

personnel. [ Dealer or KMG-factory staff ]
Because it is possible to influence the behavior of the pump regulation
system.
On the following pages are only the necessary setups described.
If additional information is required, please contact KMG-Service
department.
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and
7.2
Section 7.0
Page 27
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22628c)

Method A - X1-pressure adjustment with 24V supply to separating
terminals at the X2-panel.
Pre-conditions: Normal operating temperature, correct pilot pressure setting and
the system must be free of air.
1. Make sure the change over valves (253.1 motor 1 respectively 254.1 motor
2) are in position Electronic Pump Regulation
2. Connect a pressure gauge to the respective check points (M5.1 or M5.2),
using a long pressure gauge hose to be able reading the pressure in front of
the X2-panel.
3. Selection of adjusting mode:
Turn the main key switch in on position and activate the adjusting mode as
follows:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two
test leads and disconnect the voltage thereafter.
4. Selection of the motor and the required proportional solenoid valve :
With the main key switch still in on position, select the applying terminal for
proportional solenoid valve Y61-1 or Y61-2 as follows:
Motor1 Y 61-1 No connection to 24V required.
Motor2 Y 61-2 Connect permanent 24V to terminal 53, using a test lead.
5. Adjusting the X1-pressure:
Start the motor.
Read the pressure, required = 34 0,5 bar
If necessary increase the X1-pressure as follows:
Connect 24V to terminal 54.
As long as voltage is supplied, the X1-pressure drops to zero.
After interrupting the voltage supply, the gauge pointer will move
slowly to the new present X1-pressure.
Example: Keeping voltage supply for two seconds , will increase the
X1-pressure of approximately 1bar.
The adjusted value will be saved immediately and will be available
after power off.
6. To decrease the X1-pressure connect 24V to terminal 55 and proceed as
described under item 5, keeping voltage supply for two seconds , will
decrease the X1-pressure of approximately 1bar.
7. After the adjustment is finished, remove the test leads and pressure gauge and
turn the main key switch in OFF position to deactivate the adjusting mode.
continued
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and
7.2
Section 7.0
Page 28
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22629b)

Cont'd:
Method A - Demanded power adjustment
The adjustment has to be carried out separately for each motor

1. Connect pressure gauges to check points M11.1, M11.2, M11.3 and M11.4 at
the high pressure filters.
2. Connect pressure gauges to the X1 pressure check points M5.1 and M5.2.
3. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the
hydraulic oil cooler fans are running with maximum speed.
4. Start one motor.
5. Set the MRV individually to approx. 120 bar *, to prevent the motor from
overloading during the adjustment.
6. Shift the three way cock valves (253.1 and 254.1) to position Hydraulic
(constant) Regulation Mode.
7. Set the X1-pressure at pressure reducing valves (253.2 and 254.2) > 34 bar **, to
ensure that the pumps remain in Q-max. flow position during the adjustment.
8. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position
until the hydraulic system stalls), and increase the pressure at all 4 MRVs *
equally until the motors draw 128 Ampere. (reading of text display)
Expected system pressure at 128 Ampere = 4 times 172 bar (peak point).
Record this pressure for other tests.
If the operating pressure is higher respectively the motor current is

lower than required there is probably not the full volume available.
*Altering the MRV-Setting:
Turning the set screw (c) cw the pressure will increase.
Turning the set screw
ccw the pressure will decrease.
**Altering the X1-Setting:
Loosen the lock nut (e).
Turning the set screw (f) cw the pressure will increase.
continued
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and
7.2
Section 7.0
Page 29

Cont'd:
Method A - Demanded power adjustment
9.
Store the demanded power (peak point) into the MC7 as follows:
a) Activate the adjusting mode:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using test
leads and disconnect the voltage thereafter.
b) Select the demanded power adjusting mode (Motor 1):
Connect 24V, simultaneously to terminal 50 and 52 permanent.
c) Select the demanded power adjusting mode (Motor 2):
Connect 24V, simultaneously to terminal 50, 52 and 53 permanent.
d) Stall the hydraulic with the values of item 8 (Peak point)
4 times 172 bar (all pumps Qmax position and cooler fans with max. speed).
=> 128 Ampere (each motor)
e) Save the actual measured power:
Connect 24V to terminal 55 for 1 second and disconnect the voltage thereafter.
The actual measured power will be saved immediately as the
demanded power
10. Re-set the X1-pressure at pressure reducing valves (253.2 and 254.2) as
recorded**.
11. Shift the three way cock valves (253.1 and 254.1) to position Electronic
Regulation Mode
12. Reset the MRVs to 310 bar+5bar , and remove the gauges.
13. After the adjustments are finished, remove the test leads and pressure gauges, stop
the motors and turn the main key switch in OFF position to deactivate the
adjusting mode.

continued
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and
7.2
Section 7.0
Page 30
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636)

Cont'd:
Method A - PID - Factor adjustment to obtain the most efficient pump
regulation characteristic.
With the PID-Factor adjustment (proportional, integral and
differential factors) it is possible to influence the regulation dynamics.
The PID-Factor adjustment range is between 80% and 120%
The voltage at the analogue output (terminal 60) represents the actual
adjusted value. (80% = 0VDC / 100% = 2,5VDC / 120%= 5VDC)
This factor is multiplied with all PID parameters.
)
1.
Jerky movements while lifting and swinging at the same time:

b) Select the PID-factor adjusting mode:
Connect 24V, to terminal 50 permanent, using a test lead.
c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the
value (represents the actual adjusted value)
d) Reduce the voltage in steps of 250mV until the system works smoothly, by
connecting 24V to terminal 55. (As close as possible to the boarder line)
2.
No Jerky movements:
b) Select the PID-factor adjusting mode:
Connect 24V, to terminal 50 permanent, using a test lead.
c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the
value (represents the actual adjusted value)
e) Increase the voltage in steps of 250 mV until the system jerks, by connecting
24V to terminal 54. (As close as possible to the boarder line)
f) Now reduce the voltage in steps of 250mV until the system works smoothly
again, as described under item 1d.
3.
After the adjustments are finished, remove the test leads and multi-meter, stop the
motors and turn the main key switch in OFF position to deactivate the adjusting
mode.
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and
Section 7.0
Page 31
7.2 Electronic Pump Regulation System

7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357d)
Method B -
With the electronic service tool (EST) BB-3 connected to the serial
interface X13 (located in the operators cab)
1.
2.
3.
4.
Make sure the respective change over valve is in position Electronic Pump
Regulation
Connect a pressure gauge to check point M5.1 and M5.2, using long pressure
gauge hoses to be able reading the pressure inside the operators cab.
Connect the electronic service tool (BB-3) to the data link adapter X13,
with key switch (1S1) in OFF position.
Turn key switch (1S1) in ON position:
After switching on the power for the Control panel BB-3 the following
functions are carried out and shown on the display:
4.1
Self-test and baud rate recognition:
The BB-3 automatically recognizes the rate
of data transmission from the MC electronics.
4.2
Identification:
On recognition of the MC electronics the
relevant software in the BB-3 will be started up.
4.3
Main menu:
Initialization of remote control unit BB-3 is complete.
One of the four main menu items can be selected using the given keys.
First screen (main menu) after connection and Key switch turned ON in German.
F1
F2
PROC
TE ACH
Language selection
To change the language press simultaneously
the buttons ALT + Clear
ALT
CLEAR
Config/Cal.
Diagnostic
Status
Storage
The language selection menu appears
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
continued
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and
7.2
Section 7.0
Page 32

Method B
Cont'd:
Language selection
Press button 2
The language will change to English

and the display show the main menu
1.
2.
3.
4.
Deutsch
English
- - - - -
One of the four main menu items can be selected using the given keys.
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and
7.2
Section 7.0
Page 33

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

Only with password.
Config/Cal.
Diagnostic
Status
Storage
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
Change from SET 1 to SET 2:

SET 1
Press
F1
Config/Cal
Press
ALT
in the same time
1
2
3
4
Demand Power
Max current
PID - Factor
Error Lamp
A password will be requested

Enter password (number: 570875)
1
Press
...
MENU
SET 2
to go back to the main menue
To switch back to SET 1 repeat this procedure

or switch off and on the MC7.
PC8000-6-E_Sec_7-0_#12048_rev1.doc
?: _
1
2
3
4
Configuration
PID Control
Low Voltage
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
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34
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and
7.2
Section 7.0
Page 34

Method B
Number of motor selection:
Activate adjustment mode SET 2 as
described on page 33
Press
F1
Config/Cal
Press
Configuration
Press
No of motors
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
1
2
3
4
Configuration
PID Control
Low Voltage
1
2
3
4
No of valves
No of motors
Select desired number of motors
No of motors
use
motor
No of motors
motors
1
2
3
4
No valves
No motors
Press
or
ENTER Acceptation
Press. 2 x MENU Return to sub menu.
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
Save setting to the EEPROM of the MC7 as described at page 38.
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and
7.2
Section 7.0
Page 35
7.2.3 Checks and adjustments Micro-controller MC7, illustration (Z 22357d)

Method B
X1-Pressure (maximum current) Adjustment:
F1
Press
Config/Cal
If sub menu SET 2 is displayed change to

sub menu SET 2 as described on page 33.
Press
Max current
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
1
2
3
4
Demand Power
Max current
PID - Factor
Error Lamp
1
2
3
4
Valve
Valve
Valve
Valve
Select desired valve

Press
or
Press
Valve 1, Motor1
Valve 1, Motor2
Example Motor 1, Valve1
Start the respective motor. Do not load the motor.

Check the X1-pressure with a pressure gauge and set
it to the desired value by:
pressing
Press
or
ENTER
Press. 2 x
Acceptation
MENU
Return to main menu
1
2
1
2
Mot.
Mot.
Mot.
Mot.
1
1
2
2
1 Valve 1 Mot. 1
0 1001
71
1 Valve 1 E1
0 1001
78
1
2
3
4
Valve
Valve
Valve
Valve
F1
F2
PROC
TE ACH
1
2
1
2
Mot.
Mot.
Mot.
Mot.
1
1
2
2
Config/Cal.
Diagnostic
Status
Storage
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and
7.2
Section 7.0
Page 36

Method B
Demanded power adjustment:
Press
F1
Config/Cal

Press
Configuration
1
2
3
4
Demand Power
Max current
PID-Factor
Error Lamp
1
2
3
4
Set demand m.
Set demand m.
Demand power
Demand power
Select desired demand power adjustment

Press
or
Press
SET 1
demand power Motor1
demand power Motor2
1
2
1
2
1 Set demand m. 1
001
0
Example Motor 1
and
Load respective Motor with max power
Press ENTER
Selection
Start?
> <ENTER>
Cancel?
> <ENTER>
Press ENTER
Starting
Function ended
Saved
Press <ENTER>
Press ENTER Confirm
Press. 2 x
MENU
Return to main menu
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
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and
7.2
Section 7.0
Page 37
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636a)

Method B
PID-Factor adjustment:
Jerky movements while lifting with full bucket and swinging at the same time:
Reduce jerking Reduce the PID-Factor in short steps.
To obtain the most efficient pump regulation characteristic adjust to the PID-Factor until
the system jerks as close as possible to the boarder line.
Press
F1
F1
F2
PROC
TE ACH
Config/Cal

SET 1
Press
PID-Factor.
Press
PID-Factor.
Adjust the PID-Factor

by pressing .
or
Press
ENTER
Acceptation
and check the machine movement again

if necessary repeat PID-Factor adjustment
Press. 2 x
MENU
Return to main menu.
Config/Cal.
Diagnostic
Status
Storage
1
2
3
4
Demand Power
Max current
PID-Factor
Error Lamp
1
2
3
4
PID-Factor
1 PID-Factor
801201%
100
1
2
3
4
PID-Factor
F1
F2
PROC
TEACH
Config/Cal.
Diagnostic
Status
Storage
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and
7.2
Section 7.0
Page 38

Method B
Storage all new settings to the MC7:
This menu item permits storage of all edited parameters to the EEPROM
of the MC electronics
Activate storage menu
F1
F2
PROC
TE ACH
Save Params
1
2
3
4
Press ENTER
Store parameters
Teach?
> <ENTER>
Cancel?
> <ENTER>
Press. MENU
Return to main menu.
1
2
3
4
Press TEACH
Press
Config/Cal.
Diagnostic
Status
Storage
Save Params
Default Rarams
Get EEPROM
Send EEPROM
Save Params
Default Rarams
Get EEPROM
Send EEPROM
If all adjustments are correct and stored in the MC7, proceed as follow:
Stop the motors and turn key switch (S1) in OFF position
Disconnect the electronic service tool (BB-3) and the pressure gauges.
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and
7.2
Section 7.0
Page 39

Method C -
With a laptop computer and BODEM software connected to the

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

4. Start the computer.
5. Click on the Bodem - icon to start the program.
continued
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and
7.2
Section 7.0
Page 40

Method C
Cont'd:
Starting the program
6. The program starts (only) the first time with the Demo Version.
7. Open menu FILE INTERFACE , select the required interface connection

(Standard COM1), confirm with OK and leave the program.
8. Start the program again. Now the computer is connected to the Microcontroller.
During uploading of the MC7 data to the PC a window opened and shows some
hardware and software information.
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and
7.2
Section 7.0
Page 41

Method C
Language selection
Open menu FILE Language , select the required language and confirm with OK .
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and
7.2
Section 7.0
Page 42

Method C
Entering of the password:
The password is only required to adjust the number of valves or

engines and for fine tuning of special regulation parameters. All other
adjustments are possible without the password.
Open menu Parameters and select Enter password. Write the correct password (570875)
and confirm with OK.
After entering a correct password and confirming with OK the

BODEM software start a new upload from the MC7 memory to the PC.
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and
7.2
Section 7.0
Page 43

Method C
Number of Motor selection:
Pre condition: The correct password was entered as described on page 42.
Open Parameters and select Display / Edit Parameters. Then select in the left window
Configuration. Now on the right side there are two pull down menus.
Example: select for PC 8000 1 valve per motor and 2 Motors.
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
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and
7.2
Section 7.0
Page 44

Method C
X1-Pressure (maximum current) Adjustment:
Make sure the change over valve is in position Electronic Pump Regulation
Connect a pressure gauge to the respective check point (M5.1 or M5.2), using a long pressure
gauge hose to be able reading the pressure inside the operators cab.
Open menu Parameters select Display/Edit parameters and Max current,
start respective motor without load and wait 30 sec. The X1-pressure will raise to the max.
adjusted value. If necessary adjust the required pressure (according to the final test report or
hydraulic diagram) with the respective slide bar. (Valve 1 Mot. 1 is the X1-1 pressure and
Valve 1 Mot. 2 the X1-2 pressure).
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
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and
7.2
Section 7.0
Page 45

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

Screen without password.
The demand power adjustment is possible in both modes.
continued
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and
7.2
Section 7.0
Page 46

Method C
Cont'd: DEMAND POWER ADJUSTMENT:
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system
must be free of air.
1.
2.
3.
4.
5.
6.
7.
8.
Connect pressure gauges to check points M11.1, M11.2, M11.3 and M11.4
at the high pressure filters.
Connect pressure gauges to the X1 pressure check points M5.1 and M5.2.
Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the
Shift the three way cock valves (253.1 and 254.1) to position Hydraulic
Start one motor.
Set the MRVs of main valve block I, II, III and IV individually to approx. 120
bar *, to prevent the motor from overloading during the test.
Set the X1-pressure at pressure reducing valve (253.2) > 34 bar **, to ensure
that the pumps remain in Q-max. flow position during the adjustment.
Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop
position until the hydraulic system stalls), and increase the pressure at all 4
MRVs * equally to the demand power pressure written in the final test report
e.g. PC8000, S/N 12037 = 172 bar. Check the current drawn of the respective
motor at this stage (reading of text display)
Expected: approx. ~ 128 Ampere. Record this values for other tests.
continued
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and
Section 7.0
Page 47
7.2 Electronic Pump Regulation System

Method C
Cont'd:
Demand power adjustment:
9.
Select Execute of menu point Set demand m. 1 for motor 1 or

Set demand m. 2 for motor 2.
Select Start to set the actual power as demand power. Confirm with OK. The
new actual demand power will be only shown after a new upload of the MC7
settings. Exit the BODEM software and start again.
10. Stop motor and repeat from item 5 for the second motor.
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and
7.2
Section 7.0
Page 48

Method C
PID Factor adjustment:
This adjustment is required to obtain the most efficient pump regulation characteristic.
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
With the PID-Factor adjustment (proportional, integral and
differential factors) it is possible to influence the regulation dynamics.
This factor is multiplied with all PID parameters.
Only one factor / adjustment for both motors
Open Parameters and select Display / Edit Parameters. Select in the left window PID
control. Adjust now the PID-Factor with the slide bar or write direct the requested
value to the window with the % value. Write new adjustment permanent to the MC7
EEPROM with Apply and confirm with OK.
Jerky movements while lifting and swinging at the same time: Reduce the PID-Factor in
short steps until the system works smoothly. (As close as possible to the boarder line)
No Jerky movements:
1. Increase the PID-Factor in short steps until the system jerks. (As close as possible to the
boarder line)
2. Now reduce the PID-Factor in short steps until the system works smoothly again.
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and
7.3
Section 7.0
Page 49

7.3.1. General
The pilot pressure pumps (9.1 and 9.3) deliver the oil through the pressure filters
(68.1 and 68.7) to port A of the pressure relief valve (252.2) for limiting the pump
support pressure X4 to 60 bar. By the function of pressure reducing valve
(252.1), the X4 pressure of 60 bar is reduced to the pilot pressure X2 of 45 bar.
The common X2 pressure will be reduced by the function of pressure reducing
valves (253.2 motor 1 and 254.2 motor 2) to the necessary constant X1
pressure, to prevent the motors from overloading.
For testing purposes the pump regulation system can be changed to

the hydraulic operation mode. In case of a failure in the electronic
regulation system the hydraulic operation mode can also be used for
emergency operation.
The standard operation mode of the pump regulation system is the
Electronic Operation Mode.

(1 - 4)
Main hydraulic pumps (driven by Motor 1)
(5 - 8)
Main hydraulic pumps (driven by Motor 2)
(9.1)
Pilot pressure pump (driven by Motor 1)
(9.3)
Pilot pressure pump (driven by Motor 2)
(68.1 +68.7)
Pilot pressure filter unit
(252.2)
Pressure relief valve 60 bar (X4)
(252.1)
Pressure reducing valve 45 bar (X2)
(252.3 + 252.4) Check valve
(253.2)
hydraulic constant regulation mode " (Motor 1)
(254.2)
hydraulic constant regulation mode " (Motor 2)
(Y61-1)
electronic operation mode" (Standard mode Motor 1)
(Y61-2)
electronic operation mode" (Standard mode Motor 2)
(253.1)
Change over valve: "Electr. or Hydr. pump regulation" Motor 1
(254.1)
Change over valve: "Electr. or Hydr. pump regulation" Motor 2
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and
7.3
Section 7.0
Page 50

7.3.2. X1-pressure adjustment (constant-pressure), illustration (Z 22639d)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Connect pressure gauges to check points M11.1, M11.2, M11.3 and M11.4
at the high pressure filters.
Connect pressure gauges to the X1 pressure check points M5.1 and M5.2.
Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the
Shift the three way cock valves (253.1 and 254.1) to position Hydraulic
Start motor 1.
Set the MRVs of main valve block I, II, III and IV individually to approx. 120
bar *, to prevent the motor from overloading during the test.
Set the X1-pressure at pressure reducing valve (253.2) to approx. 11 bar **
MRVs * equally to 260 bar.
Check the current drawn of motor 1 at this stage (reading of text display)
Expected approx. 120 Ampere. Record this values for other tests.
Stop motor 1 and start motor 2 .
Set the X1-pressure at pressure reducing valve (254.2) to approx. 11 bar **
MRVs * equally to 260 bar.
Check the current drawn of motor 2 at this stage (reading of text display)
Expected approx. 120 Ampere. Record this values for other tests.
Shift the three way cock valves (253.1 and 254.1) to position Electronic
regulation.
Reset the MRVs * to 310 bar+5bar , and remove the gauges.

Remove dust cap (d).
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51
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and
7.6
Section 7.0
Page 51
Energy efficiency
Legend for illustration (25960a)
(1-8)
Main pumps
(E6)
PLC (programmable logic controller)
(I)
Inputs (analogue and digital)
(O)
Outputs (digital)
C
Controls (lever, pedal) signal
S
Solenoid valve control
M19
Test port, flow control pressure
M55
Test port, output of Y146
M56
Test port, output of Y147
(Y17)
Idle time control, (Pump control system)
(Y17a) Q-max (reduced oil flow at too cold oil)
(Y146) Flow control valve (pump No 1, 2, 3, 5, 6, 7)
(Y147) Flow control valve (pump No 4 and 8)
(265)
Pressure reducing valve reduced pump flow
7.6.1. General
Energy, which is not used to do active movement, can be considered in loss
energy.
Although energy cannot be destroyed it can be converted into heat which is
useless for performing work through hydraulics. The not used energy cause
increasing power consumption.
With the following measures an optimizing of the energy efficiency in our
machines optimized oil delivery of specified pumps in relation to definite
movements of the excavator.
The PLC controls the solenoid valves. Generally logic is during single
function we have full pump flow and in combined function it reduces the oil
flow. Except the pumps for the swing system, this are back in maximum flow
during swing function.
The remote control pressure X3 on pump port Pst controls the maximum
permissible pump flow. With decreasing pressure the pump volume decreases
as well. A pre-set pressure reducing valve (265) is responsible to limit the X3
pressure for the reduced pump flow Qred.
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52
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and
7.6
Section 7.0
Page 52
Energy efficiency
Legend for illustration (25961a)
(c)
Lock nut
(d)Set screw
(M19)
Test point (Pst-pressure, flow reduction)
(Y146) Flow reduction solenoid valve (pump No 1, 2, 3, 5, 6, 7)
(Y147) Flow reduction solenoid valve (pump No 4,and 8)
(265)
Pressure reducing valve reduced pump flow - Qred
(255.4) Pressure reducing valve Qmax (X3 = Pst= 15 bar)
Values are based for machine working from see level up to 3600m.
Machines working on higher altitude require a reduced Qmax setup
which influences the test values.
X3 or Pst: both are the same pressure. It is the pressure to control the
maximum permissible pump output flow. Pst is the port name of the
main pump
7.6.2. Checks and adjustments, flow control (Qred)

To check or adjust the function of the Energy efficiency system it is
necessary to follow the instructions below.
1. Connect a test gauge (0-60 bar) to port M19. It is located at the pilot
control plate at the right bottom corner close to the pressure reducing
valve (265).
2. Let both engines / motors run. Diesel engine shift to high idle.
3. Turn superstructure 90 right to the travel direction.
4. Apply the swing parking brake.
5. Move bucket close to the side frame and raise one track off the ground
just to get the track free.
6. Activate the travel pedal of the lifted track fully in one direction. Make
sure that there is no other function activated.
7. Test of max. pump volume. Y146 and Y147 must be de-energized.
Check the time of fife (5) sprocket revolutions. See table Pump Flow
control test values next page for the required time.
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and
Section 7.0
Page 53
8. Test of reduced pump flow (flow reduction). Y146 must be energized.

Activate carefully the swing function in one direction against the parking
brake. The lever must be fully activated. In the same time activate the
travel function of the lifted track also fully in one direction.
Check the time of fife (5) sprocket revolutions.
See table Pump flow control test values for the required time.
9. To verify the result repeat test from item 4 but now with the left track site.
10. If the value is within the tolerance check resulting Pst pressure at the
gauge of test port M19 and record value for future tests as a reference.
If adjustment is required
a. Loosen lock nut (c) of the pressure reducing valve.
b. Turn clockwise set screw (d) of the pressure reducing valve 265 to
reduce or counter clockwise to increase the sprocket speed.
Adjust the sprocket speed to 69 1 sec at 5 revolutions.
c. Look set screw with the lock nut.
Pump flow control test values
No. Function
Y146
[Volt]
Y147 Sprocket right

[Volt] time / 5 rev
Sprocket left
time / 5 rev
Only travel right
54 1 sec
54 1 sec
Travel right and swing
24
24
69 1 sec
69 1 sec
Only travel left
54 1 sec
54 1 sec
Travel left and swing
24
24
69 1 sec
69 1 sec
Additionally of the flow control valves Y146 and Y147 the valve Y17
and Y17a controls the pump angel (pump volume). See table below.
It means there are also influences of the pause time function (no activated
controls), hydraulic oil temperature and service switch S155.
Pst = 0 bar = Qmin (pause time)
Pst = 15 bar = Qmax (pause time or low oil temperature)
Pst = 181 = Q reduced (flow control)
(determined via above procedure).
Pst = 45 bar = Qmax
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Operating Hydraulic
Section 8.0
Page 1

Section
8.0
Page
Operating Hydraulic
General
8.1
Hydraulic for the attachment cylinder FSA and BHA
8.2
Hydraulic for the swing circuit
8.3
Hydraulic for the travel circuit
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8.0
2
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01.12.05
Operating Hydraulic
8.0
Section 8.0
Page 2
General
Overall view of the Hydraulic system, illustration (Z 22676b):
(1 8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Main pumps
High pressure filters
Main control blocks
Attachment cylinders
Swing motors
Rotary joint
Travel motors
General information
The control blocks, the piping to the distributor manifold and the connecting
hoses to the attachment are different between the Backhoe Attachment (BHA)
and the Front Shovel Attachment (FSA). If a conversion is required, contact
the service department for further information.
Function:
Study together with the circuit diagram.

The following numbering refers to the hydraulic circuit diagram.
Each main pump (1 to 8) delivers oil trough the high pressure filter (18.1 to 18.4)
to port P of the main control blocks (14 to 17).
This results in four main circuits.
If all spools of the control blocks (14 to 17) are in neutral position, the oil leaves
the block at port T and returns via return oil pipes (L23 to L26), return oil
collector tube, back pressure valve (26) and the return oil filters (51.1 - 51.7) into
the tank.
The function of back pressure valve (26) ensures:
- sufficient oil supply for all anticavitation valves
- and that sufficient oil is forced through the oil coolers.
If a control lever or pedal is actuated, pilot pressure oil moves the spools of the
control blocks, directing the oil flow from the main pumps to one side of the
user (either cylinders or motors). From the opposite side of the user the oil
returns to the control block and from there via the return oil circuit back into
the tank.
Each circuit is provided with one MRV (also called primary valve, at least one
SRV (also called secondary valve) and at least one flow restrictor.
continued
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Operating Hydraulic
8.0
Section 8.0
Page 3
General
Cont'd:
Floating function of boom and stick cylinders FSA:
illustration (Z 22677c):
The Excavator operates automatically with the float position for boom and stick
activated. That means the lowering movement of boom and stick is always done
in the float position.
For deactivation of the float position, two push buttons are installed:
a) S95 in the right joy stick (E19) for the Boom function
b) S98 in the left joy stick (E20) for the Stick function
Press the respective button and keep it depressed as long as the float position shall
be deactivated.
When releasing the button the float position is activated again.
Function:
There are different spools in the main control blocks (I, II, III and IV) for boom
and stick installed.
Spools without a symbol (standard) are connecting the rod side of the cylinders
with the pump supply line and the piston side with the tank.
Spools with #-symbol (lowering with free pump circulation) are connecting the
piston side of the cylinders with the tank only.
Spools with $-symbol (floating) are connecting the piston side of the cylinders
with the rod side and also with the tank.
Only by lowering the boom or retracting the stick is the floating function active if
the button on the joy stick is not pushed. The piston and rod side of the respective
cylinders are in floating position direct connect to the return line (tank). By
external force the cylinder can move up or down with negligible hydraulically
resistance.
To push down the boom or retract the stick by hydraulically force, the function of
the floating spools must be interrupted, by activating the respective button on
the joy sticks.
Boom: S95 ON K160 ON
Float position deactivated

S95 OFF K160 OFF
Float position activated
S98 ON K170 ON
S98 OFF K170 OFF
Stick:
Float position deactivated

Float position activated
Special spool with (#$)-symbol in control block II for bucket dump
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Hydraulic for the

Attachment Cylinders
Section 8.1
Page 1

Section
8.1
Page
Hydraulic for the attachment cylinder FSA
8.1.1 Electric / Hydraulic Flowchart Boom raising
8.1.2 Electric / Hydraulic Flowchart Boom lowering
8.1.3 Electric / Hydraulic Flowchart Stick extending
8.1.4 Electric / Hydraulic Flowchart Stick retracting
8.1.5 Electric / Hydraulic Flowchart Bucket filling (curl)
8.1.6 Electric / Hydraulic Flowchart Bucket emptying
8.1.7 Electric / Hydraulic Flowchart Clam opening
8.1.8 Electric / Hydraulic Flowchart Clam closing
8.1.9 Checks and adjustments of the
Main Relief Valves- MRVs (Primary valves)
8.1.10 Checks and adjustments of the
Service Line Relief Valves - SRVs (Secondary valves)
Boom cylinder piston side FSA
Boom cylinder piston rod side FSA
Stick cylinder piston side FSA
Stick cylinder piston rod side FSA
Bucket cylinder piston side FSA
Bucket cylinder piston rod side FSA
Clam cylinder piston rod side FSA
Clam cylinder piston side FSA
8.1.11 Checks and adjustments for the lowering speed.
Flow Restrictors
Boom cylinder FSA
Stick cylinder FSA
Bucket cylinder FSA
Clam cylinder
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2
3+4+5
6
7+8+9
10
11
12
13
14
15 + 16
17 + 18
19 + 20
21 + 22
23 + 24
25 + 26
27
28
29
30
31
32
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Hydraulic for the

Section 8.1
Page 2
8.1.1 Electric / Hydraulic flowchart Boom raising FSA

Legend for illustration (Z 22678e):
(E19)
Control lever (Joy stick)
(-Y)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(gn)
Colour code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E49)
Ramp time module
(A3)
Service module, adjustable 10...0...+10 Volt
adjusted to +10 Volt
(A10)
Amplifier module Boom
(A10a)
(A10b)
(A10c)
(K58)
Relay pilot control:
Contacts 8 / 12 and 5 / 9 only closed while lifting the boom.
(K160)
Contacts 2/ 10 and 1 / 9 closed in normal operating mode.
Contacts 6/ 10 and 5 / 9 closed while disable auto-float boom.
(K72)
Contacts 6 / 10 only closed while extending the stick.
(K80)
Contacts 6 / 10 only closed while filling the bucket.
(K205)
Relay hydraulic flow heating:
Contacts 8 / 12 only closed while heating system is switched on.
(102.1 102.4)
(Y23 + Y25)
Proportional solenoid valve
(Y29 + Y35)
(Y23A)
(Y29A + Y35A) Directional solenoid valve
(I + III + IV)
Main control blocks
(73)
Electrical signal flow.
Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5 of
the amplifier modules (A10 to A10c) and further to the proportional and directional
solenoid valves of the remote control blocks (102.1, 102.2, 102.3, and 102.4).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure oil
flows to the pilot pressure ports of the main control blocks (I , III and IV).
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I , III and IV)
and arrives via distributor manifold (73) at the hydraulic cylinders.
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Hydraulic for the

Section 8.1
Page 3
8.1.2 Electric / Hydraulic flowchart Boom lowering FSA

Single movement in normal operating mode (Auto Float ON )
(E19)
(+Y)
(+10V)
(gn)
(X2...)
(E49)
Ramp time module
(A3)
(A10)
(A10a)
(A10b)
(A10c)
(K58)
Relay Contacts 8 / 12 and 5 / 9 only closed while lifting the boom.
(K160)
Relay Contacts 2 / 10 and 1 / 9 closed in normal operating mode.
Contacts 6 / 10 and 5 / 9 closed while disable auto-float.
(K72)
Relay Contacts 6 / 10 only closed while extending the stick.
(K80)
Relay Contacts 6 / 10 only closed while filling the bucket.
(K205)
(102.1 102.4)
(Y23 + Y25)
(Y29 + Y35)
(Y23B + Y25B) Directional solenoid valve
(I IV)
Main control blocks I IV
(73)
flows to the pilot pressure ports of the main control blocks (I to IV).
Hydraulic oil flow
Only oil of main pumps 4+8 flows through the standard spool in control block (II) to the
rod side of the boom cylinders. The spool with #-symbol (lowering with free pump
circulation) in control block (III) is connecting the piston side with the tank only. The
floating spools($) in control blocks (I + IV) are connecting the piston side of the
cylinders with the rod side and also with the tank.
Now the boom can move down by gravity, since all pressure lines are connected via
distributor manifold (73) and the control blocks to one common return line.
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Hydraulic for the

Section 8.1
Page 4

Combined movement with stick out and bucket fill (Auto Float ON )
(E19)
(+Y)
(+10V)
(gn)
(X2...)
(E49)
Ramp time module
(A3)
(A10)
(A10a)
(A10b)
(A10c)
(K58)
(K160)
(K72)
(K80)
(K205)
(102.1 102.4)
(Y23)
(Y29 + Y35)
(Y23B)
(Y29B + Y35B)
(I IV)
(73)
Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at terminal 5 of the
amplifier modules (A10 + A10b A10c) and further to the proportional and directional solenoid
valves of the remote control blocks (102.1, 102.3, and 102.4).
Amplifier module (A10a) is not active , because the function of bucket fill or stick extend will
in turn open the relay contacts of K80 or K72.
When the proportional and directional solenoid valves are energized pilot pressure oil flows to
the pilot pressure ports of the main control blocks (I, III and IV).
Hydraulic oil flow
No pump delivery to the cylinders, because the standard spool in control block (II) is not
involved. The spool with #-symbol (lowering with free pump circulation) in control block (III)
is connecting the piston side with the tank only. The floating spools($) in control blocks (I + IV)
are connecting the piston side of the cylinders with the rod side and also with the tank.
The boom can move up and down by external force (Floating), since all pressure lines are
connected via distributor manifold (73) and the control blocks to one common return line.
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Hydraulic for the

Section 8.1
Page 5

Single movement with push button S95 depressed (Auto Float OFF)
(E19)
(S95)
Push button Auto Float OFF
(+Y)
(+10V)
(gn)
(X2...)
(E49)
Ramp time module
(A3)
(A10)
(A10a)
(A10b)
(A10c)
(K58)
(K160)
(K72)
(K80)
(K205)
(102.1 102.4)
(Y25)
(Y29 )
(Y25B)
(Y29B)
(I IV)
(73)
Electrical signal flow
The auto float button in joy stick (E19) is depressed, with the result that relay K160 is
energized. Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at
terminal 5 of the amplifier modules (A10a and A10b) and further to the proportional
and directional solenoid valve of the remote control blocks (102.2 and 102.3).
flows to the pilot pressure ports of the main control blocks (II and III).
Hydraulic oil flow
The oil of main pumps 4+8 flows through the standard spool in control block (II) and
arrives via distributor manifold (73) at the rod side of the boom cylinders.
The spool with #-symbol (lowering with free pump circulation) in control block (III)
has a closed pressure port and is connecting the piston side with the tank only. The
floating spools ($) in control blocks (I + IV) are not involved.
Now a pressurized lowering of the boom is possible.
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6
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Hydraulic for the

Section 8.1
Page 6
8.1.3 Electric / Hydraulic flowchart Stick extending FSA

(E20)
(+Y)
(+10V)
(gn)
(X2...)
(E48)
Ramp time module
(A3)
(A8)
Amplifier module Stick
(A8a)
(A8b)
(A8c)
(K58)
Relay Contacts 6/10 only closed when lifting the boom.
(K71)
Relay Contacts 6 / 10 only closed when boom up or down.
(K72)
Relay Contacts 5 / 9; 7 / 11 and 8 / 12 closed when stick out.
(K73)
Relay Contacts 5 / 9; only closed when traveling or swinging.
(K78)
Relay Contacts 6 / 10; only closed when bucket dump.
(K80)
Relay Contacts 7 / 11 and 8 / 12; only closed when bucket fill.
(K170)
Relay Contacts 2 / 10; 3 / 11 and 4 / 12 closed in normal operating
mode.
Contacts 6 / 10; 7 / 11 and 8 / 12 closed when auto-float OFF.
(K205a)
Contacts 5 / 9 and 6 / 10 only closed while heating system is
switched on.
(K207b)
(102.1 102.4)
(Y21 + Y26)
(Y31 + Y34)
(I IV)
(73)
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to IV) and
arrives via distributor manifold (73) at the hydraulic cylinders.
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7
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Hydraulic for the

Section 8.1
Page 7
8.1.4 Electric / Hydraulic flowchart Stick retracting FSA

Single movement in normal operating mode (Auto Float ON )
(E20)
(-Y)
(-10V)
(gn)
(X2...)
(E48)
Ramp time module
(A3)
(A8)
(A8a)
(A8b)
(A8c)
(K58)
(K71)
(K72)
Relay Contacts 5 / 9; 7 / 11 and 8 / 12 only closed when stick out.
(K73)
(K78)
(K80)
(K170)
Relay Contacts 2 / 10; 3 / 11 and 4 / 12 closed in normal operating mode.
(K205a)
Contacts 5 / 9 and 6 / 10 only closed while heating system is switched on.
(K207b)
(102.1 102.4)
(Y21 + Y26)
(Y31 + Y34)
(Y21B + Y26B)
(Y31B + Y34B)
(I IV)
(73)
Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the
amplifier modules (A8 to A8c) and further to the proportional and directional solenoid valves of
the remote control blocks (102.1, 102.2, 102.3, and 102.4).
the pilot pressure ports of the main control blocks (I to IV).
Hydraulic oil flow
Oil of main pumps 4+8 (control block II) and main pumps 1+5 (control block IV) flows through
their standard spools to the rod side of the stick cylinders. The spool with #-symbol (lowering
with free pump circulation) in control block (I) is connecting the piston side with the tank only.
The floating spool($) in control blocks (III) is connecting the piston side of the cylinders with
the rod side and also with the tank.
Now the stick can move down by gravity, since all pressure lines are connected via distributor
manifold (73) and the control blocks to one common return line.
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8
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Hydraulic for the

Section 8.1
Page 8

Combined movement with boom up and bucket fill (Auto Float ON )
(E20)
(-Y)
(-10V)
(gn)
(X2...)
(E48)
Ramp time module
(A3)
(A8 A8c)
Amplifier modules Stick
(K58)
(K71)
(K72)
(K73)
(K78)
(K80)
(K170)
Relay Contacts 2 / 10; 3 / 11 and 4 / 12 closed in normal operating mode.
(K205a)
(K207b)
(102.1 + 102.3)
(Y21)
(Y31)
(Y21B)
(Y31B)
(I + III)
Main control blocks I + III
(73)
Signal voltage of joy stick (E20) arrives via ramp time module (E48) only at terminal 5 of the
amplifier modules (A8 + A8b) and further to the proportional and directional solenoid valves of
the remote control blocks (102.1 + 102.3).
Amplifier modules (A8a+ A8c) are not active, because the function of bucket fill or boom up
will in turn open the relay contacts of K80 or K58.
the pilot pressure ports of the main control blocks (I and III).
Hydraulic oil flow
No pump delivery to the cylinders, because the standard spools in control block (II +IV) are not
involved. The spool with #-symbol (lowering with free pump circulation) in control block (I) is
connecting the piston side with the tank only. The floating spool ($) in control blocks (III) is
connecting the piston side of the cylinders with the rod side and also with the tank.
The stick can move up and down by external force (Floating), since all pressure lines are
connected via distributor manifold (73) and the control blocks to one common return line
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9
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Hydraulic for the

Section 8.1
Page 9

Single movement with push button S98 depressed (Auto Float OFF)
(E20)
(S98)
Push button Auto Float OFF
(-Y)
(-10V)
(gn)
(X2...)
(E48)
Ramp time module
(A3)
(A8 A8c)
Amplifier modules Stick
(K58)
(K71)
(K72)
(K73)
(K78)
(K80)
(K170)
Relay Contacts 2 / 10; 3 / 11 and 4 / 12 closed in normal operating
mode.
(K205a)
(K207b)
(102.1 102.4)
(Y21 + Y26)
(Y34)
(Y21B+ Y26B)
(Y34B)
(I + II + IV)
Main control blocks I + II + IV
(73)
The auto float button in joy stick (E20) is depressed, with the result that relay K170 is
energized. Signal voltage of joy stick (E20) arrives via ramp time module (E48) only at terminal
5 of the amplifier modules (A8, A8a and A10c) and further to the proportional and directional
solenoid valve of the remote control blocks (102.1, 102.2 and 102.4).
the pilot pressure ports of the main control blocks (I and III).
Hydraulic oil flow
Oil of main pumps 4+8 (control block II) and main pumps 1+5 (control block IV) flows through
their standard spools and arrives via distributor manifold (73) at the rod side of the stick
cylinders. The spool with #-symbol (lowering with free pump circulation) in control block (I)
has a closed pressure port and is connecting the piston side with the tank only. The floating
spool ($) in control block (III) is not involved.
Now a pressurized lowering of the stick is possible.
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Hydraulic for the

Section 8.1
Page 10
8.1.5 Electric / Hydraulic flowchart Bucket filling FSA

(E19)
(-X)
(-10V)
(ws / gn)
(X2...)
(A9 A9c)
Amplifier modules Bucket
(A3)
(E17)
EBL module (Electronic Bucket Leveling)
(K50)
Relay Contacts 6 / 10 closed under normal operating conditions
i.e. hydraulic oil temperature and grease lube systems are o.k.
(K58)
Relay Contacts 7 / 11 only closed when lifting the boom.
(K71)
(K73)
(K74)
Relay Contacts 5 / 9; only closed when stick in or out.
(K80)
Relay Contacts 5 / 9; only closed when bucket fill.
(K205)
(102.1 102.4)
(Y22 + Y27)
(Y30 + Y33)
(Y22A+ Y27A) Directional solenoid valve
(Y30A+ Y33A) Directional solenoid valve
(I IV)
(73)
Signal voltage of joy stick (E19) arrives via relay contacts 10/6 of K50 at terminal 19 of
the EBL module (E17). From (E17) the signal voltage arrives via several relay contacts
at terminal 5 of the amplifier modules (A9 to A9c) and further to the proportional and
directional solenoid valves of the remote control blocks (102.1, 102.2, 102.3 and 102.4).
Hydraulic oil flow
Now the oil of all main pumps flows through the main control blocks (I, II, III, IV) and
arrives via distributor manifold (73) at the piston side of the bucket cylinders.
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Hydraulic for the

Section 8.1
Page 11
8.1.6 Electric / Hydraulic flowchart Bucket emptying FSA

(E19)
(+X)
(+10V)
(ws / gn)
(X2...)
(A9 A9c)
Amplifier modules Bucket
(A3)
(E17)
EBL module (Electronic Bucket Leveling)
(K50)
Relay Contacts 6 / 10 closed under normal operating conditions
i.e. hydraulic oil temperature and grease lube systems are o.k.
(K58)
Relay Contacts 7 / 11 only closed when lifting the boom.
(K71)
(K73)
(K74)
Relay Contacts 5 / 9; only closed when stick in or out.
(K80)
Relay Contacts 5 / 9; only closed when bucket fill.
(K205)
(102.1 102.4)
(Y22 + Y27)
(Y30 + Y33)
(Y22B+ Y27B) Directional solenoid valve
(Y30B+ Y33B) Directional solenoid valve
(I IV)
(73)
Signal voltage of joy stick (E19) arrives via relay contacts 10/6 of K50 at terminal 19 of
the EBL module (E17). From (E17) the signal voltage arrives via several relay contacts
at terminal 5 of the amplifier modules (A9 to A9c) and further to the proportional and
directional solenoid valves of the remote control blocks (102.1, 102.2, 102.3 and 102.4).
Hydraulic oil flow
Oil of main pumps 2+6 (control block I) and main pumps 3+7 (control block III) flows
through their standard spools and arrives via distributor manifold (73) at the rod side of
the bucket cylinders. The spools with #-symbol (lowering with free pump circulation) in
control blocks (II +IV) are connecting the piston side with the tank only.
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Hydraulic for the

Section 8.1
Page 12
8.1.7 Electric / Hydraulic flowchart Clam opening FSA

(E24)
Control pedal
(-10V)
(rs)
Colour code of signal voltage cable (control pedal)
(X2...)
(A11)
Amplifier modules Clam
(102.4)
(Y32)
(Y32A)
(IV)
Main control block IV
(73)
Signal voltage of control pedal (E24) arrives at terminal 5 of the amplifier module
(A11) and further to the proportional and directional solenoid valves of the remote
control block (102.4).
flows to the pilot pressure ports of the main control block (IV).
Hydraulic oil flow
Oil of main pumps 1+5 (control block IV) flows through their standard spools and
arrives via distributor manifold (73) at the rod side of the clam cylinders.
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Section 8.1
Page 13
8.1.8 Electric / Hydraulic flowchart Clam closing FSA

(E23)
Control pedal
(+10V)
(rs)
Colour code of signal voltage cable (control pedal)
(X2...)
(A11)
Amplifier modules Clam
(102.4)
(Y32)
(Y32B)
(IV)
Main control block IV
(73)
Signal voltage of control pedal (E23) arrives at terminal 5 of the amplifier module
(A11) and further to the proportional and directional solenoid valves of the remote
control block (102.4).
flows to the pilot pressure ports of the main control block (IV).
Hydraulic oil flow
Oil of main pumps 1+5 (control block IV) flows through their standard spools and
arrives via distributor manifold (73) at the piston side of the clam cylinders.
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Section 8.1
Page 14
Hydraulic for the

8.1.9 Checks and adjustments of the Main Relief Valves (MRV),
illustration (Z 22690b):
There are four main relief valves (primary valves) installed, one in each main control
block, to limit the maximum pump supply line pressure (operating pressure).
Control
block circuit
Circuit I
Circuit II
Circuit III
Circuit IV
MRV in
control block
I
II
III
IV
Check
point
M11.2
M11.1
M11.3
M11.4
Functions FSA
Travel L.
Swing
Travel R.
Clam
Stick
Boom
Boom
Bucket
Bucket
Stick
Bucket
Stick
Boom
Bucket
Stick
Boom
Each MRV can be checked and adjusted individually by selecting one function of the
control block circuits.
Checking:
1. Connect the gauge to the required check point M11.1 to M11.4.
2. Start the motors.
3. Lower the attachment to the ground and apply the swing parking brake
3. Extend the bucket cylinder to the stop position until the hydraulic system stalls.
4. Read the pressure. Required: 310 + 5 bar for valve blocks I IV
If the pressure is not correct, carry out a comparative measurement with an other
function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or
other defects in the system.
Adjusting:
1. Remove protection cap (a).
2. Loosen lock nut (b).
3. Turn set screw (c) -clockwise to increase pressure, Counter-clock wise to
decrease pressure.
4. Tighten lock nut (b) and install cap (a).
Make sure that the complete MRV-valve and SRV-valve is firmly

tightened with 300 Nm.
Otherwise, internal leaks could occur which result in:
problems of correct adjustment, loud flow noises and high temperatures.
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Hydraulic for the

8.1.10
Section 8.1
Page 15
Checks and adjustments of the Service Line Relief Valves (SRV),

Boom cylinder Piston side FSA
There are four service line relief valves (secondary valves) installed at the distributor
manifold (73), to limit the maximum possible pressure peaks in the service line.
Since the opening pressure of the SRVs is higher than the setting of the Main Relief
Valves (MRVs) it is necessary to increase the main relief pressure for testing and
adjusting purposes.
Valve
SRV 132.1
SRV 132.2
SRV 132.3
SRV 132.4
MRV circuit I
MRV circuit II
MRV circuit III
MRV circuit IV
Press. check point

M16.1
M16.2
M16.3
M16.4
M11.2
M11.1
M11.3
M11.4
Location
Manifold (73) section B
Manifold (73) section B
Manifold (73) section P
Manifold (73) section P
Double high pressure filter
1.
2.
3.
4.
5.
6.
Connect gauges to all above listed check points.

Start the motors.
Extend the boom cylinder to the stop position until the hydraulic system stalls.
Remove protection cap (1) of MRV.
Loosen lock nut (2).
Increase slowly the pump supply line pressure, by turning in set screws (3)
of
the MRVs, while observing the pressure gauges. Stop as soon the
pressure does
not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
7.
8.
Since the piston side of the boom cylinders are protected by several
SRVs, the pressure gauges show the pressure of that valve with the
lowest setting.
Even when the gauges show the required pressure it is possible that
one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments
it is necessary to further increase the setting of the MRVs.
Turn set screw (3) of the MRVs turn further in, the gauge pointers will
remain at the value shown at item #6 (350 bar + 5 bar).
Tighten lock nut (2) and install cap (1).
continued
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Page 16

Cont'd:
Boom cylinder Piston side FSA
9. Adjust all four SRVs equally, until all gauges show a pressure of
360 bar.
Adjust in steps of turn, set screw (3) in the following sequence:
132.1 132.2 132.3 132.4
Remove protection cap (1) of SRVs.
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise
to decrease pressure.
10. Reduce the pressure, at SRV- 132.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
Now all gauges will show the same value of 350 bar,
but only SRV-132.1 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
132.2 132.3 132.4
Strong pulsation of the return line hoses, indicates deviation in
opening pressure of SRVs and must be avoided.
Repeat the adjusting procedure until the oil returns well-balanced
via all four service line relief valves.
12. Reset the MRVs to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protection cap (1).
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to
decrease pressure.

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illustration (Z 22692d):
Boom cylinder Piston rod side FSA
There are two service line relief valves (secondary valves) installed, in main control
blocks III and IV, to limit the maximum possible pressure peaks in the service line.
On machines with hydraulic oil heating system the standard SRV is replaced by a
pressure increasing valve (PIV) with two different pressure settings (remote
controlled).
Since the opening pressure of the SRV and PIV is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for testing
and adjusting purposes.
Valve
SRV 33.8
PIV 262
MRV circuit II
1.
2.
3.
4.
5.
6.
7.
8.
Press. check point

M11.1
M11.1
M11.1
Location
Connect gauges to the above listed check points.

Disconnect the pilot pressure line L47 at port X of the pressure increasing
valve and close the line with a suitable plug..
Loosen lock nut (4) of the pressure increasing valves (PIV) and turn in set
screw (5) until piston (8) comes to stop.
Start one engine and let it run with max. speed.
Retract the boom cylinder to the stop position until the hydraulic system stalls.
(With button S95 in R.H. joystick E19 activated)
of the MRV, while observing the pressure gauge. Stop as soon as the pressure
does not raise any further.
The gauge pointer should remain at 350 bar + 5 bar.
Since the piston rod side of the boom cylinders are protected by
several SRVs, the pressure gauges show the pressure of that valve
with the lowest setting.
continued
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illustration (Z 22692d):
Cont'd:
Boom cylinder Piston rod side FSA
9. Adjust the SRV (PIV), until all gauges show a pressure of 360 bar.
SRV
a) Remove protective cap (1) of the SRV.
b) Loosen lock nut (2).
c) Turn set screw (3) -clockwise to increase pressure, Counterclock wise to decrease pressure.
d) Tighten lock nut (2).
PIV
a) Loosen lock nut (6)

b) Turn set screw (7) -clockwise to increase pressure, Counterclock wise to decrease pressure.
observing the gauge.
11. Reduce the pressure, at PIV 262 to a value below the required value, and
then increase up to the required pressure (350 bar), while observing all
gauges.
12.
Adjust the lower setting of the pressure increasing valve 262. Turn out
(ccw) set screw (5) until the gauge show the required lower
pressure (100 bar).
via all service line relief valves.
Reset the MRVs to 310 bar + 5 bar after the check / adjustment is finished
Stop engine.
Install all protective caps.
Reconnect the pilot line L20 to the pressure increasing valve 262 to
port X.
13.
14.
15.
16.

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Section 8.1
Page 19

Stick cylinder Piston side FSA
adjusting purposes.
Valve
SRV 131.5
SRV 131.6
SRV 131.7
SRV 131.8
MRV circuit I
MRV circuit II
MRV circuit III
MRV circuit IV
Press. check point

M19.1
M19.2
M19.3
M19.4
M11.2
M11.1
M11.3
M11.4
Location
Manifold (73) section H
Manifold (73) section H
Manifold (73) section K
Manifold (73) section K
Single HP filter, L.H.
1.
2.
3.
4.
5.
6.

Start the motors.
Extend the stick cylinder to the stop position until the hydraulic system stalls.
of
pressure does
7.
8.
Since the piston side of the stick cylinders are protected by several
lowest setting.
continued
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20
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Section 8.1
Page 20

Cont'd:
Stick cylinder Piston side FSA
360 bar.
131.5 131.6 131.7 131.8
sequence:
131.6 131.7 131.8
as follows:
decrease pressure.

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Section 8.1
Page 21

Stick cylinder Piston rod side FSA
There are two service line relief valves (secondary valves) installed, in main control
blocks I and IV, to limit the maximum possible pressure peaks in the service line.
adjusting purposes.
Valve
SRV 33.1
SRV 33.7
MRV circuit II
MRV circuit IV
Press. check point

M11.1
M11.4
M11.1
M11.4
Location
Double high pressure filter R.H.
Double high pressure filter L.H.
Double high pressure filter R.H.
Double high pressure filter L.H.
1.
2.
3.

Start the motors.
Retract the stick cylinder to the stop position until the hydraulic system stalls.
(With button S95 in R.H. joystick E19 activated)
4. Remove protection cap (1) of MRV.
5. Loosen lock nut (2).
6. Increase slowly the pump supply line pressure, by turning in set screws (3)
of
pressure does
7.
8.
Since the piston rod side of the stick cylinders are protected by
several SRVs, the pressure gauges show the pressure of that valve
with the lowest setting.
continued
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22
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Section 8.1
Page 22

Cont'd:
Stick cylinder Piston rod side FSA
9. Adjust both SRVs equally, until the gauges show a pressure of
360 bar.
33.1 33.7
11. Proceed with the other valves in the same manner.

as follows:
decrease pressure.

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Section 8.1
Page 23

Bucket cylinder Piston side FSA
adjusting purposes.
Valve
SRV 131.1
SRV 131.4
SRV 131.11
SRV 131.12
MRV circuit I
MRV circuit II
MRV circuit III
MRV circuit IV
Press. check point

M17.1
M17.2
M17.4
M17.3
M11.2
M11.1
M11.3
M11.4
Location
Manifold (73) section C
Manifold (73) section E
Manifold (73) section N
Manifold (73) section N
1.
2.
3.
4.
5.
6.

Start the motors.
Extend the bucket cylinder to the stop position until the hydraulic system stalls.
of
pressure does
7.
8.
Since the piston side of the bucket cylinders are protected by several
lowest setting.
continued
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24
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Section 8.1
Page 24

Cont'd:
Bucket cylinder Piston side FSA
360 bar.
131.1 131.4 131.12 131.11
sequence:
131.4 131.12 131.11
as follows:
decrease pressure.

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Bucket cylinder Piston rod side FSA
There are three service line relief valves (secondary valves) installed, in main control
blocks I, II and IV, to limit the maximum possible pressure peaks in the service line.
adjusting purposes.
Valve
SRV 33.2
SRV 33.3
SRV 33.6
MRV circuit I
MRV circuit III
Press. check point

M11.2 + M11.3
M11.2 + M11.3
M11.2 + M11.3
M11.2
M11.3
Location
1.
2.
3.
4.
5.
6.

Start the motors.
Retract the bucket cylinder to the stop position until the hydraulic system stalls.
of
pressure does
7.
8.
Since the piston side of the bucket cylinders are protected by several
lowest setting.
continued
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26
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Section 8.1
Page 26

Cont'd:
Bucket cylinder Piston rod side FSA
9. Adjust all SRVs equally, until the gauges show a pressure of
360 bar.
33.2 33.3 33.6
11. Proceed with the other valves in the same manner.

as follows:
decrease pressure.

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Clam cylinder Piston Rod side (clam opening) FSA
There is one service line relief valve (secondary valve) installed at the distributor
Since the opening pressure of the SRV is higher than the setting of the Main Relief
adjusting purposes.
Valve
SRV 131.9
MRV circuit IV
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Press. check point

M19.5
M11.4
Location
Manifold (73) section L

Start the motors.
Retract the clam cylinder (open the bucket) to the stop position until the
hydraulic system stalls.
Remove protection cap (1) of MRVs.
Increase slowly the pump supply line pressure, by turning in set screws (3) of
MRV in control block IV, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
If necessary correct the adjustment as follows:
Reduce the pressure, at SRV 131.9 to a value below the required value, and then
increase up to the required pressure (350 bar), while observing all gauges.
Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows:
Remove protective cap (1).
decrease pressure.
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Section 8.1
Page 28

Clam cylinder Piston side (clam closing) FSA
There are two service line relief valves (secondary valves) installed in block (92), at
distributor manifold (73), to limit the maximum possible pressure in the service line
when closing the bucket.
To avoid damages at the clam shell, due to improper operation, the SRVs should be
adjusted in a way that the pressure is just sufficient to keep the bucket closed.
Valve
SRV block 92
MRV circuit IV
1.
2.
3.
4.
Press. check point

M20.1 (operating pressure)
M20.2 (dump line pressure)
M20.3 dump line pressure)
M11.4
Location
Manifold (73) section F

Start one motor.
Raise the attachment and bring the back wall of the bucket in a horizontal
position (bucket dump).
Depress pedal bucket closing until the hydraulic system stalls. Release the
pedal back to neutral position.
The bucket must stay closed. That means the clam-cylinders must not be
retracted by the force (weight) of the clam shell.
Adjust the SRVs as follows:
Remove protective cap (1) of SRVs.
Turn set screw (3) -clockwise to increase pressure,
Counter-clock wise to decrease pressure, with
depressed pedal clam closing.
Adjust the SRVs equally (same dump line pressure at M20.2 and M20.3), until
the gauge at check point M20.1 show a pressure of 220 bar.
5.
Now reduce the pressure at the SRVs equally in steps of 5 bar until the bucket
opens by gravity (check with released pedal).
Read the pressure and increase the setting with 10%, to compensate the weight
of material stuck at the clam shell.
For standard buckets the pressure is 150 bar, reinforced or with heavy
wear package attached, the pressure maybe raised up to 200 bar.
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Section 8.1
Page 29
Checks and adjustments of the lowering speed, illustration (Z 22699a):

Purpose of the Flow Restrictors:
To avoid an interruption of the pump delivery.
To provide an uniform and smooth cylinder travel.
To limit the return oil flow through the control block to the maximum permissible
volume.
Maximum permissible lowering speed for boom:
Function
Boom down (FSA)
Cylinder retracting time/meter (s /m)

1,5
Total time(s)
4,7
Adjustments / Checks:
1. Use a stop watch to measure the cylinder running time.
2. Raise the fully extended attachment with empty bucket to the maximum height
position (A).
3. Activate service switch S155 (located in the cab base) during the checks and
adjustments, to ensure that the main pumps are in Qmax position.
4. Rapidly move the control lever (E19) to the front end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop watch).
Lower the boom so, that the bucket stops just above the ground.
5. If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves 132.1,
132.2, 132.3 and 132.4 at the distributor manifold (73).
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow the valves must be set
synchronously. The adjusting screws have to be turned in by the same amount of
revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary.

7. If the adjustment is finished tighten lock nut (1) and reset service switch S155.
If it is impossible to move the cylinder over the whole way, mark a

distance of one meter with permanent pen P/N 621 566 40 on the
piston rod and measure the time for only one meter movement.
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Section 8.1
Page 30

volume.
Maximum permissible lowering speed for stick:
Function
Stick in (FSA)

0,8
Total time(s)
2,2
position (A).
4. Rapidly move the control lever (E20) to the rear end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop watch).
Adjust as follows:
revolutions.
O.K.


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volume.
Maximum permissible lowering speed for bucket:
Function
Bucket empty (FSA)

1,1
Total time(s)
3,1
position (A).
4. Rapidly move the control lever (E19) to the r.h. end position (start the stop watch)
and hold it until the final position (B) is reached.(stop the stop watch).
Adjust as follows:
revolutions.
O.K.


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Checks and adjustments of the lowering speed, illustration (Z 22702):

volume.
Maximum permissible lowering speed for Clam:
Function
Clam closing (FSA)

-----
Total time(s)
2,8
position (A).
4. Rapidly push the control pedal (E23) to the end position (start the stop watch) and
hold it until the final position (B) is reached.(stop the stop watch).
permissible time or uncomfortable, the speed must be reduced by altering throttle
valve 131.9 at the distributor manifold (73).
Adjust as follows:
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Hydraulic for the Swing Circuit
Section 8.2
Page 1

Section
8.2
Page
Hydraulic for the swing circuit
8.2.1
Swing Circuit (Brief description)
2+3
8.2.2
Swing Motor
4+5
8.2.3
Swing Gear Box
8.2.4
Swing Parking Brake (Gear house Brake)
8.2.5
Swing Brake Valve
8+9
8.2.6
Electric / Hydraulic flowchart Swing Left
10
8.2.7
Electric / Hydraulic flowchart Swing Right
11
8.2.8
Checks and adjustments for the swing circuit
12 + 13
8.2.9
Function check for the hydraulic swing brake
14
8.2.10
Function check for the swing parking brake
15
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2
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Section 8.2
Page 2
8.2.1 Swing Circuit

(4 + 8)
Main pumps
(II) Control block
(20.1 + 20.2 + 20.3) Swing motors
Brief description (Service circuits)
(Study together with the for the machine valid hydraulic and electric circuit
diagram).
The swing motors (20.1 + 20.2 + 20.3) are driven by the pumps (4 + 8).
The oil flows from the pumps through high pressure filters to the control
block (II).
With the spools in neutral position oil flows via the return oil line (L24) into
the collector tube and further to the tank.
On its way to tank the oil must flow through the back pressure valve (26) and
the return oil filter (51.1 - 51.7). (Back pressure valve function see section 4.)
When operating the control lever for "Swinging" the pump line is connected
in the control block (II) with the corresponding service line (A1 or B1) to the
swing motors (20.1 + 20.2 + 20.3).
The oil flows from the control block through each one of the swing brake
valves (49.1 + 49.2 + 49.3); description see page 8 and 9) and the swing
motors (20.1 + 20.2 + 20.3).
Each swing gear includes one spring loaded multi disk brake (House brake)
for locking the superstructure.
The leak oil (case drain) flows through the line (L42 + L43 + L44) and the
leak oil filter (66) back to tank.
continued
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Section 8.2
Page 3
Cont'd.:
8.2.1 Swing Circuit:
(4 + 8)
(II)
(49.1 + 49.2 + 49.3)
(50.1 + 50.2 + 50.3)
Y24
Y24a + Y24b
Y127
Main pumps
Control block
Swing brake valve blocks
Swing motors
proportional solenoid valve => control block II
directional solenoid valves => control block II
proportional solenoid valve (hydraulic swing brake)
Brief description (Control circuits)

When the lever (E20) is moved out of its neutral position, proportional solenoid
valves Y24 and directional solenoid valves Y24a (L.H.-swing) or Y24b (R.H.swing) are energized simultaneously, so that
pilot pressure oil is send to one side of the control
block (II). At the same time by the function of
proportional solenoid valve Y127 pilot pressure
is present at port X of each brake valve block
thus a maximum pressure built up in the service
lines is possible.
i.e. Swing speed = Oil flow of pump 4+8
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8.2.2
Section 8.2
Page 4
Swing Motor
Axial piston motor A2FLM (with SL-bearing)
The axial piston units of product group A2FM with fixed displacement can
operate as a hydraulic motor only.
The drive speed is proportional to the consumption capacity.
The output torque increases with the pressure drop between high and low
pressure side.
The motor converts hydrostatic energy into mechanical energy.
(1)
(2)
(3)
(4)
(5)
(5a)
(6a)
(6b)
(7)
(8)
Drive shaft
Housing
Case drain port
Retaining plate
Piston
Pivot (center) pin
Upper dead point
Lower dead point
Cylinder
Control lens
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
End plate
Centering spring
Taper roller bearing
Spring
Slipper pads
Thrust washer
Roller bearing
Circlip
Sealing flange
Radial seal ring
Description of the SL-bearing (SL = slipper bearing)

The main part of the axial forces is supported by the slipper pads (13) which
are installed on the driving circular side of the drive shaft.
Each piston is allocated to one slipper pad.
These slipper pads are located in the cylinder chamber and get pressurized via
piston borings (5). The slipper pads support themselves on the thrust washer
(14) and discharge axially the tapered roller bearing (11).
Without pressure the slipper pads are kept on the thrust washer by means of
spring (12).
continued
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5
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Section 8.2
Page 5
Cont'd.:
8.2.2 Swing Motor
Axial piston motor A2FLM (with SL-bearing), illustration (Z 21936):
Function:
The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine
the output drive direction of the drive shaft (1).
Direction of rotation:
"Clockwise"
= Direction of flow A to B
"Counter-Clockwise" = Direction of flow B to A
with view onto drive shaft!
Via the control lens (8) the oil is directed to the cylinder bores.
The piston (5) is moved from the lower (6b) to the upper dead point (6a) by
means of the force acting on it and causes the drive shaft to rotate. On further
rotation of the drive shaft (additional pistons are pressurized) this piston is
moved towards the lower dead point again and oil of the cylinder chamber is
forced out through the kidney formed openings of the control lens. This oil is
fed back to the tank via the return line.
If the supply and return line is changed it changes the output drive direction
of the drive shaft.
By means of the angled arrangement of the cylinder (7) (bent axis design), a
certain piston stroke is produced which results in a fixed displacement per
revolution of the drive shaft. According to the size of the applied flow this
produces a specific output speed.
The output torque at the drive shaft is dependent on the size of the motor and
the required operating pressure.
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Section 8.2
Page 6
8.2.3 Swing Gear Box

(1) Drive housing
(2) Drive shaft
(3) Sun gear shaft
(4) House brake
(Multi disk brake)
(5) Breather filter
Drive shaft housing
(6) Oil level gauge (dipstick)
Drive shaft housing
(7) Disk brake housing
(8) Cylindrical roller bearing
(9) Internal ring gear
(10) Cylindrical roller bearing
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Bearing ring
Cartridge
Spherical roller bearing
Oil drain plug, gear box
Oil level gauge (dipstick)
Gear box
First planetary stage
Drive shaft to second stage
Second planetary stage
Radial seal ring
Drive pinion
Grease line port
The swing gear is of compact design with a two stage planetary gear including a
multi disk house brake.
The gear is bolted to the superstructure and fits firmly due to the machined
diameter (A) and the bolt torque.
The torque loaded on the hydraulic motor is transmitted by drive shafts (2)
and sun gear shaft (3) to the first planetary stage (17).
The sun shaft (17) of the first planetary stage transmits the torque into the
second planetary stage (19). By the planetary gears the output drive shaft is
rotated and transmits the torque to the pinion (21).
The drive housing, and the gearbox are filled with gear oil.
Aeration is done by breather filters.
To lubricate the pinion bearing port (22) is connected to the central
lubrication system.
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7
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Section 8.2
Page 7
8.2.4 Swing Parking Brake (Gear house Brake)

The Spring Loaded Multi-disk Brake is a safety brake; applied by
spring force and released by oil pressure.
(1)
Disk housing
(2)
Thrust washer
(3)
Inner disks (lamellas)
(4)
Outer disks (lamellas)
(5)
Sinus (spacing) ring
(6)
Piston
(7)
Quad-Rings with back- up rings
(8)
Quad-Rings with back- up rings
(9)
(10)
(11)
(12)
(13)
Springs
Thrust washer
Circlip
Drive shaft
Oil pressure port
Function:
Brake applied:
The outer disks (4) engaged to the housing by serration and the inner disks (3) in
serrated connection with drive shaft (12) are pressed together by the springs (9).
This results in a fixed connection between housing and drive shaft.
Brake released:
Oil pressure via port (13) reaches the bottom of the piston (6) and forces the
piston upwards against the thrust washer (10).
This function eliminates the spring force onto the disks so that the sinus
(spacing) rings can keep the outer disks (4) apart, thus the brake is released.
The releasing pressure is 19 - 20 bar, the maximum permissible pressure
60 bar.
This is a so named "Wet Brake" because the brake housing is splash lubricated
by gear oil.
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8
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Section 8.2
Page 8
8.2.5 Swing Brake Valve

(1) Pressure increasing valve
(items 6 - 13)
(2) Check valve circuit A
(3) Check valve circuit B
(4) Anti-cavitation valve circuit B
(5) Anti-cavitation valve circuit A
(6) Jet bore, of main piston plug
Ports:
(Y)
(T)
(A)
(A1)
(B)
(B1)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Spring of main piston

Jet bore
Valve poppet
Spring
Intermediate piston
Pilot pressure piston
Main piston
Leak oil
Return oil
Service line from control block
Service line to the motor
Service line from control block

(MA) Circuit A
(MB) Circuit B
Explanation of the function by the symbol:
When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X".
The pilot pressure pre-loads these valves.
The oil for the hydraulic motor from the control block arrives the service line
port A or B, depending if a R.H. or a L.H. swing motion is carried out.
The ports A and B are internally connected to the ports A1 and B1 and these
ports in turn with the hydraulic motor.
The operating pressure, at either port A or B closes the anti-cavitation valves
(4 or 5) and opens the check valves (2 or 3).
That means by the check valves (2 or 3) the service lines are connected to the
pressure increasing valve.
When ever the pressure is higher than the setting of the pressure increasing
valve, this valves opens and dumps the oil into the return line (T) to tank.
The pressure can be checked at the check points MA or MB.
continued
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8.2
9
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Section 8.2
Page 9
Cont'd.:
8.2.5
Swing Brake Valve, illustration (Z 21935)

If after a swing motion the joy stick is put into neutral position without
using the foot brake, the superstructure is turned by inertial force and the
hydraulic motor acts as a pump because it is driven by the swing gear.
In this period the pressure in the service line is lower than the pressure in
the return line, because there is a back pressure valve at the tank, and oil is
forced through the anti-cavitation valves into the service line.
Function of the pressure increasing valve.
When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X". The pilot
pressure pre-loads these valves.
By applying pilot pressure via the external port X to piston (12), the pretensioning of the pressure spring (10) is increased by the amount of the piston
stroke "S", which results in the actual valve setting.
The system pressure is in front of the main piston (13) and via the jet bore (6)
also in the chamber of the spring (7) and via the jet bore (8) at the pressure
relief valve poppet (9).
Due to the force balance the piston (13) is kept in its position supported by
the spring (7).
Overcomes the system pressure the setting of the valve (9), this valve opens a
channel to the dump line port (Y). Due to the drop of force the piston (13) is
moved to the right.
The pressure line gets connected with the return line (T).
Damped opening and closing are obtained by the throttled volumetric change
that is caused by the jet bores.
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10
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Section 8.2
Page 10
8.2.6 Electric / Hydraulic flowchart Swing Left

(E20)
(E22)
Control pedal swing brake
(-X)
(-10V)
(ws/gn)
Colour code of signal voltage cable ( Joy stick) white/green
(br gn)
Colour code of voltage cable ( brake pedal) brown green
(X2...)
(E50 + E50b)
Ramp time modules
(A7)
Amplifier module Swing (Y24 + Y24a/b Block II)
(A16)
Amplifier module Swing brake
(Y127)
Proportional solenoid valve Swing brake
(K190)
Relay Swing brake without ramp time
(102.2)
Remote control valve block
(Y24)
(Y24A)
(II)
Main control block II
(24)
(49.1 49.3)
(PIV)
Pressure increasing valve
(20.1 20.3)
Swing motors
The electrical signal flow. [
]
Start of swing with control block II:
(E20) => (E50) =>
=> (A7 terminal 3)

=> (A7 terminal 7-8)
Simultaniously (E20) => (K190 contacts 1 / 4) => (E50b) =>

(K190 contacts 5 / 6) => =>=> => =>=> => (A16 terminal 7-8)
=> (Y24a)
=> (Y24)
=> (Y127)
The hydraulic signal. (pilot pressure) [

]
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the caps at the main control blocks.
Proportional valve Y127 will increase the pilot pressure at the pressure
increasing valves (PIV) in relation to the lever deflection.
The hydraulic oil flow [
]
Maximum swing speed is obtained when the oil volume of main pumps (4, 8) via
block II is directed to swing motors (20.1 20.3).
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Section 8.2
Page 11
8.2.7 Electric / Hydraulic flowchart Swing Right

(E20)
(E22)
Control pedal swing brake
(+X)
(+10V)
(ws/gn)
Colour code of signal voltage cable ( Joy stick) white/green
(br gn)
Colour code of voltage cable ( brake pedal) brown green
(X2...)
(E50 + E50b)
Ramp time modules
(A7)
Amplifier module Swing (Y24 + Y24a/b Block II)
(A16)
Amplifier module Swing brake
(Y127)
Proportional solenoid valve Swing brake
(K190)
Relay Swing brake without ramp time
(102.2)
Remote control valve block
(Y24)
(Y24b)
(II)
Main control blocks II
(24)
(49.1 49.3)
(PIV)
(20.1 20.3)
Swing motors
The electrical signal flow. [
]
Start of swing with control block II:
(E20) => (E50) =>
=> (A7 terminal 9)

=> (A7 terminal 7-8)
Simultaniously (E20) => (K190 contacts 1 / 4) => (E50b) =>

(K190 contacts 5 / 6) => =>=> => =>=> => (A16 terminal 7-8)
=> (Y24b)
=> (Y24)
=> (Y127)
The hydraulic signal. (pilot pressure) [

]
pressure oil flows to the caps at the main control blocks.
Proportional valve Y127 will increase the pilot pressure at the pressure
increasing valves (PIV) in relation to the lever deflection.
The hydraulic oil flow [
]
Maximum swing speed is obtained when the oil volume of main pumps (4, 8) via
block II is directed to swing motors (20.1 20.3).
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12
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8.2.8
Section 8.2
Page 12
It is important that the complete MRV-valve and the Pressure

Increasing Valve is firmly (with 300 Nm) tightened. Otherwise,
internal leaks could occur which result in problems of correct
adjustment, loud flow noises and high temperatures.
Whenever pressure checks are carried out, they must be carried out
for all swing motors, to make sure the control lines and the check
valves in the brake valve blocks are in good condition.
Because the Swing motors are working hydraulically in combined
operation, the pressure gauge shows the pressure of the pressure
increasing valve with the lowest setting. Even when the gauge shows
the required pressure it is possible that one valve has a higher setting.
Therefore lower the pressure on one valve below the required pressure
and then increase up to required pressure. Proceed with next valves in
the same manner.
High pressure check / adjustment

1. Connect a pressure gauge to check point M11.1 at the high pressure filter units.
2. Disconnect the pilot pressure lines from the T-unions and close the lines with a
suitable plug (P).
3. Loosen lock nut (3) of all pressure increasing valves (PIV) and screw in set screw
(4) until piston (5) comes to stop.
4. Start one motor.
5. Lower attachment to ground and apply house brake with switch S29.
6. Adjust the MRV-pressure to ~350 bar.
7. Actuate either L.H. or R.H. rotation until the hydraulic system stalls.
Read the pressure, required = 330 5 bar.
8. If the gauge shows a smaller or greater value the pressure increasing valves must
be adjusted:
a) Loosen lock nut (1) of the first pressure increasing valve PIV (49.1).
b) Adjust pressure with set screw (2) of PIV (49.1) to ~340 bar.
If the pressure wont increase, turn set crew (2) of the other PIVs (49.2
+ 49.3) a turn further in (c.w.).
c) Secure by tightening lock nut (1).
d) Loosen lock nut (1) of the second PIV (49.2).
e) Reduce the pressure with set screw (2) of PIV (49.2) to a value of about
320 bar, and then increase up to the required pressure of 330 bar.
f) Secure adjusted set screw (2) by tightening lock nut (1)
g) Loosen lock nut (1) of the third PIV (49.3).
h) Reduce the pressure with set screw (2) of PIV (49.3) to a value of about
i) Secure adjusted set screw (2) by tightening lock nut (1)
continued
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13
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8.2.8
Section 8.2
Page 13

Cont'd.:
j) Loosen lock nut (1) of the first PIV (49.1).
k) Reduce the pressure with set screw (2) of PIV (49.1) to a value of about
l) Secure adjusted set screw (2) by tightening lock nut (1)
Low pressure check / adjustment
9.
[Swinging down path (drifting) with still disconnected pilot pressure line]
Actuate either L.H. or R.H. rotation until the hydraulic system stalls.
a) Loosen lock nut (3) of all (PIVs) and reduce the pressure equally with
set screws (4) to a value of about 130 bar, secure setting with lock nut (3)
b) Loosen lock nut (3) of the first PIV (49.1).
c) Reduce the pressure with set screw (4) of PIV (49.1) to a value of about
d) Secure adjusted set screw (4) by tightening lock nut (3)
e) Loosen lock nut (3) of the second PIV (49.2).
f) Reduce the pressure with set screw (4) of PIV (49.2) to a value of about
g) Secure adjusted set screw (4) by tightening lock nut (3)
h) Loosen lock nut (3) of the third PIV (49.3).
i) Reduce the pressure with set screw (4) of PIV (49.3) to a value of about
j) Secure adjusted set screw (4) by tightening lock nut (3)
10. Re-connect the pilot pressure line.

11. Re-set MRV-pressure and remove the gauges after the check / adjustment is
finished
opening pressure of PIVs and must be avoided.
via all three pressure increasing valves.
Brake pilot pressure - check / adjustment
1.
Connect the gauge to the check point M4.
2.
Start motors.
3.
Depress fully the foot brake pedal (E22) and read the pressure.
The pressure must be 24 +1 bar.
Alter the position of the potentiometer R2 of the amplifier A16 until the
pressure is 24 +1 bar.
Basic adjustment for A16 see section 5
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Section 8.2
Page 14
8.2.9 Function check for hydraulic swing brake

(M39) Pressure check point (Pressure to pressure increasing valve)
(S22) Switch Position of access ladder
(S28) Switch Operators seat
(Y120) Solenoid valve hydraulic swing brake ON - OFF
(Y127) Proportional solenoid valve hydraulic swing brake
Safety circuit (automatic actuation)
The hydraulic swing brake will be applied automatically when the access
ladder and/or the service arm of the central refilling system is not in its
completely lifted position and/or if the operators seat is not occupied.
Brake apply pressure
1. Connect gauge to check point (M39).
3. Lift the access ladder to the end position.
4. Check the pressure at check point(M39) under the following conditons:
a) Seat is occupied and access ladder complete up.
0 bar=> released.
No message should appear on the text display
b) Seat is occupied and access ladder down.
The message Pilot control cut out should appear
45 bar=> applied.
c) Seat is not occupied and access ladder complete up.

The message Pilot control cut out should appear
45 bar=> applied.
Operation circuit (manual actuation through joystick or brake pedal)

To shorten the braking angle of the superstructure either the brake pedal must
be actuated or the a counter action of the joystick is required.
As a result, proportional valve Y127 will vary the pilot pressure at the
pressure increasing valves (PIV) in relation to the lever deflection.
Brake apply pressure
5. Apply the parking brake. Therefore move toggle switch (S29) in position 1
6. Actuate either the joystick (L.H. or R.H.) or the swing brake pedal and read the
pressure.
Required: 0 <=> 24 bar. (variable i.e. proportional to the lever deflection)
7. Disconnect the pressure gauge.
In case of malfunction check the electrical control system and the

function of solenoid valve Y120 and/or Y127.
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Section 8.2
Page 15
8.2.10 Function check for the swing parking brake

(M1.2) Pressure check point (X2 - pilot pressure)
(M10) Pressure check point (Pressure to swing parking brake)
(B16) Pressure switch
(Y5)
Solenoid valve swing parking brake ON - OFF
(252.1) Pressure reducing valve
Parking Brake Release Pressure. (House Brake Pressure)
1. Connect gauge to check point (M1.2).
2. Start both motors and read the pressure. Required = 45 3 bar.
If not, correct the pilot pressure adjustment. (refer to Section 5).
3. Apply the parking brake. Therefore move toggle switch (S29) in
position 1, now the following message should appear:
Swing gear house brake ON
4. Actuate either L.H. or R.H. rotation, the machine should not turn.
If the machine turns the parking brake must be repaired.
5. Release the parking brake. Therefore move toggle switch (S29) in
position 0, now the swing function must be possible again and
the monitor returns to standard display.
In case of malfunction check the electrical control system

and the function of solenoid valve Y5.
Function Check of pressure switch B16

1. Connect pressure gauge to check point (M10).
2. Start the motors. Gauge must show normal pilot pressure X2 = 45 3 bar.
3. Move toggle switch (S29) in position 0
4. Set pilot pressure reducing valve (252.1) to 22 bar.
5. Unplug and reconnect solenoid valve Y5 to allow pressure relieve from
pilot pressure line to house brake.
The text display must show Swing gear house brake ON
6. Increase the pilot pressure up to 26 bar.
Swing gear house brake ON must disappear.
7. Reset pilot pressure X2 to 45 3 bar.
Pressure at B16 <24 bar => Brake applied (ON)

Pressure at B16 >24 bar => Brake released (OFF)
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Hydraulic for the Travel Circuit
Section 8.3
Page 1

Section
8.3
Page
Hydraulic for the travel circuit
8.3.1 Travel Circuit (Brief description)
2+3
8.3.2 Travel Motor
8.3.3 Rotary distributor
8.3.4 Travel Gear Box
8.3.5 Travel Parking Brake (Gear house Brake)
8.3.7 Electric / Hydraulic flowchart Travel forward
8.3.8 Electric / Hydraulic flowchart Travel backward
10
8.3.9 Checks and adjustments for the travel circuit
11
8.3.10 Function check for the travel parking brake
12
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8.3
2
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Section 8.3
Page 2
8.3.1 Travel Circuit

(2 + 3 + 6 + 7)
(I + II + III + IV)
(22.1 22.4)
(39.1+ 39.2)
(77.1 77.4)
(59)
(96)
(147)
(Y16)
(Y20 + Y20a/b)
(Y28 + Y28a/b)
(L36)
(L38)
(L39)
Main pumps
Control blocks
Travel motors
Travel brake valves
Travel parking (house) brakes
Rotary distributor
Main oil reservoir
Pressure reducing valve (35 bar)
Solenoid valve for travel parking brake
Remote control valves (control block I => L.H. crawler)
Remote control valves (control block III => R.H. crawler)
Return oil line
Case drain (leak oil) line
Pilot pressure line to the travel parking brake
Brief description (Control circuits)

(Study together with the hydraulic and electric circuit diagram).
When the pedals E21a and E21b are moved out of there neutral
position, proportional solenoid valves Y20 and Y28 and simultaneously
the directional solenoid valves Y20a or Y20b (L.H.-crawler) and Y28a
or Y28b (R.H.- crawler) are energized.
(E21a) Control pedal
A forward => Y20 +Y20b
Left track
B reverse => Y20 +Y20a
(E21b) Control pedal

A forward => Y28 +Y28b
Right track
B reverse => Y28 +Y28a
continued
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3
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Section 8.3
Page 3
8.3.1 Travel Circuit

Cont'd.:
Illustration (Z 22717):
Brief description (Service circuits)
(Study together with the hydraulic and electric circuit diagram).
The L.H. travel motors (21.1 + 21.2) are driven by the pumps (2 + 6) and the
R.H. travel motors (21.3 + 21.4) are driven by the pumps (3 + 7).
The oil flows from the pumps through the high pressure filters to the control
blocks (I + III).
In neutral position of the spools the oil flows via the return oil lines (L23 +
L25) into the collector tube and further to the tank.
On its way to tank the oil must flow through the back pressure valve (26) and
the return oil filter (51.1 - 51.7). (Back pressure valve function see section 4.)
When operating the foot pedal for "Travelling" the pump line of each control
block is connected with the corresponding service line (A1 or B1) via the
rotary distributor (59) and travel brake valves (39.1 + 39.2) to the travel
motors (22.1 22.4).
The travel brake valve acts as a flow control valve in order to avoid the travel
motors picking up speed when travelling downhill.
Each travel gear includes a spring loaded multi disk brakes (House brakes 77.1
77.4). They are used as parking brakes, automatically applied by the function of
Y16 whenever the prime mover is switched OFF.
The brake release pressure (X2 pressure reduced to 35 bar by valve 147) is
monitored by the pressure switch (B48).
The leak oil (case drain) flows through the line (L38) and the leak oil filter (66)
back to tank.
Anti cavitation circuit
Due to terminal leakage and in order to avoid a vacuum in the system, e.g.
due travelling downhill, additional oil must be fed into the circuit.
This is done by the anti cavitation valves (32.1 + 32.2 respectively 32.9 + 32.10).
Function:
The line from port T of the control blocks is connected to the return oil pipe
at the tank. Due to the adjustment of the back pressure valve (26) there is
under any circumstance enough oil under pressure available at the anti
cavitation valves. Any time the pressure in the service line to the motors is
less than the back pressure additional oil is forced through the anti cavitation
valves into the circuit.
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Section 8.3
Page 4
8.3.2 Travel Motor

Axial piston motor A2FLM
The axial piston units of product group A2FM with fixed displacement can
operate as a hydraulic motor only.
The drive speed is proportional to the consumption capacity.
The output torque increases with the pressure drop between high and low
pressure side.
The motor converts hydrostatic energy into mechanical energy.
(1)
(2)
(3)
(4)
(5)
(5a)
(6a)
(6b)
(7)
Drive shaft
Housing
Case drain port
Retaining plate
Piston
Pivot (center) pin
Upper dead point
Lower dead point
Cylinder
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Control lens
End plate
Taper roller bearing
Roller bearing
Thrust washer
Circlip
Circlip
Sealing flange
Radial seal ring
Function:
The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine
the output drive direction of the drive shaft (1).
Direction of rotation:
"Clockwise"
= Direction of flow A to B
"Counter-Clockwise" = Direction of flow B to A
with view onto drive shaft!
Via the control lens (8) the oil is directed to the cylinder bores.
The piston (5) is moved from the lower (6b) to the upper dead point (6a) by
means of the force acting on it and causes the drive shaft to rotate. On further
rotation of the drive shaft (additional pistons are pressurized) this piston is
moved towards the lower dead point again and oil of the cylinder chamber is
forced out through the kidney formed openings of the control lens. This oil is
fed back to the tank via the return line.
If the supply and return line is changed it changes the output drive direction
of the drive shaft.
By means of the angled arrangement of the cylinder (7) (bent axis design), a
certain piston stroke is produced which results in a fixed displacement per
revolution of the drive shaft. According to the size of the applied flow this
produces a specific output speed.
The output torque at the drive shaft is dependent on the size of the motor and
the required operating pressure.
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5
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Section 8.3
Page 5
8.3.3 Rotary Distributor

Task:
The rotary distributor (joint) permits a hydraulic connection between the
superstructure and the undercarriage, that means between the rotating and the
stationary part.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Rotary distributor housing

Rotor
Mover
Clam ring
Cover
Sealing element
O-ring
Rotor guide rings
Splitted maze disk
Centering disk
Ports:
A-D
F
L
ST
K1/K2
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
O-ring
Race
Support flange
Ring
Seal-ring
Seal-ring
O-ring
Plug screws
Grease nipple
Service lines
Grease
Leak (case drain) oil
Control oil
Return oil to tank
Function:
During operation superstructure and under carriage constantly rotate towards each
other. Nevertheless, the travel oil motors must be supplied with hydraulic oil in
every position in which the superstructure is moved in regard to the undercarriage.
Oil is directed by the control blocks to the ports (A-D) of the housing (1).
The oil flows to the outlet ports (A-D), of the rotor (2), via ring grooves as well as
longitudinal and cross holes. The rotor is bolted to the under carriage. The sealing
of the ring grooves among one another is done by sealing elements (6/7).
The hydraulic connection for return, case drain, house brake and the track
tensioning cylinders is done via the ports (K1/K2), (L), (St) and (St).
The entering of dirt gets blocked by the half disks (9) and the collar of mover (3)
(Principe of labyrinth sealing). Both areas are connected via grease nipple (20) to
the central lubrication system which causes an additional sealing. The rotor (2) is
at the top and bottom section guided in the housing by the guide rings (8).
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6
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Section 8.3
Page 6
8.3.4 Travel gear

The travel gear consists of one spur gear set and two planetary stages.
The travel gearbox is fitted to the side frame with bolts.
(22) **
Motor drive housing with house brake
(9 / 10)
Spur gear stage
(15)
Drive shaft to 1. planetary gear
(7)
1. Planetary gear
(8)
Internal geared double wheel for the first planetary gear
(12)
Drive shaft to 2. planetary gear
(4)
Bearing ring
(6)
Bearing ring
(2)
2. Planetary gear
(3)
Internal geared double wheel for the second planetary gear
**
For more information see picture on next page
Function:
The spur gear (9/10) is driven by two hydraulic motors via the input drive
shafts (11, see illustration Z21389 on the following page).
The 1. planetary gear (7) is driven by the shaft (15) which is connected to the
spur gear.
The planetary gear supports themselves in the internal geared wheel (8)
which causes that the 2. planetary gear (2) is driven by the shaft (12).
The sprocket drive shaft is driven via the splines of the planetary carrier (2).
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Section 8.3
Page 7
8.3.5 Travel parking brake (Gear house brake)

The Spring Loaded Multi-disk Brake is a safety brake; applied by spring
force and released by oil pressure.
(1)
Drive shaft
(90)
Springs
(18)
Disk carrier
(91)
Piston
(27)
Intermediate ring
(92)
Quad-Rings
(29)
Inspection cover
(93)
Oil pressure port
(39)
Ball bearing
(94)
Oil level plug
(43)
Radial seal ring
(95)
Oil drain plug
(44, 47,+58) O-Ring
(96)
Housing
(50)
Cover bolts
(97)
Oil filler plug *
(57)
Brake fitting bolts
(98)
Thrust washer
(53+74)
Seeger clip ring
(99)
Inner and outer disks
(83 + 82)
Bolt and lock washer
(100)
Retainer
* The brake must be released for oil change!
Function:
Brake applied:
The outer disks (99) engaged to the housing (96) by serration and the inner
disks (99) in serration connection with the drive shaft (11) are pressed together
by the springs (90). This results in a fixed connection between housing (96) and
shaft (11).
Brake released:
Oil pressure via port (93) reaches the bottom of the piston (91) and forces the
piston against the retainer (100).
This function eliminates the spring force onto the disks thus the brake is
released.
The releasing pressure is 21 - 23 bar, the maximum permissible pressure 50 bar.
This is a so named "Wet Brake" because the brake housing is filled with gear oil.
The oil must be filled in after removing the filler plug (97) up to the edge of the
level control plug (94) thread.
For more information refer to the OPERATION AND

MAINTENANCE MANUAL, PARTS BOOK and REPAIR MANUAL
of the corresponding machine.
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8
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Section 8.3
Page 8

Task:
Travel brake valves control the oil flow from the hydraulic motor to the tank
depending on operating pressure. This braking action prevents the motors from
over speeding.
Function:
Spring force keeps the spool in the lowest flow position. with increasing
operating pressure the opening for the return oil flow becomes larger.
On its way to the hydraulic motor the oil flows from A to A1 respectively from
B to B1 depending on the selected travel motion.
Example:
Operating pressure at port A moves spool (1) against the force of the spring (2)
and opens the way for the return oil (B1 to B).
Check valve (3) prevents a direct oil flow from B1 to B.
If the operating pressure decreases to such an extend that the spring force
overcomes the pressure, the flow to the tank becomes restricted, resulting in
braking of the machine.
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Section 8.3
Page 9
8.3.7 Electric / Hydraulic flowchart Traveling forward

(E21a)
Foot pedal left crawler
(E21b)
Foot pedal right crawler
(+10V)
(rs)
Colour code of signal voltage cable ( footpedal)
(X2...)
(E51)
Ramp time module
(E52)
Ramp time module
(A12)
Amplifier module left crawler
(A13)
Amplifier module right crawler
(K177)
Relay Controlled by cable drum switches 5S6 and 5S7.
Contacts 5/9 and 6/10 closed in normal operating condition.
(102.1 + 102.3) Remote control valves
(Y20 + Y28)
(I + III)
Main control blocks
(59)
Rotary distributor
(22.1 22.4)
Hydraulic motors
(29.2 + 29.3)
Manifold
(39.1 39.2)
Travel brake valves
Electrical signal flow. [
]
Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51
+ E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the
proportional and directional solenoid valves of the remote control blocks
(102.1 and 102.3).
The directional solenoid valves Y20B and Y28B are only deactivated with
open contacts of relay K177 i.e. the power supply cable is to tight (5S6) or the
safety winding is used (5S7), which results in interruption of forward traveling.
Hydraulic signal flow. (pilot pressure) [
]
pressure oil flows to the caps at the main control blocks. (I + III)
Hydraulic oil flow. [
]
Now the oil of the main pumps flows through the main control blocks (I + III) and
arrives via Rotary distributor (59) and travel brake valves (39.1 39.2) at the
hydraulic travel motors.
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Section 8.3
Page 10
8.3.8 Electric / Hydraulic flowchart Traveling backward

(E21a)
Foot pedal left crawler
(E21b)
Foot pedal right crawler
(-10V)
(rs)
Colour code of signal voltage cable ( footpedal)
(X2...)
(E51)
Ramp time module
(E52)
Ramp time module
(A12)
Amplifier module left crawler
(A13)
Amplifier module right crawler
(K178)
Relay Controlled by cable drum switches 5S6 and 5S4.
Contacts 5/9 and 6/10 closed in normal operating condition.
(K179)
Relay Controlled by cable drum switches 5S8.
Contacts 5/9 closed in normal operating condition.
(K180)
Relay Controlled by cable drum switches 5S9.
Contacts 6/10 closed in normal operating condition.
(102.1 + 102.3) Remote control valves
(Y20 + Y28)
(I + III)
Main control blocks
(59)
Rotary distributor
(22.1 22.4)
Hydraulic motors
(29.2 + 29.3)
Manifold
(39.1 39.2)
Travel brake valves
Electrical signal flow. [
]
Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51 +
E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the
proportional and directional solenoid valves of the remote control blocks (102.1
and 102.3).
The directional solenoid valves Y20A and Y28A are deactivated with open
contacts of relay K178 i.e. the power supply cable is to slack (5S6) or the cable
drum is full (5S4), which results in interruption of backward traveling.
Y20A is also deactivated with open contacts of relay K179 i.e. to strong deflection
to the left (5S8), => interruption of backward traveling the L.H. crawler only.
Y28A is also deactivated with open contacts of relay K180 i.e. to strong
deflection to the right (5S9), => interruption of backward traveling the R.H.
crawler only.
Hydraulic signal flow. (pilot pressure) [
]
pressure oil flows to the caps at the main control blocks. (I + III)
Hydraulic oil flow. [
]
Now the oil of the main pumps flows through the main control blocks (I + III) and
arrives via Rotary distributor (59) and travel brake valves (39.1 39.2) at the
hydraulic travel motors.
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Section 8.3
Page 11
8.3.9 Checks and adjustments for the travel circuit

(1) Protective cap
(59)
Rotary distributor
(2) Locknut
(32.1 + 32.2) Anti cavitation valves L.H.
(3) Set screw
(32.9 + 32.10) Anti cavitation valves R.H
(127) Main control block I
(39.1 + 39.2) Travel brake valves
(129) Main control block III
(M11.. M31..) Pressure check points
Pressure check of the Service Line Relief Valves (SRV)
1. Connect pressure gauge to the required check points :
L.H. track
M11.2 = Operating pressure for the L.H.-motors
M31.1 = SRV- pressure L.H.-travel forward
M31.2 = SRV- pressure L.H.-travel backward
R.H. track
M11.3 = Operating pressure for the R.H.-motors
M31.3 = SRV- pressure R.H.-travel forward
M31.4 = SRV- pressure R.H.-travel backward
2. Unplug solenoid valve Y16 (located at the central control and filter panel)
to keep the parking brake applied.
3. Start both motors.
4. Engage carefully the desired travel motion and keep the pedal in final
position to built up max. pressure.
5. Increase slowly the MRV-pressure while observing the pressure gauge.
Gauge value must remain at 310bar + 5bar.
If the gauge shows a smaller or greater value the SRV must be adjusted
A faulty Anti-cavitation Valve (32.1 + 32.2, 32.9 + 32.10) or a leaking

seal of the rotary joint (59) can influence the SRV pressure reading /
setting. Repair or replace faulty parts if necessary
Adjusting the SRVs :

+
1. Set MRVs to 320 bar 10 bar (using an attachment cylinder function)
2. Engage carefully the desired travel motion and keep the pedal in final position
to built up max. pressure.
3. Lower the pressure at the required SRV to 290 bar and then increase up to the
required pressure of 310bar. Proceed with next valves in the same manner.
+
4. Re-set MRVs to 310 bar 5 bar (using an attachment cylinder function)
and re-plug the solenoid valve Y16.
How to adjust MRVs and SRVs:
a) Remove protective cap (1) and loosen lock nut (2).
b) Adjust pressure with set screw (3).
c) Secure adjustment by tightening lock nut (2) and replace cap (1).
d) Re-check pressure setting.
It is important that the complete MRV-valve and SRV-valve is firmly

(with 300 Nm) tightened.
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Section 8.3
Page 12
8.3.10 Function check for the travel parking brake

(252.1) Pressure reducing valve
(B48) Pressure switch
(E35) Text display
(M1.2) Pressure check point

(M9)
(Y16) Solenoid valve
Parking Brake Release Pressure. (House Brake Pressure)

1. Connect gauge to check point (M1.2).
2. Start both motors and read the pressure. Required = 45 3 bar.
If not, the X-2 pilot pressure adjustment must be corrected. (refer to Section 5).
3. Disconnect plug connection from solenoid valve Y16, now the following message
should appear:
Travel gear house brake ON
4. Operate the travel pedals, the machine should not travel.

If the machine moves the parking brake must be repaired.
5. Reconnect plug connection to solenoid valve Y16, now the travel function must
be possible again and the monitor returns to standard display.
In case of malfunction check the electrical control system and the

function of solenoid valve Y16.
Function Check of pressure switch B48

1.
Connect pressure gauge to check point (M9).
2.
Start the motors. Gauge must show normal pilot pressure X2 = 45 3 bar.
3.
Set pilot pressure relief valve (252.1) to 22 bar.
4.
Unplug and reconnect solenoid valve Y16 to allow pressure relieve
from pilot pressure line to house brake.
The text display must show Travel gear house brake ON
5.
Increase the pilot pressure up to 26 bar.
Travel gear house brake ON must disappear.
6.
Reset pilot pressure X2 to 45 3 bar.
Pressure at B48 <24 bar => Brake applied (ON)

Pressure at B48 >24 bar => Brake released (OFF)
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Hydraulic Track Tensioning System Section 9.0

Page 1

Section
9.0
Page
Hydraulic Track Tensioning System
General
9.1
Functional description
3+4
9.2
9.3
Tensioning Cylinder
9.4
Adjustments / Checks
7 + 8 + 9 + 10
9.5
Functional test
10
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9.0
General:
(21)
Rotary distributor (joint).
(ST)
Supply line, pilot pressure from travel parking brake circuit
(118.1)
Supply line shut-off cock.
"O" = open
(118.2 + 118.3) Service shut-off cocks.
"C" = closed
(118.4)
Main shut-off cocks.
(119.1 + 119.2) Membrane accumulator, 1,3 liter (pre-charge pressure 31bar)
(120.1 120.4)
Bladder accumulator, 5 liter (pre-charge pressure 150bar)
(121.1 + 121.2) Check valves (prevents feedback pressure to pilot pressure)
(124.1 124.4)
Track tensioning cylinders
(125.1 + 125.2) Check valves (prevents a cross-over flow)
(141)
Pressure increasing valve.
The hydraulic track tensioning system ensures automatically the correct track
tension.
The pilot pressure pumps (9.1 and 9.3) will supply oil to all four tensioning
cylinders (124.1 124.4).
The maximum pressure is limited by pressure increasing valves (141).
The pressure in the tensioning cylinders transmits the required force to move
the guide wheels to the front, until the correct track tension is obtained.
External forces acting at the guide wheels will be absorbed through the
pressure accumulators (119.1 + 119.2, first stage) and (120.1 120.4, second
stage).
For information about the preventative track inspection, refer to the

Operation and Maintenance Manual.
Functional description on next page
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Page 3
9.1
Functional description:
Illustration Z 22756a and Z 22757a (on next page):
Under normal operating condition shut-off cock (118.4) located on the

valve block (140) in the car body is closed. The shut-off cock (118.1)
located on the valve block (140) in the car body and (118.2 and 118.3)
located inside the side frames are open.
The oil flow of the pilot pressure pumps (9.1 + 9.3), filtered by pressure filters
(68.1 + 68.7) enters port "P" of solenoid valve Y16, via the common pilot
pressure supply line (45 bar) of the central control and filter panel (36).
If solenoid valve Y16 is actuated (i.e. pressure at sensor B48), the oil for the
travel parking brake (reduced to 35 bar by the function of valve 147), flows via
rotary joint (21), shut-off cock (118.1), the orifice, the two check valves (121.1 +
121.2) and the shut-off cocks (118.2 + 118.3) the into the tensioning cylinders
(124.1 124.4).
The resulting force moves the guide wheels toward the front, until the correct
track tension is obtained.
Simultaneously the system is via check valves (125.1 + 125.2) connected to the
pressure increasing valve (141).
External forces acting at the guide wheels will be absorbed through the pressure
accumulators (119.1 + 119.2, first stage) and (120.1 120.4, second stage).
Purpose of the pressure increasing valve
The two system pressures
35 bar with engine stopped

310 bar with engine running
are controlled by the pressure increasing valve as follows.
With stopped motor and switched off ignition there is no pilot pressure (L39) at
pressure increasing valve (141) and only the lowest adjusted pressure of 35 bar
remains in the system.
As soon as the motor has been started, the pilot pressure acts on the pressure
increasing valve. As a result the system pressure can rise to the adjusted pressure
of 310 bar.
continued
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9.1
Functional description:
Cont'd.:
Illustration (Z 22757a):
Cushioning Function
When the tensioning cylinders (124.1 124.4) are moved in by external
forces, the none return valves (121.1 + 121.2) will be closed.
A certain amount from the displaced oil of the tensioning cylinders is taken
up by the pressure accumulators.
First stage:
at a pressure higher than 31 bar, oil is taken up by the side frame

accumulators (119.1 + 119.2).
Second stage: at a pressure higher than 150 bar, oil is taken up by the center
section accumulators (120.1 120.4).
The system pressure can rise up to 310 bar pressure increasing valve (141)
setting.
With reduction of external forces, the oil is pushed back by the accumulator
pressure into the tensioning cylinders.
If the displaced oil volume was higher than the accumulators could take up,
oil is added from the pilot pressure circuit, as soon as the pressure in the lines
to the tensioning cylinder is lower than 35 bar.
To avoid serious damages to the pilot pressure system in case of a faulty
check valve, pressure relief valve (257.1) with a 55 bar setting is installed.
For information about the preventative track inspection, refer to the

Operation and Maintenance Manual.
To check the accumulator charging pressure refer to PARTS &
SERVICE NEWS AH01531a latest edition.
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Page 5
9.2
The pressure increasing valve is a remote controlled pressure relief

valve.

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11+12)
(13+14)

Valve poppet
Compression spring
Main piston
Closing spring
Set screw - low pressure 35 bar
Set screw - high pressure 310bar
Piston
Pin
Jet bore
Lock nut
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the P
port.
If static pressure increases above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely to tank (T1). This oil generates a pressure
drop in the spring chamber of the main spool, the closing force of the spring
(6) is cancelled, and the main piston (5) opens to allow the pump flow to flow
to tank (T2).
port X, the pre-tensioning of the pressure spring (3) is increased by the amount
of the piston stroke "S" and system pressure is increased correspondingly.
of the screw ~ 150 bar.
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9.3
Tensioning cylinder:
(1)
Cylinder tube
(2)
Piston
(3)
Piston guide ring
(4)
Piston guide strap
(5)
Seal ring (light)
(6)
O-ring
(7)
Scraper
(8)
Retracting device
(9)
Seal ring (dark)
(M) Bleeder port

(P)
Oil supply
Maximum permissible piston stroke 360mm!

During bench test an external stroke limitation must be used!
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Page 7
9.4
(1+3+5) Lock nut
(2+4+6) Set screw
(147)
Pressure reducing valve Track tensioning system (35 bar)
(252.1)
Pressure reducing valve for pilot pressure X2 (45bar)
(252.2)
Pressure relief valve for pump support pressure X4 (60bar)
(257.1)
Pressure relief valve Safety valve for Travel brake / Track
tensioning system (55 bar)
(M1.1)
Check point X4 pressure (60 bar)
(M1.2)
Check point X2 pressure (45 bar)
(M9.1)
Check point Travel parking brake / Track tensioning safety
pressure (55 bar)
(M9.2)
Check point Track tensioning operating pressure (35 bar)
(Y16)
Solenoid valve travel parking brake
Checking / Setting the 55 bar pressure relief valve (257.1) safety valve
1.
Connect pressure gauges to check point M1.1 + M1.2 + M9.1
2.
Start the both motors.
3.
Check the X4-pressure at M1.1, required 60 bar.
If necessary correct the setting by the function of valve 252.1 as follow:
4.
Unplug solenoid valve Y16.
5.
Increase the pilot pressure X2 by the function of valve 252.2 to ~ 60 bar.
6.
Check the Safety-pressure at M9.1, required 55bar.
If necessary correct the setting by the function of valve 257.1 as follow:
7.
Re-connect solenoid valve Y16.
8.
Re-set the X2-pressure to 45 bar by the function of valve 252.2
Checking / Setting the 35 bar pressure reducing valve (147) supply pressure
1.
Connect a pressure gauge to check point M9.2.
2.
Start the both motors.
3.
Read pressure, required = 35+2 bar
If readjustment is required proceed as follow
a) remove dust cap (a) and loosen lock nut (b).
b) Set pressure with set screw (c).
c) Tighten lock nut (b) and re-install cap (a).
continued
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Page 8
9.4
Cont'd.:
(1)
Piston
(2)
Lock nut
(3)
Set screw - high pressure
310bar
(4)
Lock nut
(5)
Set screw - low pressure 35 bar
(P)
Plug
(X)
Pilot pressure port
(141)
(118.1)
(118.3)
(118.4)
(119.2)
(120.3 / .4)
(124.3 / .4)
(M11.5)
(M29.2)
(M29.4)
(MRV)

Service shut-off cock supply line
Service shut-off cock in the side frame (or the L.H.-side)
Main shut-off cock
Membrane accumulator 31 bar
Bladder accumulators 150 bar
Pressure check point (Main control block IV) pump 5
Pressure check point at the track tensioning cylinders L.H.-side
Pressure check point at the bladder accumulators L.H.-side
Main relief valve Operating pressure of main control block IV
Checking / Setting the pressure increasing valve

Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system
must be free of air.
The description is only for the R.H. track. The same procedure applies also
for the L.H. side.
Basic Adjustment:
1.
Connect a pressure gauge to check point M11.5
2.
Start the motors.
3.
Increase the MRV-setting (Block IV), to ~ 330 to 340 bar.
4.
Switch OFF the motors, open cock valve (118.4) to allow pressure
relieve of track cylinders, and close it again.
continued
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9.4
Cont'd.:
5.
6.
7.
8.
9.
10.
Move the pressure gauge from M11.5 to M29.4

Connect pressure check point M11.5 with pressure check point M29.2,
using a long pressure gauge hose. (required for the oil supply)
Disconnect the pilot pressure line at port X of the pressure increasing
valve (141) and close the hose with a plug (P).
Loosen lock nut (4) of the pressure increasing valve and screw in set
sleeve (5) until piston (1) comes to stop. (substitution of 35bar pilot
pressure)
Start the motors
Stall the hydraulic with the clam opening function (clam cylinders
completely retracted) and observe pressure at check point M29.4.
A pressure of 310 + 5 bar must reached within a time period of 10 15
minutes and must remain at this value.
The maximum pressure will be shown only after the accumulators are
completely filled with oil.
When the pressure reaches the pre-charge gas pressure ( 31 bar and
150 bar) the gauge pointer moves slower depending on the gas
compression.
If the gauge shows a lower or higher value the pressure increasing valve
must be adjusted.
Setting procedure, high pressure stage (Valve 141)
a)
b)
Adjust pressure with set screw (3).
c)
Secure adjustment by tightening lock nut (2).
d)
Re-check pressure setting.
11.
The low pressure setting of the pressure increasing valve must now be
reset (with the pilot pressure line at port X still disconnected):
Setting procedure, low pressure stage (Valve 141)
a)
completely retracted) and observe pressure at check point M29.4.
b)
loosen lock nut (4) and turn set screw (5) ccw until gauge at
check-point M29.8 shows 35 bar.
c)
Tighten lock nut (4).
d)
continued
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9.4
Cont'd.:
12.
13.
Switch OFF the motors and open cock (118.4) to allow pressure relieve.
Re-connect the pilot pressure line to port X of the pressure increasing
valve (141).
Remove the pressure gauge hose between pressure check point M11.5
and pressure check point M29.2.
Close the cock (118.4).
Re-set MRV (Block IV)to 310 + 5 bar after the check / adjustment is
finished.
13.
15.
16.
9.5
Functional Test
After all adjustments are finished, do the following:
a)
Bleed all air from the system
b)
Place shutoff and pressure relief cocks into correct operating position.
c)
Connect pressure gauge to check point (M29.4).
d)
Start motors.
e)
Travel approx. 10 m with the shovel.
f)
Stop the motors.
g)
The pressure must drop to 35 bar.
If the pressure remains the at a higher or lower pressure*, re-adjust the low
pressure setting at the pressure increasing valve (141).
PC8000-6-E_Sec_9-0_#12048_rev0.doc
The pressure may drop below 35 bar after a longer time, this is o.k.
because of internal leakage.
09.12.05
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09.12.05
Access ladder
hydraulically operated
Section 10.0
Page 1

Section
10.0
Page
Access ladder hydraulically operated
10.0 General
10.1
Function of hydraulically operated access ladder
3+4
10.2
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10.0
2
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Access ladder
Section 10.0
Page 2
10.0 Access ladder hydraulically operated

General
Legend for illustration Z22813a
(A)
Access ladder in lowered position
(B)
Access ladder in upper position (Working position)
(C)
Stop bar
(D)
Inner pivot bracket of the access ladder
(E)
Pull chain for emergency lowering of the access ladder
(Z)
Hydraulic cylinder
(36)
(S84) Ladder control switch for lowering the Ladder
(S84B) Ladder control switch for lifting the Ladder
(S84A) Safety switch for emergency lowering of the access ladder. When the
chain (E) is being pulled down with the motor running the pilot control
system is made inoperative preventing further movement of the shovel.
(S22) Safety sensor, located on ladder pivot bracket
Function of sensor (S22):
Cut out of the pilot control system and actuation of the hydraulic
swing brake with the ladder in lowered position.
(S91) Monitor and control sensor
Function of sensor (S91):
This sensor monitors the ladder position and controls the moving speed
of the ladder. In case the sensor (S22) fails to function properly, the
sensor (S91) prevents unintended movement of the ladder.
The access ladder is hydraulically operated by the hydraulic cylinder (Z) with
the pilot pressure X4 of 60 bar. The movement of the ladder is controlled by
the function of switch:
S84:
=> Lowering the ladder
S84B
=> Lifting the ladder
Lifting the ladder is only possible with the motor running. The lowering
movement is possible by hydraulic force with the motor running or by the
force of gravity with the motor at stand sill.
If the ladder is not in the final upper position the pilot control is
switched off and solenoid valve Y120 activates the hydraulic swing
brake. The display in the operators cab shows a message.
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3
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Access ladder
Section 10
Page 3
10.1 Function of hydraulically operated access ladder

Legend for illustration Z22814
(2 + 6)
Main pumps
(9.1 + 9.3)
Pilot pumps
(36)
(68.1 + 68.7)
Filter with filter monitoring switch B22-1 / B22-2
(157)
Solenoid valve Y123a/b
(252.1)
Pressure relieve valve (45 bar) X2-pressure
(252.2)
Pressure reducing valve (60 bar) X4-pressure
(252.3 + 252.4) Check valves
(258.1)
Solenoid valve Y125
(258.3)
Pressure relieve valve (safety valve 70 bar)
(258.4)
Shuttle valve
(258.5 + 258.6) Check valves
(258.7)
Orifice
Y125
Solenoid valve: lowering speed control (OFF => reduced speed)
Y123A
Solenoid valve: ON => ladder up
Y123B
Solenoid valve: ON => ladder down
Prime drive is running
Study together with illustration Z22814 and the electric diagram on the next page.
The pumps (9.1 + 9.3) are delivering the oil through the filters (68.1 + 68.7) and
via check valves (252.3 + 252.4) to port A of pressure relief valve (252.2).
The pressure relief valve (252.2) maintains the adjusted pressure of 60 bar, called
X4-pressure.
The X4-pressure passes check valve 258.6 and is present at port P of solenoid
valve Y123A/B. If solenoid valve Y123 A or B is energized the oil flows to the
cylinder and the ladder will move up or down. By the function of shuttle valve
(258.4) both service lines are connected to safety valve (258.3), which limits the
pressure to 70 bar.
Return oil from cylinder (137) flows back via solenoid valve Y123A/B to
solenoid valve Y125.
Y125 = ON => Maximum cylinder speed, return oil flow not restricted when
both proximity switches S22 and S91 are not activated (ladder
between top and bottom end position)
Y125 = OFF => Reduced cylinder speed, return oil flow is restricted by orifice
(258.7) when one of the proximity switches S22 (ladder up) or
S91 (ladder down) is activated i.e. cushioning function just
before the final upper or lower end position is reached.
If the ladder is in the top position the activated sensor S22 de-energizes Y125
and energizes Y123A, with the result that the cylinder of the ladder is always
charged with pressure in this position.
If switch S84 is in neutral position and the ladder in bottom position sensor
S91 de-energise all solenoids (Y125; Y123 A+B) and the ladder is blocked.
continued
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4
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Access ladder
Section 10.0
Page 4
10.1 Function of hydraulically operated access ladder

Cont'd:
Prime drive is not running and the ladder is in the final upper position
With switch S84 activated in position 2 (ladder down) solenoid valve Y123B
and relay K132 are active. Y123B connects the piston side of the cylinder to
the return line and K132 activates Y125, so that the oil can return without
resistance to the tank. Now the ladder can move down only by its own mass
(due to the force of gravity). The operator has to push the ladder slightly until
it starts moving down by its own weight.
The rod site of the cylinder receives oil via anti-cavitation valve (258.5).
It is not necessary to activate the key switch, because the involved
components are directly battery supplied via fuse F17.
There is an additional pull switch S84A below the ladder support. With this
switch activated the ladder can moved down from the ground.
Make sure that there are no obstacles in the moving range of the
ladder. Stop raising the ladder by releasing the control switch (S84) if
there are any obstacles in the moving range.
Mount the ladder only in completely lowered position.
Do not lift persons or objects (tools) with the hydraulic access ladder.
Serious injury or death could occur.
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10.0
5
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Access ladder
Section 10.0
Page 5
10.2 Adjustments / Checks

Legend for illustration Z22815a
(1 + 3) Lock nut
(2 + 4) Set screw
(252.2) Pressure relieve valve (60 bar) X4-pressure
(258.3) Pressure relieve valve (safety valve 70 bar)
(A)
Access ladder in lowered position
(B)
Access ladder in upper position (Working position)
(C)
Stop bar
(D)
Inner pivot bracket of the access ladder
(E)
Pull chain for emergency lowering of the access ladder
(36)
(S84) Ladder control switch for lowering the Ladder
(S84B) Ladder control switch for lifting the Ladder
(S84A) Safety switch for emergency lowering of the access ladder. When the
chain (E) is being pulled down with the motor running the pilot control
system is made inoperative preventing further movement of the shovel.
(S22) Safety sensor, located on ladder pivot bracket, Function of sensor (S22):
Cut out of the pilot control system and actuation of the hydraulic swing
brake with the ladder in lowered position.
(S91) Monitor and control sensor, Function of sensor (S91):
This sensor monitors the ladder position and controls the moving speed
of the ladder. In case the sensor (S22) fails to function properly, the
sensor (S91) prevents unintended movement of the ladder.
Checking / Setting the 70 bar pressure relief valve (258.3) safety valve
1.
Connect pressure gauges to check point M1.1 and M37.1.
2.
Start both motors.
3.
Lift the ladder to the final upper (working) position, using switch (S84B)
4.
Check the X4-pressure at M1.1 and M37.1, required 60 bar.
5.
Increase slowly the X4-pressure, by turning in set screws (2) of pressure
relieve valve (252.2), while observing the pressure gauges. Stop as soon
the pressure does not raise any further.
The gauge pointers should remain at 70 bar 2 bar.
6.
If necessary correct the setting as follow:
a) Turn set screw (2) of valve (252.2) a turn further in, the gauge
pointers will remain at the value shown under item #5
b) Set the pressure of 70 bar 2 bar with set screw (4) at valve (258.3).
7.
Reset valve (252.2) to 60 bar and tighten lock nut (1), adjustment is
finished.
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Cable drum
Section 11.0
Page 1

Section
11.0
Cable drum
Page
11.0
General
11.1
Components
11.2
Function
11.2.1 Controlling of the drive motor
11.2.2 Travel motion control
11.3
Checks and Adjustments
11.4
Description and operating instruction for cam switch 5S4 and 5S6
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11.0
2
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Cable drum
Section 11.0
Page 2
11.0 Cable drum

General
Legend for Illustration Z 22831a
(5M6)
Brake motor
(5S3)
Rotation direction indicator (switch)
(5R1)
Resistor for brake motor torque adjustment
(5S4)
Gear type cam switch for resistor controlling and for
monitoring of the two last cable windings.
(5S6)
Pendulum control cam switch, to detect slack or tight cable
(5S8, 5S9)
Proximity switch to detect cable deflection to right or left
(5S10, 5S11)
Proximity switch for ground contact protection.
Task:
The cable drum, driven by a brake motor with slip ring rotor, is installed to
wind up or unwind the power supply cable automatically.
1. To considerably improve the mobility of the excavator.
2. To make the operation safer (Material and personnel) i.e. less risk to
damage the cable when travelling backwards and less danger of injury
because the cable must not manual moved.
3. To increase the lifetime of the cable, because the cable is not dragging on
the ground.
For the optimal use of the cable drum it is necessary that the operator
understands the system very well.
Regular maintenance is essential
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11.0
3
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Cable drum
Section 11.0
Page 3
11.1 Components
(5M6)
Brake motor
(5S1)
Service switch for manual actuation of cable drum.
(5S3)
(5R1)
(5S4)
Gear type cam switch for resistor controlling and for
monitoring of the two last cable.
(5S6)
Pendulum control cam switch, to detect slack or tight cable.
(5S8, 5S9)
Proximity switch to detect cable deflection to right or left
(5S10, 5S11)
Proximity switch to detect ground contact
(5K7, 5K8, 5K12, 5K13) Relay for brake motor direction controlling
(5K10, 5K11)
Relay for brake motor torque controlling
(5F13)
Circuit breakers
(5B79)
Brake motor temperature probe
(F79)
Motor temperature control unit
(X8)
Terminal box
The resistor 5R1 serves as a series resistor for a three- phase motor with a slip ring rotor
(stand still, sliding rotor-brake motor)
It is a resistor with one or more taps (as a function of drum design), to make a selection of
different star bridges possible. The taps serve to regulate the motor and brake torque during
winding up and unwinding.
With service switch 5S1 is it possible to control the cable drum manually in both directions
(windup, unwind, stop and automatic)
The terminal box X8 contains the terminal rails , the relays 5K7, 5K8, 5K10, 5K11, circuit
breakers 5F13 + 5F14 and motor temperature control unit F79.
Direction of rotation monitoring switch 5S3 opens its contact and de-energizes 5K10 and
5K11 while unwinding (traveling forward) and eliminates the resistor which controls the
star bridge. (Lowest tensioning force)
Gear type cam switch 5S4* reduces the tensioning as soon as half of the cable is unwinded
(contact 21/22 opens and de-energizes 5K11) or stops reverse travelling as soon as the max.
length of the cable is winded up (contact 31/32 opens and de-energizes K178).
The proximity switch 5S8 stops L.H. crawler reverse travelling at too much deflection of
the power supply cable to the left (contact br/sw opens and de-energizes K179).
The proximity switch 5S9 stops R.H. crawler reverse travelling at too much deflection of
the power supply cable to the right (contact br/sw opens and de-energizes K180).
Pendulum control cam switch 5S6* stops forward travelling at too tight power supply
cable (contact 11/12 opens and de-energizes K177) or reverse travelling at too much slack of
power supply cable (contact 21/22 opens and de-energizes K178).
The limit switch 5S7* stops forward travelling by de-energizing K177 as soon as the safety
cable length on the drum gets unwinded.
The motor temperature control unit F79 interrupts all travel motions as soon as drive
motor 5M6 reaches a critical temperature (monitored by sensor 5B79).
*Refer to page 7 for adjustment procedure
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11.0
4
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Cable drum
Section 11.0
Page 4
11.2 Function
(5M6)
Brake motor
(5S3)
(5R1)
(5S4)
Gear type cam switch for resistor controlling
(5K7, 5K8)
Relay for brake motor direction controlling
(5K10, 5K11) Relay for brake motor torque controlling
(5F13)
Circuit breakers
(F79)
Motor temperature control unit
(X2 + X8)
Terminal board
D53
Time relay at the X2 board
11.2.1 Controlling of the drive motor
General:
In the automatic mode of control switch 5S1, the power supply to drive motor 5M6 is
controlled by the function of the travel control system, which controls relay 5K7, i.e.
while traveling the contacts of 5K7 are closed and kept closed for further 10 seconds
after stopping the travelling motion (controlled by time relay D53), before the power
supply will be interrupted and the motor brake is active.
The torque of drive motor 5M6 is controlled by the function of the relay 5K10 and
5K11; which changes the resistance at the star bridge (5R1). Both relay are
simultaneously controlled by switch 5S3 (Direction of rotation monitoring switch),
to ensure the lowest tensioning force while unwinding (i.e. traveling forward)
Winding up (automatic mode of control switch 5S1):
While winding up the NC-contact of switch 5S3 remains closed which allows
voltage to the relay 5K10 and (if the contact 21/22 of switch 5S4 is closed) also to
5K11.
Example travelling reverse:
Cable length on drum: Max. Max. => 5K10 ON + 5K11 ON => max. torque
Cable length on drum: Min. Max. => 5K10 ON + 5K11 OFF => reduced torque
Unwinding (automatic mode of control switch 5S1):
The NC-contact of switch 5S3 opens while traveling forward and de-energizes
simultaneously 5K10 and 5K11, with the result that there is just enough torque to
hold the cable tight.
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11.0
5
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Section 11.0
Page 5
Cable drum
11.2 Function
11.2.2 Travel motion control, illustration Z 22835
General:
The cable drum is equipped with safety switches for the protection of the power
supply cable during travelling and turning operations. Movements which could
damage the power cable are automatically switched off.
Cable condition
Monitored by
Travel shut off relay
Directional
Solenoid valves
Travel response
K177
Y20b + Y28b
crawler left + crawler right
Switch / contacts
1. Too tight
5S6 / 1112
forward motion stopped

2. Too slack
5S6 / 2122
K178
Y20a + Y28a

reverse motion stopped
3. Too strong deflection to the left
5S8 / brsw
K179
Y20a
crawler left
4. Too strong deflection to the right
5S9 / brsw
K180
Y28a
crawler right
5. Maximum permissible cable

length on the drum
5S4 / 3132
6. Safety cable winding unwinded
5S4 / 1112
K178
Y20a + Y28a

K177
Y20b + Y28b

forward motion stopped
7. Ground contact
5S10 and/or 5S11
K178
Y20a + Y28a

)
)
If the reverse motion stopped because of a activated ground contact

switch 5S10 or 5S11 it is possible to activate the reverse motion manually
via activation of horn switch at the left control lever in the cab.
Refer to section 8.3 in this Manual for further information.
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11.0
6
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Cable drum
Section 11.0
Page 6
11.3 Checks and Adjustments

(5S3)
No adjustment required. Check the function of contact 2/P.
The built-in switch must open while unwinding.
(5S4)
Gear type cam switch for resistor controlling and safety switch
to detect full cable drum and the last two safety cable windings.
The contact 31/32 must open as soon as the maximum
permissible cable length is on the drum, travel reverse will stop
by deactivated relay K178.
As soon as the last second winding comes up contact 11/12
opens and travel forward will stop by deactivated relay K177.
Adjusting procedure see section 11.4 on next page and check the
function under operating conditions.
(5S6)
Pendulum control cam switch, to detect slack or tight cable.

Adjust the switch in such a way that contact 11/12 opens at
too tight cable and contact 21/22 opens at too slack cable.
Check the function under operating conditions. Make sure
that the shock absorber at the pendulum will work in its
permissible range.
Adjusting procedure see section 11.4 on next page.
(5S7)
(5S8, 5S9)
Proximity switch to detect cable deflection to right or left.

Adjust the distance between switch and metal bar to 7mm.
Check the function under operating conditions.
(F79)
Motor temperature control unit with monitoring LEDs.

(R) red LED on => motor temperature to high.
(G) green LED on => permissible temperature range.
Hysteresis:
Rcold 1k, Rswitch point 3k (Sensor between P1 and P2)
Check the function with potentiometer.
(D53)
Time relay for power cut off after 10 seconds without travelling.
Check adjustment, refer to service Bulletin 21-584 for more
information.
(X2 + X8)
Terminal board
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11.0
7
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Cable drum
Section 11.0
Page 7
11.4 Description and operating instruction for cam switch 5S4

Legend for Illustration Z 22837
(1) Micro switch housing
(2) Actuator (Roller lever)
(3) Cam disc
(4) Adjusting spanner
(5) Cup spring
(6) Tension nut
The cam discs (3), arranged in pairs on the centering discs, can be adjusted
individually and continuously by means of a adjusting spanner (4) The centering
discs can be reversed and are fixed to the square shaft without clearance.
Adjustment can be performed in any position without having to turn the control
shaft. The cam discs, separated from each other by the guard plate, slide past each
other without touching during adjustment. The cam ring next to the cam ring to be
adjusted will not shift and remains in the set position.
Hollow-type rivets prevent accidental shifting of the cam discs.
By selecting the appropriate contact - either make or brake - any angle between 0
and 350 can be set without changing the cam rings.
When the cam hits the actuator (2), the latter will operate the micro switch (1).
Adjustment of the switch mechanism.
1. Loosen the tensioning nut (6) with the handle of the adjusting spanner (4).
2. Bring the adjusting spanner (4) in the position shown on illustration Z22837.
3. Set the cam discs (3) to the required position.
4. Adjust all other cam discs, following this procedure.
5. When all cam discs have been adjusted, tighten the tensioning nut.
PC8000-6-E_Sec_11-0_#12044_rev1.doc
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Hints for reading the

Hydraulic Circuit Diagram
Section 12.0
Page 1

Section
12.0
Page
Hints for reading the hydraulic circuit diagram
General
12.1
28.11.05
Symbols
12.1.1 Lines, unions
12.1.2 Components, valves
12.1.3 Sensors
12.1.4 Valves, valve components
12.1.5 Pumps, motors, cylinders
12.1.6 Assemblies and main components
2
5
5-6
7
8
9-12
13-14
15-16
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12.0
2
28.11.05
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Section 12.0
Page 3
12.0 General:
Legend for Illustration Z22987
)
Item
28.11.05
The illustrations are used for exemplary explanations only.

Use original circuit diagram for detailed reading
There are more symbols on the following pages shown as in the
diagrams drawn. Some symbols of the diagrams not shown in the
following pages.
Description
Number / Code
Explanation
Diagram No. and Type of the 897 895 40 a

respective machine
PC8000-E
Diagram No. only for the

respective machine
Respective Serial No.
Sheet-No. / Quantity of sheets 01 / 04
1st of four sheets
Co-ordinates to describe the

location of a component
Page 1 on co-ordinate C vertical

and 10 horizontal Remote control
valve 102.1
Component-No. 127
Line-No. with cross hint,
12041
1 C 10
127
L37/3B9
Main control block I

Case drain line (Line No.37)
comes from / goes to sheet 2
coordinate E7
All the components drawn in neutral and pressure less position.

Full wide continues black line shows a main component or assembly. (Ex.: Valve
and Filter panel, Main pump, Hydraulic tank, ...)
Continues black line shows a main hydraulic line. This lines are temporary or
continues load with high or pilot pressure.
Broken line shows a return, drain or control oil line.
Black dot shows a connection point. The position of this connection is not definitely
fixed.
White dot shows a connection or port of a component with a fix definitely position
or port number.
Page 1 shows the high pressure main hydraulic circuits with all pilot control valves,
control blocks, distributor manifold and cylinders or motors.
Page 2 shows all main pumps and pilot pressure pumps with the main pump control
system and the other auxiliary pilot pressure circuits as lubrication system and
ladder.
Page 3 shows the main pump control arrangement, the auxiliary circuits with oil
cooling system and the hydraulic tank.
Page 4 shows the car body hydraulic with travel brakes, travel motors and track
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12.0
4
28.11.05
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12.1
Section 12.0
Page 5
Symbols
12.1.1 Lines, unions
Symbol
Description
Used as / at / on
Oil supply line, can be a

hose or a pipe.
Return oil line, can be a

hose or a pipe.
Case drain (leak) oil line,

can be a hose or a pipe.
Control oil line, can be a

hose or a pipe.
Crossed lines
Pipes or hoses not

connected
Connection point, is a
connection of hydraulic
lines without definite
position
Component connection
point, is a connection with
a definite position at a
component
Plugged connection point,
can be plugged with any
kind of plugs.
Connection between
several lines
Plugged line inside of a

manifold, can be plugged
with different kind of plugs.
Not used connection

points.
28.11.05
Suction line or pressurized

line of main hydraulic circuit
or pilot pressure circuit or
auxiliary circuits (e.g. fan
drive).
Return lines, connected to
the return oil filter chamber
of the main oil reservoir.
Return lines, connected to
the case drain (leak) oil filter
chamber of the main oil
reservoir.
Pilot control line, pump
regulation line and parking
brake control lines.
Connection to components
like, valve blocks, tanks,
pumps, ...
Not used connection
points.
PC8000-6-E_Sec_12-0_#12048_rev0.doc
12.0
6
12.1
Symbols
12.1.1 Line, union
Symbol
10
Description
Used as / at / on
Compensator,
Compensate line length
differences depend on
vibration and temperature.
Quick coupling,
is a special union with
integrated check valve
Oil tank outlet to the

pumps
12
Blind, Orifice,
not adjustable with
orifice diameter in mm
e.g. Oil cooler inlet,
13

With a special quick
coupling.
HP Filter, Fan valve

block....at all important
circuits
14
Distributor block
Connection of lines with

the same destination e.g.
return lines to tank
11
28.11.05
Tank drain couplings, often

removed lines (e.g. at grease
systems with removable
barrels).
PC8000-6-E_Sec_12-0_#12048_rev0.doc

12.1
Section 12.0
Page 7
Symbols
12.1.2 Components, valves
Symbol
Description
Used as / at / on
Accumulator,
is filled with nitrogen gas
with for the respective
accumulator specified
pressure
Screen filter,
the screen size is 1.0 mm
Input line to the remote

control valves, return oil
collecting tube, track
tensioning system
17
Oil cooler,
Hydraulic oil cooler,

PTO oil cooler
18
Breather filter,
On top of PTO or
hydraulic tank
19
Spray nozzles,
inside of a case for
cooling and lubricating
Gearbox (PTO) cooling

and lubricating system
15
16
Installed in suction lines to

the pumps, oil tank outlet,
return oil collecting tube
continued
28.11.05
PC8000-6-E_Sec_12-0_#12048_rev0.doc
12.0
8
12.1
Symbols
12.1.3 Sensors
Symbol
Description
Used as / at / on
20
Pressure switch / sensor

Input = pressure
Output = electrical signal
analogue or digital
e.g. return / leak oil

chamber (digital), high
pressure filter (analogue)
21
Pressure switch
Input = pressure
Output = digital electrical
The switch point is 24 bar
e.g. swing or travel

detection PC3000,
22
Temperature sensor,
Input = temperature
Output = electric signal
proportional to the
temperature
e.g. hydraulic tank
23
Level sensor,
Input = fluid level
Output = electrical signal
analogue or digital
Hydraulic tank, fuel tank
24
Chip sensor,
Input = contaminate oil
Output = electrical digital
signal
Main pumps
28.11.05
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12.1
Section 12.0
Page 9
Symbols
Symbol
Description
Used as / at / on
25
Manuel operated unit

Lever
Valve in track tensioning

system,
26
Electric / magnetic
operated unit
Solenoid
Solenoid valve
27
Pilot pressure
controlled unit
Pressure relief valve, disc

brake, ...
28
Spring,
with fixed force
Solenoid valves,
29
Spring adjustable
spring force is adjustable
Pressure relieve valves,....
30
Check valve
In drawn pos.: from right
to left free flow, from left
to right blocked flow.
31
Check valve spring

loaded
Opened in flow direction
only against spring force
= pressure
Double check valve,
in drawn pos.: opened
only from the left to the
bottom or from the right
to bottom
e.g. main pump outlet,

swing brake valve block,
anti cavitation valves at
main control blocks or
distribution manifold
By pass of the return oil
filter, by pass of
secondary filter
32
28.11.05
Swing brake control,
PC8000-6-E_Sec_12-0_#12048_rev0.doc
12.0
10
12.1
Symbols
Symbol
33

Description
Used as / at / on
Shut-off Valve with
Gate valve between main oil
monitoring switch,
reservoir and suction tank
the adjustable switch
monitors the valve position
34
2/2 control valve

manual operated,
2/2 cock valve
Track tensioning system
35
3/2 control valve

manual operated,
3/2 cock valve
Change over valve from

electronically pump
regulation to emergency
mode (hydraulically
pump regulation)
36
4/2 directional control valve

as solenoid valve
4/2 way solenoid valve,
electrically controlled.
Neutral position:
P-A and B-T connected.
Variable throttle valve
hydraulically controlled
pilot control port pressure
less = maximum restriction
3/2 directional control
solenoid valve, seat
design = leak oil free
neutral = port P-A open
4/3 directional control
solenoid valve
in neutral all ports closed
External pilot
controlled proportional
floating valve
e.g. swing parking brake,

travel parking brake,
ladder controlling,,
37
38
39
40
28.11.05
Travel brake valve,

located in the car body
Service arm controlling
Ladder controlling,
service arm controlling
PC 3000 and PC4000

with floating system
PC8000-6-E_Sec_12-0_#12048_rev0.doc

12.1
Section 12.0
Page 11
Symbols
12.1.4 Valves and valve components
Symbol
Description
Used as / at / on
41
Main control valve

Standard control valve for
standard function
two directions of cylinder or
In neutral position:
motor.
open pump flow (P-PU) and
control port flushing (T a, T
b), in position a or b closed
circulation port (P- PU)
42
Main control valve

pressure less lowering
Neutral position: open pump
flow (P-PU), control port
flushing (T a, T b)
Position b: closed circulation
port (P-PU), normal function
P B and B - T,
Position a: open circulation
port P PU, only port B T
connected
Main control valve floating
function
Neutral position: open pump
flow (P-PU), control port
flushing (T a, T b),
Position b: closed circulation
port (P-PU), normal function
P B and B - T,
Position a: open circulation
port (P PU) = A, B, T, P
connected together via tank
Pressure reducing valve,
assembly
Variable inlet pressure at port
B and constant lower output
pressure at port A, output
pressure is adjustable.
43
44
28.11.05
Control valve for pressure

less lowering. Used to assist
the floating function of boom
and stick,
Control valve with floating

function in position a,
e.g. floating valve for boom
or stick, .
Emergency mode
pressure (X3-pressure),
pilot oil pressure
PC8000-6-E_Sec_12-0_#12048_rev0.doc
12.0
12
12.1
Symbols
12.1.4 Valves and valve components
Symbol
Description
Used as / at / on
45
Pressure relief valve,

direct controlled and
adjustable
e.g. ladder controlling,

service arm controlling ..
46

with anti cavitation
valve (check valve)
Assembly, external drain
at port Y
Secondary relieve valve

at main control blocks
47

pressure relieve valve with
variable setting, pilot
pressure controlled via port
X. Low pilot pressure = low
relieve pressure
Swing brake block, track

tensioning system.
48
Proportional pressure
valve, reduce the
pressure in port A
proportional to the
solenoid current.
4 port proportional
pressure relief valve,
direct operated by a
proportional solenoids.
Remote control valves to

control the main control
blocks,
50
Pressure relief valve,

mechanical and
hydraulically via pilot
port X adjustable, oil
drain port Y
Radiator and oil cooler

fan drive
51
Throttle check valve

with secondary relieve
valve, throttle and
secondary valve
mechanical adjustable,
external drain at port Y.
Distribution manifold
normally in the line to the
cylinder piston side.
49
28.11.05
Pump regulation, only

output port A is used for
our systems
PC8000-6-E_Sec_12-0_#12048_rev0.doc

12.1
Section 12.0
Page 13
Symbols
12.1.5 Pump, motor, cylinder
Symbol
Description
Used as / at / on
52
Single acting Cylinder,

pressurised moving only
in one direction, return by
external force
Track tensioning system
53
Double acting Cylinder,

Cylinder in which the fluid
pressure operates alternately
in both directions (forward
and backward strokes)
A = Piston side
B = Rod side
Attachment i.e. boom,

stick, bucket or clam
cylinder
54
Drive shaft of a motor

or pump with one
direction
Main pumps, swing

motor, fan drive, travel
drive
55
Hydraulic pump with fix

volume per revolution
suction port S and pressure
outlet P
Fan pump, circulation

pump, pilot pump, PTO
lubrication pump
56
Hydraulic pump with

variable output volume
per revolution
with external case drain
Main pumps
57
Hydraulic pump
assembly
with pump bearing
lubrication, one direction
and external case drain
Main pumps
28.11.05
PC8000-6-E_Sec_12-0_#12048_rev0.doc
12.0
14
12.1
Symbols
12.1.5 Pump, motor, cylinder
Symbol
Description
Used as / at / on
58
Variable hydraulic
pump with charge
pump
and external drive shaft
bearing lubrication
Main pump
59
Hydraulic motor
can be used in both
direction, with external
case drain L
Fan motor
60
Motor with disc brake

disc brake is spring
loaded it means:
pressure less pilot line =
maximal brake torque
Travel motor
61
Variable swing motor

with integrated control
valves and flushing
valves
Swing motor PC5500
28.11.05
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12.1
Section 12.0
Page 15
Symbols
12.1.6 Assembly and main components
Symbol
Description
Used as / at / on
62
Lubricant pump drive

differential cylinder with
integrated control valves
to propel the grease pump
Lubricant pump station

for central lubrication
system and swing ring
lubrication system
63
Swing brake valve

assembly,
act as a hydraulical back
pressure system parallel
to a motor with variable
pressure setting and
independent pressure
side. Input port A or B
and outlet on the opposite
connection to the motor..
Swing brake system.
64
Rotary joint
Upper part with
connections drawn to
the top, lower part with
connections drawn to
the bottom
Hydraulical connection
between superstructure
and car body
65
Travel brake valve block

with secondary pressure
relieve valve
is connected in the line to
the travel motors. The
return oil flow is restricted
according to the pressure
inlet.
mounted in the supply

line to the travel motors,
is located in the car body
28.11.05
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12.0
16
12.1
Symbols
12.1.6 Assembly and main components
Symbol
Description
Used as / at / on
66
Remote control lever to

blocks
Control lever in the

operators cabin
67
Remote control pedal to

blocks
Control lever in the

operators cabin
68
Hydraulic oil tank with

leak and return oil filter,
back pressure valve and
sensors
Main hydraulic tank
28.11.05
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28.11.05
Section 12.0
Page 17
PC8000-6-E_Sec_12-0_#12048_rev0.doc

Electric Circuit Diagram
Section 13.0
Page 1

Section
13.0
Page
Hints for reading the electric circuit diagram
13.1
Designation of electrical devices
13.2
Symbols
3+4
13.3
General information
5+6
13.4
Reading a circuit diagram
7+8

Section 13.0
Page 2
13.1 Designation of electrical devices

Indicating letter
A
B
C
D
E
F
G
H
K
L
M
N
P
Q
R
S
T
U
V
W
X
Y
Z
Kind of component
System, subassembly, parts group, trigger boxes, control units
Transducer for conversion of non-electrical variables to electrical
variables, and vice versa.
Speed sensors, pressure sensors, pressure switches, oil-pressure
switches, temperature sensors
Condenser, capacitor, Condensers and capacitors, general
Elements with time lag, memory elements, binary elements
Various devices and equipment
Protection device
Fuses, current protection circuits
Power supply, generator
Batteries, generators, alternators
Monitor, alarm, signaling device
Indicator lights, signal lights, headlights, warning buzzers, horn
Relay, contactors
Inductor
Coils, windings
Motor
Regulators, amplifiers
Measuring instrument
High voltage switching units
Resistors, heating devices
Switches, selectors
Transformer
Modulator, converter from one electrical in an other electrical value
Semiconductor, electron tubes, diodes, rectifiers, zener diodes
Transmission path, conductor, antenna
Terminal, Plug, Plug and socket connection
Electrically actuated mechanical device
Solenoid-operated valves
Compensating units, filters, limiters cable connection
13.0
3

Section 13.0
Page 3
13.2 Symbols
Our common used symbols in accordance to VDE/IEC (Association of
German Electrical Engineers DIN 40710 - 40716 and the International
Electrical Commission) differ for the most part from the symbols in
accordance to JIC/ASA (Joint Industrial Concil and American Standard
Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3).
For this reason the following comparative chart.
1) Normally open
contact
2) Maintained
contact
4) Normally
closed contact
5)
7) Manual operated
switch isolator,
disconnect switch
10) NO contact with
time lag
8) Foot-operated
push-button
switch
11) Multi-position
switch selector
13) Contacts with

time lag
14) Resistor
general
16) Battery
17) Tapped
resistor
18) Voltmeter
19) Inductive
resistance
20) Continuously
adjustable,
general
21) Recording
instrument
22) With iron core
23) Adjustable in
steps
24) Signal lamps

pilot lights
25) Continuously
adjustable
26) Potentiometer
rhesostat
27) Operating coil

solenoid
28) Transformer
29) Capacitor
general,
continuously
adjustable
30) Rectifier, semi

conductor
Push-button
switch
3) Single pole
two way contact
break before make
6) Limit switch
NO contact
NC contact
9) Pressure
operated switch
12) Indicating
instrument
(general) symbol
15) Ammeter
13.0
4

Section 13.0
Page 4
13.2 Symbols
31) Rectifier bridge
32) Thermal over load limit
33) Phase, 4-wire system
34) Current transformer
35) Undervoltage relay
36) Junction of conductors
37) Voltage transformer
38) Temperature relay
39) Junction
40) Circuit interrupter
41) Contactor
42) Terminal
43) Circuit breaker, three

phase
44) Generator (G)Motor (M)
45) Terminal
46) Thermal over- ground,

load protection
47) 3-phase-motor
48) Earthing, general
49) Magnetic over- socket

current protection
50) 3-phase squirrel cage
51) Plug and
52) Slipring motor
53) Fuse with bolted contacts 54) 3-phase squirrel cage

induction motor in
Star-delta starting
55) Thermal overload relay 55) Two speed motor
(tapped windings)
(for ex. 8 to 4 poles)
13.0
5

Section 13.0
Page 5
13.3 General information

Komatsu circuit diagrams
Each sheet has the following information in the bottom right hand corner:
Diagram Number
example: 897 844 40
Machine Type
example: PC4000-6
Sheet Number and Total Number of sheets 01/63 - 02/ . etc.
Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the
top and bottom lines, and lettered down from F (at the top) to A (at the bottom)
along the left and right side lines.
This coordinate system enables you to find components easily.
On the table of contents, page one, the individual circuits are listed up with the
respective page number.
Example: The circuit for the superstructure lighting is shown on page 39.
Pages number two, three and four are cross reference lists of component codes
related to page numbers.
Example: The relay with the component code K1-1 is shown on page 8.
On page five is a list of answers to frequently asked questions (FAQ) concerning
abbreviations, function of components (e.g. time relays) mathematical symbols etc.
used in the diagram.
All electrical components are connected via cable harnesses to the main switch
board X2. There is only one Plug connector in between, which is always located
close to the respective component like sensors, solenoids etc.
All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the
wire. (see illustration)
The first part of the code shows the required connection and the second part gives
the information what is connected at the other side of the wire.
Example:
going to
coming from
coming from
going to
X2S
45
= X2-Board, terminal group S

= Terminal No 45
Y136 = Plug connector to solenoid

.1 = Terminal 1 of connector
All circuits are shown currentless and all relays and switches are in neutral position.
13.0
6

Section 13.0
Page 6
13.3 General information

Explanation of the Drawing Concept
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Drawing number
Sheet number / quantity of sheets
Designation of drawing
Designation of component or assembly
Column (vertical sections)
Lines (horizontal sections)
Component symbol
Neutral wire / machine ground
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Designation of phase
Phase strip
Terminal strip and terminal
Cable plug and pin number
Relay coil
Relay contacts, partially with detailed information
Cross reference for the continuation, Page / Column
Indication where the relay contact opens or closes
Location of the Main Terminal Boxes

(X1)
Dashboard inside the cabin
(X2)
Main switch board inside the cab base
(3E14-1) Electronic control module (ECM- Quantum) left bank of the engine
(3E54-1) Electronic control module (ECM- Cense) flywheel end of the engine
13.0
7

Section 13.0
Page 7
13.4 Reading a Circuit Diagram.

Examples are shown by sectional drawings out of the electric circuit
diagram 897 844 40 page 08.
)
(1)
Section F8 / sheet 08
The hint F11/06.1 indicates that the wire from F11 is continued on
sheet 06 column 1.
(2)
Section C4 / sheet 08
Shown is the relay coil K51-1 only and not its contacts.
The contacts are shown somewhere else in the diagram.
Switching and contact positions are shown below at the foot of that
particular circuit in row C-C as shown below.
Example for K51-1:

08.5
:
:
:
1
5
2
6
3
7
4
8
9
10
11
12
opens on sheet 8 section 5 when relay is energized

Not used
Not used
Not used
When diodes are fitted to a relay, they are fitted to allow a current flow in one
direction only. An LED* (Light Emitting Diode) indicates a current flow if it
lights up.
When diodes ** are fitted anti-parallel to a relay coil, they absorb the high
induced voltage caused by making and breaking the current flow through the
coil.
This occurs each time we operate a switch supplying current to the coil. The
diode effect allows the induced current to circulate within the coil windings and
decay when the energy to the coil is cut.
*
**
LED between A1 and coil

Diode between A1 and A2.
(3)
Section F7 / sheet 08
Connectors and Terminals are identified by a letter and number
code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked
with a metal bridge.
continued
13.0
8

Section 13.0
Page 8
Cont.:
13.4 Reading a Circuit Diagram.
(4)
Section E 1 sheet 08
The components have a letter and a number prefix, and these are
explained below in rows A and B.
Components are depicted in a system unique to VDE/IEC
(Association of German Electrical Engineers DIN 40710-40716 and
the International Electrical Commission) or to KMG standard.
S27 = Toggle switch (with non-automatic return)
a.
F11
b.
F11 / 10.5 =
Power line F11, comes from circuit breaker F11, sheet

08 section 8 and continues on sheet 10 section 5.
c.
S27 / 20.7 =
Line S27, comes from switch S27, sheet 08 section 1

and continues on sheet 20 section 7.
Circuit breaker (24V power supply)
Function:
If switch S27 is actuated, terminal A and B are connected and 24VDC will
energize the coils of K121 and K121a on page 08 and simultaneously via line
S27 a digital input to the PLC on sheet 20 section 7.
Now the machine can be operated in emergency mode and a warning text
appears on the display.
Electronic Control System

ECS
Section 14.0
Page 1

Section
14.0
Page
Electronic Control System ECS
14.1
14.2
14.3
14.4
14.5
14.6
General Design of the ECS-T System
14.1.1
14.1.2
14.1.3
14.1.4
3
3
4
5 + 6 +7
Input and outputs of the PLC

Task
PLC DIGSY plus
Definitions; Symbols and Abbreviations
How to Proceed due Maintenance and Installation
8+9
14.2.1
14.2.2
14.2.3
10 + 11
12
13
Meaning of the Status LEDs

Short Circuit Marker -LED MK
Diagnostic for Temperature-Module ANM
Front Connector Arrangement
14
14.3.1
14.3.2
14.3.3
14.3.4
14 + 15
16 + 17
18
19
Front Connector Arrangement BIM-Module

Front Connector Arrangement, ANM-Module
Ground connection of the Control Unit
Interface-Connection COM SP /SK
Power supply
20
14.4.1
14.4.2
14.4.3
14.4.4
14.4.5
20
21
22
22
22
Operation Voltages +24 V

Safety Precautions for Faultfinding
CPU Voltage Range
Electric Classification
Fuse
Function explanations with electrical diagram
23
14.5.1
14.5.2
14.5.3
14.5.4
23
24
25 + 26
27
General
Pressure Measuring
Temperature Measuring
Temperature Resistance Chart PT100
Hints for reading the functional flow charts
28
14.6.1
14.6.2
28
29
PC8000-6-E_Sec_14-0_#12048_rev0.doc
General
Example
30.11.05
14.0
2
PC8000-6-E_Sec_14-0_#12048_rev0.doc
30.11.05

ECS
Section 14.0
Page 2
14.1 General Design of the ECS System

ECS
Legend:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
I/ O
Illust. Z 21407a
PLC Programmable Logic Control (DIGSY plus )

Text display
Keys for function control and pre-adjustments
Outlet X27 for data transfer
Field computer system (like MODULAR MINING)
Printer
Memory card unit
Laptop
Input / Output data transfer
Items 5 to 8 are optional equipment
Meaning of the PLC front cover codes
BIM
Binary Module
ANM
Analog Module
MK
Short Circuit Memory
A
Digital Output
E
Digital Input
DIAG
Diagnostic
More in detail see page 4
PC8000-6-E_Sec_14-0_#12048_rev0.doc
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14.0
3
PC8000-6-E_Sec_14-0_#12048_rev0.doc
30.11.05

ECS
14.1.1
Section 14.0
Page 3
Input and Output of the PLC, Illust. Z 21408

PLC = Programmable Logic Control
(Programmable Logic Control = Control system with a write-readingmemory, whose content can be altered (via an serial interface) by a PC and
the resp. Software.
No mechanical action necessary.)
14.1.2
Task
The PLC receives from the monitored excavator components the actual
values and does an evaluation.
The evaluation results in a control and display function.
See I / O connection table (chapter 10) and electric circuit diagram for I / O
levels and ports.
The picture shows as an example the application for a two motor

version.
PC8000-6-E_Sec_14-0_#12048_rev0.doc
30.11.05
14.0
4
PC8000-6-E_Sec_14-0_#12048_rev0.doc
30.11.05

ECS
14.1.3
Section 14.0
Page 4
PLC DIGSY plus (circuit diagram code E6)

Legend for illustration Z 21409b
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Central Processing Unit (CPU) board.

Binary Module (BIM) board.
Analogues Module (ANM) board.
MK Output short circuit marker LED red
Input state-LED green, Inputs E1.1 - E1.8 up to E14.1-E14.8
Input or Output State-LED red (A2/ E9, Af/E10, A6/E11,
A8/E12, A14/E21) Can be used as Inputs or Outputs
Output state-LED red, Output A1.1 - A1.8 up to A13.1-E13.8
Diagnostic-LED (DIAG), (green flashing = OK.)
5Volt Voltage-LED (+5V), (green = OK.)
Diagnostic LED for ANM
COM SP Interface (COM SP) (Text display connection)
COM SK Interface (COM SK) (PC-Connection)
Binary Module BIM-plug-in location (slots) (X1-X5)
Analog Module ANM-plug-in location (slots) (X6-X8)
Ground Connection (GND)
The quantity and configuration of the BIM and ANM Module can be
vary, depend on the excavator type and additional options.
MK-LED, The short circuit marker are used to indicate an external short to GND
MK1, MK3, MK5, MK7 & MK9- LED for outputs A1.1 - A1.8
A3.1 - A3.8, A5.1 - A5.8, A7.1 - A7.8 & A13.1 A13.8
MK2, MK4 , MK6, MK8 and MK10 if there groups as outputs used
A MK-marker is placed, if an output (e.g. A1.1) gets from the program an output signal
and at the same output happens an external short. The red MK 1-LED lights ON
If there is a short all outputs of the resp. Output group i.e.. A1.1 - A1.8)
are switched Off
The short circuit marker remains until the control system gets switched
Off/ON (after eliminating the short).
State-LED Input lights up with a present 24 Volt signal.

State-LED Output lights up with a switched On output.
5V-LED, indicate specified operation states by different colors and duration of
lightning (Continuos On or flashing).
DIAG-LED, indicate specified operation states by different colors and duration of
lightning (Continuos On or flashing).
PC8000-6-E_Sec_14-0_#12048_rev0.doc
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30.11.05

ECS
14.1.4
Section 14.0
Page 5
Bit
Sign used for corresponds to

Sign used for not equal to
A bit is the smallest unit for information. It can assume only two
conditions: logical 0 or logical 1 ( also referred to as logical L-Level and
logical H-Level).
Boolean algebra Mathematical rules for binary variables and conditions. For Boolean
equations the following signs are used:
Logical AND operation (AND or &)
Logical OR operation (OR or >=1)
Logical Negation (NOT or 0)
Byte
Unit for Information unit comprised of 8 bits. A byte can assume a value
between 0 and 255.
Word
Memory unit comprised of 2 byte or 16 bit. A word covers the numeric

range from 32767 to +32767.
Clock
Signal pulse
VWP
VerWaltungProgramm: (management program) A control program

created by the user.
AWP
AnWender Program: (Application program, user program) A control

program created by the user.
AWL
AnWeisungsListe: (instruction sequence) Representation of a program

using alphanumeric signs and symbols as defined in DIN 19239.
Programming in AWL (selection logic) is the at present widely applied
method of programming.
CMOS
Complementary Metal-Oxide Semiconductor: Complementary metaloxide semiconductor technology with very low-level closed circuit
current. These semiconductors are used above all for accumulator and
battery buffering.
RAM
Random Access Memory: Read-write memory in which each memory cell

can be addressed in order to read, write or delete at any time. RAM losses
all of its information when the computer is turned off which is why it is
often buffered by accumulators or batteries.
EPROM
Erasable Programmable Read Only Memory: Read-only memory erasable

by ultraviolet light and electrically programmable. With this memory type,
the contents remain intact in the event of a power failure. In the case of
DIGSY plus this memory contains the management program (firmware).
continued
PC8000-6-E_Sec_14-0_#12048_rev0.doc
30.11.05
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30.11.05

ECS
14.1.4
Section 14.0
Page 6
Cont'd:
EEPROM
Electrically Erasable Programmable Read-Only Memory (also called

E2PROM):Electrically erasable and programmable memory. In the event
of a power failure, the contents of this type of memory remain intact. The
DIGSY plus application program (AWP) is loaded into this type of
memory.
COMPILER A program that translates the instructions of a programming language

(e.g. instruction sequence [AWL]) into machine code (processor
instructions).
EDITOR
Utility program for the creation and changing of programs.
Loop
Program loop.
Off-Line
Operational method of a programming device without attached

automation device.
On-Line
Operational method of a programming device (PC) is connected to the

automation device thereby enabling data and programs to be read or
changed.
PC
Personal Computer: Programmable unit for the DIGSY plus .
Watch-Dog: Internal supervisory unit in computers and automation devices used to

recognize system and memory errors.
CPU
Central Processing Unit: Control and central unit in an automation

device usually based on a microprocessor. It can read the application
program code and run the instructions contained therein.
Cycle Time
Time required for the application program to run through once.

continued
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ECS
14.1.4
Section 14.0
Page 7
Cont'd:
Coding Types and Number Systems
ASCII
American Standard Code for Information Interchange: A standardized

information processing code developed in the USA based on
7 bits = 0 127 (7-bit code), (extended ASCII-code of 8-bit = 0 - 255)
Digital
(Eng. Digit) is the representation of a continuos value or a physical

quantity (e.g. voltage) in several levels as a numeric value.
With regard to automation devices one also refers to word processing
in which case a word is a number (e.g. 573).
Analogue
is the representation of a continuos physical quantity (e.g. current or

voltage) which corresponds to the value of a proportional condition
(e.g. rotational speed, routing, temperature, etc.)
For an automation device this physical value converted into 1024 levels,
for example (10-bit analogues-digital conversion). The digitalized value
thus acts within a defined range (e.g. 0 0 volts to 1024 10 volts) in
proportion to a certain input quantity (e.g. voltage). Conversely, by using
a digital-analog conversion, a digitalized value can be converted into a
continuous output signal (current, voltage).
Numeral
A value expressed in one digit: from 0 to 9 in the decimal system and 0-F
in the hexadecimal system.
Number
Value consisting of one or more numeric characters.
Baud
Unit used in serial transmission of data: bits per second (bit/s).
Baud Rate
Modulation rate or transmission speed of serial transmission of binary

numbers. The DIGSY plus uses a baud rate of 2400 baud for
communication and down-loading.
Binary
Numbers, data and information which are exclusively expressed using

the two values 0 and 1 are bivalent = binary dates and information,
exclusive with the use of digits 0 and 1 (e.g. 1 = current 0 = no current).
Dual(Binary) Number (Dual = 2) is the simplest binary numeric expression. Each

position is arranged according to increasing powers of 2.
Example: 13463dec. = 0011 0100 1001 0111dual
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ECS
14.2
Section 14.0
Page 8
Keep in mind
- BE CAREFUL
- BE ALERT
- THINK ABOUT WHAT YOU ARE DOING
Any PERSON doing any work in or around the machine must be familiar
with the local SAFETY INSTRUCTIONS and with the specific SAFETY
INSTRUCTIONS REGARDING TO HIS OCCUPATION.
Serious damage may happen at unqualified actions at the System or
Unit or when not paying attention to the hints given in this manual or
on labels at the units
Qualified persons in sense of the safety relevant hints in this manual or on the
product, are persons which are
either as project engaged person familiar with the safety concept for
automatic control systems;
or as operating personal for the use of an automatic control system being
instructed;
or having the authorization and occupation to put such systems into operation
or doing repair work as well as having the authorization and occupation to put
such systems/units into operation regarding the power
circuits and there safety standards and, to earth and to mark it.
continued
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ECS
14.2
Section 14.0
Page 9
Contd.:
Serious damage may happen at irrelevant opening and improper repair.
Open always the resp. circuit breaker before opening a unit.
I/O cables may only be connect or disconnect in a powerless state.
A BIM module will be damaged while supplying an external power
of 24VDC to the inputs and/ or outputs. If it is necessary for
faultfinding or external unit checks the connection to the PLC has to be
interrupted.
Without power interruption the interface cable are only allowed to be
disconnect or connect when following preconditions are given:
1. The cable must be shielded and the shield must be connected to the
cover of the plug-in connector.
2. A potential balance must be made by connecting the GND
potential parts of the plug connector parts before connecting
the cables.
Replace the fuses only by fuses which matches the values given in the
technical dates
Do not through batteries into open flame and do not solder at their cell
body, explosion can occur (max. Temperature 100 C). Do not open and
do not recharge batteries that contain lithium or mercury. Replace
them by same type only!
Dispose batteries and accumulators as special waste.
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ECS
14.2.1
Section 14.0
Page 10
Meaning of the Status LEDs, Illust. Z 21431b

The DIGSY plus performs by the function of the Status LEDs (5V and DIAG) and
the so named Diagnostic Words* (DW1 up to DW256) many data and statuses.
With a PC and the Program- and Diagnostic Software the. Diagnostic Words are
visible on a monitor.
The following sections explain the diagnostic possibilities more in detail.
* Can be called-up by PC assistance only.
Table: Statuses of the +5 V-LED and their meaning
LED
Effect
Cause
5 V-LED
Voltage
green
o.k.
5 V-LED
CPU not working
Supply
red
(RESET)
< 4,65V
DIAG-LED red
5 V-LED
CPU not working
Supply
OFF
(except the
is missing
LED is defect)
Fuse S1
defect
Remedy
Check the
+24 V Supply
if not o.k. *)
Check the
+24 Volt
Replace the **
Fuse F1
LED defect
(if DIAG
LED is ON)
*)
others
*)
Watchdog
in operation
*)
5 V-LED
flashing
red/green
cyclically
new starts
red/
orange
Continuos Reset
Component fault
*)
** Replacement only after co-ordination with Komatsu Mining Germany, Dept. 8124.1
*) = Return PLC to manufacturer
continued
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ECS
Section 14.0
Page 11
14.2.1
Meaning of the Status LEDs, Illust. Z 21431b
Contd.:
Table: State of the DIAG-LED and their meaning
LED
Effect
Cause
DIAG-LED
Program
Communication via
green
in operation
Interface COM-SP
not active
(interrupted)
COM-SP<> Text
display
DIAG-LED
ProgramTemperature
orange
state
inside housing
unchanged
too high
+24 VCPU < 14 V
Increase the voltage
Accumulator voltage
too low
Replace the
accumulator module
Fixed operands
deleted
Check the
accumulator
connections
SPS in start loop

after voltage ON
wait
programming in
operation
EEPROM not
Initialized
Stop the
programming *1)
Initialize
EEPROM *1)
EEPROM- or
RAM- fault
Initialize
EEPROM *1)
if the fault is
still present *2)
Start program *1)
DIAG-LED
RED
DIAG-LED
OFF
Program
not running (stopped)
Program
not running
(except LED
defect)
Program
stopped
No Program
otherwise LED
defect
DIAG
ProgramCommunication via
flashing
state
Interface COM-SP
or COM-SK active
unchanged
Color State
COM-SP Text
depending
Display
COM-SK (PC)
*1) Function of the Programming Software PROSYD
*2) = Return PLC to manufacturer
PC8000-6-E_Sec_14-0_#12048_rev0.doc
Remedy
Check the cable
connection and the
Interface port
External cooling
Load program *1)

*2)
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ECS
14.2.2
Section 14.0
Page 12
Short Circuit Marker -LED MK

The short circuit markers are used to indicate a short of the outputs at an external
short to GND.
A MK marker will be initialized if by the user-program an output signal is
given and at the same output is an external short present.
The MK marker remains until (after short elimination) the control system is
switched OFF and ON.
See also Section 14.1.3 page 4
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ECS
14.2.3
Section 14.0
Page 13
Diagnostic for Temperature-Module ANM

For the function control a two-color LED is used, visible at the front cover.
The diagnostic - LED indicates following states:
- LED red:
System in reset mode or range overflow of
one or more analog outputs.
- LED green:
Ordinary operation, no range overflow.
- LED red/green flashing (2Hz) Watch-dog timer response or cyclically

overflow of one ore more analog outputs.
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ECS
Section 14.0
Page 14
14.3 Front Connector Arrangement

14.3.1
Front Connector Arrangement, BIM Module (Digital Input / Output)
.This is an example for the first Slot. Additional BIM Modules can
be vary depend on configuration of the variable input/output port
A2/E9/ A4E10, A6/E11, A8/E12 or A14/E21.
The configuration for the respective excavator is written in the
EA-Configuration chart (EA-Belegungsliste) see Appendix.
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Symbol
Input 1.1
Input 1.2
Input 1.3
Input 1.4
Input 1.5
Input 1.6
Input 1.7
Input 1.8
Input 9.1
Input 9.2
Input 9.3
Input 9.4
Input 9.5
Input 9.6
Input 9.7
Input 9.8
0 V (GND)
Input 2.2
Input 2.4
Input 2.6
Input 2.8
Operand
E 1.1
E 1.2
E 1.3
E 1.4
E 1.5
E 1.6
E 1.7
E 1.8
E 9.1
E 9.2
E 9.3
E 9.4
E 9.5
E 9.6
E 9.7
E 9.8
E2.2
E2.4
E2.6
E2.8
Definition
Input 1 of the input group. 1
Input 2 of the input group. 1
Input 3 of the input group 1
Input 1 of the output group 2
Ground
continued
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ECS
Section 14.0
Page 15

14.3.1
Front Connector Arrangement, BIM Module (Digital Input / Output)
Contd.:
Pin
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Symbol
Output 1.1
Output 1.2
Output 1.3
Output 1.4
Output 1.5
Output 1.6
Output 1.7
Output 1.8
UE/A
UE/A
UE/A
UCPU
Input 2.1
Input 2.3
Input 2.5
Input 2.7
Output 1.1
Output 1.2
Output 1.3
Output1.4
Output1.5
Output 1.6
Output 1.7
Output 1.8
UE/A
UE/A
UE/A
UCPU
0 V (GND)
Operand
A 1.1
A 1.2
A 1.3
A 1.4
A 1.5
A 1.6
A 1.7
A1.8
E 2.1
E 2.3
E 2.5
E 2.7
A 1.1
A 1.2
A 1.3
A 1.4
A 1.5
A 1.6
A 1.7
A1.8
Definition
Output 1 of the output group 1
Under Load Voltage
Under Load Voltage
Under Load Voltage
DIGSY (plus)- Operation Voltage
Under Load Voltage
Under Load Voltage
Under Load Voltage
DIGSY (plus)- Operation Voltage.
Ground / GND
UE/A =
Voltage.
Input / Output
There are two pins (two channels) parallel connected only for output A1.1
A1.8 (the same for additional boards A3, A5, A7, A13).
E1, E2,...E7, E13 and E14 input port fix configured.

A2/E9, A4/E10, A6/E11, A8/E12 and A14/E21 variable input or output
ports depend on software programming.
A1/A9, A3/A10, A5/A11, A7/A12 and A13/A21 output ports fix
configured.
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ECS
Section 14.0
Page 16

14.3.2
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Front Connector Arrangement, ANM-Module (Analogues Input)

.This is an example for the first ANM slot. Additional ANM modules
configuration can be vary depend on configuration (temperature or
pressure).
The configuration for the respective excavator is written in the EAConfiguration chart (EA-Belegungsliste) see Appendix and the
respective electric diagram.
PIN-NAME
KR
KG
KA
GND/ANA
GND/ANA
GND/ANA
GND/ANA
A1I
A1U
A2I
A2U
A3I
A3U
A4I
A4U
A4G
A3G
A2G
GND/ANA
GND/ANA
GND/ANA
E8G
E7G
E6G
E5G
OPERAND
AW Z.1
AW Z.1
AW Z.2
AW Z.2
AW Z.3
AW Z.3
AW Z.4
AW Z.4
COMMENTARY
Relay contact
Relay contact
Relay contact
Analog GND
Analog GND
Analog GND
Analog GND
Current output 1
Tension output 1
Current output 2
Tension output 2
Current output 3
Tension output 3
Current output 4
Tension output 4
GND Output 4
GND Output 3
GND Output 2
Analogues - GND
Analogues - GND
Analogues - GND
GND input 8
GND input 7
GND input 6
GND input 5
All pins are internal connected

continued
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ECS
Section 14.0
Page 17

14.3.2
Front Connector Arrangement, ANM-Module (Analogues Input)
Contd.:
PIN
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
PIN-NAME
A1G
4U+E4G
A2G
E3G
A3G
E2G
A4G
E1G
GND/ANA
E8
GND/ANA
E7
GND/ANA
E6
GND/ANA
E5
A1G
E4
E4
E3
E3
E2
E2
E1
E1
OPERAND
EW Z+1.4
EW Z +1.3
EW Z +1.3
EW Z +1.3
EW Z.4
EW Z.4
EW Z.3
EW Z.3
EW Z.2
EW Z.2
EW Z.1
EW Z.1
COMMENTARY
GND - Output 1
GND - Input 4
GND - Output 2
GND - Input 3
GND - Output 3
GND - Input 2
GND - Output 4
GND - Input 1
Analogues GND
Input (U/I) 8
Analogues GND
Input (U/I) 7
Analogues GND
Input (U/I) 6
Analogues GND
Input (U/I) 5
GND Output 1
Input (U/I) 4
Input (U/I) 4
Input (U/I) 3
Input (U/I) 3
Input (U/I) 2
Input (U/I) 2
Input (U/I) 1
Input (U/I) 1
All pins are internal connected
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ECS
Section 14.0
Page 18

14.3.3
Ground connection of the Control Unit

Attention: The complete shield of the analog cable must be connected to the ground
(GND) bolt of the PLC housing. This bolt must be connected to the X2
frame / machine ground by a cable (as short as possible) with 2,5 mm2
cross section.
When using plug connectors with metal boxes and connected shield the
additional complete shielding of the analog cable with the ground bolt is
not necessary. But attention must be played that the metal box is connected
by screws with the PLC housing.
The twisted signal lines are pair wise shielded and already via the 50-pol
female part of the connector connected to ground. The single shielding at
the free end of the cable must not be connected with earth.
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ECS
Section 14.0
Page 19

14.3.4
Interface-connection COM SK / SP
Legend for illustration Z 21425a (Exemplary picture about what possible)

(1)
Text display
(2)
PLC
(3)
Plug socket X27
(4)
Laptop computer
(5)
Memory card system
(6)
Portable printer
(7)
Field dispatch system
Cables:
VL3
VL4
VL5
VL6
VL7
VL8
X27 to Laptop
X27 to Memory Card System
24V Power supply to Memory Card System
X27 to Portable Printer
24V Power supply to Portable Printer
X27 to Field Computer System
Communication interface:
COM-SK => Programming interface (Baud rate 19200)
COM-SP => Communication with text display (Baud rate 9600)
Data cables and/or communication systems are optional equipment.

For more detailed information see OPERATION MANUAL of the
shovel
and the Software Program for the individual Communication System
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ECS
Section 14.0
Page 20
14.4 Power supply

14.4.1
Operation Voltages +24 V, Illust. Z 21426
Study together with the relevant circuit diagram
50-pin SUB Connector:
+ 24 V CPU-Supply:
GND:
+ 24 V I/O-Supply:
Pin 33 and 49
Pin 17 and 50
Pin 30 - 32, 46 48
This supply voltage is the operating voltage for the module outputs. It must
be strong enough to carry the load current of all outputs.
It is provided with a LOAD-DUMP protection to protect (for short times)
wrong polarity and over voltage peaks.
Wrong polarity causes destroying of the module!
External 24 V supply to the outputs causes destroying of the module!
See next page for more information
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ECS
Section 14.0
Page 21
14.4 Power supply

14.4.2
Safety Precautions for Faultfinding, Illust. Z21427
As already mentioned no external 24 V supply is allowed to the

outputs of the BIM modules of the PLC.
If it is necessary while tracing faults, the cable to the PLC must be
disconnected subsequent to a component check, thus as relays,
solenoids or others by the PLC controlled components.
Procedure: Study together with the relevant circuit diagram
1.
Find the terminal between the component and the PLC.
2.
Example terminal 8X2-280 for the solenoid valve 8Y6.1.
3.
Disconnect the wire on one side of the terminal.
4.
5.
Now supply 24 V to the solenoid and check function of it.

Finally re-connect the wire to the terminal
Binary Outputs A
2A-Short circuit proof
Each single Output of the Output group can withstand a load of 2A, but the
total load must not exceed 10 A. The Output group will be switched OFF if
one of the Output becomes overloaded (> 2 A), the short circuit marker will
be set and the MK- LED comes ON.
(A1 MK1, A3 MK3, A5 MK5)
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ECS
Section 14.0
Page 22
14.4 Power supply

14.4.3
CPU Voltage Range
Electrical requirements +24 supply volt
14 V up to 36 V without any restrictions regarding the max. current
consumption of 4 amps out of the +5 V logic voltage.
At voltage drops below 18 V the 2amps-outputs switched OFF due to
safety reasons. The short circuit markers initiated.
The +24 V CPU is monitored on the CPU plus
DB16.1
After the diagnostic bit Under-voltage UCPU DB16.1 has been set, all
access to the EEPROM memory of the CPU plus is blocked
A drop below 9V results in a reset.
During and after voltage drops according to DIN 40839 part 2 operates the
CPU plus normally.
14.4.4
Electric classification
The voltage supply meets the requirements according to:
ISO 7637-2 Automotive Technique 24V
DIN 0871-B
IEC 801-4 step 4, VDE 0843-4.
DIN/VDE 0470 part1 (old DIN 40050)
14.4.5
Fuse
TR5 / 2.5AT IEC 127-3 Manufacturer Wickmann,
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ECS
Section 14.0
Page 23
14.5 Function explanations with electrical diagram

14.5.1
General
Signal Status
Voltage level:
1 = 24 V* between E (Input) and GND
0 =
0 V** between E (Input) and GND
* 13 V up to actual supply voltage

** 0V up to 5 V
The left half of the picture shows so named PULL-DOWN resistors and the
right half PULL-UP resistors. The resistors are installed to get a low ohmical
input. A system with contacts only leads to a (high ohmical) input if dust or
moisture bridges the contacts.
PULL-DOWN resistors are installed with a normal NC contact (means with a
de-energized relay or normal closed switch contact) thus the ECS recognize a
fault after switching ON the system.
PULL-UP resistors are installed with a normal NO contact (means with a deenergized relay or normal open switch contact) thus the ECS recognize a fault
after switching ON the system.
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ECS
Section 14.0
Page 24

14.5.2
Pressure Measuring (Hydraulic System), Illustration Z 22805

(study with the respective circuit diagram)
(Program run see Flowchart)
Analog Inputs:
EW 14.1 for pressure sensor B87A (0 up to 500 bar)
Measuring channel: 0......10 V
Function:
- Voltage supply for the pressure sensor: 24 V
- Output voltages Ua (OUT+, pin 2) of the pressure sensors:
Sensor 0 0,4 bar
K= 25 V / bar
Sensor 0 60 bar
K= 0,1667 V / bar
Sensor 0 500 bar
K= 0,02 V / bar
(Pressure sensors with +1 V Offset)
Possible voltage checks:
24 V Supply between supply line 15 (start at circuit breaker) and GND.
Output voltage OUT (pin 2) of the sensor
between GND. Use respective circuit diagram for terminal numbers.
* How to calculate the Output voltage Ua:
Ua = output voltage proportional to the pressure input.
P = input pressure
K = calculation factor for the respective pressure sensor.
Ua = (P x K) + 1 V
Example for 200 bar and a 0 500 bar sensor:
Ua = (200 x 0,02) + 1 V = 5 V
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ECS
Section 14.0
Page 25
14.5.3 Temperature Measuring and trouble shooting Illustration Z22803a

General:
(study with the respective circuit diagram)
The signal of the PT100 temperature probe cant connect direct to the ANM
Module (Analog input of the PLC). A temperature transducer module change
the PT100 signal (Ohm) into a suitable current (mA) signal for the ANM
Module. The temperature probe is connected with a four wire technique to
compensate the line resistance of the long wire between the X2 switch board
and the temperature probe.
Analog Inputs (eg.: Hydraulic oil temperature sensor B15)
The temperature probe B15 is with 4-wire technology (distorting compensation)
connected to the transducer U15 terminal 1, 4, 2, and 3 (measuring range: -50
C......+150 C). The output terminal 5 and 6 of the transducer is connected to the
ECS analog input EW 2.1 (input range 4 20 mA). The transducer need 24 V
power supply via terminal 7 and 8 (+24V, ground).
Function:
The temperature transducer convert the
measured values from the PT100 temperature
probe into electrically standardized analog
signals. With the four wire technique the length
and the cross section of the wires are not
important; because the electrical resistance of the
two current lines gets compensated. The sensor
is supplied with a low electrical current from the
temperature transducer (I+ and I-). Additional to
the temperature probe (PT100) resistance the
line resistance influence the current flow what
falsified the PT100 measurement. To
compensate the line resistance there are two
additional lines (U+ and U-) close to the PT100
connected. Via this lines the transducer measure
exact a tension drop between in- and output of
the PT100 probe witch is only created by the
PT100 resistance. Because there is no current flow through this lines which
are influenced by the line resistance (compared to hydraulic system- its like
a test hose with a pressure gauge). The module convert this tension drop into
a current signal (4-20mA) which is proportional to the temperature.
In the interest of proper function must the line resistance not exceed 50 .
Additional the lines must be shielded according to the standards. The picture
shows the wiring of a PT100 probe to a temperature transducer in four wire
technique.
continued
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26
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ECS
14.5.3
Section 14.0
Page 26
Temperature Measuring and trouble shooting, illustration Z22803a

Contd.:
Possible measurements PT100:
Disconnect the wires at the resistor and measure the resistance across the
resistor.
Compare the measured resistance with the values given in the table on next
page.
If the value correspond to the temperature measured with an other temperature
gauge the PT100 resistor is OK.; otherwise replace resistor.
Wiring:
Disconnect the wires at the resistor and inside X2-box at the temperature
transducer terminal 1, 2, 3, and 4.
Measure the line resistance to the ground.
All single wire resistance must be the same.
Transducer:
Connect a Ampere-meter in line between terminal 5 of the transducer and the
disconnected wire to the ECS. Select mA range and check the current. The value
must compare to the PT100 resistance with the following calculation:
I = [( 50 + t ) x 0,08 ] + 4
t = temperature [C]
(Check temperature via PT100 resistance and temperature chart next page)
I = current [mA] to the ECS
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30.11.05
Section 14.0
Page 27

ECS
14.5.4
Temperature Resistance Chart PT100

Basic Values in Ohm according to DIN 43 76
For Measuring Resistor PT100
-0
-1
-2
-3
-4
-5
-6
-7
-8
-9
-50
80,31
79,91
79,51
79,11
78,72
78,32
77,92
77,52
77,13
76,73
-40
84,27
83,88
83,48
83,08
82,69
82,29
81,89
81,50
81,10
80,70
-30
88,22
87,83
87,43
87,04
86,64
86,25
85,85
85,46
85,06
84,67
-20
92,16
91,77
91,37
90,98
90,59
90,19
89,80
89,40
89,01
88,62
-10
96,09
95,69
95,30
94,91
94,52
94,12
93,73
93,34
92,95
92,55
100,00
99,61
99,22
98,83
98,44
98,04
97,65
97,26
96,87
96,48
100,00
100,39
100,78
101,17
101,56
101,95
102,34
102,73
103,12
103,51
10
103,90
104,29
104,68
105,07
105,46
105,85
106,24
106,63
107,02
107,40
20
107,79
108,18
108,57
108,96
109,35
109,73
110,12
110,51
110,90
111,28
30
111,67
112,06
112,45
112,83
113,22
113,61
113,99
114,38
114,77
115,15
40
115,54
115,93
116,31
116,70
117,08
117,47
117,85
118,24
118,62
119,01
50
119,40
119,78
120,16
120,55
120,93
121,32
121,70
122,09
122,47
122,86
60
123,24
123,62 124,01, 124,39
124,77
125,16
125,54
125,92
126,31
126,69
70
127,07
127,45
127,84
128,22
128,60
128,98
129,37
129,75
130,13
130,51
80
130,89
131,27
131,66
132,04
132,42
132,80
133,18
133,56
133,94
134,32
90
134,70
135,08
135,46
135,84
136,22
136,60
136,98
137,36
137,47
138,12
100
138,50
138,88
139,26
139,64
140,02
140,39
140,77
141,15
141,53
141,91
110
142,29
142,66
143,04
143,42
143,80
144,17
144,55
144,93
145,31
145,68
120
146,06
146,44
146,81
147,19
147,57
147,94
148,32
148,70
149,07
149,45
130
149,82
150,20
150,57
150,95
151,33
151,70
152,08
152,45
152,83
153,20
140
153,58
153,95
154,32
154,70
155,07
155,45
155,82
156,19
156,57
156,94
150
157,31
157,69
158,06
158,43
158,81
159,18
159,55
159,93
160,30
16067
Example:
84 C
80 + 4 = 132,42
124,4
124,4 124,39 = 60 + 3 = 63 C
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ECS
Section 14.0
Page 28
14.6 Hints for reading the functional flow charts

14.6.1
General
Probably the best aid for trouble shooting is the confidence of knowing
the system and how to use the ECS. Every component has a purpose in
the system. The construction and operating characteristics of each one
should be understood.
Use always the electric/hydraulic circuit diagram the flowchart and
the operation manual for the specific machine.
1. Select on page 1 of the flow chart, (which contains the table of contents
and the main program) the respective subprogram, for example the
Power-Master lube system.
2. Components in the flow chart, have the same identification code as in the
electric/hydraulic circuit diagram, as shown in cross reference list (page 2-4).
For example: Relay K50 = ?
On page 2 (cross reference list) you find out that relay K50 is shown on
page 43 of the flowchart.
3. On each page of the respective subprogram you will find the functional
description in plain text.
In case of problems concerning reading the program loops, you may find
answers in the frequently asked questions list on page 6 and 7 of the flow
chart.
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29
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ECS
Section 14.0
Page 29
14.6 Hints for reading the functional flow charts

14.6.2
Example: Monitoring the X1-pressure for pump control,

illustration Z25072
Grey shaded fields in the table below shows the normal way , used from the program,
if the excavator is in standard condition.
Item
1)
query
Sensor or cable
defect?
Yes
No
B85-X : 5 sec. < --6bar
B85-X : 5 sec. : Voltage
i.e. <1V at EW13.3
between 1V and 11V at
or
EW13.3
B85-X : 5 sec. > +55,3bar
i.e. > 11V at EW13.3
2)
3)
_running_motor-x
> 15 sec ?
X1-pressure to
high?
Fault message No 1190

Motor X is running for
more than 15 seconds
B85-X : 2 sec. > 40bar
i.e. > 6,5V at EW13.3
Motor X is not running

B85-X : 5 sec. : Voltage
below 6,5V at EW13.3
Fault message No 962
PC8000-6-E_Sec_14-0_#12048_rev0.doc
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30.11.05
Section 15.0
Page 1
Lubrication System
Table of contents
Page
General Function
Oscillation Cylinder and Control Block
Adjustments
One line system
Electrical function
Capacitive analog sensor for lubricant level monitoring
Adjustments
End Line pressure switch
Injectors
3
9
11
13
17
21
Function Pinion type (dummy wheel) system

Electrical Function (dummy wheel) system
Capacitive analog sensor for lubricant level monitoring
Adjustments
End-Of-Line Switch setting
Injectors
Components
Hydraulically driven lube pump
Injectors
End-Line Switch
In line Filter
Vent valve (Solenoid valve)
27
31
35
29.12.05 rev.5
23
25
37
39
41
45
51
53
55
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15.0
2
Lubrication System
Section 15.0
Page 3
Lubrication System
General Function
Legend: illustration Z 24042a

(1)
Lubricant pump drive (Hydraulic cylinder)
(2)
Solenoid valve (Oil pressure supply)
(3)
Flow control valve
(4)
Pressure reducing valve
(5)
Hydraulic oil supply line (Pilot pressure)
(6)
Hydraulic oil return line
(7)
Vent valve (Solenoid valve, de-energized open to barrel)
(8)
Grease supply line to injectors
(9)
Lubricant level indication (capacitively analog sensor)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Lubricant barrel
Pump mechanism
Lubricant filter
Hydraulic pressure test plug (Operating pressure)
Lubricant pressure gauge (Operating pressure)
Vent line to barrel
Breather
Electrical terminal box
Cylinder pressure must not exceed 650 psi (45 bar)
continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
4
Lubrication System
Cont'd.
X-axis
Y-axis
Time
Lubricant supply line pressure
PI
S+
PH
SPR
PT
Pressure Increasing
Switch point ON of the end of line pressure switch
Pressure Holding
Switch point OFF of the end of line pressure switch
Pressure Relieve
Pause Time
Section 15.0
Page 5
Lubrication System
Function of a lubrication cycle
illustration Z24042c and Z22023a
PT-phase
With the pump and controller system in a rest state a pre-set pause time interval
occurs as determined by the PLC.
Diagram position (a):
A 24 VDC signal from the PLC activate solenoid valve (2) that opens and activate
the lubrication pump. (*). As solenoid valve (2) opens hydraulic oil flows through
the pressure reducing valve (4), it lowers the hydraulically pilot oil pressure to the
operating range of the hydraulic driven lube pump. The reduced pilot oil pressure
operates now the grease pump. The oil cylinder shuttles the grease cylinder at 18
20 double strokes per minute and delivering 612 680 cm (37.3 41.5 in) of
lubricant per minute (approx. 550 612 g / 19.64 21.45 oz.)
At the same time a 24 V signal energize release valve (7), it close now the release
line to the lubrication container.
PI-phase
With energized release valve (7) (*) and solenoid valve (2) the pump continues to
cycle until maximum pressure is achieved and the injectors have metered
lubricant to the bearings.
S+ point, diagram position (b)
When the maximum system pressure is reached the end-of-line switch (*) open its
contact. In the normal application is the end-of-line switch adjusted to 185 bar
(2630 psi. ).The pressure increasing phase is now finished.
The open pressure switch (*) signals the controller to stop the pumping cycle and
the controller terminates the signal to the solenoid valves (2) The pilot oil flow to
the pump stops.
Solenoid valve 2
Y7, CLS
Vent valve 7
Y7a, CLS (1)
end-of-line switch
B43, CLS
Y8a, CLS (2)

Y9, SLS
Y9a, SLS
B46, SLS
SLS = Slew Ring Teeth Lubrication System

CLS = Central Lubrication System
(*) check respective circuit diagram
continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
6
Lubrication System
Cont'd.
X-axis
Y-axis
Time
Lubricant supply line pressure
PI
S+
PH
SPR
PT
Pressure Increasing
Switch point ON of the end of line pressure switch
Pressure Holding
Switch point OFF of the end of line pressure switch
Pressure Relieve
Pause Time
Lubrication System
Section 15.0
Page 7
Cont'd.
PH-phase
Release valve (7) is still energized to keep the pressure in the lubricant line for a
fix adjusted time (pressure holding time normally 5 min).
Diagram position (c):
With expired pressure holding time vent valve (7) de-energize. It opens the
release line to the lubricant container. The lubricant line pressure drop to zero so
the injectors can recharge for the next lubricant injection. (PR-phase).
PR-phase
In the pressure relieve phase the end of line switch (*) move back to neutral
contact position it signals the PLC that the lube pressure relieve phase is now
active.
PT-phase
The system is now at rest (pause time), ready for another lube cycle and the
sequence repeats itself.
29.12.05 rev.5
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15.0
8
Lubrication System
Section 15.0
Page 9
Lubrication System
Oscillation Cylinder and Control Block, illustration Z 21174
Description:
Oscillation cylinder (6) is auto directional controlled, non pressure related. This
differential cylinder is connected to the pilot pressure suppliy line (P) and a tank
line (T). The speed is contolled by a flow contol valve (3) and the maximum
working pressure is controlled by a pressure reducing valve (2).
Function:
The Oscillatin cylinder (6) starts as soon pilot pressure is send via the connection
(P) to the control block (1). Design related the cylinder (6) retract always first
after start or from any position the piston has stopped before. When the cylinder
reaches the fully retracted position the flow will be redirected automatically and
the cylinders moves in the extending position. If the cylinder comes to an stop in
between the end positions weather the oil supply get stopped or the cylinder is
hold back by a higher work resistance than the supply pressure, the cylinder
changes direction and retracts.
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
10
Lubrication System
Lubrication System
Adjustments
Section 15.0
Page 11
(illustration Z21175b):
Stroke speed
For a sufficient lube pump operation 18 20 double strokes / min for the pump
drive cylinder are required. Therefore the flow reducing valve (3) has to be
adjusted accordingly.
Procedure:
1. Remove electrical plug connection form the discharge valve (7), so no
pressure built up will take place during the following test.
2. Start motor.
3. Switch ON the lube system annually and count strokes per minute, visible
on the moving up and down of pipe (1).
a. Loosen lock nut (3.1)
b. Turn adjustment (3) until the right number of strokes is achieved.
turn set screw ccw for more speed and cw to reduce the speed
c. Tighten lock nut (3.1).
Working pressure
The pressure reducing valve (2) mounted in the oscillation control block reduce
the supply pressure internally to maximal allowed 45 bar.
The pressure ration is 6,55 to 1, that means 45 bar supply pressure result in 295 bar
maximum lubricant pressure.
At the end of line pressure switch the pressure should be 180 0,5 bar. With the
lubricant line resistance and different lubricant viscosity the pressure at the
lubricant pump output must be higher as 180 bar. For standard condition adjust the
maximum pump pressure to 220 bar 250 bar, depend on lubricant line resistance
and different lubricant viscosity.
Procedure:
1. Disconnect quick coupling (8), so the pump will be blocked when started.
2. Start motor.
3. Switch ON the lube system manually, the gauge should show 220-250 bar.
a. Loosen lock nut (2.1)
d. Turn adjustment (2) until the right pressure is shown at the gauge.
turn set screw ccw for lower pressure and cw to increase the pressure
b. Tighten lock nut (2.1).
c. Reconnect quick coupling (8).
)
29.12.05 rev.5
If the required pressure cant be adjusted, check adjustment of the 60

bar pilot pressure valve (X-4 pressure) at the filter and control panel in
the machinery house.
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15.0
12
Lubrication System
Section 15.0
Page 13
Lubrication System
One line system

Legend: illustr. Z 21176
(1)
(2)
Solenoid valve (Oil pressure supply)
(3)
Flow control valve
(4)
(5)
(6)
(7)
Vent valve (Solenoid valve, de-energized open to barrel)
(8)
(9)
Lubricant level indication (capacitively analog sensor)
(10)
Lubricant barrel
(11)
Pump mechanism
(12)
Lubricant filter
(13)
(14)
(15)
Vent line to barrel
(16)
End-of-line switch
(17)
(Pressure check point)
(18)
Injector block
(19)
Lubricant feed line to bearing
Function:
As soon as the adj. "Pause-Time" is finished the solenoid valves
(2) and (7) are energized. The lubricant pump (1) start to pump lubricant in
the lubricant supply line.
By the function of the solenoid valve (7) the port to the vent line (15) (return
line to the lubricant container) is closed, thus a pressure built up is possible.
The high-pressure barrel pump (1) supplies lubricant into the supply line (8). It
continuos through the lubricant filter (12) to the injectors (metering valves) (18).
The picture shows an example only. The hole system includes much
more injectors which are connected via pipes or hoses to the supply
line (8).
In the Injectors the lubricant forced with full pump pressure via the feed lines
(19) to the lube points.
The actual operating pressure can be monitored at the pressure gauge (14)
and checked at the pressure check point (17).
continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
14
Lubrication System
Lubrication System
Section 15.0
Page 15
Cont'd.
Illustr. Z 21176
When all injectors pistons have reached there final position no more lubricant
is accepted from the supply line which causes a pressure increase in the
supply line (8).
As soon as the pressure reaches the adjusted value of the end-of-line switch
(16) the solenoid valves (2) de-energized and the lubricant pump switched
Off. Depend on different factory settings vent valve (7) de energize together
with solenoid valve (2) or after a fix adjusted time of max. 5 minutes.
With de-energized solenoid valve (7) the port to vent line (15) ( return line to
the lubricant container ) opened and release the lubricant and lubricant
pressure in to the container.
With the diminishing pressure in the main line the pistons of the injector (18)
are forced by spring force in their initial position and the discharge chambers
are filled with grease for the following lubrication cycle.
The system is now prepared for a new lubrication cycle. The operation is reinitiated after the next "Pause Time" is elapsed.
The proper build-up of the pressure in the supply line (8) is monitored by the
end-of-line switch (16).
If the pressure adjusted at the end-of-line switch will not reached within the
adjusted "Monitoring Time" the fault message Central lubrication system
fault comes up on the text display and the system switch off
Grease qualities to be used:

According to NLGI classes 000, 00, 0 and 1 according to the lowest
ambient temperature in the operation area
1. The content of molybdenum must not exceed 5 %.

2. Only synthetic graphite allowed in graphite contained lubricants
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
16
Lubrication System
Lubrication System
Section 15.0
Page 17
Electrical function. illustr. Z 21177a
It follows an exemplary explanation for a central lubrication system

for machines equipped with PLC System. For details see the circuit
diagram of the respective machine. The Lubrication Systems are
PLC controlled. No relay adjustment necessary.
Central lubrication system controlling :
The PLC from the ECS System controls the whole lubrication systems.
The solenoid valves (Y7, Y7A or Y9, Y9A) on top of the lubrication stations are
direct connected to digital output ports of the PLC.
On a few machines there are additional relays between PLC outputs and the
solenoid valves.
Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a
PLC internal time counter the grease system start a lubrication cycle.
The lubrication cycle starts.
If the pause time elapsed the PLC energize both solenoid valves (Y7, Y7A or
Y9, Y9A) of the respective lubrication system. The motor must run. The pilot
pump pressure activate now the lubrication pump and the lubrication pressure to
the injectors increase.
If the lubricant pressure reach the adjusted pressure of the end-of-line pressure
switch (B43 or B46) its contact change and the PLC input signal change.
The PLC de energize the respective lubrication pump supply valve (Y7 or Y9) to
stop the pump. For the next 5 min the respective pressure releasing valve (Y7A
or Y9A) are continued energized to keep the lubricant pressure still on a high
level to be able all injectors inject the hole adjusted amount of lubricant.
After the 5 min. pressure holding time the PLC de energize the respective
pressure releasing valve (Y7A or5 Y9A) The lubricant pressure drops and the
injectors move by spring load back in its initial position. A PLC internal counter
is still counting a additional decreasing time to monitor the end-of-line pressure
switch (B43 or B46) position. The PLC internal time counter is still counting up
to the next lubrication cycle.
The lubrication cycle is finished.
continued
29.12.05 rev.5
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15.0
18
Lubrication System
Lubrication System
Section 15.0
Page 19
Cont'd:
Illustr. Z 21177a
The next lubrication cycle starts after the decreasing time and pause time has
expired.
With the switch S24 an additional lubrication can be carried out any time provided
the end of line pressure switch (B43) contact is closed.
Monitoring:
The orderly built-up of the pressure in the lubricant supply line is monitored by
the end-of-line switch (B43 or B46).
If the pressure adjusted at the end-of-line switch is not reached within the adjusted
maximal increasing time the PLC switch off both solenoid (Y7 and Y7A or Y9
and Y9A) valves and send the fault message Central lubrication system fault or
Swing ring lubrication system fault to the text display at the dash board.
If the excavator is still working additional four hours with faulty lubrication
system the PLC stop the bucket function. This function is to prevent trouble
depend on a lack of lubricant.
Continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
20
Lubrication System
Section 15.0
Page 21
Lubrication System
Capacitive analog sensor for lubricant level monitoring,

Illustration Z 21179f
Task:
A lubricant (L) maximum filling level monitoring is necessary to prevent an
overfilling of the grease barrel (C) via the refilling system (only systems with
refilling arm). The PLC use the analog level signal from the sensor to activate a
lamp at the refilling arm just in the moment when the lubricant container is full.
The sensor (S) is mounted on top of the lubricant container and reaches into the
lubricant.
The refilling level activate only a message at the text display to inform that the
lubricant level must be filled up. The message comes up if the lubricant level
reach 5% (910 mm from the cover plate).
The minimum level stop the respective lubrication pump and release the
lubricant pressure until the lubricant level reach the 0% mark (950 mm from the
cover plate). It is necessary to stop the lubrication system with empty lubricant
container to prevent the lubrication pump from running dry. With empty
lubricant container the bucket motion will be switched off after four hours.
Function:
The capacitively level sensor (S) check continuous the lubricant level (L) and
convert the capacitive signal into a current signal between 4 and 20mA. The
current signal increase with increasing lubricant level.
Use the specific electric circuit diagram and program flow charts.
29.12.05 rev.5
The capacitively proximity switch used in our machines are

programmed by the supplier and therefor no adjustment or settings
required.
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
22
Lubrication System
Lubrication System
Section 15.0
Page 23
Adjustments
End line switch setting. Illustration Z 21180
1.
Connect pressure gauge to check point.
Use an other gauge as for checking hydraulic pressures because the

gauge remains filled with grease after the test
2.
3.
4.
Start motor.
Start a lube cycle with the dashboard switch S24.
+
Watch pressure gauge. At a pressure of 180 10 bar the end-line switch
must react and the lubricants pump must stop.*
If at the same time the pressure shown at the built-in gauge is noted
down, this pressure can be taken for later on checks as a reference
pressure.
180 bar is the normal setting.
Under particular circumstances it may be necessary to increase the
pressure slightly
If re-setting is required:
5.
Screw out screw 1 and take off cover 2.
6.
Alter the spring tension with adjustment screw 3 that the switch
operates at 180 bar.
7.
Install cover 2 and screw 1.
continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
24
Lubrication System
Section 15.0
Page 25
Lubrication System
Cont'd:
Injectors, illustr. 21181:
Series SL-1 injector:
Lubricant output adjustable from 0.13 up to 1.3 cm per cycle. Hydraulic type
fitting with screw type cover cap is provided for initial filling of feeder line, and
may also be used for visual check of injector operation.
Series SL-1 injectors incorporate a stainless steel visual indicator.
Lubricant output adjustable from 0.82 up to 8.2 cm per cycle.
Designed for systems where a high amount of lubricant is required.
Principle of operation similar to series SL-1.
Adjusting the lubricant output:
1.
Loosen lock nut (C).
2.
Turn adjusting screw (A) counterclockwise (OUT) for more lubricant
output or clockwise (IN) for less lubricant output.
3.
Tighten lock nut (C).
29.12.05 rev.5
The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
26
Lubrication System
Section 15.0
Page 27
Lubrication System
Function Pinion type (dummy wheel) system.

Legend:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Z 21183a
Solenoid valve Y9 (Oil pressure supply)
Flow control valve
Vent valve Y9A (Solenoid valve, de-energized open)
Lubricant level indication
Lubricant barrel
Pump mechanism
Lubricant filter
Vent line to barrel
Breather
Electrical terminal box
Principle of operation:
By the lubricant pump, the lubricant is supplied to the centered bore hole (B) of the
lubrication type pinion (R). Bore hole (B) must be perfectly aligned to the center of
the lubrication type pinion (A) to be greased, so that lubricant leaves the tooth flank
always when the gear tooth is in contact. The grease outlet (D) of the lubricating type
pinion is arranged at a different angle for each tooth, so that the lubricant is distributed
in a uniform and perfect manners on the tooth flank of the drive pinion to be
lubricated.
Function:
As soon as the adjusted "Pause-Time" elapse the solenoid valves (2 + 7). energized
and the lubricant pump (1) start to pump lubricant.
By the function of the solenoid valve (8) the port to the vent line (15) (return line to
the lubricant container) closed, thus a pressure built up is possible.
The high-pressure lubricant pump (1) supplies lubricant into the supply line (8). It
continuos through the lubricant filter (12) to the injectors (metering valves) (18).
The picture shows an example with one pinion only. There are also
machines which have more lubrication type pinion (dummy wheel).
By the injectors the lubricant is forced with full pump pressure via the feed line
(19) to the centered bore hole (B) of the lubricating type pinion (R).
continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
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28
Lubrication System
Lubrication System
Section 15.0
Page 29
Cont'd.
Illustr. Z 21183a
The actual operating pressure can be monitored at the pressure gauge (14)
and checked at the pressure check point (17). When all injector pistons have
reached there final position no more lubricant will accepted from the supply
line (8) which causes a pressure increase in the supply line.
Depend on different factory settings vent valve (7) de energize together with
solenoid valve (2) or after a fix adjusted time of max. 5 minutes.
With de-energized solenoid valve (7) the port to vent line (15) ( return line to
the lubricant container ) opened and release the lubricant and lubricant
pressure in to the container.
With the diminishing pressure in the main line the pistons of the injector (18)
are forced by spring force in their initial position and the discharge chambers
fill up with grease for the following lubrication cycle.
The system is prepared for the next lubrication cycle. The operation is
reinitiated after the next "Pause Time".
The proper build-up of the pressure in the supply line (8) is monitored by the
end-of-line switch (16).
If the pressure adjusted at the end-of-line switch is not reached within the
adjusted "Monitoring Time" the fault message Slew ring gear lubrication
system fault is shown on the text display and the pump switch off.
Grease qualities to be used:

According to NLGI classes 000, 00, 0 and 1 according to the lowest
ambient temperature in the operation area
29.12.05 rev.5
1. The content of molybdenum must not exceed 5 %.

2. Only synthetic graphite must be contained in graphic lubricants
PC8000-6-E_Sec_15-0_#12048_rev0.doc
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30
Lubrication System
Lubrication System
Electrical function.
Section 15.0
Page 31
Illustration Z 21177b
It follows an exemplary explanation for a Slew Ring Lubrication

System for machines equipped with ECS System. For details see the
circuit diagram of the respective machine. The Lubrication Systems
are controlled through the ECS. No relay adjustment required.
Slew Ring Gear Lubrication (Teeth lubrication) controlling :
The PLC from the ECS System control the whole lubrication systems.
Solenoid valves (Y9, Y9A) on top of the lubrication container are direct
connected to digital output ports of the PLC.
On few machines there are additional relays between PLC and the solenoid
valves.
Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a
PLC internal time counter the grease system start a lubrication cycle.
The lubrication cycle starts.
If the pause time elapsed and the swing function was activated for a short time
the PLC energize both solenoid valves ( Y9 , Y9A ). To start one swing ring
gear lubrication cycle the swing function must be activated one time.
If the lubricant pressure reach the adjusted pressure of the end of line pressure
switch its contact change the position now the input port of the PLC change.
The PLC de energize the respective lubrication pump supply valve (Y9) to stop
the pump. For the next 5 min the respective pressure releasing valve (Y9A) are
continued energized to keep the lubricant pressure still on a high level to be able
all injectors inject the hole amount of lubricant.
After 5 min. pressure holding time the PLC de energize the respective pressure
releasing valve (Y9A) The lubricant pressure drops and the injectors move by
spring load back in its initial position. A internal counter is still counting a
additional decreasing time to prevent a to early new lubrication cycle with the
risk of not complete reset injectors.
The lubrication cycle is finished.
continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
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32
Lubrication System
Lubrication System
Section 15.0
Page 33
Cont'd:
Illustr. Z 21177b
The next lubrication cycle starts after the decreasing time and pause time has
expired.
With the switch S26 an additional lubrication can be carried out any time provided
the end of line pressure switch (B46) contact is closed.
Monitoring:
The orderly built-up of the pressure in the lubricant supply line is monitored by
the end-of-line switch (B46).
If the pressure adjusted at the end-of-line switch is not reached within the adjusted
maximal increasing time the PLC switch off both solenoid valves (Y9 and Y9A)
and send the fault message Central lubrication system fault to the text display at
the dash board.
If the excavator was working additional four hours with faulty lubrication system
the PLC stop the bucket function. This function is to prevent trouble depend on a
lack of lubricant.
Continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
34
Lubrication System
Section 15.0
Page 35
Lubrication System
Capacitive analog sensor for lubricant level monitoring,

Illustration Z 21179f
Task:
A lubricant (L) maximum filling level monitoring is necessary to prevent an
overfilling of the grease barrel (C) via the refilling system (only systems with
refilling arm). The PLC use the analog level signal from the sensor to activate a
lamp at the refilling arm just in the moment when the lubricant container is full.
The sensor (S) is mounted on top of the lubricant container and reaches into the
lubricant.
The refilling level activate only a message at the text display to inform that the
lubricant level must be filled up. The message comes up if the lubricant level
reach 5% (910 mm from the cover plate).
The minimum level stop the respective lubrication pump and release the
lubricant pressure until the lubricant level reach the 0% mark (950 mm from the
cover plate). It is necessary to stop the lubrication system with empty lubricant
container to prevent the lubrication pump from running dry. With empty
lubricant container the bucket motion will be switched off after four hours.
Function:
The capacitively level sensor (S) check continuous the lubricant level (L) and
convert the capacitive signal into a current signal between 4 and 20mA. The
current signal increase with increasing lubricant level.
Use the specific electric circuit diagram and program flow charts.
29.12.05 rev.5
The capacitively proximity switch used in our machines are

programmed by the supplier and therefor no adjustment or settings
required.
PC8000-6-E_Sec_15-0_#12048_rev0.doc
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36
Lubrication System
Lubrication System
Section 15.0
Page 37
Adjustments
End of line switch setting, illustration Z 21185
1.
Use an other gauge as for checking hydraulic pressures because the

gauge remains filled with grease after the test
2.
3.
4.
5.
Connect pressure gauge to check point close to the end of line pressure
switch.
Block the swing function with the swing ring parking, use the switch at
the dash board.
Start motor.
Start a lube cycle with the dashboard switch S26 and activate for a short
time the swing function to the left or right.
+
Watch pressure gauge. At a pressure of 180 10 bar the end of line
switch must react and the lubricants pump must be stopped.*
If at the same time the pressure shown at the built-in gauge is noted
down, this pressure can be taken for later on checks as a reference
pressure.
But be careful this pressure is higher than the pressure shown at the test
gauge because of the long distance between pump and end of the
supply line.
180 bar is the normal setting.

Under particular circumstances it may be necessary to increase the
pressure slightly
If re-setting is required:
6.
7.
8.
Screw out screw (1) and take off cover (2).

Alter the spring tension with adjustment screw (3) that the switch
operates at 180 bar.
Install cover (2) and screw (1).
continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
38
Lubrication System
Section 15.0
Page 39
Lubrication System
Cont'd:
Injectors, illustr. 21181:
Lubricant output adjustable from 0.13 up to 1.3 cm per cycle. Hydraulic type
fitting with screw type cover cap is provided for initial filling of feeder line, and
may also be used for visual check of injector operation.
Series SL-1 injectors incorporate a stainless steel visual indicator.
Lubricant output adjustable from 0.82 up to 8.2 cm per cycle.
Designed for systems where a high amount of lubricant is required.
Principle of operation similar to series SL-1.
Adjusting the lubricant output:
1.
Loosen lock nut (C).
2.
Turn adjusting screw (A) counterclockwise (OUT) for more lubricant
output or clockwise (IN) for less lubricant output.
3.
Tighten lock nut (C).
29.12.05 rev.5
The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
40
Lubrication System
Section 15.0
Page 41
Lubrication System
Hydraulically driven Power Master III lube pump, illustr. Z 21186

Legend: (more detailed see parts list 90-0781) Fig.: 12
(P)
Hydraulic oil supply
(T)
Hydraulic oil return
(Pr)
(Q)
Flow regulator valve
(1)
Hydr. actuator piston
(2)
Oscillator control block
(3)
Pump tube
(4)
Breather port
(5)
Grease outlet port
(6)
Piston rod
(7)
Breather plug
(8)
Ball, outlet check valve
(9)
Ball and seat, check valve
(10)
Main piston and plunger
(11)
Piston rod set
(12)
Inlet valve
(13)
Scoop piston
(14)
Grease inlet
HINT:
Loss of pressure or to short pump strokes indicates:
A
Foreign material lodged under Piston Ball Checks or between Upper

and Lower Inlet Checks (8 + 9).
To correct this problem the upper lower inlet checks (8 + 9) and inlet
valve (13) should be removed and cleaned thoroughly.
If sealing surfaces between upper and lower inlet checks (8 + 9) are
rough or pitted, replace or resurface if damages are slight.
Shovel rod packing worn or damaged. Before installing new packing,

inspect surface of shovel rod and replace if rough or pitted.
Do not grip shovel rod when disassembling lower pump tube assembly.
continued
29.12.05 rev.5
PC8000-6-E_Sec_15-0_#12048_rev0.doc
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42
Lubrication System
Lubrication System
Section 15.0
Page 43
Trouble shooting, illustr. Z 21186

If the following procedures do not correct the problem, contact a factory
authorized service center.
PROBLEMS:
CYLINDER PRESSURE GAUGE DOES NOT REGISTER PRESSURE.
A.
Check system pressure to pump.
B.
Check for 24 VDC signal at solenoids.
C.
Pressure reducing valve set too low. Check pressure.
PUMP PRESSURE BUILT UP VERY SLOWLY OR NOT AT ALL.
A.
B.
C.
D.
E.
F.
G.
H.
29.12.05 rev.5
No oscillation of pump, check oscillation control block (2).

Pressure reducing valve (Pr) may be setting too low.
Grease viscosity may be too high for the actual ambient temperature.
If pressure is not building up at all, solenoid valve (pilot pressure
supply solenoid) may be inoperative.
Pump piston (11) and inlet checks may have foreign matter trapped
causing leakage. Remove, inspect and clean if necessary.
Inspect sealing surface on upper and lower checks (8 + 9). Replace if
rough or pitted.
Replace scoop piston if rough or pitted. Replace rod packing (15) if
it is leaking.
Inspect lubricant supply line for leaks or breaks.
PC8000-6-E_Sec_15-0_#12048_rev0.doc
15.0
44
Lubrication System
TS 12037-upE-GB-0
HYDRAULIC MINING EXCAVATOR

PC8000E-6
Machine model
Serial numbers
12037 and up
PC8000E-6
40 Troubleshooting
Troubleshooting procedures
Copyright 2010 KOMATSU MINING GERMANY GmbH
PC8000E-6 S/N 12037 and up
SHOP MANUAL
SHOP 12037-xE-GB-0
HYDRAULIC EXCAVATOR
PC8000E-6
Machine model
Serial number
PC8000-6
12037 and up
50 Assembly and disassembly
PC8000E-6
Overview
Overview
1 INTRODUCTION
2 SAFETY
3 SUPERSTRUCTURE
4 UNDERCARRIAGE
5 ATTACHMENT
6 SERVICE INFORMATION
7 TOOLS CATALOGUE
8 PARTS & SERVICE NEWS
9 SUPPLIERS DOCUMENTATION
Version 2010/1
PC8000-6E
Overview - 1
Overview
Overview - 2
PC8000-6E
Version 2010/1
Table of contents
1 INTRODUCTION........................................................................................ 1-1
1.1
CONTENTS OF THE BINDER ........................................................................................................... 1-2
1.2
FOREWORD ...................................................................................................................................... 1-3

1.2.1 SERVICE ............................................................................................................................... 1-4
2 SAFETY ..................................................................................................... 2-1

2.1
GENERAL INFORMATION ................................................................................................................ 2-2

2.1.1 METHOD OF USING THIS MANUAL .................................................................................... 2-2
2.2
SAFETY INSTRUCTIONS.................................................................................................................. 2-4

2.2.1 GENERAL PRECAUTIONS ................................................................................................... 2-4
2.2.2 PREPARATIONS BEFORE WORK ....................................................................................... 2-6
2.2.3 PRECAUTIONS DURING WORK.......................................................................................... 2-7
2.2.3.1 PRECAUTIONS WITH HIGH PRESSURE OIL ..................................................... 2-9
2.2.4 WARNING OF SPECIAL DANGERS................................................................................... 2-10
2.2.4.1 ELECTRICAL ENERGY ....................................................................................... 2-10
2.2.4.2 GAS, DUST, STEAM AND SMOKE..................................................................... 2-11
2.2.4.3 NOISE .................................................................................................................. 2-11
2.2.4.4 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES ................................... 2-11
2.2.4.5 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT................ 2-12
2.2.4.6 HEAT.................................................................................................................... 2-12
2.2.4.7 HEIGHT................................................................................................................ 2-12
2.2.5 SPECIAL SAFETY EQUIPMENT ........................................................................................ 2-15
2.2.5.1 SAFETY HARNESS IN CONFORMITY WITH
EN 361 (EUROPEAN STANDARD) ..................................................................... 2-15
2.2.5.2 INSTRUCTIONS FOR USE ................................................................................. 2-17
2.2.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS........................................... 2-19
2.2.5.4 INSTRUCTIONS FOR USING THE FALL ABSORBER ...................................... 2-21
2.2.6 SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION ............................................... 2-22
2.2.7 SAFETY HINTS FOR LIFTING HEAVY PARTS.................................................................. 2-25
2.2.8 SAFETY HINTS FOR WIRE ROPES................................................................................... 2-25
2.2.9 SAFETY HINTS FOR SLING ACCESSORY ....................................................................... 2-27
2.3
GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM ................................................. 2-28
2.4
EXPLANATION OF ABBREVIATIONS ........................................................................................... 2-31
3 SUPERSTRUCTURE................................................................................. 3-1
3.1
SUPERSTRUCTURE OVERVIEW ..................................................................................................... 3-2
3.2
SERVICE CRANE (OPTIONAL) ........................................................................................................ 3-5

3.2.1 REMOVAL OF THE SERVICE CRANE ................................................................................. 3-5
3.2.2 REPLACEMENT OF THE SERVICE CRANE ....................................................................... 3-7
3.3
ENGINE HOUSE ROOF ..................................................................................................................... 3-8

3.3.1 REMOVAL OF THE ROOF PLATES ..................................................................................... 3-8
3.3.2 REPLACEMENT OF THE ROOF PLATES.......................................................................... 3-14
3.3.3 FRONT ROOF SECTION .................................................................................................... 3-15
3.3.3.1 REMOVAL OF THE FRONT ROOF PLATES ...................................................... 3-15
3.3.3.2 REPLACEMENT OF THE FRONT ROOF PLATES ............................................ 3-18
Version 2010/1
PC8000-6E
TOC - 1
Table of contents
3.4
BATTERIES...................................................................................................................................... 3-19
3.4.1 REMOVAL OF THE BATTERIES ........................................................................................ 3-19
3.4.2 REPLACEMENT OF THE BATTERIES ............................................................................... 3-21
3.5
ELECTRIC MOTORS .......................................................................................................................

3.5.1 REMOVAL OF THE FRONT ELECTRIC MOTOR (MOTOR 1) ...........................................
3.5.2 REPLACEMENT OF THE FRONT ELECTRIC MOTOR (MOTOR 1)..................................
3.5.3 REMOVAL OF THE REAR ELECTRIC MOTOR (MOTOR 2) .............................................
3.5.4 REPLACEMENT OF THE REAR ELECTRIC MOTOR (MOTOR 2) ....................................
3.5.5 FINAL ALIGNMENT OF THE ELECTRIC MOTORS ...........................................................
3.5.6 CAPACITOR ASSEMBLIES ................................................................................................
3.5.6.1 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 1) ...............................
3.5.6.2 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 1) ......................
3.5.6.3 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 2) ...............................
3.5.6.4 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 2) ......................
3-22
3-22
3-26
3-28
3-28
3-29
3-32
3-33
3-35
3-35
3-35
3.6
FLEXIBLE COUPLING.....................................................................................................................
3.6.1 VULKAN COUPLING ASSEMBLY.......................................................................................
3.6.1.1 REMOVAL OF THE VULKAN COUPLING ..........................................................
3.6.1.2 REPLACEMENT OF THE VULKAN COUPLING .................................................
3-36
3-36
3-37
3-39
3.7
PTO...................................................................................................................................................
3.7.1 MAIN PUMPS ......................................................................................................................
3.7.1.1 REMOVAL OF MAIN PUMPS ..............................................................................
3.7.1.2 REPLACEMENT OF MAIN PUMPS.....................................................................
3.7.2 PTO OIL PUMPS (AUXILIARY PUMPS) .............................................................................
3.7.2.1 REMOVAL OF THE PTO OIL PUMPS (AUXILIARY PUMPS).............................
3.7.2.2 REPLACEMENT OF THE PTO OIL PUMPS (AUXILIARY PUMPS) ...................
3.7.3 PUMP DISTRIBUTOR GEARBOX (PTO)............................................................................
3.7.3.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ...........................
3.7.3.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ..................
3-40
3-40
3-42
3-45
3-47
3-47
3-47
3-48
3-50
3-54
3.8
HYDRAULICS .................................................................................................................................. 3-55

3.8.1 HYDRAULIC COOLER FAN DRIVE PUMPS ...................................................................... 3-55
3.8.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMPS...................... 3-56
3.8.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMPS ............ 3-58
3.8.2 ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY ...................................................... 3-59
3.8.2.1 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLER
FAN ASSEMBLY.................................................................................................. 3-62
3.8.2.2 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER
FAN ASSEMBLY.................................................................................................. 3-65
3.8.2.3 REMOVAL OF ADDITIONAL HYDRAULIC OIL COOLER FANS AND MOTORS 3-66
3.8.2.4 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER FANS
AND MOTORS ..................................................................................................... 3-67
3.8.2.5 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLERS ........................ 3-68
3.8.2.6 REPLACEMENT OF THE ADDITIONAL HYDRAULIC OIL COOLERS .............. 3-71
3.8.2.7 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY ...... 3-72
3.8.2.8 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY..... 3-74
3.8.3 HYDRAULIC OIL COOLER ASSEMBLY ............................................................................. 3-76
3.8.3.1 REMOVAL OF THE HYDRAULIC OIL COOLER FAN ASSEMBLIES ................. 3-80
3.8.3.2 REPLACEMENT OF HYDRAULIC OIL COOLER FAN ASSEMBLIES................ 3-84
3.8.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FAN AND MOTOR.................. 3-86
3.8.3.4 REPLACEMENT OF HYDRAULIC OIL COOLER FAN AND MOTOR ................ 3-88
TOC - 2
PC8000-6E
Version 2010/1
Table of contents
3.8.3.5 REMOVAL OF THE HYDRAULIC OIL COOLERS .............................................. 3-90

3.8.3.6 REPLACEMENT OF THE HYDRAULIC OIL COOLERS ..................................... 3-94
3.8.3.7 REMOVAL OF THE HYDRAULIC OIL COOLER ASSEMBLY ............................ 3-96
3.8.3.8 REPLACEMENT OF THE HYDRAULIC OIL COOLER ASSEMBLY ................. 3-100
3.8.4 PILOT OIL PUMP (GEAR PUMP) ..................................................................................... 3-101
3.8.4.1 REMOVAL OF THE PILOT OIL PUMP .............................................................. 3-101
3.8.4.2 REPLACEMENT OF THE PILOT OIL PUMP .................................................... 3-103
3.8.5 MAIN GATE VALVE........................................................................................................... 3-104
3.8.5.1 REMOVAL OF THE MAIN GATE VALVE .......................................................... 3-104
3.8.5.2 REPLACEMENT OF THE MAIN GATE VALVE................................................. 3-105
3.8.6 HYDRAULIC OIL RESERVOIR ......................................................................................... 3-106
3.8.6.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR......................................... 3-108
3.8.6.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR ............................... 3-111
3.8.7 MAIN CONTROL VALVE BLOCKS ................................................................................... 3-113
3.8.7.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS................................... 3-114
3.8.7.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS ......................... 3-117
3.8.8 MAIN RELIEF VALVES (MRV) .......................................................................................... 3-118
3.8.8.1 REMOVAL OF THE MRV ON THE MAIN CONTROL VALVE BLOCK ............. 3-118
3.8.8.2 REPLACEMENT OF THE MRV ON THE MAIN CONTROL VALVE BLOCK .... 3-119
3.8.9 SERVICE LINE RELIEF VALVES (SRV) ........................................................................... 3-120
3.8.9.1 REMOVAL OF THE SRV ON THE MANIFOLD ................................................. 3-120
3.8.9.2 REPLACEMENT OF THE SRV ON THE MANIFOLD ....................................... 3-122
3.8.9.3 REMOVAL OF THE SRV ON THE MAIN CONTROL VALVE BLOCK .............. 3-123
3.8.9.4 REPLACEMENT OF THE SRV ON THE MAIN CONTROL VALVE BLOCKS .. 3-125
3.8.10 ANTI-CAVITATION VALVES (ACV) ................................................................................. 3-126
3.8.10.1 REMOVAL OF THE ACV ON THE MANIFOLD ................................................. 3-127
3.8.10.2 REPLACEMENT OF THE ACV ON THE MANIFOLD ....................................... 3-131
3.8.10.3 REMOVAL OF THE ACV ON THE MAIN CONTROL VALVE BLOCKS............ 3-132
3.8.10.4 REPLACEMENT OF THE ACV ON THE MAIN CONTROL VALVE BLOCKS .. 3-133
3.8.11 THROTTLE CHECK VALVES .......................................................................................... 3-134
3.8.11.1 REMOVAL OF THE THROTTLE CHECK VALVES ON THE MANIFOLD......... 3-138
3.8.11.2 REPLACEMENT OF THE THROTTLE CHECK VALVES ON THE MANIFOLD 3-140
3.8.12 MANIFOLD ........................................................................................................................ 3-141
3.8.12.1 REMOVAL OF THE MANIFOLD ........................................................................ 3-141
3.8.12.2 REPLACEMENT OF THE MANIFOLD .............................................................. 3-143
3.9
SLEW SYSTEM..............................................................................................................................
3.9.1 SLEW GEAR......................................................................................................................
3.9.1.1 REMOVAL OF THE SLEW GEAR .....................................................................
3.9.1.2 REPLACEMENT OF THE SLEW GEAR............................................................
3.9.2 SWING MOTOR ................................................................................................................
3.9.2.1 REMOVAL OF THE SWING MOTOR ................................................................
3.9.2.2 REPLACEMENT OF THE SWING MOTOR ......................................................
3.9.3 SLEW PARKING BRAKE ..................................................................................................
3.9.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) .............
3.9.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) ..........
3.9.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) .......................
3.9.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) ..............
3.9.4 DYNAMIC SLEW BRAKE ..................................................................................................
3.9.4.1 REMOVAL OF THE SLEW BRAKE VALVE ......................................................
3.9.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE .............................................
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3-145
3-148
3-151
3-154
3-155
3-158
3-161
3-163
3-166
3-169
3-172
3-176
3-179
3-181
TOC - 3
Table of contents
3.9.5
SWING CIRCLE................................................................................................................. 3-182

3.9.5.1 REMOVAL OF THE SWING CIRCLE ................................................................ 3-184
3.9.5.2 REPLACEMENT OF THE SWING CIRCLE ....................................................... 3-187
3.10 LUBRICATION SYSTEM ...............................................................................................................

3.10.1 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL) ...........................................
3.10.1.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY.................................
3.10.1.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY .......................
3.10.2 LUBRICATION PUMP STATION .......................................................................................
3.10.2.1 REMOVAL OF THE LUBRICATION PUMP STATION ......................................
3.10.2.2 REPLACEMENT OF THE LUBRICATION PUMP STATION .............................
3.10.2.3 REMOVAL OF THE LUBRICATION PUMP .......................................................
3.10.2.4 REPLACEMENT OF THE LUBRICATING PUMP..............................................
3-192
3-192
3-194
3-196
3-198
3-202
3-204
3-205
3-207
3.11 OPERATORS CAB .......................................................................................................................

3.11.1 REMOVAL OF THE OPERATORS CAB...........................................................................
3.11.2 REPLACEMENT OF THE OPERATORS CAB .................................................................
3.11.3 VISCOUS CAB-MOUNTS..................................................................................................
3.11.3.1 REMOVAL OF THE VISCOUS CAB-MOUNTS .................................................
3.11.3.2 REPLACEMENT OF THE VISCOUS CAB-MOUNTS........................................
3.11.4 FRONT WINDOW (WINDSCREEN) ..................................................................................
3.11.4.1 REMOVAL OF THE FRONT WINDOW .............................................................
3.11.4.2 REPLACEMENT OF THE FRONT WINDOW ....................................................
3.11.5 OPERATORS SEAT .........................................................................................................
3.11.5.1 REMOVAL OF THE OPERATORS SEAT .........................................................
3.11.5.2 REPLACEMENT OF THE OPERATORS SEAT ...............................................
3.11.6 ECS....................................................................................................................................
3.11.6.1 REMOVAL OF THE ECS TEXT DISPLAY .........................................................
3.11.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY ...............................................
3-208
3-211
3-216
3-218
3-218
3-220
3-222
3-222
3-223
3-224
3-224
3-225
3-226
3-226
3-226
3.12 CAB BASE (MEDIUM VOLTAGE SWITCH CABINET).................................................................

3.12.1 REMOVAL OF THE CAB BASE ........................................................................................
3.12.2 REPLACEMENT OF THE CAB BASE ...............................................................................
3.12.3 PUMP CONTROLLER .......................................................................................................
3.12.3.1 REMOVAL OF THE PUMP CONTROLLER.......................................................
3.12.3.2 REPLACEMENT OF THE PUMP CONTROLLER .............................................
3-227
3-227
3-230
3-233
3-233
3-234
3.13 ACCESS LADDER .........................................................................................................................

3.13.1 REMOVAL OF THE ACCESS LADDER ............................................................................
3.13.2 REPLACEMENT OF THE ACCESS LADDER...................................................................
3.13.3 REMOVAL OF THE ACCESS LADDER CYLINDER.........................................................
3.13.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER ...............................................
3-236
3-239
3-243
3-245
3-247
3.14 COUNTERWEIGHT........................................................................................................................ 3-248

3.14.1 REMOVAL OF THE COUNTERWEIGHT .......................................................................... 3-248
3.14.2 REPLACEMENT OF THE COUNTERWEIGHT ................................................................. 3-251
3.15 SUPERSTRUCTURE LIFTING ......................................................................................................
3.15.1 LIFT THE SUPERSTRUCTURE (PLATFORM, PN 910 605 40 ONLY) ............................
3.15.2 DUMP THE SUPERSTRUCTURE (PLATFORM, PN 910 605 40 ONLY) .........................
3.15.3 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE ...........................
3.15.4 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE.............................
3-252
3-252
3-255
3-256
3-261
3.16 HIGH VOLTAGE SWITCH CABINET ............................................................................................ 3-265

3.16.1 REMOVAL OF THE HIGH VOLTAGE SWITCH CABINET................................................ 3-266
3.16.2 REPLACEMENT OF THE HIGH VOLTAGE SWITCH CABINET ...................................... 3-270
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3.17 SLIP RING UNIT ............................................................................................................................ 3-272

3.17.1 REMOVAL OF THE SLIP RING UNIT ............................................................................... 3-273
3.17.2 REPLACEMENT OF THE SLIP RING UNIT...................................................................... 3-277
4 UNDERCARRIAGE.................................................................................... 4-1
4.1
UNDERCARRIAGE OVERVIEW ....................................................................................................... 4-2
4.2
TRAVEL SYSTEM.............................................................................................................................. 4-4

4.2.1 TRACK GROUP..................................................................................................................... 4-4
4.2.1.1 CHANGING OF THE TRACK GROUP .................................................................. 4-4
4.2.2 SPROCKET ........................................................................................................................... 4-9
4.2.2.1 REMOVAL OF THE SPROCKET ASSEMBLY ...................................................... 4-9
4.2.2.2 REPLACEMENT OF THE SPROCKET ASSEMBLY ........................................... 4-14
4.2.3 GUIDE WHEELS (IDLERS) ................................................................................................. 4-16
4.2.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY ............................................... 4-16
4.2.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY ..................................... 4-18
4.2.4 TRACK TENSIONING ACCUMULATORS .......................................................................... 4-19
4.2.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS ................................ 4-19
4.2.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS ....................... 4-21
4.2.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS ............................... 4-22
4.2.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS ...................... 4-23
4.2.5 TRACK TENSIONING VALVE BLOCK................................................................................ 4-24
4.2.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK ............................... 4-24
4.2.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK...................... 4-26
4.2.6 TRACK TENSIONING CYLINDERS .................................................................................... 4-27
4.2.6.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS ................................... 4-27
4.2.6.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS .......................... 4-29
4.2.7 SUBSTITUTE THE HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM......... 4-31
4.2.7.1 SUBSTITUTE THE HYDRAULIC HOSES INSIDE THE CAR BODY .................. 4-33
4.2.7.2 SUBSTITUTE THE HYDRAULIC HOSE BETWEEN CAR BODY
AND CRAWLER FRAME ..................................................................................... 4-33
4.2.7.3 SUBSTITUTE THE HYDRAULIC HOSES INSIDE THE CRAWLER FRAME...... 4-35
4.2.7.4 SUBSEQUENT WORK ........................................................................................ 4-36
4.2.8 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE).................................................. 4-37
4.2.8.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK ....................................... 4-40
4.2.8.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK .............................. 4-42
4.2.9 TRAVEL MOTOR................................................................................................................. 4-43
4.2.9.1 REMOVAL OF THE TRAVEL MOTORS.............................................................. 4-43
4.2.9.2 REPLACEMENT OF THE TRAVEL MOTORS .................................................... 4-45
4.2.10 TRAVEL PARKING BRAKE................................................................................................. 4-46
4.2.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE ................................................ 4-48
4.2.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE....................................... 4-51
4.2.11 TRAVEL GEARBOX ............................................................................................................ 4-57
4.2.11.1 REMOVAL OF THE TRAVEL GEARBOX............................................................ 4-58
4.2.11.2 REPLACEMENT OF THE TRAVEL GEARBOX .................................................. 4-61
4.2.12 CARRIER ROLLER ............................................................................................................. 4-63
4.2.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY ........................................ 4-63
4.2.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY ............................... 4-66
4.2.13 TRACK ROLLER ................................................................................................................. 4-67
4.2.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY ............................................ 4-67
4.2.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY ................................... 4-69
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4.3
4.4
CAR BODY.......................................................................................................................................
4.3.1 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH MOUNTING PINS) .........................................................................................
4.3.2 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH MOUNTING PINS) .........................................................................................
4.3.3 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH BOLTED CONNECTION)...............................................................................
4.3.4 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH BOLTED CONNECTION)...............................................................................
4.3.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS
4.3.5 ROTARY JOINT...................................................................................................................
4.3.5.1 REMOVAL OF THE ROTARY JOINT ..................................................................
4.3.5.2 REPLACEMENT OF THE ROTARY JOINT .........................................................
4-70
4-70
4-74
4-78
4-81
4-84
4-88
4-90
4-93
CABLE DRUM ASSEMBLY............................................................................................................. 4-94

4.4.1 REMOVAL OF THE CABLE DRUM ASSEMBLY ............................................................... 4-95
4.4.2 REPLACEMENT OF THE CABLE DRUM ASSEMBLY ....................................................... 4-97
5 ATTACHMENT........................................................................................... 5-1
5.1
TOC - 6
FACE SHOVEL (FSA)........................................................................................................................ 5-2

5.1.1 FSA OVERVIEW.................................................................................................................... 5-2
5.1.2 USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS................................ 5-3
5.1.3 BOOM .................................................................................................................................... 5-4
5.1.3.1 REMOVAL OF THE BOOM.................................................................................... 5-4
5.1.3.2 REPLACEMENT OF THE BOOM .......................................................................... 5-9
5.1.3.3 REMOVAL OF THE BOOM CYLINDERS ............................................................ 5-14
5.1.3.4 REPLACEMENT OF THE BOOM CYLINDERS................................................... 5-19
5.1.4 STICK................................................................................................................................... 5-22
5.1.4.1 REMOVAL OF THE STICK .................................................................................. 5-22
5.1.4.2 REPLACEMENT OF THE STICK......................................................................... 5-26
5.1.4.3 REMOVAL OF THE STICK CYLINDERS ............................................................ 5-30
5.1.4.4 REPLACEMENT OF THE STICK CYLINDERS ................................................... 5-35
5.1.5 BULL CLAM BUCKET.......................................................................................................... 5-38
5.1.5.1 REMOVAL OF THE BULL CLAM BUCKET ......................................................... 5-40
5.1.5.2 REPLACEMENT OF THE BULL CLAM BUCKET................................................ 5-44
5.1.5.3 REMOVAL OF THE BUCKET CYLINDERS ........................................................ 5-46
5.1.5.4 REPLACEMENT OF THE BUCKET CYLINDERS ............................................... 5-51
5.1.5.5 REMOVAL OF THE CLAM CYLINDERS ............................................................. 5-56
5.1.5.6 REPLACEMENT OF THE CLAM CYLINDERS.................................................... 5-60
5.1.6 GROUND ENGAGING TOOLS (GET)................................................................................. 5-64
5.1.6.1 REMOVAL AND REPLACEMENT OF THE GET................................................. 5-66
5.1.7 HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT ......................................... 5-68
5.1.7.1 SUBSTITUTE THE BOOM ARC HOSES............................................................. 5-68
5.1.7.2 SUBSTITUTE THE BOOM CYLINDER HOSES .................................................. 5-72
5.1.7.3 SUBSTITUTE THE STICK ARC HOSES ............................................................. 5-76
5.1.7.4 SUBSTITUTE THE STICK CYLINDER HOSES .................................................. 5-82
5.1.7.5 SUBSTITUTE THE BUCKET CYLINDER HOSES .............................................. 5-86
5.1.7.6 SUBSTITUTE THE CLAM CYLINDER HOSES ................................................... 5-92
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5.2
METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT .....................................

5.2.1 CHECK THE OPERATION OF THE METERING VALVES (GREASE INJECTORS) .......
5.2.2 REMOVAL OF THE METERING VALVES (GREASE INJECTORS).................................
5.2.3 REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS) .......................
5-100
5-101
5-102
5-103
5.3
CYLINDER BYPASS TEST ........................................................................................................... 5-104
6 SERVICE INFORMATION ......................................................................... 6-1

6.1
FLUIDS AND LUBRICANTS.............................................................................................................. 6-2
6.2
FILLING CAPACITIES ....................................................................................................................... 6-3
6.3
WORK INSTRUCTIONS .................................................................................................................... 6-4

6.3.1 REMOVE / INSTALL THE CRAWLER CARRIER ................................................................. 6-4
6.4
WEIGHT TABLES ..............................................................................................................................

6.4.1 SUPERSTRUCTURE ............................................................................................................
6.4.1.1 UNDERCARRIAGE................................................................................................
6.4.1.2 FACE SHOVEL ATTACHMENT (FSA) ..................................................................
6.5
TORQUE CHARTS ACCORDING TO ISO ......................................................................................

6.5.1 METRIC STANDARD THREAD...........................................................................................
6.5.2 METRIC FINE THREAD ......................................................................................................
6.5.3 SAE FLANGE CONNECTIONS ...........................................................................................
6-10
6-10
6-11
6-12
6.6
BLIND PLUGS .................................................................................................................................

6.6.1 DUMMY PLATES FOR SAEFLANGES .............................................................................
6.6.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ...........................................
6.6.3 PLUGS AND FITTINGS ACCORDING TO EN ISO 84 34-1 ...............................................
6-14
6-14
6-16
6-17
6.7
CONVERSION TABLE.....................................................................................................................
6.7.1 METHOD OF USING THE CONVERSION TABLE .............................................................
6.7.2 MILLIMETER - INCH & KILOGRAM - POUND....................................................................
6.7.3 LITER - U.S. GALLON & LITER - U.K. GALLON.................................................................
6.7.4 NM- FT.LB ...........................................................................................................................
6.7.5 BAR - PSI - KPA - MPA .......................................................................................................
6.7.6 BASIC VALUES IN OHM ACCORDING TO DIN 4376 / IEC 751 ........................................
6.7.7 TEMPERATURE..................................................................................................................
6-18
6-18
6-19
6-20
6-21
6-22
6-23
6-24
6.8
TOOLS ............................................................................................................................................. 6-25

6.8.1 STANDARD TOOL CASE.................................................................................................... 6-25
6.8.2 USED SPECIAL TOOLS (OVERVIEW) ............................................................................... 6-27
6-5
6-5
6-8
6-9
7 TOOLS CATALOGUE................................................................................ 7-1

8 PARTS & SERVICE NEWS ....................................................................... 8-1
AH00511
Installation procedure for the swing circle / Slew Ring (SR)
AH00514
Track group - Hints for sprocket exchange
AH00515
Final drive: Wear and tear measurements Mounting procedures
AH00519
Adhesive lubricants for the Slew Ring Gear
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TOC - 7
Table of contents
AH01513
Bleeding of hydraulic pumps
AH01516
Lift off the superstructure platform from the undercarriage for instance to change the swing circle (slew ring)
AH01523
Replacement of the elastic coupling (Electro drive shovels)
AH01531
Hydraulic accumulators - testing and refilling
AH02513
Testing wear and tear of swing circle bearing
AH02521
Track group wear measurement
AH03506
Hydraulic oil cooler and water cooler fan bearings
AH03510
ESCO bucket tooth system
AH03528
Pilot control safety line
AH04518
Welding procedure for welded counterweight
AH05501
Abnormal vibration on hydraulic pipes
AH05510
Bearing flushing of the A4VS variable displacement axial piston pump
AH05511
Dual cone seal ring mounting
AH05518
Swing circle pinion
AH05525
Suction elbows of the main Pumps
AH05535
Hints for replacing by the slewing gear of an other manufacturer
AH05546
Automatic lubrication system - Vent valve (PN 769 879 73)
AH06512
Travel gears - Brake and motor adapter housings - Oil Change
AH06524
Hydraulic cylinder
AH06530
Relieving of the track chain tension
AH06544
Hydraulic track tensioning system Pressure increasing valve
AH06545
Hydraulic cylinder bushings
AH08504
Windscreen
AH08507
Steel structure
AH08508
Bushings of the attachment and at the undercarriage
TOC - 8
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Version 2010/1
Table of contents
AH08516
Hoses between boom and stick
AH08532
9 SUPPLIERS DOCUMENTATION ............................................................. 9-1

AVANTI HYTORQUE
Version 2010/1
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TOC - 9
Table of contents
This page was left blank intentionally.
TOC - 10
PC8000-6E
Version 2010/1
Introduction
1 INTRODUCTION
Version 2010/1
PC8000-6E
1 -1
Contents of the binder
1.1
Introduction
CONTENTS OF THE BINDER
Assembled in this file are the R&R Procedures with explanations

of removing, installing, and adjustments of the major components
and circuits for your KOMATSU Hydraulic Mining Shovel.
1 -2
PC8000-6E
Version 2010/1
Introduction
1.2
Foreword
FOREWORD
Observe the instructions in this manual for:

z
Your Personal SAFETY
Operating SAFETY, and
READY and EFFICIENT PERFORMANCE of your

KOMATSU Hydraulic Mining Shovel.
With this R&R Procedures Manual, KOMATSU provides you with

the description of proper removal and replacement procedures of
main components.
How do you find "your" desired information?

In the TABLE OF CONTENTS all R&R PROCEDURES are
shown in their sequence of description.
CAUTION
Periodic preventive inspections and maintenance are the
surest means of keeping the machine in proper working
order. Prompt detection and correction of minor irregularities
and immediate replacement of worn out or broken parts will
prevent failures and avoid expenses.
Replace damaged graphics and symbols.

Observe safety precautions to prevent injury and damage.
If, after reading this R&R Procedures Manual, you can give us
suggestions and comments for improvements - please do not
hesitate to contact us.

Service Training and Manuals
Department 8151.30
P.O. Box 18 03 61
D - 40570 Dsseldorf
GERMANY
WARNING
Personnel entrusted with work on the machine must have
read the section 2 SAFETY before beginning work. Reading
the instructions after work has begun is too late.
Version 2010/1
PC8000-6E
1 -3
Foreword
Introduction
Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee.
In order to keep your shovel in first-class operating condition only
use genuine spare and wear parts.
The use of any part other than the genuine part releases the
KOMATSU MINING GERMANY GmbH from any guarantee.
1.2.1
SERVICE
In all your written or phoned inquiries, please indicate the model

and serial number of your shovel.
1 -4
PC8000-6E
Version 2010/1
Safety
2 SAFETY
Version 2010/1
PC8000-6E
2 -1
General information
Safety
2.1
GENERAL INFORMATION
2.1.1
METHOD OF USING THIS MANUAL
When removing or installing a unit assembly, the order of work

and techniques used are given for the removal procedure. The
order of work for the installation is only given if the installation procedure differs from installation in reverse order of removal, for
example any special technique needs to be applied.
Tightening torques according to ISO are not explicitly given in the
installation procedures.
For tightening torques according to ISO, refer to section 6.5 on
page 6-10.
Figure references that appear in the operation procedures use
the format (Fig. 4-12, Pos. 4), which means position number 4 in
figure 12 of section 4.
Special requirements such as listing of special tools or size or
numbers of blind plugs etc. are listed in a table at the beginning of
each operation procedure.
Special tools that appear in the lists are given with part name, part
number, and quantity
(2 x thread protector, PN 409 329 40).
For the special tools list, refer to section 6.8.2 on page 6-27.
The following text designations are used in the manual with the
following intend:
Refers to listings of none particular order.
Refers to working steps within the procedures.
The following symbols are used in the manual to designate additional information as shown in the following examples:
Kind and amount of drained fluids
(e.g. drain oil, 1500 liters).
Lifting weight of an assembly (e.g. 140 kg).

Kind and amount of fluids to fill
(e.g. fill oil, 1500 liters).
Special tightening torques for bolts etc., if not
according to ISO (e.g. 129 Nm).
General information concerning a section, e.g.
tightening torques according to ISO, refer to section
6.5 on page 6-10.
Special authorized personnel is required.
2 -2
PC8000-6E
Version 2010/1
Safety
General information
All PARTS & SERVICE NEWS which are mentioned in the procedures are listed in chapter 8. The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest
edition is always filed to the binder of this manual.
The following symbols and designations are used in the manual
to designate instructions of particular importance:
DANGER
Refers to orders and prohibitions designed to prevent serious injury or death.
WARNING
Refers to orders and prohibitions designed to prevent injury
or extensive damage.
CAUTION
Refers to special information and/or orders and prohibitions
directed towards preventing damage.
NOTE: Refers to special information on removing or installing

assemblies, for example if any special technique needs
to be applied.
Version 2010/1
PC8000-6E
2 -3
Safety instructions
Safety
2.2
SAFETY INSTRUCTIONS
2.2.1
GENERAL PRECAUTIONS
CAUTION
Proper service and repair is important for safe machine operation. The service and repair techniques recommended by
Komatsu Mining Germany and described in this manual are
both effective and safe. Some of these techniques require
the use of tools specially designed by Komatsu Mining Germany for the specific purpose.
NOTE: Always attend to local regulations regarding the Personal

Protective Equipment.
WARNING
z
Mistakes in operation and service are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL
carefully BEFORE operating the machine.
Before carrying out any greasing or repairs, read all the

precautions given on the decals which are fixed to the
machine.
When carrying out any operation, always wear safety

shoes and a helmet. Do not wear loose work clothes or
clothes with buttons missing.
Always wear safety glasses when hitting parts with a

hammer.
Always wear safety glasses when grinding parts with a
grinder, etc.
Assure fire prevention according to the Operation &

Maintenance Manual.
If welding repairs are needed, refer to the welding precautions given in the Operation & Maintenance Manual.
When carrying out any operation with two or more workers, always agree on the operating procedure before
starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang
UNDER REPAIR signs on the controls in the operator's
cab.
Keep all tools in good condition and learn the correct

way to use them.
2 -4
PC8000-6E
Version 2010/1
Safety
Safety instructions
WARNING
Decide on a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure
that there is no dirt or oil on the floor. Smoke only in the
areas provided for smoking. Never smoke while working.
DANGER
Hazardous Voltage!
Risk of electric shocks. Death or serious burns may result.
An pilot control safety line monitores all safety relevant components at the high voltage system. This pilot control safety
line must be connected properly at the excavator and at the
power plant / external transformer station. For further information about the monitored components, refer to the PARTS
& SERVICE NEWS No. "AH03528" and the wiring diagram of
the excavator.
Version 2010/1
PC8000-6E
2 -5
Safety instructions
2.2.2
Safety
PREPARATIONS BEFORE WORK

WARNING
Before beginning any work operations set the maintenance

safety switch (Fig. 2-1, Pos. 3) to -0- position to prevent starting of the engines during the work. Fold up the flap (Fig. 2-1,
Pos. 2) and secure this position by inserting a padlock into
the holes (Fig. 2-1, Pos. 4) of the flap (Fig. 2-1, Pos. 2) and the
safety switch (Fig. 2-1, Pos. 1).
Fig. 2-1
WARNING
z
Before adding oil or making repairs, park the machine on

hard, level ground large enough to accommodate the
machine, boom, and additional working equipment
(crane mobile working platforms, forklift etc.).
If the ground condition is too poor to guarantee safe and

stable stand of the machine and the additional working
equipment (crane mobile working platforms, forklift etc.),
make sure that the machine is moved to a place with
appropriate ground conditions.
Block the tracks to prevent the machine from moving.
Before starting work, lower bucket, hammer, or any other

work equipment to the ground. If this procedure is not
possible, insert the safety pin or use blocks to prevent
the work equipment from falling. Additionally, be sure to
lock all the control levers and hang warning signs on
them.
When disassembling or assembling, support the

machine with blocks, jacks, or supports before starting
work.
Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the handrails, ladders, or steps when getting on or off the
machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders, or steps, use a stand
to provide safe footing.
2 -6
PC8000-6E
Version 2010/1
Safety
Safety instructions
DANGER
Hazardous Voltage!
Any work on the high voltage system has to be carried out by
authorized electricians having the permission to work on
high voltage systems only.
Perform the grounding procedure of the high voltage system,
refer to section 2.3 on page 2-28.
2.2.3

WARNING
When removing the oil filler cap, drain plug, or hydraulic

pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. The oil can be very hot, so
be careful not to get burnt. Wait for the oil to cool down
before carrying out work.
Before starting work, isolate the machine according to

local regulations.
Remove the leads from the battery. ALWAYS remove the
lead from the negative (-) terminal first.
When raising heavy components (25 kg or more), use a

hoist or crane.
Check that the wire rope, chains, and hooks are free from
damage.
Install the lifting equipment at the correct places. Use a

hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any
part still raised by the hoist or crane.
When removing covers which are under internal pressure or under pressure from a spring, always leave two
bolts in position on opposite sides. Slowly release the
pressure, then slowly loosen the bolts to remove.
When removing components, be careful not to break or

damage the wiring.
Damaged wiring may cause electrical fires.
When removing any piping, stop the fluids from spilling

out. If any oil drips on to the floor, wipe it up immediately.
Oil on the floor can cause you to slip, or can even start
fires.
Version 2010/1
PC8000-6E
2 -7
Safety instructions
Safety
WARNING
z
As a general rule, do not use gasoline to wash parts.
Be sure to assemble all parts in their original places

again. Replace any damaged parts with new parts.
WARNING
z
When installing hoses and wires, be sure that they will

not be damaged by contact with other parts when the
machine is being operated.
When installing high pressure hoses, make sure that

they are not twisted. Damaged tubes are dangerous, so
be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
When assembling or installing parts, always use the

specified tightening torques. When installing protective
parts such as guards, or parts which vibrate violently or
rotate at high speed, be particularly careful to check that
they are installed correctly.
When aligning two holes, never insert your fingers or

hand. Be careful not to get your fingers caught in a hole.
DANGER
Danger of explosion!
Serious injury, permanent disfigurement, and scarring may
result!
Special care must be taken before welding, flame-cutting,
and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create
explosive gases which will accumulate in the chambers of
the counterweight. These gases must be expelled before
welding, flame-cutting, and grinding operations are carried
out on the counterweight.
Follow the instructions given in PARTS & SERVICE NEWS
No. "AH04518" for expelling the gases from the counterweight chambers.
2 -8
PC8000-6E
Version 2010/1
Safety
Safety instructions
2.2.3.1 PRECAUTIONS WITH HIGH PRESSURE OIL

DANGER
The hydraulic system is always under internal pressure.
When inspecting or replacing piping or hoses, always check
that the pressure in the hydraulic circuit has been released. If
the circuit is still under pressure, it will lead to serious injury.
do not carry out any inspection or replacement operation.
If there is any leakage from the piping or hoses, the surrounding

area will be wet, so check for cracks in the piping and hoses and
for swelling in the hoses.
WARNING
When carrying out inspections, wear full-face protection and
penetration resistant clothing and gloves.
DANGER
There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it contacts your eyes directly. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place
with clean water, and consult a doctor immediately for medical attention.
Fig. 2-2
WARNING
Leaks in high-pressure hoses may cause fire or defective
operation, which may lead to serious injury.
z
Replace the hose if a damaged or leaking hydraulic fitting is found.
Replace the hose if a frayed or cut covering or an

exposed reinforcement wire layer is found.
Replace the hose if a covering is swollen in places.
Replace the hose if movable portions are wisted or

crushed.
Replace the hose if foreign material (splinters etc.) is

embedded in the covering of the hose.
Version 2010/1
PC8000-6E
2 -9
Safety instructions
2.2.4
Safety
WARNING OF SPECIAL DANGERS
2.2.4.1 ELECTRICAL ENERGY

WARNING
z
Use only original fuses and circuit breakers with the

specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.
Work on the electrical system or equipment may only be

carried out by a skilled electrician himself or by specially
instructed personnel under the control and supervision
of such electrician and in accordance with the applicable
electrical engineering rules.
If provided for in the regulations, the power supply to

parts of the machine, on which inspection, maintenance,
and repair work is to be carried out must be cut off.
Before starting any work, check the de-energized parts
for the presence of power and ground or short-circuit
them in addition to insulating adjacent live parts and elements.
If your machine comes into contact with a live wire:

z
do not leave the machine.
drive the machine out of the hazard zone.
warn others against approaching and touching the

machine.
have the live wire de-energized.
do not leave the machine until the damaged line has

been safely de-energized.
The electrical equipment of the machine is to be

inspected and checked at regular intervals. Defects such
as loose connections or scorched cables must be rectified immediately.
Necessary work on live parts and elements must be carried out only in the presence of a second person who can
cut off the power supply in case of danger by actuating
the emergency shut-off or main power switch. Secure the
working area with a red-and-white safety chain and a
warning sign. Use insulated tools only.
Any work on the high voltage system has to be carried

out by authorized electricians having the permission to
work on high voltage systems only.
2 - 10
PC8000-6E
Version 2010/1
Safety
Safety instructions
2.2.4.2 GAS, DUST, STEAM AND SMOKE

WARNING
z
Carry out welding, flame-cutting and grinding work on

the machine only if this has been expressly approved, as
there may be a risk of explosion and fire.
Special care must be taken before welding, flame-cutting

and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can
create explosive gases which will accumulate in the
chambers of the counterweight. These gases must be
expelled before welding, flame-cutting and grinding operations are carried out on the counterweight. Danger of
explosion.
Follow the instructions given in PARTS & SERVICE
NEWS No. "AH04518" for expelling the gases from the
counterweight chambers.
Before carrying out welding, flame-cutting and grinding

operations, clean the machine and its surrounding from
dust and other inflammable substances and make sure
that the premises are adequately ventilated (risk of explosion).
2.2.4.3 NOISE
WARNING
z
During operation, all sound baffles must be closed.
Always wear the prescribed ear protectors.
2.2.4.4 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES

WARNING
When handling oil, grease, and other chemical substances,
observe the product-related safety regulations given in the
material safety data sheet (MSDS).
Version 2010/1
PC8000-6E
2 - 11
Safety instructions
Safety
2.2.4.5 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT

WARNING
z
Work on hydraulic equipment and the air conditioning

system may only be carried out by persons having special knowledge and experience in this systems.
Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair any damage
immediately. Splashed oil may cause injury and fire.
Depressurize all system sections and pressure pipes

(hydraulic system, compressed-air system) to be
removed in accordance with the specific instructions for
the unit concerned before carrying out any repair work.
Refrigerant in the air conditioning system must be

sucked off by authorized service specialists only before
opening the refrigerant loop (e.g. removing pipes).
Hydraulic, air conditioning and compressed-air lines

must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths, and quality
of the hoses must comply with the technical requirements.
2.2.4.6 HEAT
WARNING
z
Do not start working on hot machine parts until the temperature is below 50 C.
Be careful when handling hot materials (risk of burning

or scalding) such as:
Hot cables
Hydraulic oil
Grease
Use gloves when handling hot machine parts.
2.2.4.7 HEIGHT
WARNING
When working in heights above 1.00 m, a special safety harness is required, refer to section 2.2.5 on page 2-15.
2 - 12
PC8000-6E
Version 2010/1
Safety
Safety instructions
Version 2010/1
PC8000-6E
2 - 13
Safety instructions
Fig. 2-3
2 - 14
Safety
Safety harness in conformity with EN 361

PC8000-6E
Version 2010/1
Safety
2.2.5
Safety instructions
2.2.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

The safety harness (Fig. 2-3) should only be used together with
connectors according to EN 354, and fall arrest according to
EN 355, or fall protection devices according to EN 360.
Legend for Fig. 2-3:
(1)
Safety harness according to EN 361
(2)
Strap-type fall absorber according to EN 355
(3)
Ladder to cab roof and railings (attachment points)
(4)
Protection hoods for roof mounted air conditioning, if

so equipped
(A)
Shoulder strap
(B)
Back plate
(C)
Catching hook
(D)
Shoulder-strap fixing
(E)
Belly strap
(F)
Holding hook
(G)
Hold-back hook
(H)
Pelvis strap
(J)
Leg strap
WARNING
Always use the safety harness (Fig. 2-3, Pos. 1) in conjunction with strap-type fall absorber (Fig. 2-3, Pos. 2), before
mounting onto the loader attachment or other unsecured
places of the shovel.
NOTE: The illustration (Fig. 2-3) shows a typical use of the

safety harness. Shovels with the new type operators cab
are not equipped with ladder (Fig. 2-3, Pos. 3), because
the air conditioner unit of the new type cab is located on
the back wall of the cab.
Version 2010/1
PC8000-6E
2 - 15
Safety instructions
Fig. 2-4
2 - 16
Safety

PC8000-6E
Version 2010/1
Safety
Safety instructions

Open the lock and lift the harness by the catch hook (Fig. 2-4,
Pos. C). The blue straps (leg straps Fig. 2-4, Pos. J) must be at
the bottom. The harness is being put on just like a jacket. Pull the
belly strap (Fig. 2-4, Pos. E) through the lock, as shown in the
illustration, and secure it.
By closing the breast strap, you avoid the shoulder straps to sideslip. Bring the leg straps (Fig. 2-4, Pos. J) around the legs to the
front, pull them in, as shown in the illustration, and tighten them.
Adapt the harness to body form, seeing to perfect fit, in particular
that the catching hook (Fig. 2-4, Pos. C) is aligned in the centre of
the back.
The safety harness should belong to its wearer personally.
The safety harness should only be used together with connectors
according to EN 354, and fall arrest according to EN 355, or fall
protection devices according to EN 360.
The attachment point for the safety harness should be above the
wearer, and the carrying capacity of the attachment point should
be sufficient to correspond with the minimum carrying capacity
according to EN 795.
z
Before using the harness:

z
Carry out a visual check of the system or components.

The correct functioning and perfect working order have to
be assured.
Make sure that the recommendations for use with other

components of the system are observed in conformity
with the instructions for use.
WARNING
The system or component must no longer be used, if there

are any doubts in respect of its safe condition. The equipment has to be inspected by the manufacturer or by a qualified person.
It is essential for safety reasons that a fall protection system
or system component which has already been subjected to
fall is removed from the service and sent back to the manufacturer or to an authorized qualified repair shop for maintenance and renewed testing.
Version 2010/1
PC8000-6E
2 - 17
Safety instructions
Fig. 2-5
2 - 18
Safety

PC8000-6E
Version 2010/1
Safety
Safety instructions
Fall protection systems have to be treated with care and to be

kept clean and ready for use. It has to be warned against bringing
the systems into contact with acids or other caustic liquids and
gases, oils, detergents, or sharp-edged objects.
If the harness has become wet during use or cleaning, do not dry
near a fire or other sources of heat, but rather in a natural way in
not too warm rooms. Keep the harness freely suspended or
loosely rolled up.
When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest
Systems" have to be observed for protection against danger.
WARNING
At least every 12 months, the safety harness and its components have to be inspected by a competent person authorized by the manufacturer and they have to be maintained, if
the manufacturer considers it to be necessary.
2.2.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK

HOOKS OF THE SAFETY HARNESS
During the holding function, the connectors may only be placed
around a mast or any other construction between the two holding
hooks, so that the free fall is limited to max. 0.5 m.
It should be strictly seen to it that the connector is not slung
around constructions with too small diameters or sharp edges.
With the lateral holding hooks, work may only be carried out on
horizontal or almost horizontal surfaces (roofs). The connectors
have to be adjusted in such a way that the area, where danger of
falling down prevails, cannot be reached.
Version 2010/1
PC8000-6E
2 - 19
Safety instructions
Fig. 2-6
2 - 20
Safety

PC8000-6E
Version 2010/1
Safety
Safety instructions
2.2.5.4 INSTRUCTIONS FOR USING THE FALL ABSORBER

Strap-type fall absorber according to EN 355 (type E.K.N.-BFD)
Use
Within a fall-arrest system, the strap-type fall absorber (Fig. 2-6,
Pos. 2) has to be used in conjunction with a safety harness
(Fig. 2-6, Pos. 1) according to EN 361. The maximum length
including the safety rope must not exceed 2.0 m. For longer
ropes, a rope-shortening device has to be applied in addition.
Fix the rope to the attachment point and attach the strap-type fall
absorber to the catching hook in the back of the safety harness.
The attachment point should be above the wearer and its minimum carrying capacity should be 10 kN, according to
EN 795.
The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor get them burnt
by welding sparks.
Storing and maintenance
The strap-type fall absorber has to be kept dry in an airy and
shady room. It must not be exposed to acids, caustic chemicals,
nor to an aggressive atmosphere, and contact with any oil has to
be avoided. If the strap-type fall absorber is dirty, it may be
cleaned with a little water and a light-duty detergent. Dry it in a
shady place (nowhere near fire or other sources of heat). Protect
it from sharp-edged objects.
Inspection
Prior to use, all parts have to be inspected for safe condition and
damages. At least once a year, the strap-type fall absorber has to
be tested by a competent person. A damaged or used strap-type
fall absorber has to be removed from the service immediately.
The strap-type fall absorber must not be changed in any way.
Repair work has to be done by the manufacturer or by an authorized qualified repair shop.
Version 2010/1
PC8000-6E
2 - 21
Safety instructions
2.2.6
Safety
SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION

WARNING
The hydraulic hoses undergo natural aging.

Hence, as they are safety critical parts, their usable lifetime is
limited.
For further information refer to the Operation and Maintenance Manual, chapter 4, section "REPLACEMENT OF
HYDRAULIC HOSE LINES AND FUEL HOSE".
To avoid damage to the hydraulic hose lines, follow the installation procedures listed below:
CAUTION
Pay attention to the Natural curvature of the hose!
Fig. 2-7
CAUTION
Do not twist the hoses during installation!
Fig. 2-8
2 - 22
PC8000-6E
Version 2010/1
Safety
Safety instructions
CAUTION
Mount angled flanges at first!
Fig. 2-9
CAUTION
Pay attention to the changing in hose length, depending on
the pressure inside the hose!
Fig. 2-10
CAUTION
Pay attention to the bending radius!
Fig. 2-11
Version 2010/1
PC8000-6E
2 - 23
Safety instructions
Safety
CAUTION
Pay attention to the bending radius!
Fig. 2-12
2 - 24
PC8000-6E
Version 2010/1
Safety
2.2.7
Safety instructions
SAFETY HINTS FOR LIFTING HEAVY PARTS
NOTE: In order to avoid damage to the lifting devices or parts

that have to be lifted, use edge protection at all sharp
edges.
CAUTION
Heavy parts (25 kg or more) must be lifted with a hoist etc.
CAUTION
If any part cannot be removed from the machine smoothly by
hoisting, the following checks should be made:
Check for the removal of all bolts fastening the component to
other parts.
Check for existence of another part causing interference with
the component to be removed.
2.2.8
z
SAFETY HINTS FOR WIRE ROPES
Use adequate ropes depending on the weight of the parts to

be hoisted, referring to the below table:
Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter
[mm]
10.0
11.2
12.5
14.0
16.0
18.0
20.0
22.4
30.0
40.0
50.0
60.0
Allowable load
[Metric tons]
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
CAUTION
The allowable load value is estimated to be 1/6 or 1/7 of the
breaking strength of the rope used.
WARNING
The table above may differ from local standards.
Always attend to local standards when using wire ropes.
Version 2010/1
PC8000-6E
2 - 25
Safety instructions
Safety
Sling wire ropes around the middle portion of the hook. Slinging near the tip of the hook may cause the rope to slip off the
hook during hoisting, which may cause a serious accident.
Hooks have the maximum strength at the middle portion, see
Fig. 2-13.
Do not sling a heavy load with one rope alone, but sling it with
two or more ropes wound symmetrically around the load.
WARNING
Slinging with one rope may cause turning of the load during
hoisting, untwisting of the rope, or slipping of the rope from
its original winding position on the load, which may cause a
serious accident.
Fig. 2-13
Do not sling a heavy load with ropes forming a wide hanging

angle from the hook. When hoisting a load with two or more
ropes, the force subjected to each rope will increase with the
hanging angles.
Figure 2-14 shows the variation of allowable load (kg) where
hoisting is made with two ropes, each of which is allowed to
sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of total
weight can be lifted. This weight becomes 1000 kg when two
ropes make a 120 hanging angle. On the other hand, two
ropes are subject to an excessive force as large as 4000 kg if
they sling a 2000 kg load at a lifting angle of 150.
Fig. 2-14
2 - 26
PC8000-6E
Version 2010/1
Safety
2.2.9
Safety instructions
SAFETY HINTS FOR SLING ACCESSORY

WARNING
Always attend to local standards when using sling accessory.
Do not use rigid eye bolts from steel C 15 for lifting

(e.g. DIN 580). These eye bolts may only be loaded vertically
or with a maximum permissible angle of 45 to the ring.
Always use suitable swivel hoist rings according to local standards or Vario-Starpoint hoist rings recommended by
Komatsu, see following table:
Thread
Komatsu Part Number
Tightening Torque
M8
941 650 40
10 Nm
M10
941 651 40
10 Nm
M12
906 519 40
25 Nm
M16
906 780 40
60 Nm
M20
906 782 40
115 Nm
M24
906 783 40
190 Nm
M30
906 421 40
330 Nm
M36
906 233 40
590 Nm
DANGER
Vario-Starpoint hoist rings are not suited for turning under
load.
After installing Starpoint hoist ring disengage the star key.
Adjust ring plane in direction of pull before attaching sling
accessory.
DANGER
Eye bolts or sling accessory which is not suitable can result
in serious accidents.
Check that the wire rope, chains, and hooks are free from
damage.
Install the lifting equipment at the correct places. Use a hoist

or crane and operate slowly to prevent the component from
hitting any other part. Do not work with any part still raised by
the hoist or crane.
Version 2010/1
PC8000-6E
2 - 27
Grounding procedure of the high voltage system
2.3
Safety
GROUNDING PROCEDURE OF THE HIGH VOLTAGE

SYSTEM
Special tools:
Measuring rod, PN 232 390 40 (for voltage range 3...6 kV)

Measuring rod, PN 232 389 40 (for voltage range 5...10 kV)
Universal grounding short-circuting device, PN 232 386 40
Additional equipment:
n/a
Electrician with permission to work on high voltage systems
The below procedure must be carried out for safety reasons,

before any work is carried out on the high voltage system of the
excavator.
DANGER
Hazardous Voltage!
z
The following safety measures have to be carried out

before any work on the high voltage system by authorized electricians having the permission to work on high
voltage systems only.
Carry out the work according to the local safety regulations.
All safety devices requested by the local safety regulations must be available and used for any work on the
high voltage systems.
Safety Measures
z
Switch off the power supply from the power station and
ground the power supply line securely.
Remove the padlock or the bolt (Fig. 2-1, Pos. 1) and open
the flap (Fig. 2-1, Pos. 2) at the high voltage switch cabinet
(Fig. 2-1, Pos. 3) to gain access to the load cut-off.
DANGER
Hazardous Voltage!
Do not open the high voltage switch cabinet door (Fig. 2-1,
Pos. 4) until the load cut-off is in OFF position.
Fig. 2-1
2 - 28
PC8000-6E
Version 2010/1
Safety
Turn the load cut-off (Fig. 2-2, Pos. 2) to OFF position using
the key (Fig. 2-2, Pos. 1).
DANGER
Hazardous Voltage!
Do not open the switch cabinet door (Fig. 2-2, Pos. 4) until
the load cut-off is in OFF position.
Remove the padlock and open high voltage switch cabinet

door (Fig. 2-2, Pos. 4).
Make sure that the power supply from the power station is
switched off by placing a measuring rod (Fig. 2-2, Pos. 5) to
the ball headed stud (Fig. 2-2, Pos. 3) of the load cut-off
switch copper bar.
The indication on the measuring rod must show zero potential.
Fig. 2-2
Make sure the grounding harness (Fig. 2-3, Pos. 4) is ready

for use.
NOTE: The grounding harness is part of the universal grounding

short-circuting device, PN 232 386 40.
z
Connect the grounding harness (Fig. 2-3, Pos. 4) as follows:

z
Connect the long single cable (Fig. 2-3, Pos. 6) of the

harness to a threaded stud (Fig. 2-3, Pos. 8) and secure
it with the wing nut (Fig. 2-3, Pos. 7).
Connect the three remaining cables of the grounding harness to the ball headed studs (Fig. 2-3, Pos. 1) of the
load cut-off switch copper bars by means of the clamps
(Fig. 2-3, Pos. 2), using the insulated extension rod
(Fig. 2-3, Pos. 5).
Secure the clamps (Fig. 2-3, Pos. 2) by tightening the Fig. 2-3
screws (Fig. 2-3, Pos. 3) using the insulated extension
rod.
NOTE: The insulated extension rod is part of the universal

grounding short-circuting device, PN 232 386 40.
Version 2010/1
PC8000-6E
2 - 29
Safety
DANGER
Hazardous Voltage!
Carry out the next steps after relieving the residual voltage
from load cut-off switch bars only.
Remove one cable (Fig. 2-4, Pos. 1) of the grounding harness from its ball headed stud at the load cut-off switch copper bars using the insulated extension rod (Fig. 2-4, Pos. 3).
Touch all mounting bolts (Fig. 2-4, Pos. 4) of the phase lines
(L1, L2 and L3) at each current transformer (Fig. 2-4, Pos. 1),
located on the opposed wall of the high voltage switch cabinet
with the cable (Fig. 2-4, Pos. 1) alternately.
Fig. 2-4
NOTE: These connections will also relief the residual voltage

from the capacitors.
z
Reconnect the cable to the ball headed stud at the load

cut-off switch copper bar.
Make sure the grounding harness remains connected as long

as any work at the excavator is carried out.
After work:
z
After work is finished, remove the grounding harness from the

load cut-off switch and store it in a safe place.
DANGER
Hazardous Voltage!
For safety reasons, the access to the high voltage switch
cabinet must be blocked for unauthorized personnel.
Lock the switch cabinet door with an appropriate padlock.
Close the door (Fig. 2-5, Pos. 4) of the high voltage switch
cabinet and lock the door with the provided padlock.
Close the flap (Fig. 2-5, Pos. 2) of the load cut-off switch and
secure the flap with the provided padlock or a bolt (Fig. 2-5,
Pos. 1).
Fig. 2-5
Switch on the power supply from the power station.
2 - 30
PC8000-6E
Version 2010/1
Safety
2.4
Explanation of abbreviations
EXPLANATION OF ABBREVIATIONS
Abbrev.
Definition
Ampere
AC
Alternating Current
ACV
Anti-Cavitation Valve
API
American Petroleum Institute
BHA
Backhoe Attachment
Degree Celsius
CLS
Central Lubrication System
CO
Cut Off function (main pump)
DC
Direct Current
DFT
Dry paint Film Thickness [1/1000 inch]
FSA
Front Shovel Attachment
GET
Ground Engaging Tools
HP
High Pressure
HT
High Tension
kV
Kilo Volt (1000 Volt)
LED
Light Emitting Diode
MRV
Main Relief Valve
PIV
PTO
Power Take-Off (Pump Distributor Gear)
Qmax
Maximum pump delivery = maximum swash

plate angle
Qmin
Minimum pump delivery = minimum swash plate

angle
1/2 Qmax
1/2 pump delivery
SLS
Swing circle pinion Lubrication System
SRV
Secondary Relief Valve
Volt
WFT
Wet paint Film Thickness [1/1000 inch]
1/min
Revolutions Per Minute (RPM)
Version 2010/1
PC8000-6E
2 - 31
Explanation of abbreviations
Safety
2 - 32
PC8000-6E
Version 2010/1
Superstructure
3 SUPERSTRUCTURE
Version 2010/1
PC8000-6E
3 -1
Superstructure overview
Superstructure
3.1
SUPERSTRUCTURE OVERVIEW
Fig. 3-1
PC8000-6E, Superstructure - top view
3 -2
PC8000-6E
Version 2010/1
Superstructure

(1)
Hydraulically operated access ladder
(2)
Operators cab
(3)
Slew gears
(4)
Hydraulic oil coolers
(5)
Main hydraulic oil reservoir
(6)
Return oil reservoir with return oil filters
(7)
Main control valve block
(8)
Front PTO (pump distributor gear)
(9)
Flexible coupling with protection cover
(10)
Front electric motor (motor 1)
(11)
Cooling air intake
(12)
(13)
Rear PTO (pump distributor gear)
(14)
Rear electric motor (motor 2)
(15)
Motor connecting box
(16)
Counter weight
(17)
Slip ring unit
Version 2010/1
PC8000-6E
3 -3
Fig. 3-2
Superstructure
PC8000-6E, Superstructure - side view
(1)
Operators cab
(2)
Support frame
(3)
Cab base (medium voltage switch cabinet)
(4)
Swing circle
(5)
Cooling air intake
(6)
Hydraulically operated access ladder
(7)
Counterweight
(8)
Cooling air outlet
(9)
Stairway
(10)
High voltage switch cabinet
3 -4
PC8000-6E
Version 2010/1
Superstructure
service crane (optional)
3.2
SERVICE CRANE (OPTIONAL)
3.2.1
REMOVAL OF THE SERVICE CRANE
Special tools:
n/a
Crane
Service crane MGK: 2050 kg
Dogman/rigger
Prepare an area of flat ground large enough to accommodate

the machine, boom, and crane.
Park the machine on the prepared flat ground area.
NOTE: If the ground condition is too poor to guarantee safe and

equipment (crane, mobile working platforms, forklift, etc.),
make sure that the machine is moved to any location with
appropriate ground condition.
z
Isolate the machine according to local regulations.

DANGER
Hazardous Voltage!

Version 2010/1
PC8000-6E
3 -5
Superstructure
Make sure that the safety hook of the service crane is safely
connected to the crane base (Fig. 3-3, arrow).
DANGER
Hazardous Voltage!
Risk of electric shocks. Death or burns may result.
Every work at the switch box has to be carried out by authorized electricians only.
Disconnect the wire harness from the switch box (Fig. 3-3,
Pos. 4) at the hydraulic power unit.
Sling the service crane at the crane base (Fig. 3-3, Pos. 1).
and the upper part of the crane.
Fig. 3-3
WARNING
Observe the center of gravity.

Make sure that the crane can not knock over while lifting off.
Remove the bolts (Fig. 3-3, Pos. 2) and lift the service crane
off the mounting blocks (Fig. 3-3, Pos. 3) using a crane.
DANGER
Risk of falling weights!

Death or serious injury may result.
When lifting the service crane, make sure that nobody steps
below the weight.
3 -6
PC8000-6E
Version 2010/1
Superstructure
3.2.2
REPLACEMENT OF THE SERVICE CRANE
Special tools:
n/a
Crane
Compound "KP2K", PN 324 969 40
Service crane MGK: 2050 kg
Dogman/rigger
If there is nothing mentioned explicitly, tighten all bolts according to

ISO, refer to section 6.5 on page 6-10.
DANGER
Hazardous Voltage!
Risk of electric shocks. Death or burns may result.
Every work at the switch box has to be carried out by authorized electricians only.
Carry out installation in reverse order to removal.
NOTE: Always use new mounting bolts (Fig. 3-3, Pos. 2) of

grade 10.9.
Apply compound "KP2K", PN 324 969 40 on the bolts.
Version 2010/1
PC8000-6E
3 -7
Engine house roof
Superstructure
3.3
ENGINE HOUSE ROOF
3.3.1
REMOVAL OF THE ROOF PLATES
Fig. 3-4
Roof plate overview (engine house)
3 -8
PC8000-6E
Version 2010/1
Superstructure
Engine house roof

(1)
Roof plate "cooling air intake"
(2)
Roof plate "motor"
(3)
Roof plate "PTO"
(4)
Roof plate "main pumps"
(5)
Threaded rail
(6)
Roof plate "cooling air outlet"
(7)
Bolt
(8)
Nut
(9)
Bolt
(10)
Resilient sleeve
(11)
Bolt
(12)
Lock washer
(13)
Profiled joint
(14)
Moulding material
(15)
Roof carrier
NOTE: Remove the roof plates to perform the following individual

tasks:
Removal of the electric motors
-Roof plate "cooling air intake" (Fig. 3-4, Pos. 1)
-Roof plates "motor" (Fig. 3-4, Pos. 2)
-Roof plate "cooling air outlet" (Fig. 3-4, Pos. 6)
Removal of the PTO

- Roof plate "PTO" (Fig. 3-4, Pos. 3)
- Roof plate "main pumps" (Fig. 3-4, Pos. 4)
Removal of the main pump assemblies

- Roof plate "main pumps" (Fig. 3-4, Pos. 4)
Version 2010/1
PC8000-6E
3 -9
Engine house roof
Fig. 3-5
3 - 10
Superstructure
Roof plate removal
PC8000-6E
Version 2010/1
Superstructure
Engine house roof
Special tools:
n/a
Crane
Swivel hoist rings: 4 x M12
Roof plate "motor": 185 kg
Roof plate "cooling air intake": 175 kg
Roof plate "cooling air outlet": 250 kg
Roof plate "PTO": 156 kg
Roof plate "main pumps": 175 kg
Dogman/rigger


z

WARNING
Always wear a safety harness when working at the roof.
Clear all wire harnesses from the roof plates (Fig. 3-5,
Pos. 1...4 and 6) to be removed.
WARNING
Pay attention to the Fire Detection and Suppression System.

Refer to the separate manuals "Fire Detection and Actuating
System" and "Fire Suppression System"
The wires of the Fire Detection and Suppression System
must not be bent excessively or be damaged to remain functional.
If equipped, remove the extinguishing tanks of the Fire Detection and Suppression System from the roof plate(s) to be
removed.
Version 2010/1
PC8000-6E
3 - 11
Engine house roof
Fig. 3-6
3 - 12
Superstructure
Roof plate removal
PC8000-6E
Version 2010/1
Superstructure
Engine house roof
It is recommended to remove the air outlets (Fig. 3-7, Pos. 1)

from the roof plate "cooling air outlet" (Fig. 3-6, Pos. 6).
NOTE: Check the moldings (Fig. 3-7, Pos. 2) and replace them if
required.
Fig. 3-7
z
Remove the bolts (Fig. 3-6, Pos. 7) and the nuts (Fig. 3-6,
Pos. 8) to clear all attached parts from the roof plates
(Fig. 3-6, Pos. 1...4 and 6) inside the engine house.
Remove the bolts (Fig. 3-6, Pos. 9) and the resilient sleeves
(Fig. 3-6, Pos. 10) of the roof plate(s) to be removed.
Remove the roof plates (Fig. 3-6, Pos. 1...4 and 6) from the
roof carrier (Fig. 3-6, Pos. 13) with a crane using swivel hoist
rings.
DANGER

When lifting the roof plates, make sure that nobody steps
below the weight.
Check the profiled joint (Fig. 3-6, Pos. 11) and the moulding
material (Fig. 3-6, Pos. 12) at the roof plates. Replace if
required.
Version 2010/1
PC8000-6E
3 - 13
Engine house roof
3.3.2
Superstructure
REPLACEMENT OF THE ROOF PLATES
Special tools:
n/a
Crane
Roof plate "motor": 185 kg
Roof plate "cooling air intake": 175 kg
Roof plate "cooling air outlet": 250 kg
Roof plate "PTO": 156 kg
Roof plate "main pumps": 175 kg
Dogman/rigger

z
NOTE: Always use new roof plate mounting bolts of grade 8.8.
3 - 14
PC8000-6E
Version 2010/1
Superstructure
3.3.3
Engine house roof
FRONT ROOF SECTION
3.3.3.1 REMOVAL OF THE FRONT ROOF PLATES

Special tools:
n/a

Crane
Front roof plate (max): 162 kg
Front roof frame: 310 kg
Front wall: 136.5 kg
Dogman/rigger

In order to gain free access to the assemblies hidden by the front
roof, it is necessary to remove the complete front roof frame. For
some procedures this has to be done for safety reasons, just to
avoid an inclined hoist while using a crane.
WARNING
Always wear a safety harness when working at the front roof.


z

WARNING
Pay attention to the Fire Detection and Suppression System.

Refer to the separate manuals "Fire Detection and Actuating
System" and "Fire Suppression System".
The wires of the Fire Detection and Suppression System
must not be bent excessively or be damaged to remain functional.
If equipped, remove the extinguishing tanks (Fig. 3-8, Pos. 1)

of the Fire Detection and Suppression System.
Remove the hand rails (Fig. 3-8, Pos. 2) at the front roof.
Version 2010/1
PC8000-6E
Fig. 3-8
3 - 15
Engine house roof
Fig. 3-9
3 - 16
Superstructure
Front roof section, overview
PC8000-6E
Version 2010/1
Superstructure
Engine house roof
Disconnect the hoses leading to the lubrication pump stations

from both sides of the left roof plate (Fig. 3-9, Pos. 3).
NOTE: When the hydraulic hoses are disconnected, the oil

inside the piping will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.
z
Undo the roof plate mounting bolts (Fig. 3-9, Pos. 4) and the
4 bolts (Fig. 3-9, Pos. 5) in the roof plates, then remove the
roof plates (Fig. 3-9, Pos. 1 to 3).
Clear the side wall (Fig. 3-9, Pos. 9) and the front wall part
(Fig. 3-9, Pos. 11) from the front roof frame (Fig. 3-9, Pos. 8).
Remove the front wall (Fig. 3-9, Pos. 10).
Sling the front roof frame (Fig. 3-9, Pos. 8).
Remove the bolts (Fig. 3-9, Pos. 6 and 7) connecting the front
roof frame to the engine house and to the posts. The connecting points are indicated (arrows).
Remove the front roof frame using a crane.

WARNING

When removing the front roof frame, make sure that nobody
steps below the weight.
Version 2010/1
PC8000-6E
3 - 17
Engine house roof
Superstructure
3.3.3.2 REPLACEMENT OF THE FRONT ROOF PLATES

Special tools:
n/a

Crane
Front roof plate (max): 162 kg
Front roof frame: 310 kg
Front wall: 136.5 kg
Dogman/rigger

WARNING
Always wear a safety harness when working at the front roof.
NOTE: Always use new roof plate mounting bolts of grade 10.9.
3 - 18
PC8000-6E
Version 2010/1
Superstructure
Batteries
3.4
BATTERIES
3.4.1
REMOVAL OF THE BATTERIES
Special tools:
n/a
Crane or forklift
Battery: 62 kg
Dogman/rigger
Certified electrician

the machine, boom, and crane or forklift.

z
Remove the keys from the battery main switches (Fig. 3-10,
Pos. 1).
DANGER
Danger of explosion due to hydrogen gas!

Blindness, serious injury, permanent disfigurement, and
scaring may result.
Never allow sparks or open flame near the batteries!
DO NOT short circuit or ground any terminals of the batteries!
NOTE: The batteries (Fig. 3-10, Pos. 2) are located below the
hinged floor plats (Fig. 3-10, Pos. 3) in separate boxes.
z
Remove floor plate fastening bolts and open the hinged floor
plates (Fig. 3-10, Pos. 3).
Fig. 3-10
NOTE: Wash the dirt of the floor plates (Fig. 3-10, Pos. 3) as
they can be very heavy.
z
Secure the open floor plates against falling down using the
safety chains provided.
Version 2010/1
PC8000-6E
3 - 19
Batteries
Superstructure
DANGER
Risk of electrical and fire hazard!
Death, serious injury, shock, or burns may result.
Disconnecting the batteries has to be done by a certified
electrician only.
Disconnect the ground cables (-) of both batteries first.
Disconnect the cables from the batteries (Fig. 3-11, Pos. 1).
Remove the angles (Fig. 3-11, Pos. 2) from the batteries.
Take the batteries out of the battery boxes.

WARNING
Fig. 3-11
Use the provided loops to carry the batteries.

Do not drop the battery.
3 - 20
PC8000-6E
Version 2010/1
Superstructure
3.4.2
Batteries
REPLACEMENT OF THE BATTERIES
Special tools:
n/a
n/a
Battery: 62 kg
Dogman/rigger
Certified electrician
z

DANGER
Risk of electrical and fire hazard!

Death, serious injury, shock, or burns may result.
Connecting the batteries has to be done by a certified electrician only.
Connect the positive cables (+) of the batteries first.
WARNING
Avoid spilling any electrolyte on hands or clothing.
Clean hands or clothing immediately if electrolyte was
spilled.
Repair or replace all broken wires immediately.
All terminals must be clean and securely fastened.
Never paint connections.
DANGER
Danger of explosion due to hydrogen gas!
Blindness, serious injury, permanent disfigurement, and
scaring may result.
Never allow sparks or open flame near the batteries!
DO NOT short circuit or ground any terminals of the batteries!
Version 2010/1
PC8000-6E
3 - 21
Electric motors
3.5
Superstructure
ELECTRIC MOTORS
The excavator is powered by two ABB electric motors:

Model:
AMA 500L4A BAHXYH
Type:
ABB induction motor
Rated power:
1450 kW
3.5.1
REMOVAL OF THE FRONT ELECTRIC MOTOR (MOTOR 1)
Special tools:
n/a
Crane
Electric motor: 5600 kg
Dogman/rigger
For further information about the needed blind plugs, refer to section
6.6 on page 6-14.
z


z

DANGER
Hazardous Voltage!

3 - 22
PC8000-6E
Version 2010/1
Superstructure
Electric motors
WARNING
Do not carry out the following work on a hot motor. Wait until
the temperature of the motor is below 50 C.
Disobedience may result in personal injury from heated
parts.
Remove the necessary roof plates for motor removal, refer to

section 3.3.1 on page 3-8.
Remove the cover (Fig. 3-12, Pos. 1) of the motor connecting

box.
Disconnect the tree phase cables (Fig. 3-12, Pos. 3) in the

motor connecting box and pull the cables out of the housing.
Open the cable clamps (Fig. 3-12, Pos. 2) to clear the phase
cables from the motor connecting box.
Fig. 3-12
Remove the cover of the auxiliary terminal box (Fig. 3-13,

Pos. 1).
Disconnect and remove the wire harnesses (e.g. temperature

monitoring) from the auxiliary terminal box. Clear the wire
harnesses from the electric motor.
Disconnect the protective earth from the electric motor.
Fig. 3-13
Version 2010/1
PC8000-6E
3 - 23
Electric motors
Superstructure
Fig. 3-14 Removal of the electric motor

z
Loosen the adjusting bolts (Fig. 3-14, arrows) and the jacking
bolts (Fig. 3-14, Pos. 1) on both sides of the motor.
Unscrew the nut (Fig. 3-14, Pos. 2) and remove the motor fixing bolt (Fig. 3-14, Pos. 3).
Remove the flexible type coupling (Fig. 3-14, Pos. 4), refer to
section 3.6 on page 3-36.
3 - 24
PC8000-6E
Version 2010/1
Superstructure
Electric motors
Attach the motor (Fig. 3-15, Pos. 1) to a crane using two lifting bars (Fig. 3-15, Pos. 3).
CAUTION
Make sure not to damage the motor cooler assembly

(Fig. 3-15, Pos. 2).
z
Use the Lifting eyes at the motor (Fig. 3-15, Pos. 1) only.
Use suitable lifting bars (Fig. 3-15, Pos. 3) which are long
enough that the lifting accessory does not come in contact with the motor cooler assembly.
Fig. 3-15
Lift the motor out of the engine house using a crane.

DANGER

When removing the motor, make sure that nobody steps
below the weight.
Remove the compensation plates (Fig. 3-14, Pos. 5).
NOTE: The compensation plates should be used as pattern for

some new plates which may be needed in the alignment
procedure.
Version 2010/1
PC8000-6E
3 - 25
Electric motors
3.5.2
Superstructure
REPLACEMENT OF THE FRONT ELECTRIC MOTOR (MOTOR 1)
Special tools:
n/a
Crane
Electric motor: Electric motor: 5600 kg
Dogman/rigger
DANGER
Hazardous Voltage!
Prepare the motor seats before mounting.
NOTE: The seats must be free from dirt and rust.

z
Attach the new motor (Fig. 3-16, Pos. 1) to a crane using two
lifting bars (Fig. 3-16, Pos. 3).
CAUTION
Make sure not to damage the motor cooler assembly

(Fig. 3-16, Pos. 2).
z
Use the Lifting eyes at the motor (Fig. 3-16, Pos. 1) only.
Use suitable lifting bars (Fig. 3-16, Pos. 3) which are long
enough that the lifting accessory does not come in contact with the motor cooler assembly.
Fig. 3-16
3 - 26
PC8000-6E
Version 2010/1
Superstructure
Electric motors
Fig. 3-17 Replacement of the electric motor

z
Lift the motor into the engine house using a crane.

DANGER

When removing the motor, make sure that nobody steps
below the weight.
Screw in the jacking bolts (Fig. 3-17, Pos. 1) completely.
Insert new motor fixing bolts (Fig. 3-17, Pos. 3) of the grade
10.9 and secure the bolts with the nuts (Fig. 3-17, Pos. 2).
Tighten the nut hand-tight.
If required, install the couplings input drive hub onto the

motor power take-off shaft (H7 drive fit), refer to section
3.6.1.2 on page 3-39.
Version 2010/1
PC8000-6E
3 - 27
Electric motors
Superstructure
Carry out the alignment procedure, refer to section 3.5.5 on

page 3-29.
DANGER
Hazardous Voltage!
De-isolate the machine according to local regulations and

according to the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.
Check the direction of the electric motors rotation.

Change the connection of the phase lines if required.
Install a new flexible type coupling (Fig. 3-17, Pos. 4), refer to
section 3.6 on page 3-36.
Carry out further installation in reverse order to removal.

WARNING
Before each motor starting make sure that all controls are in
neutral position. Be sure to sound the signal horn before
starting to make your intention clear.
NOTE: Before starting the motors pay attention to the hydraulic

oil temperature. Refer to the Operation & Maintenance
Manual, chapter 3, section "STARTING PROCEDURE".
3.5.3
REMOVAL OF THE REAR ELECTRIC MOTOR (MOTOR 2)
The removal of the rear electric motor is analogously the same as

the removal of the front electric motor, refer to section 3.5.1 on
page 3-22.
3.5.4
REPLACEMENT OF THE REAR ELECTRIC MOTOR (MOTOR 2)
The replacement of the rear electric motor is analogously the

same as the replacement of the front electric motor, refer to section 3.5.2 on page 3-26.
3 - 28
PC8000-6E
Version 2010/1
Superstructure
3.5.5
Electric motors
FINAL ALIGNMENT OF THE ELECTRIC MOTORS
Special tools:
n/a
2 x Dial gauge (minimum requirement)

Laser alignment set (recommended), PN 232 713 40 + PN 232 714 40
For the alignment procedure the following preconditions are considered:

A new electric motor is installed.
The new motor is jacked up by the jacking bolts.
The flexible coupling is not installed yet.
The couplings hubs are already installed at the motor power takeoff shaft and at the PTO drive shaft.
NOTE: Due to higher accuracy, it is recommended to make all
measurements in the alignment procedure with a laser
alignment set instead of dial gauges. Observe the
instructions given in the manual of the laser alignment
set.
z
Rotate the motors rotor and check the axial clearance.
NOTE: The sleeve bearings of the motor must be lubricated

properly before turning the motor.
Rough adjustment
z
Move the motor (Fig. 3-18, Pos. 1) by using the adjusting

bolts (Fig. 3-18, Pos. 3) and the jacking bolts (Fig. 3-20,
Pos. 1) until the drive shaft center line and the center line at
the PTO drive shaft are aligned roughly.
Adjust the desired mounting distance between the hubs by

using the adjusting bolts (Fig. 3-18, Pos. 3).
For the proper mounting distance for the coupling, refer to the
PARTS & SERVICE NEWS No. "AH01523".
NOTE: Leave all adjusting screws only lightly tightened.

Fig. 3-18
Run-out check
The alignment procedure is started by measuring the run-out of
the coupling hubs. This measurement will show any inaccuracy of
the shaft and / or hubs.
z
The run-out of the coupling hub in respect to the bearing

housing of the motor is measured.
Place the dial gauges according to Fig. 3-19 to measure the

run-out at the coupling hub.
Similarly check the run-out of the coupling hub at the PTO

drive shaft in respect to its bearing housing.
A simple lever arm is needed to turn the rotor of the electric

motor.
Fig. 3-19
Version 2010/1
PC8000-6E
3 - 29
Electric motors
Superstructure
Fig. 3-20 Alignment of the electric motors

Final alignment:
z
Mount the dial gauges as shown in Fig. 3-21.
NOTE: It is practical to adjust the dial gauges in such way that

approximately half of the scale is available in either direction. Check the rigidity of the gauge brackets in order to
eliminate the possibility of sag.
z
Measure and record readings for parallel (Fig. 3-21, Pos. 1),
angular (Fig. 3-21, Pos. 2) and axial misalignment in four different positions: top, bottom, right and left, i.e. every 90,
while both shafts are turned simultaneously.
NOTE: For the permissible alignment tolerances for the coupling,

refer to the PARTS & SERVICE NEWS No. "AH01523".
3 - 30
PC8000-6E
Fig. 3-21
Version 2010/1
Superstructure
Electric motors
Align the motor vertically by turning the jacking bolts

(Fig. 3-20, Pos. 1).
Measure the distance between the bottom of the motor feet

and the powerframe.
Manufacture corresponding compensation plates (Fig. 3-20,

Pos. 5) and position the compensation plates between powerframe and motor feet.
Loosen the jacking bolts and tighten the fixing bolts /nuts
(Fig. 3-20, Pos. 2 and 3) to the specified torque:
Tightening torque for motor fixing bolts and nuts
(Fig. 3-20, Pos. 2 and 3): 3100 Nm
Check the alignment again. Make corrections if necessary.
Record the data for future checks.
Version 2010/1
PC8000-6E
3 - 31
Electric motors
3.5.6
Superstructure
CAPACITOR ASSEMBLIES
Fig. 3-22 Capacitor assemblies, overview

(1)
Capacitor assembly
(2)
Motor connecting box
(3)
Cooling air intake
(4)
Junction cable
(5)
Cable clamp
(6)
Bolt
3 - 32
PC8000-6E
Version 2010/1
Superstructure
Electric motors
The capacitor assembly is a 3-phase capacitor bank, in Y-connection. Each capacitor in the bank has a built in pressure monitoring
device.
The capacitor assembly operates as an operating capacitor to
generate the phase displacement for the electric motor.
NOTE: it is not nessecary to dismantle the cooling air intake
(Fig. 3-22, Pos. 3) before removing the capacitor assembly (Fig. 3-22, Pos. 1). Therefore a second person is
required to handle the assembly.
3.5.6.1 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 1)

Special tools:
n/a
Crane
Capacitor assembly: 50 kg

2nd. person to handle the assembly


z

DANGER
Hazardous Voltage!

Version 2010/1
PC8000-6E
3 - 33
Electric motors
Superstructure
WARNING
Do not carry out the following work on a hot capacitor
assembly.
Wait until the temperature of the capacitor assembly is below
50 C.
Disobedience may result in personal injury from heated
parts.
Disconnect the wire harnesses from the pressure monitoring

devices (Fig. 3-23, Pos. 1).
Disconnect the ground wire from the cable cland (Fig. 3-23,
Pos. 2).
Fig. 3-23
Remove the cover (Fig. 3-24, Pos. 1) of the connecting box

(Fig. 3-24, Pos. 2).
Disconnect the phase lines of the junction cable

(Fig. 3-24, Pos. 4).
Open the cable clamp (Fig. 3-24, Pos. 3) and remove the
junction cable from the connecting box.
Remove the mounting bolts (Fig. 3-24, Pos. 5) and lift the
capacitor assembly off its mounting position.
NOTE: A second person is required to handle the assembly.

Fig. 3-24
3 - 34
PC8000-6E
Version 2010/1
Superstructure
Electric motors
3.5.6.2 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 1)

Special tools:
n/a
Crane
Capacitor assembly: 50 kg

2nd. person to handle the assembly
DANGER
Hazardous Voltage!

WARNING
Before each motor starting make sure that all controls are in
neutral position. Be sure to sound the signal horn before
starting to make your intention clear.
NOTE: Before starting the motors pay attention to the hydraulic

oil temperature. Refer to the Operation & Maintenance
Manual, chapter 3, section "STARTING PROCEDURE".
3.5.6.3 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 2)

The removal of the capacitor assembly for the rear electric motor
(Motor 2) is analogously the same as the removal of the capacitor
assembly for the front electric motor (Motor 1), refer to section
3.5.6.1 on page 3-33.
3.5.6.4 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 2)

The replacement of the capacitor assembly for the rear electric
motor (Motor 2) is analogously the same as the replacement of
the capacitor assembly for the front electric motor (Motor 1), refer
to section 3.5.6.2 on page 3-35.
Version 2010/1
PC8000-6E
3 - 35
Flexible coupling
Superstructure
3.6
FLEXIBLE COUPLING
3.6.1
VULKAN COUPLING ASSEMBLY
Fig. 3-25 Vulkan coupling assembly

The Vulkan coupling is a torsionally flexible rubber coupling, that
compensates axial, angular and, to a certain degree, radial displacement of the connected machines.
The Vulkan coupling transfers the torque without any slippage.
The disc-shaped elastic element with "plug-in" teeth at the outer
radius (PTO side) can be replaced without dismantling the motor
and the pump distributor gearbox (PTO) respectively.
3 - 36
PC8000-6E
Version 2010/1
Superstructure
Flexible coupling

(1)
Coupling assembly
(2)
Bolt
(3)
Bolt
(4)
Bolt
(5)
Nut
(6)
Cover ring
(7)
PTO drive hub
(8)
Motor drive hub
(9)
Key
(10)
Bolt
(11)
Ring
(12)
Bolt
(13)
Motor power take-off shaft
(a)
Mounting distance
Refer to PARTS & SERVICE NEWS No "AH01523".
3.6.1.1 REMOVAL OF THE VULKAN COUPLING

Special tools:
n/a
Chain hoist
Coupling assembly: 38 kg
Cover ring: 94 kg
Dogman/rigger

the machine.

Version 2010/1
PC8000-6E
3 - 37
Flexible coupling
Superstructure
NOTE: Check if a lifting eye (Fig. 3-26, Pos. 1) is installed at the

roof plate over the coupling. Use the lifting eye to hook a
chain hoist.
If no lifting eye is installed, it has to be welded to the roof
plate.
WARNING
For welding follow the welding precautions given in the
Operation & Maintenance Manual, chapter 4, section "WELD
REPAIRS" and refer to the PARTS & SERVICE NEWS
No. "AH08507".
Fig. 3-26
Remove the coupling protection cover (Fig. 3-27, Pos. 1).
Fig. 3-27
z
Remove the vulkan coupling according to PARTS & SERVICE NEWS No "AH01523".
NOTE: The motor drive hub (Fig. 3-28, Pos. 5) is a component

part of the electric motor and is not delivered with the
coupling.
z
Carry out the next three steps only if required.

z
Remove the bolts (Fig. 3-28, Pos. 1) and take the PTO
drive hub (Fig. 3-28, Pos. 2) off the PTO.
Remove the bolt (Fig. 3-28, Pos. 3) and the ring

(Fig. 3-28, Pos. 4).
Draw the motor drive hub (Fig. 3-28, Pos. 5) off the motor
power take-off shaft (Fig. 3-28, Pos. 6) and remove the
Fig. 3-28
key (Fig. 3-28, Pos. 7).
3 - 38
PC8000-6E
Version 2010/1
Superstructure
Flexible coupling
3.6.1.2 REPLACEMENT OF THE VULKAN COUPLING

Special tools:
n/a
Chain hoist
Coupling assembly: 38 kg
Cover ring: 94 kg
Dogman/rigger

NOTE: The motor drive hub (Fig. 3-28, Pos. 5) is a component

part of the electric motor and is not delivered with the
coupling.
z
Carry out the next three steps only if required.

z
Insert the key (Fig. 3-29, Pos. 7) into the motor power
take-off shaft (Fig. 3-29, Pos. 6).
Press the motor drive hub (Fig. 3-29, Pos. 5) onto the
motor power take-off shaft (H7 drive fit) (Fig. 3-28,
Pos. 6) using the bolt (Fig. 3-29, Pos. 3) and the ring
(Fig. 3-29, Pos. 4).
Install the PTO drive hub (Fig. 3-29, Pos. 2) to the PTO Fig. 3-29
and insert the mounting bolts (Fig. 3-29, Pos. 1).
NOTE: Use new mounting bolts (Fig. 3-29, Pos. 1) of grade 10.9.
Apply compound "KP2K", PN 324 969 40 to the bolts.
Use a new mounting bolt (Fig. 3-29, Pos. 3) of grade 8.8.
Apply oil SAE 10 to the mounting bolt
Tighten all mounting bolts to the specified tightening
torque.
Tightening torques
for mounting bolt (Fig. 3-29, Pos. 3): 2170 Nm
for mounting bolts (Fig. 3-29, Pos. 1): 360 Nm
z
Install the new vulkan coupling according to PARTS & SERVICE NEWS No "AH01523".
Version 2010/1
PC8000-6E
3 - 39
PTO
Superstructure
3.7
PTO
3.7.1
MAIN PUMPS
Fig. 3-30 Main pumps assembly
3 - 40
PC8000-6E
Version 2010/1
Superstructure
PTO

(1)
Main pump 1
(2)
Main pump 2
(3)
Main pump 3
(4)
Main pump 4
(5)
Main pump 5
(6)
Main pump 6
(7)
Main pump 7
(8)
Main pump 8
(9.1
to
9.4)
Gear pumps
(PTO-oil, pilot oil)
(10.1
and
10.3)
Auxiliary pumps
(hydraulic cooler fan drive pumps)
The rotative energy from each main motor propels the gears in
the pump distributor gear boxes (Fig. 3-30, Pos. 9,
Pos. 10) and the gears propel the main pumps (Fig. 3-30,
Pos. 1 to 8) and auxiliary pumps (Fig. 3-30, Pos. 10.1 and 10.3).
The pumps create a hydraulic oil flow to the cylinders or hydraulic
motors. The main high pressure hydraulic circuits are supplied by
eight swash plate type variable displacement pumps (Fig. 3-30,
Pos. 1 to 8). The main pumps 2, 4, 6, and 8 are additionally
equipped with gear pumps (Fig. 3-30, 9.1 to 9.4).
Version 2010/1
PC8000-6E
3 - 41
PTO
Superstructure
3.7.1.1 REMOVAL OF MAIN PUMPS

Special tools:
n/a
Crane
Oil drain pans
Main pump assembly with flanged gear pump: 524 kg
Dogman/rigger
6.6 on page 6-14.
NOTE: The removal of all main pumps is analogously always the

same.
Fig. 3-31
z


z
Relieve the pressure in the hydraulic system, refer to the

Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
3 - 42
PC8000-6E
Version 2010/1
Superstructure
PTO
Close the hand wheel (Fig. 3-32, Pos. 1) of the main gate
valve between the suction oil reservoir and the main oil reservoir.
To accelerate the draining of oil from the pumps, loosen the

vent plugs on the main pumps, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".
Transfuse the oil from the suction oil reservoir into the main
oil reservoir, refer to the Operation & Maintenance Manual,
chapter 3, section "TRANSFUSION PROCEDURE".
Fig. 3-32
Remove the roof plate "main pumps", refer to section on

page 3-11.
If equipped, remove fasteners for the hoses of the main pump

assembly to be removed.
Drain the oil of the resp. drive shaft housing
(Fig. 3-33, Pos. 6), approx. 1.5 liters by removing the
drain plug (Fig. 3-33, Pos. 2).
Remove the level opening plug (Fig. 3-33, Pos. 1) to
speed up the draining procedure.
NOTE: When the plugs are removed, the oil inside the drive shaft
housing will flow out. Catch it in an oil pan.
z
Mark all pipes and hoses at that main pump assembly of the
main pump to be removed.
Fig. 3-33
WARNING
Hot hydraulic oil!
Do not carry out the following work on a hot machine. Wait
until the temperature of the hydraulic oil is below 50 C.
Disobedience may result in personal injury from heated oil.
Version 2010/1
PC8000-6E
3 - 43
PTO
Superstructure
Disconnect the SAE-flanges of the pressure hose and the

suction hose from the gear pump (Fig. 3-34, Pos. 4) of the
main pump to be removed.
NOTE: When the pump hoses are disconnected, the oil inside
the piping will flow out. Catch it in an oil pan.
z
Disconnect the leak oil hose and all control hoses from the
control block (Fig. 3-34, Pos. 1).
Disconnect the bearing flushing/lubrication hose from the

right side of the pump mounting flange.
Disconnect the high pressure hose (Fig. 3-34, Pos. 2) from

the main pump assembly.
Disconnect the suction hose (Fig. 3-34, Pos. 3) at the bottom

side of the pump.
Fig. 3-34
z
Sling pump assembly as shown in Fig. 3-35.
Remove mounting bolts. Then remove pump assembly by

pulling it out of the pump distributor gear box.
DANGER

When removing the main pump assembly, make sure that
nobody steps below the weight.
NOTE: To simplify the removal, move the pump assembly lightly

up and down.
Fig. 3-35
When the pump assembly is removed, oil will flow out of

the drive shaft housing. Catch it in an oil pan.
z
Check the O-ring (Fig. 3-35, Pos. 1) at the pump assembly

flange and replace it if required.
3 - 44
PC8000-6E
Version 2010/1
Superstructure
PTO
3.7.1.2 REPLACEMENT OF MAIN PUMPS

Special tools:
n/a
Crane
Paste Optimol White, PN 999 039
Main pump assembly with flanged gear pump: 524 kg
Dogman/rigger
Observe the safety hints for hydraulic hose installation, refer to section
2.2.6 on page 2-22.
NOTE: When mounting a new pump, activate the external flushing of bearing. Refer to the PARTS & SERVICE NEWS
No. "AH05510".
z
NOTE: Use "Optimol White" on the spline shaft of the pump.

Use new bolts with grade 8.8 at the mounting flanges of
the main pump.
Tighten the bolts to the specified tightening torque.
Tightening torque for the mounting bolts:
510 Nm
NOTE: For connecting the suction hose, refer to the
Always use new O-rings at the SAE-flange connections
and hose fittings.
Refill specified lubricant in the drive shaft housing,
approx. 1.5 liters, refer to the Operation & Maintenance
Manual, chapter 4, section "PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL
LEVEL".
Fill up to the lower edge of the level plug opening (Fig. 336, Pos. 1).
For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".
Fig. 3-36
Version 2010/1
PC8000-6E
3 - 45
PTO
Superstructure
Bleed air from the hydraulic system, refer to the Operation &
Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS
AND PULSATION DAMPER" and the PARTS & SERVICE
NEWS No. "AH01513".
Add specified hydraulic oil up to the specified level.
Adjust main pump, refer to the Service Manual.
Check for leaks and proper operation.
Check the hydraulic oil level again and correct the oil level if
required.
3 - 46
PC8000-6E
Version 2010/1
Superstructure
3.7.2
PTO
PTO OIL PUMPS (AUXILIARY PUMPS)
The PTO gear oil pumps (Fig. 3-37, Pos. 9.2 and 9.4) for the PTO
gear lubrication aspirate gear oil from the PTO gear boxes sump
and pump it through filters and coolers back to the PTOs.
The Pumps are mounted at main pump 4 and 8.
Fig. 3-37
NOTE: The removal of the PTO gear oil pump (front electric
motor, Fig. 3-38, Pos. 1) is analogously the same as the
removal of the PTO gear oil pump (rear electric motor,
Fig. 3-38, Pos. 2).
Fig. 3-38
3.7.2.1 REMOVAL OF THE PTO OIL PUMPS (AUXILIARY PUMPS)

z
The removal of the PTO gear oil pumps (Fig. 3-37,

Pos. 9.2 and 9.4) is analogously the same as the removal of
the pilot oil pumps, refer to section 3.8.4.1 on page 3-101.
3.7.2.2 REPLACEMENT OF THE PTO OIL PUMPS (AUXILIARY PUMPS)

z
The replacement of the PTO gear oil pumps (Fig. 3-37,

Pos. 9.2 and 9.4) is analogously the same as the removal of
the pilot oil pumps, refer to section 3.8.4.2 on page 3-103.
Version 2010/1
PC8000-6E
3 - 47
PTO
3.7.3
Superstructure
PUMP DISTRIBUTOR GEARBOX (PTO)
Fig. 3-39 Pump distributor gearbox
3 - 48
PC8000-6E
Version 2010/1
Superstructure
PTO

(1)
Oil level gauge
(2)
Oil filler plug
(3)
Breather filter
(4)
(5)
Flange for heater studs
(6)
Main pump drive shaft housing
(7)
(8)
Oil filler plug with breather pipe of pump drive shaft

housing
(9)
(10)
Oil drain plug of PTO gear
(11)
Suction line connection for gear oil cooling
(12)
Gear oil temperature probe mounting bore
(13)
Thermostat switch mounting cover plate
(14)
Return line connection from gear oil cooler
(15)
Return line connection from cooling system relief

valve
(D)
Drive flange
(M)
Power take-off for main pumps
(R)
Power take-off not used and sealed with a blind plate
(C)
Power take-off for hydraulic oil cooler fan drive pump
NOTE: Detail "S".

The arrows at detail "S" indicate the spray direction of the
jet borings. Pay attention when disassembling / assembling.
The pump distribution gear (PTO gear) is from a spur gear design
and driven by an electric motor. It is equipped with an external
lubrication/cooling system.
The PTO gear runs in anti-friction bearings and it has been provided with a splash lubrication system. The oil supply of the bearings and tooth contacts takes place by an injection. The
gearwheels are of case-hardened steel. The hydraulic pumps are
directly attached to the gearbox. The O-rings included in the delivery seal the unit statically and reliably.
The gearbox housing is a one-piece design and made of grey
cast iron. The Gearbox design allows a direct attachment to the
electric motor via a connection flange. The gearbox has been provided with connections for a separate cooling system or for a preheating system.
Always check the gearbox oil level with unlocked dip stick and
stopped electric motors.
Version 2010/1
PC8000-6E
3 - 49
PTO
Superstructure
3.7.3.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO)

Special tools:
n/a
Crane
Oil drain pans
PTO: 2450 kg
Control and filter plate assembly: 237 kg
Dogman/rigger
6.6 on page 6-14.
z
Remove the roof plates "PTO" and "main pumps", refer to

section on page 3-11.
NOTE: The removal of the pump distributor gearbox 1 (Fig. 3-40,

Pos. 1) and pump distributor gearbox 2 (Fig. 3-40,
Pos. 2) is analogously the same.
Drain the gear oil of the PTO to be removed, approx.
140 liters. Refer to the Operation & Maintenance
Manual, chapter 4, section "PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL".
z
Remove main pump assemblies, refer to section 3.7.1 on

page 3-40.
Fig. 3-40
z
Remove the hydraulic cooler fan drive pump from the PTO to
be removed, refer to section 3.8.1.1 on page 3-56.
Relieve the pilot pressure at the pressure check point M40 for
the accumulator, refer to the Service Manual.
3 - 50
PC8000-6E
Version 2010/1
Superstructure
PTO
Fig. 3-41 PTO 1+2 with control and filter plates
(1)
Pump distributor gearbox (PTO), electric motor 1
(2)
Control and filter plate (electric motor 1)
(3)
Pump distributor gearbox (PTO), electric motor 2
(4)
Control and filter plate (electric motor 2)
Mark and disconnect all hydraulic lines and electrical wires

leading to the control- and filter plate assembly of the PTO to
be removed (Fig. 3-41, Pos. 2 respectively Fig. 3-41, Pos. 4).
NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan.
Version 2010/1
PC8000-6E
3 - 51
PTO
Superstructure
Attach the control and filter plate assembly (Fig. 3-42, Pos. 3)
of the PTO to be removed to a crane.
Remove the mounting bolts (Fig. 3-42, Pos. 1) with resilient

sleeves (Fig. 3-42, Pos. 2).
Remove the control and filter plate assembly (Fig. 3-42,

Pos. 3) using a crane.
DANGER

When removing the control frame assembly make sure that
Fig. 3-42
z
Disconnect all hydraulic hoses (Fig. 3-43, Pos. 1) from the

PTO (Fig. 3-43, Pos. 2).
NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan.
z
Disconnect and clear all retainers for hydraulic hoses and

electrical wires from the PTO.
Fig. 3-43
3 - 52
PC8000-6E
Version 2010/1
Superstructure
PTO
Disconnect the temperature sensor (Fig. 3-44, B49-1 and

B49-2).
Disconnect the heating and the thermal switch if equipped.
Remove the torsion type coupling, refer to section 3.6 on

page 3-36.
Fig. 3-44
z
Attach the PTO to a crane, using the lifting eyes (Fig. 3-45,
arrows).
Remove the bolts (Fig. 3-45, Pos. 2) with resilient sleeves

(Fig. 3-45, Pos. 2) attaching the PTO to the support.
Fig. 3-45
z
Remove the PTO using the crane.

DANGER

When removing the PTO, make sure that nobody steps below
the weight.
Version 2010/1
PC8000-6E
3 - 53
PTO
Superstructure
3.7.3.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO)

Special tools:
Hydraulic testing kit, PN 232 591 40
Paste "Optimol White" PN 999 039

Crane
PTO: 2450 kg
Control and filter plate assembly: 237 kg
Dogman/rigger

z
If required, install the temperature sensor, the heating, and

the thermal switch to the replacement PTO.
NOTE: Always use new O-rings at all SAE-flange connections.

NOTE: Use new mounting PTO bolts of the grade 10.9. Apply
compound "KP2K", PN 324 969 40 on the PTO mounting
bolts (Fig. 3-46, Pos. 2) and tighten the bolts to the specified tightening torque.
Tightening torque for the PTO mounting bolts:
1770 Nm
Fig. 3-46
Refill specified gear oil into the PTO, approx.

140 liters.
Refer to the Operation & Maintenance Manual,
chapter 4, section "PTO (PUMP DISTRIBUTOR
GEAR) - CHANGE OIL".
z
Warm up the machine, test the pressure of the circulation

pump and adjust if required. Refer to the Service Manual for
further information.
3 - 54
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8
HYDRAULICS
3.8.1
HYDRAULIC COOLER FAN DRIVE PUMPS
The hydraulic cooler fan drive pump is a fixed displacement pump

with variable setting. The pump of the type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an
internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft
The hydraulic cooler fan drive pumps are mounted at both PTOs
(Fig. 3-47, Pos.1 and Pos. 2).
Fig. 3-47
Each hydraulic fan drive pump (Fig. 3-48, Pos. 10.1 and 10.3)
supplies one hydraulic oil cooler fan drive, one additional oil
cooler fan drive, and one PTO cooler fan drive.
Fig. 3-48
Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of
an adjusting screw.
z
With an increase in the swivel angel, the pump output

increases together with the necessary drive torque.
With a decrease in the swivel angel, the pump output

decreases together with the necessary drive torque.
NOTE: When increasing to maximum swivel angle, there is a

danger of cavitation and over-speeding the hydraulic
motor.
Version 2010/1
PC8000-6E
3 - 55
Hydraulics
Superstructure
3.8.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMPS

Special tools:
n/a
Chain hoist
Crane
Oil drain pan
Hydraulic cooler fan drive pump: 74 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Fig. 3-49
3 - 56
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
NOTE: Check if a lifting eye (Fig. 3-50, Pos. 1) is installed at the

roof plate over the pump. Use the lifting eye to hook a
chain hoist.
If no lifting eye is installed, it has to be welded to the roof
plate.
WARNING
Operation & Maintenance Manual, chapter 4, section "WELD
REPAIRS" and refer to the PARTS & SERVICE NEWS
No. "AH08507".
Fig. 3-50
WARNING
Hot hydraulic oil!
Disconnect the pressure hose (Fig. 3-51, Pos. 2) and the suction hose (Fig. 3-51, Pos. 1) from the hydraulic cooler fan
drive pump (Fig. 3-51, Pos. 3).
NOTE: When the hoses are disconnected, the oil inside the piping will flow out.
Catch it in an oil pan.
z
Connect the pump to by a chain hoist and remove the four

mounting bolts (Fig. 3-51, Pos. 4).
Remove the hydraulic cooler fan drive pump (Fig. 3-51,

Pos. 3) by pulling it out of the PTO.
Fig. 3-51
NOTE: To simplify the removal, move the pump lightly up and

down.
When the pump is removed, oil will flow out of the spline
shaft housing. Catch it in an oil pan.
z
Check the O-ring at the pump flange and replace it if required.
Remove the hydraulic cooler fan drive pump.
Version 2010/1
PC8000-6E
3 - 57
Hydraulics
Superstructure
3.8.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMPS

Special tools:
Rotational speed infrared probe DS03, PN 793 788 73
Crane
Chain Hoist
Hydraulic cooler fan drive pump: 74 kg
Dogman/rigger
2.2.6 on page 2-22.
z

Always use new O-rings at the SAE-flange connections.
Use new bolts (Fig. 3-51, Pos. 4) with grade 8.8 at the
mounting flanges.
179 Nm
Refill the pump drive shaft housing (Fig. 3-52, Pos. 1)

up to the specified level.
For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND
LUBRICANTS".
NEWS No. "AH01513".
Fig. 3-52
z
3 - 58
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Check and adjust the speed of the hydraulic cooler fan, refer
to the Operation and Maintenance Manual, chapter 3, section
"ELECTRONIC MONITORING AND CONTROL SYSTEM
ECS".
3.8.2
ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY
There are two cooler elements mounted in one frame on top of

the standard hydraulic oil cooler. The air stream needed for the
cooling is produced by hydraulically driven fans. The air flows
from inside to outside through the coolers.
For better cleaning, the cooler frames are mounted via hinges to
the cooler support so the cooler frames can be opened ("swing
out cooler").
Fig. 3-53
The two cooler fans are driven by hydraulic motors. Each motor is
supplied by one hydraulic pump.
The hydraulic pump (Fig. 3-54, Pos. 2) on PTO 1 (Fig. 3-54,
Pos. 1) supplies the first hydraulic fan motor (Fig. 3-54, Pos. 3).
Pos. 4) supplies the second hydraulic fan motor (Fig. 3-54,
Pos. 6) at the additional cooler fan assembly.
The fans are mounted directly to the hydraulic motor fan shaft.
Fig. 3-54
Version 2010/1
PC8000-6E
3 - 59
Hydraulics
Superstructure
Fig. 3-55 Additional hydraulic oil cooler circuit

3 - 60
PC8000-6E
Version 2010/1
Superstructure
Hydraulics

(1)
(2)
Lines to hydraulic oil reservoir
(3)
Line to fan motor
(4)
Line to fan motor
Oil delivery of both fan drive pumps is directed to the additional

cooler elements after leaving the four driven motors and flows
back into the filter chamber of the main oil reservoir.
This ensures that a constant oil volume circulates through the
additional cooler, independent of the main return oil flow.
Version 2010/1
PC8000-6E
3 - 61
Hydraulics
Superstructure
3.8.2.1 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLER FAN ASSEMBLY

Special tools:
n/a
Oil drain pan

Crane
Additional hydraulic oil cooler fan assembly: 104 kg
Dogman/rigger
6.6 on page 6-14.
Fig. 3-56 Additional hydraulic oil cooler fan assembly
3 - 62
PC8000-6E
Version 2010/1
Superstructure
Hydraulics

(1)
Fan motor
(2)
Bolt
(3)
Fan cross-head
(4)
Fan
(5)
Locking plate
(6)
Bolt
(7)
Bolt
(8)
Washer
(9)
Adapter


z


WARNING
Hot hydraulic oil!

DANGER
Danger of hydraulic pressure!
Blindness, serious injury, permanent disfigurement or scaring may result.
The hydraulic system may pressurized. Make sure, that the
pressure is relieved before any hydraulic line will be
removed.
Version 2010/1
PC8000-6E
3 - 63
Hydraulics
Superstructure
Disconnect all hydraulic hoses and leak oil hoses from the
hydraulic motors at the additional hydraulic oil cooler fan
assembly.
NOTE: When the hoses are removed, the oil inside the hoses
and the hydraulic motors will flow out.
z
Remove the protective gratings (Fig. 3-57, Pos. 1).
Remove the additional hydraulic oil cooler fan assembly

(Fig. 3-57, Pos. 2) from the additional hydraulic oil cooler
using a crane.
WARNING
Fan blades could have sharp edges. Use gloves!
CAUTION
Fig. 3-57
Remove the assembly carefully in order not to damage the

oil cooler or the fan blades.
DANGER
Risk of fallen weights!
When removing the additional hydraulic cooler fan assembly
make sure, that nobody steps below the weight.
3 - 64
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.2.2 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER FAN ASSEMBLY

Special tools:
n/a
Oil drain pan

Crane
Additional hydraulic oil cooler fan assembly: 104 kg
Dogman/rigger

z

WARNING
CAUTION
Install the assembly carefully in order not to damage the oil
cooler or the fan blades.
NEWS "AH01513".
ECS".
Version 2010/1
PC8000-6E
3 - 65
Hydraulics
Superstructure
3.8.2.3 REMOVAL OF ADDITIONAL HYDRAULIC OIL COOLER FANS AND MOTORS

Special tools:
n/a
Oil drain pan

Hydraulic oil cooler fan assembly: 104 kg
Fan: 17 kg
Adapter: 3 kg
Fan cross-head: 44 kg
Fan motor: 10 kg
Dogman/rigger
6.6 on page 6-14.
z
Remove the additional hydraulic oil cooler fan assembly, refer

Fig. 3-58 Additional hydraulic oil cooler fan assembly
3 - 66
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
WARNING
Remove the attaching bolts (Fig. 3-58, Pos. 6) with the locking plates (Fig. 3-58, Pos. 5). Discard the locking plates.
Remove the bolt (Fig. 3-58, Pos. 7), the washer

(Fig. 3-58, Pos. 8) and the adapter (Fig. 3-58, Pos. 9).
Remove the cooler fan (Fig. 3-58, Pos. 4).
Remove the four bolts (Fig. 3-58, Pos. 2) and remove the
hydraulic motor (Fig. 3-58, Pos. 1) from the fan cross-head
(Fig. 3-58, Pos. 3).
3.8.2.4 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER FANS AND

MOTORS
Special tools:
n/a
Oil drain pan

Fan: 17 kg
Adapter: 3 kg
Fan cross-head: 44 kg
Fan motor: 10 kg
Dogman/rigger

z
Use new locking plates (Fig. 3-58, Pos. 5) and a new washer
(Fig. 3-58, Pos. 8).
WARNING
NEWS "AH01513".
Version 2010/1
PC8000-6E
3 - 67
Hydraulics
Superstructure
3.8.2.5 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLERS

Special tools:
n/a

Oil drain pan
Crane
Mobile elevator working platform
Additional hydraulic oil cooler: 230 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Fig. 3-59
WARNING
z
Always wear a safety harness when working at the additional hydraulic oil cooler.
Most of the following operations require the use of men

safety cages on elevator working Platforms.
3 - 68
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Open the additional hydraulic oil cooler door. Refer to the

"HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF
NECESSARY".
WARNING
Hot hydraulic oil!

Disconnect the hoses (Fig. 3-60, Pos. 1 and 2) from the additional hydraulic oil cooler.
NOTE: When the hoses are removed, oil will flow out of the oil
coolers. Catch it in an oil pan.
Fig. 3-60
z
Sling the oil cooler (Fig. 3-61).
Fig. 3-61
Version 2010/1
PC8000-6E
3 - 69
Hydraulics
Superstructure
Fig. 3-62 Removal of the additional hydraulic oil coolers

z
Remove the bolts (Fig. 3-62, Pos. 3) and the resilient sleeve
(Fig. 3-62, Pos. 2) from the angle (Fig. 3-62, Pos. 1).
Lift the additional hydraulic oil cooler (Fig. 3-62, Pos. 5) out of
the cooler frame (Fig. 3-62, Pos. 6) using a crane.
DANGER

When removing the additional hydraulic cooler make sure,
that nobody steps below the weight.
Check the condition of the buffer element (Fig. 3-62, Pos. 7)

and replace it if required.
3 - 70
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.2.6 REPLACEMENT OF THE ADDITIONAL HYDRAULIC OIL COOLERS

Special tools:
n/a

Oil drain pan
Crane
Additional hydraulic oil cooler: 230 kg
Dogman/rigger
2.2.6 on page 2-22.
WARNING
z

Use new moulding material (Fig. 3-62, Pos. 4) between the oil
cooler and the cooler frame (Fig. 3-62, Pos. 6).
NEWS "AH01513".
Version 2010/1
PC8000-6E
3 - 71
Hydraulics
Superstructure
3.8.2.7 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY

Special tools:
n/a

Oil drain pan
Crane
Additional hydraulic oil cooler assembly: 1300 kg
Dogman/rigger
6.6 on page 6-14.
z


z


WARNING

safety cages on elevator working platforms.
WARNING
Hot hydraulic oil!
3 - 72
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
DANGER
Blindness, serious injury, permanent disfigurement or scaring may result.
The hydraulic system may pressurized. Make sure, that the
removed.
Disconnect all hydraulic pressure hoses (Fig. 3-63, Pos. 3),

the return hoses (Fig. 3-63, Pos. 4) and the leak oil hoses
from the additional hydraulic fan drive motors.
Disconnect the hydraulic hoses (Fig.3-63, Pos. 1 and 2) from

the additional oil cooler assembly.
NOTE: When the hoses are disconnected, the oil inside the
hoses and the hydraulic motor will flow out.
Fig. 3-63
Remove the rail and the steps (Fig. 3-64, Pos. 1 and 2) from
the hydraulic oil cooler assembly.
Attach the additional cooler frame assembly (Fig. 3-64,

Pos. 5) to a crane.
Remove the screws (Fig. 3-64, Pos. 3) and the washers

(Fig. 3-64, Pos, 4) from the additional oil cooler frame assembly (Fig. 3-64, Pos. 5).
Remove the additional hydraulic cooler assembly (Fig. 3-64,

Pos. 5) from the hydraulic oil cooler assembly (Fig. 3-64,
Pos. 6), supported using a crane.
DANGER

When removing the additional hydraulic cooler fan assembly
make sure, that nobody steps below the weight.
Fig. 3-64
Version 2010/1
PC8000-6E
3 - 73
Hydraulics
Superstructure
3.8.2.8 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY

Special tools:
n/a

Oil drain pan
Crane
Additional hydraulic oil cooler assembly: 1300 kg
Dogman/rigger
2.2.6 on page 2-22.
WARNING
z

NEWS "AH01513".
Check and adjust the speed of the hydraulic oil cooler fan,
refer to the Operation and Maintenance Manual, chapter 3,
section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS."
Fig. 3-65
3 - 74
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Version 2010/1
PC8000-6E
3 - 75
Hydraulics
3.8.3
Superstructure
HYDRAULIC OIL COOLER ASSEMBLY
Fig. 3-66 Hydraulic oil cooler circuit
3 - 76
PC8000-6E
Version 2010/1
Superstructure
Hydraulics

(1)
Solenoid valve (4/2-directional control valve)
(2)
Back pressure valve
(3)
Return lines from control blocks
(4)
Return oil collector tube
(5)
Lines to oil cooler (hot oil)
(6)
(7)
Restrictor (shock absorbers for the hydraulic oil

cooler)
(8)
Hydraulic oil cooler
(9)
The returning oil from the system flows via the lines (Fig. 3-66,
Pos. 3) into the collector tube (Fig. 3-66, Pos. 4). On the top side
of it the back pressure valve (Fig. 3-66, Pos. 2) is installed. The
back pressure valve causes a back pressure which forces most of
the relative hot oil via the lines (Fig. 3-66, Pos. 5) to the oil cooler
(Fig. 3-66, Pos. 8).
On the flow to the hydraulic oil cooler the hydraulic oil passes the
restrictor (Fig. 3-66, Pos. 7), gets cooled in the oil cooler and then
flows through the lines (Fig. 3-66, Pos. 6) into the filter chamber
of the hydraulic oil
reservoir (Fig. 3-66, Pos. 9).
The restrictors acts as shock absorbers to prevent cooler cracks
created from pressure peaks.
Besides the back pressure valve acts as an oil flow control valve
as far as the oil temperature has not reached its steady temperature. During the warm-up period (1/2 Qmax) the back pressure
valve (Fig. 3-66, Pos. 2) is wide open, because the solenoid valve
(Fig. 3-66, Pos. 1) is energized, which results in less oil flow
through the cooler which causes the oil getting its optimum operating temperature quicker.
With increasing oil temperature the oil gets thinner, so that the
main pumps can be shifted to Qmax position and simultaneously
the solenoid valve (Fig. 3-66, Pos. 1) will be de-energized, so that
the valve piston will be closed further by the force of the spring
resulting in more oil passing the cooler.
Version 2010/1
PC8000-6E
3 - 77
Hydraulics
Superstructure
There are eight hydraulic oil cooler elements in front of the

hydraulic oil reservoir on the left-hand side of the platform.
Four cooler elements (Fig. 3-67, Pos. 3) are mounted in one
frame at a time. So two frames (Fig. 3-67, Pos. 4) are installed
with four cooler elements in each frame. The air stream needed
for the cooling is produced by hydraulically driven fans. The air
flows from inside to outside through the coolers
For better cleaning, the cooler frames are mounted via hinges to
the cooler support so the cooler frames can be opened. ("swing
out cooler").
The two cooler fans (Fig. 3-67, Pos. 1 and 2) are driven by
hydraulic motors.
Fig. 3-67
Each fan drive motor is supplied by one hydraulic pump. The
hydraulic pump (Fig. 3-68, Pos. 2) on PTO 1 (Fig. 3-68, Pos. 1)
supplies the lower hydraulic fan motor (Fig.3-67, Pos. 2).
Pos. 3) supplies the upper hydraulic fan motor (Fig. 3-67, Pos. 1).
The fans are mounted directly to the hydraulic motors drive shaft.
Fig. 3-68
3 - 78
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Version 2010/1
PC8000-6E
3 - 79
Hydraulics
Superstructure
3.8.3.1 REMOVAL OF THE HYDRAULIC OIL COOLER FAN ASSEMBLIES
Fig. 3-69 Hydraulic oil cooler fan assembly
3 - 80
PC8000-6E
Version 2010/1
Superstructure
Hydraulics

(1)
Bolt
(2)
Locking plate
(3)
Cooler fan
(4)
Drive shaft
(5)
Shaft protecting sleeve
(6)
Drive shaft seal
(7)
Bearing
(8)
Distance sleeve
(9)
Bearing group carrier
(10)
Bearing
(11)
Circlip
(12)
O-ring
(13)
Hydraulic motor
(14)
Bolt
(15)
Fan bar
Special tools:
n/a

Oil drain pan
Crane
Hydraulic cooler fan assembly: 262 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Version 2010/1
PC8000-6E
3 - 81
Hydraulics
Superstructure

WARNING
Always wear a safety harness when working at the hydraulic

oil cooler assembly.
Attach the rail (Fig. 3-70, Pos. 3) to a crane and remove the
grating (Fig. 3-70, Pos. 4) from the platform (Fig. 3-70,
Pos. 5).
Remove the bolts (Fig. 3-70, Pos. 1 and 6), the resilient
sleeve (Fig. 3-70, Pos. 2) and the nuts (Fig. 3-70, Pos. 7).
Remove the rail (Fig. 3-70, Pos. 3) from the hydraulic oil
cooler assembly (Fig. 3-70, Pos. 8), using a crane.
Fig. 3-70
z
Remove the fan cages (Fig. 3-71, Pos. 1) from the cooler
housing (Fig. 3-71, Pos. 3).
WARNING
Hot hydraulic oil!

DANGER
Blindness, serious injury, permanent disfigurement, or scaring may result.
The hydraulic system may be pressurized. Make sure that the
removed.
Fig. 3-71
z
Disconnect all hydraulic hoses and the leak oil hoses from the
fan drive motors (Fig. 3-71, Pos. 2).
NOTE: When the hoses are removed, the oil inside the hoses
and the motors will flow out.
3 - 82
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
WARNING
Remove the hydraulic oil cooler fan assembly (Fig. 3-71,

Pos. 2) from the cooler housing (Fig. 3-71, Pos. 3), supported
using a crane.
CAUTION
Remove the hydraulic oil cooler fan assembly carefully in

order not to damage the oil cooler or the fan blades.
DANGER
When removing the hydraulic oil cooler fan assembly make
sure, that nobody steps below the weight.
Version 2010/1
PC8000-6E
3 - 83
Hydraulics
Superstructure
3.8.3.2 REPLACEMENT OF HYDRAULIC OIL COOLER FAN ASSEMBLIES

Special tools:
Rotational speed infrared probe DS03, PN 793 788 73

Oil drain pan
Crane
Dogman/rigger

WARNING
oil cooler assembly.

WARNING
CAUTION
Install the assembly carefully in order not to damage the oil
cooler or the fan blades.
NEWS "AH01513".
ECS".
3 - 84
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Version 2010/1
PC8000-6E
3 - 85
Hydraulics
Superstructure
3.8.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FAN AND MOTOR

Special tools:
n/a
Crane
Oil drain pan
Fan: 78 kg
Fan bearing block: 61 kg
Fan bar: 74 kg
Fan motor: 49 kg
Dogman/rigger
3 - 86
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
WARNING
Remove the hydraulic oil cooler fan assembly, refer to section

3.8.3.1 on page 3-80.
NOTE: Carry out the two following two steps only if the cooler fan
needs to be removed.
Remove the attaching bolts (Fig. 3-72, Pos. 1) with the

locking plates (Fig. 3-72, Pos. 2). Discard the locking
plates.
Remove the cooler fan (Fig. 3-72, Pos. 3) from the drive
shaft (Fig. 3-72, Pos. 4).
hydraulic motor (Fig. 3-72, Pos. 13) from the bearing group
carrier (Fig. 3-72, Pos. 9). Discard the O-ring (Fig. 3-72,
Pos. 12).
NOTE: When the hydraulic motor is disconnected from the bearing group carrier, the oil inside the bearing group carrier
will flow out. Catch it in an oil pan.
z
If required remove the circlip (Fig. 3-72, Pos. 11), extract the
drive shaft (Fig. 3-72, Pos. 4) out of the bearing group carrier
(Fig. 3-72, Pos. 9), and remove the drive shaft seal (Fig. 3-72,
Pos. 6), the bearings (Fig. 3-72, Pos. 7 and 10), and the
sleeves (Fig. 3-72, Pos. 5 and 8).
Version 2010/1
PC8000-6E
3 - 87
Hydraulics
Superstructure
3.8.3.4 REPLACEMENT OF HYDRAULIC OIL COOLER FAN AND MOTOR

Special tools:
n/a
Crane
Fan: 78 kg
Fan bearing block: 61 kg
Fan bar: 74 kg
Fan motor: 49 kg
Dogman/rigger


3 - 88
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Carry out installation in reverse order to removal. Refer to the

NOTE: If the drive shaft (Fig. 3-73, Pos. 4) is removed, check the
drive shaft.
Check drive shaft seal (Fig. 3-73, Pos. 6) for wear and
damage. Replace if required.
NOTE: Use a new O-ring (Fig. 3-73, Pos. 12) and new locking
WARNING
Install the hydraulic oil cooler fan assembly, refer to section

3.8.3.2 on page 3-84.
NOTE: Check the oil level in the bearing group carrier (Fig. 3-73,
Pos. 9) and add oil if required, refer to the Operation &
Maintenance Manual, chapter 4, section "HYDRAULIC
OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER".
z
NEWS No. "AH01513".
ECS".
Version 2010/1
PC8000-6E
3 - 89
Hydraulics
Superstructure
3.8.3.5 REMOVAL OF THE HYDRAULIC OIL COOLERS

Special tools:
n/a

Crane
Oil drain pans
Hydraulic oil cooler: 230 kg each
Dogman/rigger
6.6 on page 6-14.
z


z

"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM"
Transfuse the oil from the return manifold into the main oil
reservoir, refer to the Operation & Maintenance Manual,
Open the hydraulic oil cooler door. Refer to the Operation &
Maintenance Manual, chapter 4, section "HYDRAULIC OIL
COOLERS - INSPECT AND CLEAN IF NECESSARY".
Fig. 3-74
WARNING
z
Always wear a safety harness when working at the

hydraulic oil cooler frame.

3 - 90
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
WARNING
Hot hydraulic oil!
until the temperature of the hydraulic oil is below
50 C. Disobedience may result in personal injury from
heated oil.
Disconnect all inlet hoses (Fig. 3-75, Pos. 1), all outlet hoses
(Fig. 3-75, Pos. 2) and all connecting hoses (Fig. 3-75,
Pos. 3) from the hydraulic oil cooler.
NOTE: When the hoses are removed, oil will flow out of the oil
coolers. Catch it in an oil pan.
Fig. 3-75
Sling the oil cooler (Fig. 3-76).
Fig. 3-76
Version 2010/1
PC8000-6E
3 - 91
Hydraulics
Superstructure
Fig. 3-77 Removal of the oil coolers

z
Remove the bolts (Fig. 3-77, Pos. 5), the resilient sleeves
(Fig. 3-77, Pos. 4), and clear the oil cooler
(Fig. 3-77, Pos. 1) from the angles (Fig. 3-77, Pos. 3).
Lift the oil cooler (Fig. 3-77, Pos. 1) out of the radiator frame
(Fig. 3-77, Pos. 6 and 7) using a crane.
DANGER

When removing the hydraulic oil cooler, make sure that
Check the buffer element (Fig. 3-77, Pos. 9) and replace it if

required.
3 - 92
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Version 2010/1
PC8000-6E
3 - 93
Hydraulics
Superstructure
3.8.3.6 REPLACEMENT OF THE HYDRAULIC OIL COOLERS

Special tools:
n/a

Crane
Glue PN 256 952 40
Hydraulic oil cooler: 230 kg each
Dogman/rigger
2.2.6 on page 2-22.
Fig. 3-78 Installation of the oil coolers
3 - 94
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
WARNING
z


Apply glue PN 256 952 40 to the profiled joints (Fig. 3-78,

Pos. 2) and attach them in the same manner as they were
fixed to the old oil cooler.
NEWS No."AH01513".
Version 2010/1
PC8000-6E
3 - 95
Hydraulics
Superstructure
3.8.3.7 REMOVAL OF THE HYDRAULIC OIL COOLER ASSEMBLY

Special tools:
n/a

Crane
4 x Swivel hoist rings: M36
Oil drain pans
Hydraulic oil cooler frame: 7320 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Open the hydraulic oil cooler door. Refer to the Operation &
Maintenance Manual, chapter 4, section "HYDRAULIC OIL
COOLERS - INSPECT AND CLEAN IF NECESSARY".
Fig. 3-79
3 - 96
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
WARNING
z
Hot hydraulic oil!

Do not carry out the following work on a hot machine.
Wait until the temperature of the hydraulic oil is below
heated oil.


Remove the additional hydraulic cooler assembly, refer to

section 3.8.2.7 on page 3-72.
cooler assembly (Fig. 3-80, Pos. 3).
Remove the lighting equipment (Fig. 3-80, Pos. 2) from the

hydraulic oil cooler assembly (Fig. 3-80, Pos. 3).
Fig. 3-80
z
Disconnect all hydraulic pressure hoses (Fig. 3-81, Pos. 3),

all return hoses (Fig. 3-81, Pos. 1), and all leak oil hoses
(Fig. 3-81, Pos. 2) from the upper and the lower hydraulic oil
cooler fan motor.
NOTE: When the hoses are disconnected, oil will flow out of the
hoses.
Fig. 3-81
Version 2010/1
PC8000-6E
3 - 97
Hydraulics
Superstructure
Disconnect the hydraulic hoses (Fig. 3-82, Pos. 1 and 2) at

the shown joints from the hydraulic oil reservoir.
NOTE: When the hoses are disconnected, oil will flow out of the
hoses.
Fig. 3-82
Insert the swivel hoist rings (M36) into the threads

(Fig. 3-83, Pos. 1) at the hydraulic oil cooler frame.
Sling the hydraulic oil cooler frame at the hoist rings.
Fig. 3-83
3 - 98
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Remove the mounting bolts and washers (Fig. 3-84, Pos. 2

up to 5) and remove the hydraulic oil cooler assembly
(Fig. 3-84, Pos. 1) from the superstructure using a crane.
DANGER

When removing the hydraulic oil cooler assembly, make sure
Rest the hydraulic oil cooler assembly on the ground on an

appropriate stand.
Fig. 3-84
z
Carry out the following steps if required.

z
Remove the rail from the hydraulic oil cooler assembly.
Attach the rail (Fig. 3-85, Pos. 3) to a crane and remove

the grating (Fig. 3-85, Pos. 4) from the platform
(Fig. 3-85, Pos. 5).
Remove the bolts (Fig. 3-85, Pos. 1 and 6), the resilient
sleeves (Fig. 3-85, Pos. 2), and the nuts (Fig. 3-85,
Pos. 7).
cooler assembly (Fig. 3-85, Pos. 8), using a crane.
Disconnect all wiring harness connectors from the

hydraulic oil cooler assembly (Fig. 3-85, Pos. 8).
If required, remove the hydraulic oil cooler fan assembly

from the hydraulic oil cooler assembly, refer to section
3.8.3.1 on page 3-80.
If required, remove the hydraulic oil cooler from the

hydraulic oil cooler assembly, refer to section 3.8.3.5 on
page 3-90.
Fig. 3-85
Version 2010/1
PC8000-6E
3 - 99
Hydraulics
Superstructure
3.8.3.8 REPLACEMENT OF THE HYDRAULIC OIL COOLER ASSEMBLY

Special tools:
n/a

4 x Swivel hoist rings: M36
Crane
Hydraulic oil cooler frame: 7320 kg
Dogman/rigger
2.2.6 on page 2-22.
WARNING
oil cooler frame.
NOTE: Use new mounting bolts and new washers (Fig. 3-86,
Pos. 2 up to 5) of grade 10.9. Apply compound "KP2K",
PN 324 969 40 and tighten the mounting bolts to the
specified tightening torque.
Tightening torque for mounting bolts (Fig. 3-86,
Pos. 2 and 5): 3100 Nm
NEWS No. "AH01513".
Fig. 3-86
3 - 100
PC8000-6E
Version 2010/1
Superstructure
3.8.4
Hydraulics
PILOT OIL PUMP (GEAR PUMP)
3.8.4.1 REMOVAL OF THE PILOT OIL PUMP

Special tools:
n/a
n/a
Pilot oil pump: 34 kg
6.6 on page 6-14.


z

Fig. 3-87
Version 2010/1
PC8000-6E
3 - 101
Hydraulics
Superstructure
The pilot oil pumps (Fig. 3-88, Pos. 9.2 and 9.4) generate the pilot
pressure that is used for all hydraulic control operations.
The pilot oil pumps (Fig. 3-88, Pos. 9.2 and 9.4) are attached to
both PTOs.
WARNING
Hot hydraulic oil!
Disconnect the SAE-flanges of pressure hose and suction

hose from the pilot oil pump (Fig. 3-88, Pos. 9.2 or 9.4).
z
Remove the four bolts (Fig. 3-89, Pos. 1) and pull the pilot oil
pump (Fig. 3-89, Pos. 2) and the joint element (Fig. 3-89,
Pos. 3 up to 6) out of the main pump (Fig. 3-89, Pos. 7).
Discard the O-rings (Fig. 3-89, Pos. 3 and 6).
Fig. 3-88
NOTE: Check the joint element (Fig. 3-89, Pos. 4) for wear and
replace it if required.
Fig. 3-89
3 - 102
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.4.2 REPLACEMENT OF THE PILOT OIL PUMP

Special tools:

Pilot oil pump: 34 kg
Dogman/rigger
2.2.6 on page 2-22.
Remove the four bolts (Fig. 3-90, Pos. 1) at the new pilot oil
pump and disconnect the joint elements (Fig. 3-90, Pos. 3 up
to 6) carefully.
To avoiding of corrosion coat the joint element surfaces and

the pump surface with Optimol White, PN 999 039.
Fig. 3-90
NOTE: Use new O-rings (Fig. 3-90, Pos. 3 and 6) and new
mounting bolts (Fig. 3-90, Pos. 1) with grade 8.8 at the
mounting flanges of the pump.
Tighten the mounting bolts to the specified tightening
torque.
74 Nm
z
NEWS No. "AH01513".
NOTE: Check and adjust the pilot pressure if required.

Refer to the Service Manual.
Version 2010/1
PC8000-6E
3 - 103
Hydraulics
3.8.5
Superstructure
MAIN GATE VALVE
The connection between the suction reservoir and the hydraulic

oil reservoir can be closed with the main gate valve to prevent oil
flow during repairs. This unit is monitored by the switch S31. It
makes sure that a motor start is not possible with a closed main
gate valve. Fault message Start blocked because of main
shut-off (gate) valve is displayed on the operators dashboard.
3.8.5.1 REMOVAL OF THE MAIN GATE VALVE

Special tools:
n/a
Hydraulic oil tank (8350 liters)

Main gate valve: 54 kg


z
Fig. 3-91
Drain hydraulic oil from the hydraulic oil reservoir,

approx. 8350 liters.
chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS
AND PULSATION DAMPER".
3 - 104
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Disconnect the harness connector S31 from the proximity

switch at the main gate valve. Refer to Fig. 3-99
on page 3-110.
Remove all bolts (Fig. 3-92, Pos. 2), dismantle the compensator (Fig. 3-92, Pos. 3), and the main gate valve
(Fig. 3-92, Pos. 1).
NOTE: When the main gate valve (Fig. 3-92, Pos. 1) and the
compensator (Fig. 3-92, Pos. 3) are removed some oil
inside the piping will flow out.
z
Check the compensator (Fig. 3-92, Pos. 3) and replace it if

required.
Fig. 3-92
3.8.5.2 REPLACEMENT OF THE MAIN GATE VALVE

Special tools:
n/a
Hydraulic oil tank (8350 liters)

Main gate valve: 54 kg
NOTE: Tighten the self locking nuts (Fig. 3-93, Pos. 1) at the
compensator (Fig. 3-93, Pos. 2) to the specified tightening torque.
Tightening torque for the self locking nuts: 70 Nm
Fill specified hydraulic oil into the hydraulic oil reservoir, approx. 8350 liters.
z
NEWS No. "AH01513".
Version 2010/1
PC8000-6E
Fig. 3-93
3 - 105
Hydraulics
3.8.6
Superstructure
HYDRAULIC OIL RESERVOIR
Fig. 3-94 Hydraulic oil reservoir
3 - 106
PC8000-6E
Version 2010/1
Superstructure
Hydraulics

(1)
(2)
(3)
Breather filter
(4)
Back-pressure valve, temperature controlled
(5)
Man hole cover
(6)
Collector pipe
(7)
Return pipe
(8)
Oil reservoir outlet (suction line)
(9)
Drain coupling
(10)
Mounting brackets
(11)
Leak oil filter
(12)
Oil reservoir outlet
(13)
Return oil filter
(14)
Compensator
(15)
Main gate valve
(16)
Leak oil line connectors
Version 2010/1
PC8000-6E
3 - 107
Hydraulics
Superstructure
3.8.6.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR

Special tools:
Hydraulic torque wrench, PN 232 615 40

Electro-hydraulic pump aggregate, PN 232 613 40
46 mm hexagon impact socket wrench, PN 232 265 40

Crane
4 x Swivel hoist rings: M 36
Hydraulic oil reservoir incl. back pressure valve: 7170 kg
Dogman/rigger
6.6 on page 6-14.
z


z

WARNING

hydraulic oil reservoir.

Drain hydraulic oil from the hydraulic oil reservoir,

approx. 8350 liters.
AND PULSATION DAMPER" and to the Operation
& Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM"
z
Remove the main gate valve, refer to section 3.8.5.1 on page

3-104.
Remove all attached parts, e.g. emergency ladder, steps,

rails, plates, etc. from the hydraulic oil reservoir.
3 - 108
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Insert swivel hoist rings (M 36) into the threads (Fig. 3-95,
Pos. 1).
Fig. 3-95
z
Disconnect the hydraulic outlet hoses (Fig. 3-96, Pos. 1),

leading from the hydraulic coolers, from the hydraulic oil reservoir.
Disconnect the hydraulic inlet hoses (Fig. 3-96, Pos. 2), leading to the hydraulic coolers, from the hydraulic oil reservoir.
Disconnect all hydraulic hoses from the return oil connector

pipe.
Loosen all clamps at the hydraulic oil reservoir to disconnect

all hydraulic hoses from the hydraulic oil reservoir.
Able and disconnect all hydraulic hoses.
NOTE: When the hydraulic hoses/pipes are disconnected, the oil

Fig. 3-96
Disconnect and remove the electrical wiring (Fig. 3-97,

Pos. 1) from the transfer pump and the hydraulic oil reservoir.
Fig. 3-97
Version 2010/1
PC8000-6E
3 - 109
Hydraulics
Superstructure
Shut the cock valves at the hydraulic hoses

(Fig. 3-97, Pos. 1) and disconnect the hydraulic hoses from
the union (Fig. 3-97, Pos. 2).
Clear all hydraulic hoses from the hydraulic oil reservoir.
NOTE: When the hydraulic hoses/pipes are disconnected, the oil

Fig. 3-98
Disconnect all wiring harness connectors (Fig. 3-99,

Pos. Bxx, Y101) and the head light assembly (Fig. 3-99,
Pos. H50 and H50a).
Remove the wiring harnesses from the hydraulic oil reservoir.
Fig. 3-99
z
Attach the hydraulic oil reservoir to a crane.
Remove two mounting bolts (Fig. 3-100, Pos. 1) from each

mounting flange (Fig. 3-100, Pos. 3) of the hydraulic oil reservoir (Fig. 3-100, Pos. 2).
Lift the hydraulic oil reservoir (Fig. 3-100, Pos. 2) off the
superstructure using the crane and place it on the ground.
DANGER

When removing the hydraulic oil reservoir, make sure that
Remove all provided parts from the hydraulic oil reservoir if

required.
Fig. 3-100
3 - 110
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.6.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR
Special tools:


Crane
Hydraulic oil reservoir incl. back pressure valve: 7170 kg
Dogman/rigger

z
Install all provided parts from the old hydraulic oil reservoir to
the new one.
NOTE: Use new filter units at the new hydraulic oil reservoir.
Check the O-rings and replace if required.
z
Replace the return oil strainer (Fig. 3-101, Pos. 4). Refer to
the Operation & Maintenance Manual, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".
NOTE: Use new gaskets (Fig. 3-101, Pos. 3 and 5) at the return
oil strainer.
Use new gaskets (Fig. 3-101, Pos. 1 and 2) at the back
pressure valve.
Check the O-rings and replace if required.
CAUTION
Replace return oil strainer (Fig. 3-101, Pos. 4) after major
repairs on the hydraulic system and after every 6000 operating hours.
Fig. 3-101
WARNING
oil reservoir.
Version 2010/1
PC8000-6E
3 - 111
Hydraulics
Superstructure
NOTE: Use new bolts (Fig. 3-102, Pos. 1) with grade 10.9 at the
mounting flanges (Fig. 3-102, Pos. 3) of the hydraulic oil
reservoir (Fig. 3-102, Pos. 2).
Tighten the bolts (Fig. 3-102, Pos. 1) to the specified
tightening torque.
1770 Nm
Fill specified hydraulic oil into the hydraulic oil reservoir, approx. 4450 liters.
chapter 4, section "HYDRAULIC SYSTEM - CHANGE
OIL, REPLACE SUCTION STRAINERS AND
PULSATION DAMPER" and to the Operation & Maintenance Manual, chapter 3, section "CENTRAL
REFILLING SYSTEM".
z
NEWS No. "AH01513".
Check and adjust the back pressure if required, refer to the

Service Manual.
3 - 112
PC8000-6E
Fig. 3-102
Version 2010/1
Superstructure
3.8.7
Hydraulics
MAIN CONTROL VALVE BLOCKS
Fig. 3-103 Main control valve blocks overview

(1)
Main control valve block I
(2)
Main control valve block III
(3)
Main control valve block II
(4)
Main control valve block IV
(5- 8)
High pressure filters
There are four main control valve blocks (I - IV) installed at the
machine.
Individual valve plugs are mounted on each main control valve
block. These valves are anti-cavitation valves (Fig. 3-104, ACV),
service line relief valves (Fig. 3-104, SRV), or main relief valves
(Fig. 3-104, MRV).
Fig. 3-104
Version 2010/1
PC8000-6E
3 - 113
Hydraulics
Superstructure
3.8.7.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS

Special tools:
n/a
Crane
Oil drain pan
main control valve blocks: 683 kg
High pressure filter: 50 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Fig. 3-105
z
Remove the front roof plates, refer to section 3.3.3.1 on page

3-15.
3 - 114
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Fig. 3-106
WARNING
Hot hydraulic oil!
Disconnect all hydraulic lines (Fig. 3-106, Pos. 3) at the

respective main control valve block.
Disconnect all pilot lines from the spool valves

(Fig. 3-106, Pos. 4) at the respective main control valve
block.
NOTE: When the hydraulic lines are removed, the oil inside the
lines will flow out. Catch it in an oil pan.
z
Discard the O-rings (Fig. 3-106, Pos. 1) and the collar ring
(Fig. 3-106, Pos. 2) of the SAE-flanges.
Disconnect the return line (Fig. 3-107, Pos. 1) at the respective main control valve block (I - IV) and discard the O-ring
(Fig. 3-107, Pos. 2) of the SAE-flange.
NOTE: When the return line is removed, the oil inside the line will
flow out. Catch it in an oil pan.
Fig. 3-107
Version 2010/1
PC8000-6E
3 - 115
Hydraulics
Superstructure
Sling the main control valve block (Fig. 3-108).

WARNING

When removing the main control valve blocks, make sure
Fig. 3-108
Remove the mounting bolts (Fig. 3-109, Pos. 1 and 3), the
nuts (Fig. 3-109, Pos. 2) and remove the respective main
control valve block (Fig. 3-109, Pos. 5) from the control valve
carrier (Fig. 3-109, Pos. 4) using a crane.
Fig. 3-109
z
If required remove all SRVs from the main control valve block,
refer to section 3.8.9.3 on page 3-123.
If required remove all ACVs from the main control valve block,
If required remove the MRV from the main control valve

block, refer to section 3.8.8.1 on page 3-118.
If required remove the load holding valves from the main control valve block.
3 - 116
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.7.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS

Special tools:
Crane
Main control valve blocks: 683 kg
High pressure filter: 50 kg
Dogman/rigger
2.2.6 on page 2-22.
NOTE: Ensure that the mating surfaces are clean and free of
paint before assembly. Fit new O-rings.
z
NOTE: Use new mounting bolts (Fig. 3-110, Pos. 1 and 3) of

grade 10.9 and new nuts (Fig. 3-110, Pos. 2) for the
respective main control valve block (Fig. 3-110,
Pos. 5). Apply compound "KP2K", PN 324 969 40 on the
bolts and tighten the bolts to the specified tightening
torque.
Tightening torque for the mounting bolts
(Fig. 3-110, Pos. 1 and 3) at the main control
valve blocks: 510 Nm
NOTE: When connecting the hydraulic piping to the main control
valve blocks, refer to the PARTS & SERVICE NEWS No.
"AH05501".
z
NEWS No. "AH01513".
Fig. 3-110
z
Check the pressure of all circuits of the valve control blocks

(use a 400 bar gauge).
Version 2010/1
PC8000-6E
3 - 117
Hydraulics
3.8.8
Superstructure
MAIN RELIEF VALVES (MRV)
MRV (main relief valves) are pilot operated relief valves. The
MRV limit the maximum pump supply line pressure. The valves
are designed with an opening characteristic. That means, if the
valve is activated after the response procedure, no further pressure increase is possible and damage is avoided.
The valves are installed in the main control valve blocks.
3.8.8.1 REMOVAL OF THE MRV ON THE MAIN CONTROL VALVE BLOCK

Special tools:
Socket wrench 36 mm, PN 232 274 40
n/a

Fig. 3-111
WARNING
Hot hydraulic oil!
Remove the MRV (Fig. 3-112, Pos. 1, 2, 3 or 4) from the main

control valve block.
NOTE: When the MRV is removed, oil will flow out of the main
control valve block. Catch it in an oil pan.
Fig. 3-112
3 - 118
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.8.2 REPLACEMENT OF THE MRV ON THE MAIN CONTROL VALVE BLOCK

Special tools:
Socket wrench 36 mm, PN 232 274 40

n/a
NOTE: Fit new O-rings to the MRV.

z
NOTE: Tighten the MRV to the specified tightening torque.

Tightening torque for MRV:
300 Nm
z
NEWS No. "AH01513".
Check and adjust the MRV. Refer to the Service Manual.

WARNING
Wear ear protection when checking the relief pressure.
Version 2010/1
PC8000-6E
3 - 119
Hydraulics
3.8.9
Superstructure
SERVICE LINE RELIEF VALVES (SRV)
The service line relief valves are pilot operated relief valves. The
SRV limit the maximum possible pressure in the service lines created by external force. The valves are designed with an opening
characteristic. That means, if the valve is activated after the
response procedure, no further pressure increase is possible and
damage is avoided. Service relief valves are located on the main
control valve blocks on the manifold and in the throttle check
valves, refer to section 3.8.11.1 on page 3-138.
NOTE: SRVs are also installed in the travel system, refer to section 4.2.8.1 on page 4-40.
3.8.9.1 REMOVAL OF THE SRV ON THE MANIFOLD

Special tools:
n/a
Crane
Oil drain pan
Double-SRV: 50 kg
Dogman/rigger
6.6 on page 6-14.
The SRV on the manifold controls the pressure for the clam cylinder piston side.
z


z

3 - 120
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Fig. 3-113
z
It is recommended to remove the front wall to avoid an

inclined hoist while using a crane, refer to section 3.3.3 on
page 3-15.
WARNING
Hot hydraulic oil!

Disconnect the hydraulic lines from the SRV (Fig. 3-114,

Pos. 2).
NOTE: When the hydraulic lines are disconnected, the oil inside
the lines will flow out. Catch it in an oil pan.
Cap the openings to avoid contamination.
z
Remove the four bolts (Fig. 3-114, Pos. 1) attaching the SRV
to the manifold (Fig. 3-114, Pos. 3).
Remove the SRV (Fig. 3-114, Pos. 2) and cap the openings
with blind plugs to avoid contamination.
Fig. 3-114
Version 2010/1
PC8000-6E
3 - 121
Hydraulics
Superstructure
Discard the O-ring (Fig. 3-115, Pos. 1).
NOTE: Carry out the following step only if required:

z
Remove the pressure relief valve (Fig. 3-115, Pos. 1)

from the valve body (Fig. 3-115, Pos. 2).
Fig. 3-115
3.8.9.2 REPLACEMENT OF THE SRV ON THE MANIFOLD

Special tools:
n/a
Crane
Double-SRV: 50 kg
Dogman/rigger

Ensure that the mating surfaces are clean and free of paint before
assembly.
z
Use a new O-ring (Fig. 3-116, Pos. 3).
NOTE: If the build-in SRV (Fig. 3-116, Pos. 1) were removed

from the valve body (Fig. 3-116, Pos. 2) tighten the
valves to the specified tightening torque.
Tightening torque for the built-in SRV:
300 Nm
Fig. 3-116
z
NEWS No. "AH01513".
Check and adjust the SRV. Refer to the Service Manual.
3 - 122
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.9.3 REMOVAL OF THE SRV ON THE MAIN CONTROL VALVE BLOCK

Special tools:
n/a
Oil drain pan
Relieve the pressure in the hydraulic system. Refer to the

reservoir. Refer to the Operation & Maintenance Manual,
Fig. 3-117
WARNING
Hot hydraulic oil!
Disconnect the hydraulic hose from the SRV (Fig. 3-118,

Pos. 2).
NOTE: When the hydraulic hose is disconnected, the oil inside

the hose will flow out. Catch it in an oil pan.
z
Remove the four bolts (Fig. 3-118, Pos. 1) attaching the SRV
to the main control valve block.
Remove the SRV (Fig. 3-118, Pos. 2) and cap the openings
with blind plugs to avoid contamination.
Fig. 3-118
Version 2010/1
PC8000-6E
3 - 123
Hydraulics
Superstructure
Discard the O-rings (Fig. 3-119, Pos. 1).
NOTE: Carry out the following steps only if required:

z
Remove the support rings (Fig. 3-119, Pos. 2) from the

valve body (Fig. 3-119, Pos. 4).

Fig. 3-119
CAUTION
Different SRVs with different pressures are installed.
If removing more than one SRV at the same time, mark the
SRV and the position where it is installed.
3 - 124
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.9.4 REPLACEMENT OF THE SRV ON THE MAIN CONTROL VALVE BLOCKS

Special tools:
n/a
paint before assembly.
z
Fit new O-rings (Fig. 3-120, Pos. 1) and support rings

(Fig. 3-120, Pos. 2) to the valve body (Fig. 3-120, Pos. 4).
NOTE: If the build-in SRV (Fig. 3-119, Pos. 3) was removed from
the valve body (Fig. 3-119, Pos. 4) tighten the valve to
the specified tightening torque.
300 Nm
Fig. 3-120
z
NEWS No. "AH01513".
Check and adjust the SRV. Refer to the Service Manual.
Version 2010/1
PC8000-6E
3 - 125
Hydraulics
Superstructure
3.8.10 ANTI-CAVITATION VALVES (ACV)
Fig. 3-121 Anti cavitation valve (ACV)

(1)
ACV housing
(2)
Valve cone
(3)
Spring
(4)
O-ring
(5)
Control leak oil bore
(6)
(S)
Supply line
(A/B)
Line connections
The anti-cavitation valves (ACV) are installed to avoid cavitation

damages on users (hydraulic cylinders) by compensating a lack
of oil when the SRV at the opposite side of the cylinder opens.
See hydraulic circuit diagram.
The circuit pressure in the line (Fig. 3-121, Pos. A/B) keeps the
valve cone (Fig. 3-121, Pos. 2) closed. The pressure of the supply line (Fig. 3-121, Pos. S) forces onto the valve cone. The valve
cone opens, whenever the pressure at the A and B side is lower
than the back pressure at the return oil port S, to allow the necessary oil supply to get into the circuit.
3 - 126
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
The ACVs are installed at the manifold and at the main control
valve blocks.
3.8.10.1 REMOVAL OF THE ACV ON THE MANIFOLD

Special tools:
n/a
Crane
Oil drain pan
Single-ACV: 32 kg
Double-ACV: 50 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Fig. 3-122
z
It is recommended to remove the front wall to avoid an

inclined hoist while using a crane, refer to section 3.3.3 on
page 3-15.
Version 2010/1
PC8000-6E
3 - 127
Hydraulics
Superstructure
Fig. 3-123 Positions of the ACVs at the manifold
3 - 128
PC8000-6E
Version 2010/1
Superstructure
Hydraulics

(142)
Double-ACV, Boom (section A - B)
(109.2)
Single-ACV, Stick cylinder rod side (section G)
(143)
Double-ACV, Stick cylinder (section H - J)
(144)
Double-ACV, Bucket cylinder (section M - N)
(145)
Double-ACV, Boom cylinder (section P -Q)
NOTE: The numbers (Fig. 3-123) are the component numbers in

the hydraulic diagram.
For further information about the ACV at the manifold,
refer to the hydraulic diagram and the Service Manual.
WARNING
Hot hydraulic oil!
In the following procedure a double-ACV (Fig. 3-124, Pos. 1) of

the manifold is removed exemplarily.
The procedure is also identical for the single-ACV (Fig. 3-124,
Pos. 2), except the removal of the throttle check valve (Fig. 3124, Pos. 3).
z
Remove the throttle check valve (Fig. 3-124, Pos. 3), refer to
Disconnect the oil pipe from the ACV.
NOTE: When the pipe is disconnected, the oil inside the piping
will flow out. Catch it in an oil pan.
Fig. 3-124
Version 2010/1
PC8000-6E
3 - 129
Hydraulics
Superstructure
Remove the four bolts (Fig. 3-125, Pos. 1) attaching the double-ACV (Fig. 3-125, Pos. 2) to the manifold.
Fig. 3-125
z
z

If required, remove the build-in ACV (Fig. 3-126, Pos. 1) from
the valve body (Fig. 3-126, Pos. 1).
Fig. 3-126
3 - 130
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.10.2 REPLACEMENT OF THE ACV ON THE MANIFOLD

Special tools:
n/a
Crane
Single-ACV: 32 kg
Double-ACV: 50 kg
Dogman/rigger

z
Fit a new O-ring (Fig. 3-127, Pos. 3).
NOTE: If the build-in ACV (Fig. 3-127, Pos. 2) was removed from
Tightening torque for the built-in ACV:
300 Nm
Fig. 3-127
z
Maintenance Manual chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS
NEWS No. "AH01513".
Version 2010/1
PC8000-6E
3 - 131
Hydraulics
Superstructure
3.8.10.3 REMOVAL OF THE ACV ON THE MAIN CONTROL VALVE BLOCKS

Special tools:
n/a
Oil drain pan
NOTE: For additional information about the ACV on the main

control valve blocks, refer to section 3.8.7 on page 3-113.
z

Fig. 3-128
WARNING
Hot hydraulic oil!
Disconnect the hydraulic hose from the ACV (Fig. 3-129,

Pos. 3).
Remove the four bolts (Fig. 3-129, Pos. 1) attaching the ACV
to the main control valve block.
Remove the block (Fig. 3-129, Pos. 2) and the ACV

(Fig. 3-129, Pos. 3).
NOTE: When the ACV is removed, the oil inside the valves will
flow out. Catch it in an oil pan.
Fig. 3-129
NOTE: For further information about the ACV at the main control
valve blocks, refer to the hydraulic diagram and the Service Manual.
3 - 132
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
Remove the O-rings (Fig. 3-130, Pos. 1) and discard them.
NOTE: Carry out the following steps only if required:

z
Remove the support rings (Fig. 3-130, Pos. 2) from the

valve body (Fig. 3-130, Pos. 3).

Fig. 3-130
3.8.10.4 REPLACEMENT OF THE ACV ON THE MAIN CONTROL VALVE BLOCKS

Special tools:
n/a
n/a
z
Fit new O-rings (Fig. 3-131, Pos. 1) and support rings

(Fig. 3-131, Pos. 2) to the valve body (Fig. 3-131, Pos. 3).
NOTE: If the build-in ACV (Fig. 3-131, Pos. 4) was removed from
Tightening torque for the built-in ACV:
300 Nm
Fig. 3-131
z
NEWS No. "AH01513".
Version 2010/1
PC8000-6E
3 - 133
Hydraulics
Superstructure
3.8.11 THROTTLE CHECK VALVES
Fig. 3-132 Throttle check valve with built-in SRV
3 - 134
PC8000-6E
Version 2010/1
Superstructure
Hydraulics

NOTE: The illustration shows the valve block upside down.
(1)
Throttle adjustment pin
(2)
Back-up ring
(3)
O-ring
(4)
Retainer
(5)
Back-up ring
(6)
O-ring
(7)
Spring
(8)
Spring cup
(9)
Throttle valve sleeve
(9.1)
Adjustable throttle holes
(9.2)
Permanent throttle holes (safety channel)
(10)
O-ring
(11)
Housing
(12)
Return line port, T
(13)
SRV
(14)
Bolt
(15)
Clip ring
(16)
Lock nut
(A)
Line ports from the control valve
(B)
Line port to the cylinder
(M)
(Y)
The maximum permissible cylinder speed is set by the pin

(Fig. 3-132, Pos.1). Depending on the pin setting, the radial holes
(Fig. 3-132, Pos. 9.1) in the valve sleeve (Fig. 3-132, Pos. 9) will
be opened partially to achieve the required throttling of the oil
flow. The safety holes (Fig. 3-132, Pos. 9.2) prevent the valve
from becoming completely closed.
For the lifting operation the valve sleeve which is guided by the
spindle (Fig. 3-132, Pos. 1) is pressed against the spring
(Fig. 3-132, Pos. 7) so that the valve will be completely open.
The build-in SRV (Fig. 3-132, Pos. 13) limits the maximum system pressure from the cylinder and relieves oil to the tank line
when the pressure reaches the valve setting.
Version 2010/1
PC8000-6E
3 - 135
Hydraulics
Superstructure
Fig. 3-133 Positions of the Throttle check valves at the manifold
3 - 136
PC8000-6E
Version 2010/1
Superstructure
Hydraulics

(92)
Throttle check valve, clam cylinder piston side

(section F)
(131.1)
Throttle check valve, Bucket cylinder piston side

(section C)
(131.4)

(section E)
(131.5)
Throttle check valve, Stick cylinder piston side

(section H)
(131.6)

(section H)
(131.7)

(section K)
(131.8)

(section K)
(131.9)
Throttle check valve, Calm cylinder rod side

(section L)
(131.11)

(section N)
(131.12)

(section N)
(132.1)
Throttle check valve, Boom cylinder piston side

(section B)
(132.2)

(section B)
(132.3)

(section P)
(132.4)

(section P)
NOTE: The numbers (Fig.3-133) are component numbers for the

hydraulic diagram.
For further information about the SRV at the manifold,
refer to the hydraulic diagram and the Service Manual.
Version 2010/1
PC8000-6E
3 - 137
Hydraulics
Superstructure
3.8.11.1 REMOVAL OF THE THROTTLE CHECK VALVES ON THE MANIFOLD

Special tools:
n/a
Crane
Oil drain pan
Throttle check valve (long version): 31 kg
Throttle check valve (short version): 28 kg
Dogman/rigger
6.6 on page 6-14.
z


z

WARNING
Hot hydraulic oil!

Fig. 3-134
It is recommended to remove the front wall to avoid inclined

hoist while using a crane, refer to section 3.3.3 on page 3-15.
3 - 138
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
In the following steps a throttle check valve on the manifold is

removed exemplarily.
WARNING
Hot hydraulic oil!
Disconnect the flex hose (Fig. 3-135, Pos. 5) from the throttle
check valve (Fig. 3-135, Pos. 1).
pipe (Fig. 3-135, Pos. 3) from the throttle check valve
(Fig. 3-135, Pos. 1).
piping and the valve will flow out. Catch it in an oil pan.
Fig. 3-135
z
Remove the four bolts (Fig. 3-136, Pos. 5) attaching the throttle check valve (Fig. 3-136, Pos. 1) to the manifold
(Fig. 3-136, Pos. 2).
Remove the throttle check valve (Fig. 3-136, Pos. 1) and the
O-ring (Fig. 3-136, Pos. 3). Discard the O-ring.
NOTE: When the throttle check valve is removed, the oil inside
the valve and the manifold will flow out. Catch it in an oil
pan. Cap the openings with blind plugs to avoid contamination.
z
If required, remove the adaptor (Fig. 3-136, Pos. 4) from the

throttle check valve.
Fig. 3-136
If required, repeat the procedure to remove the other throttle

check valves from the manifold.
If required, remove the built-in SRV (Fig. 3-132, Pos. 13) from
the throttle check valves housing (Fig. 3-132, Pos. 11).
Version 2010/1
PC8000-6E
3 - 139
Hydraulics
Superstructure
3.8.11.2 REPLACEMENT OF THE THROTTLE CHECK VALVES ON THE MANIFOLD

Special tools:
n/a
Crane
Throttle check valve (long version): 31 kg
Throttle check valve (short version): 28 kg
Dogman/rigger

Fit a new O-ring (Fig. 3-136, Pos. 3) to the throttle check
valve (Fig. 3-136, Pos. 1).
z
NOTE: If the built-in SRV (Fig. 3-132, Pos. 13) has been
removed from the housing (Fig. 3-132, Pos. 11) tighten
the valve to the specified tightening torque.
300 Nm
z
NEWS No. "AH01513".
Check and adjust the throttle check valve. Refer to the

Service Manual.
Check and adjust the built-in SRV in the throttle check valves
if required. Refer to the Service Manual.
3 - 140
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.12 MANIFOLD
3.8.12.1 REMOVAL OF THE MANIFOLD
Special tools:
n/a
Crane
Oil drain pan
Manifold incl. ACV and SRV: 1925 kg
Manifold without ACV and SRV: 725 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Remove the front roof plates, refer to section 3.3.3.1 on page

3-15.
Fig. 3-137
Version 2010/1
PC8000-6E
3 - 141
Hydraulics
Superstructure
WARNING
Hot hydraulic oil!
Remove the grating (Fig. 3-138, Pos. 1).
Disconnect all hydraulic hoses (Fig. 3-138, Pos. 2) leading to

the attachment, refer to section 5.1.7.1 on page 5-68.
Open the clamps (Fig. 3-138, Pos. 6) and remove all hydraulic piping (Fig. 3-138, Pos. 5) from the front of the manifold.
Disconnect all hydraulic lines (Fig. 3-138, Pos. 4) leading to

the ACVs and SRVs.
Remove all hydraulic piping (Fig. 3-138, Pos. 7) leading to the

main control valves from the manifold.
hydraulic lines will flow out. Catch it in an oil pan.
z
Sling the manifold.
Remove four mounting bolts (Fig. 3-138, Pos. 3).
Remove the manifold using a crane.
Fig. 3-138
DANGER
When removing the manifold, make sure that nobody steps
below the weight.
Remove the anti cavitation valves (ACV) from the manifold,

Remove the throttle check valves from the manifold, refer to

Remove the SRV from the manifold, refer to section 3.8.9.1

on page 3-120.
Remove all other attached parts from the manifold.
3 - 142
PC8000-6E
Version 2010/1
Superstructure
Hydraulics
3.8.12.2 REPLACEMENT OF THE MANIFOLD

Special tools:
n/a
Crane
Manifold incl. ACVs and SRVs: 1925 kg
Manifold without ACVs and SRVs: 725 kg
Dogman/rigger
2.2.6 on page 2-22.
Fit new O-rings to the SAE-flanges.
z
NEWS No. "AH01513".
Version 2010/1
PC8000-6E
3 - 143
Hydraulics
Superstructure
3 - 144
PC8000-6E
Version 2010/1
Superstructure
3.9
SLEW SYSTEM
3.9.1
SLEW GEAR
Slew system
Fig. 3-139 Slew gears, mounting positions overview

The PC8000-6 is equipped with three slew gear assemblies. For
further information, refer to the Service Manual.
Multi disc brakes (Fig. 3-139, Pos. 3) are installed between the
swing motors (Fig. 3-139, Pos. 2) and the gearboxes (Fig. 3-139,
Pos. 4). These brakes are safety brakes, applied by spring force
and released by hydraulic oil pressure.
To operate the rotary motion, slew brake valves (Fig. 3-139,
Pos. 1) are directly flanged to the swing motor heads. For further
information, refer to the Service Manual.
Version 2010/1
PC8000-6E
3 - 145
Slew system
Superstructure
Fig. 3-140 Slew gear assembly, overview
3 - 146
PC8000-6E
Version 2010/1
Superstructure
Slew system

(1)
Slew brake valve
(2)
Intermediate plate
(3)
Swing motor
(4)
Cover plates
(5)
Slew parking brake
(6)
Slew gear
(7)
Superstructure platform
(8)
Bolt
(9)
O-ring
(10)
Bolt
(11)
Bolt
(12)
Protection cap
(13)
Bolt
(14)
Nut
NOTE: The machine can be equipped either with a slew gear of

manufacturer "L&S" or of manufacturer "Siebenhaar".
The removal and the replacement of the slew gear by different manufacturers are analogously the same. Refer to
the data plate on each slew gear housing to find out the
manufacturer of the slew gear.
Version 2010/1
PC8000-6E
3 - 147
Slew system
Superstructure
3.9.1.1 REMOVAL OF THE SLEW GEAR

Special tools:
n/a
Crane
Swing motor with attached slew service brake valve: 330 kg
Slew gear (Siebenhaar): 1700 kg
Slew gear (L&S): 1880 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Fig. 3-141
z
Depending on the mounting position of the slew gear, remove

the front roof plates, refer to section 3.3.3.1 on page 3-15.
3 - 148
PC8000-6E
Version 2010/1
Superstructure
Slew system
Remove the bleeder valves (Fig. 3-142, Pos. 1)

Drain the gear oil from the slew gear (Fig. 3-142,
Pos. 3 respectively Pos. 5) at the drain coupling
(Fig. 3-142, Pos. 2),
approx 60 liters (Siebenhaar),
approx. 42 liters (L&S),
refer to the Operation & Maintenance Manual, chapter
4, section "SWING GEARS AND MOTOR ADAPTER
HOUSING - CHANGE OIL".
Remove the oil drain coupling (Fig. 3-142, Pos. 2) and if

equipped also remove the union (Fig. 3-142, Pos. 4) from the
slew gear (Fig. 3-142, Pos. 3 respectively Pos. 5).
Fig. 3-142
z
Remove the swing motor (Fig. 3-143, Pos. 2) from the slew
gearbox (Fig. 3-143, Pos. 3), refer to section 3.9.2.1 on page
3-155.
NOTE: Leave the hydraulic hoses and the slew service brake
valve (Fig. 3-143, Pos. 1) attached to the swing motor if
possible. If not, disconnect the hydraulic lines.
Fig. 3-143 L&S slew gear as example
Version 2010/1
PC8000-6E
3 - 149
Slew system
Superstructure
DANGER
removed.
Disconnect the oil pressure line from the slew parking brake.
NOTE: When the hydraulic lines are disconnected, the oil inside
the lines will flow out. Catch it in an oil pan.
z
Remove the cover plates (Fig. 3-144, Pos. 3) if equipped.
Remove the protection caps (Fig. 3-144, Pos. 1) from the bolt
heads and remove the slew gear mounting bolts (Fig. 3-144,
Pos. 2). Discard the bolts.
Disconnect the lubrication lines below the slew gear.
Insert swivel hoist rings (M16) displaced by 90 into the

threads of the swing motor mounting bolts and attach a crane.
Remove the slew gear (Fig. 3-144, Pos. 4) using a crane.

DANGER

When removing the slew gear, make sure that nobody steps
below the weight.
3 - 150
PC8000-6E
Version 2010/1
Superstructure
Slew system
3.9.1.2 REPLACEMENT OF THE SLEW GEAR

Special tools:
Feeler gauge (customary)
Crane
Slew gear (Siebenhaar): 1700 kg
Slew gear (L&S): 1880 kg
Dogman/rigger

NOTE: The machine can be equipped either with a slew gear of
manufacturer "Siebenhaar" or of manufacturer "L&S".
Refer to the data plate on each slew gear housing to find
out the manufacturer of the slew gear.
Both slew gears are replaceable using a special modification kit. Refer to the PARTS & SERVICE NEWS
No. "AH05535".
z

Install the new slew gear (Fig. 3-145, Pos. 4) using a crane.
DANGER

When removing the slew gear, make sure that nobody steps
below the weight.
Mount the slew gear (Fig. 3-145, Pos. 4) to the superstructure

with new mounting bolts (Fig. 3-145, Pos. 2).
Check the tooth backlash between slew ring and slew pinion
with a feeler gauge.
Refer to the PARTS & SERVICE NEWS No. "AH00511".
NOTE: Use new slew gear mounting bolts (Fig. 3-145, Pos. 2) of
grade 12.9. Apply compound "KP2K", PN 324 969 40
and tighten the bolts to the specified tightening torque.
Tightening torque for the slew gear mounting

bolts: 1030 Nm
Version 2010/1
PC8000-6E
3 - 151
Slew system
Superstructure
Install the oil drain coupling (Fig. 3-146, Pos. 2) with the union
(Fig. 3-146, Pos. 4), if equipped, at the new slew gear
(Fig. 3-146, Pos. 3 respectively Pos. 5).
Clean the bleeder valves (Fig. 3-146, Pos. 1) with compressed air from inside to outside and reinstall at the new
slew gear (Fig. 3-146, Pos. 3 respectively Pos. 5).
Fig. 3-146
z

WARNING
Make sure to use the specified bolts and the tightening

torque for the swing motor mounting bolts, refer to section
3.9.2.2 on page 3-158.
Fill specified gear oil into the slew gear,

approx. 60 liters (Siebenhaar),
approx. 42 liters (L&S).
Fill specified oil into the motor adapter housing,
approx. 0.6 liters (L&S),
up to level gauge marking (Siebenhaar).
Fill specified oil into the brake housing (Siebenhaar
only), approx. 0.2 liters.
NOTE: Refer to the Operation & Maintenance
Manual, chapter 4, section "SWING
GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL".
For the proper lubricants, refer to the Operation & Maintenance Manual, chapter 4,
section "FLUIDS AND LUBRICANTS".
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Version 2010/1
Superstructure
Slew system
Version 2010/1
PC8000-6E
3 - 153
Slew system
3.9.2
Superstructure
SWING MOTOR
Fig. 3-147 Swing motor assembly

(1)
Bolt
(12)
Bolt (only Siebenhaar)
(2)
Slew brake valve
(13)
Washer (only Siebenhaar)
(3)
O-ring
(14)
Expansion tank of the slew gear

(only Siebenhaar)
(4)
Bolt
(15)
Sleeve (only Siebenhaar)
(5)
Intermediate plate
(6)
O-ring
(7)
Bolt
(8)
Washer
(9)
Swing motor
(10)
O-ring
(11)
Slew gear
3 - 154
PC8000-6E
Version 2010/1
Superstructure
Slew system
3.9.2.1 REMOVAL OF THE SWING MOTOR

Special tools:
n/a
Crane
Oil drain pan
Swing motor: 120 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Fig. 3-148
z
Depending on the mounting position of the slew gear, remove

the front roof plates, refer to section 3.3.3.1 on page 3-15.
Version 2010/1
PC8000-6E
3 - 155
Slew system
Superstructure
WARNING
Hot hydraulic oil!
Drain the gear oil from the motor adapter housing.

Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR
ADAPTER HOUSING - CHANGE OIL"
z
Disconnect the leak oil hose, attached to the swing motor.
NOTE: When the hydraulic hose is disconnected, hydraulic oil

from inside the hoses and the swing motor will flow out.
Fig. 3-149 Removal of the swing motor
3 - 156
PC8000-6E
Version 2010/1
Superstructure
Slew system
Remove the four mounting bolts (Fig. 3-149, Pos. 1) and take
the slew brake valve (Fig. 3-149, Pos. 2) off. Discard the
O-ring (Fig. 3-149, Pos. 3). For further information regarding
the slew brake valve, refer to section 3.9.4.1 on page 3-179.
NOTE: The hydraulic hoses remain connected to the slew brake

valve.
When the slew brake valve is removed, the oil inside the
valve will flow out. Catch it in an oil pan.
z
Remove the mounting bolts (Fig. 3-149, Pos. 4) and take off
the intermediate plate (Fig. 3-149, Pos. 5). Discard the O-ring
(Fig. 3-149, Pos. 6).
Only slew gear "Siebenhaar": Remove the bolts (Fig. 3-149,

Pos. 12), with washers (Fig. 3-149, Pos. 13), and the sleeves
(Fig. 3-149, Pos. 15). Put the expansion tank (Fig. 3-149,
Pos. 14) of the slew gear aside. Discard the bolts.
Remove the bolts (Fig. 3-149, Pos. 7) and the washers

(Fig. 3-149, Pos. 8). Discard the bolts.
Sling the swing motor (Fig. 3-149, Pos. 9).
Pull the swing motor out of the slew gear (Fig. 3-149, Pos. 11)
using a crane. Place the swing motor on the ground.
DANGER

When removing the swing motor, make sure that nobody
Version 2010/1
PC8000-6E
3 - 157
Slew system
Superstructure
3.9.2.2 REPLACEMENT OF THE SWING MOTOR

Special tools:
Crane
Swing motor: 120 kg
Dogman/rigger

Fig. 3-150 Installation of the swing motor
3 - 158
PC8000-6E
Version 2010/1
Superstructure
Slew system
Fit new O-rings (Fig. 3-150, Pos. 3, Pos. 6, and Pos. 10).
z
Apply "Optimol White" to the spline shaft of the motor.
NOTE: Use new swing motor mounting bolts (Fig. 3-150,

Pos. 7 and 12) of grade 10.9. Apply compound "KP2K",
PN 324 969 40 and tighten them to the specified tightening torque.
Tightening torque for the swing motor mounting bolts: 265 Nm
z
NEWS No. "AH01513".

approx. 0.6 liters (L&S),
up to level gauge marking (Siebenhaar).
chapter 4, section "SWING GEARS AND MOTOR
ADAPTER HOUSING - CHANGE OIL".
For the proper lubricants, refer to the Operation &
Maintenance Manual, chapter 4, section "FLUIDS
AND LUBRICANTS".
Check the adjustments of the swing motors. Refer to the Service Manual for further information.
Check the slew brake valve and adjust it if required. Refer to

the Service Manual for further information.
Version 2010/1
PC8000-6E
3 - 159
Slew system
Superstructure
3 - 160
PC8000-6E
Version 2010/1
Superstructure
3.9.3
Slew system
SLEW PARKING BRAKE
NOTE: The machine can be equipped either with a slew parking

brake of manufacturer "Siebenhaar" or of manufacturer
"L&S".
For the removal and the replacement, the "L&S" slew
parking brake has to be disassembled/assembled.
The "Siebenhaar" slew parking brake assembly can be
exchanged completely.
Slew parking brake (L&S)

(1)
Disc housing
(10)
Thrust washer
(2)
Thrust washer
(11)
Circlip
(3)
Inner discs
(12)
Drive shaft
(4)
Outer discs
(13)
Oil pressure port
(5)
Sinus spacer ring
(14)
Bolt
(6)
Piston
(15)
Bearing ring
(7)
Quad ring with back up ring
(16)
Rotary shaft seal
(8)
Quad ring with back up ring
(17)
Cylinder assembly
(9)
Springs
Version 2010/1
PC8000-6E
3 - 161
Slew system
Superstructure
General:
Brake applied:
The outer disks engaged to the housing by serration and the inner
disks in serrated connection with the drive shaft are pressed
together by the springs. This results in a fixed connection
between housing and drive shaft due to the friction between the
spring pressurized discs.
Brake released:
Oil pressure via the pilot port reaches the bottom of the piston and
forces the piston upwards against the thrust washer and the
spring force. This eliminates the spring force towards the disks so
that the friction between the discs is released and the inner shaft
can rotate. Only the brake of the L&S gear box uses an additional
spacer ring (sinus ring) to keep the discs apart. It should reduce
the friction in released condition.
The minimum release pressure is 19 - 20 bar. In normal working
conditions, the releasing pressure is about 60 bar.
NOTE: The slew parking brake must only be applied with the
superstructure at a complete standstill. Applying the parking brake with the superstructure still slewing may result
in severe damage to the brake.
WARNING
z
Only use the slew parking brake in emergency situations

to stop the rotating superstructure.
If the parking brake has been used for an emergency

stop, it is necessary to shut down the excavator and to
have the parking brake of each swing gear inspected and
repaired if necessary. Contact your Komatsu dealer for
repairing the brakes.
3 - 162
PC8000-6E
Version 2010/1
Superstructure
Slew system
3.9.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S)

Special tools:
n/a
Crane
Bearing ring: 28.5 kg
Dogman/rigger
NOTE: The slew parking brake is attached to the slew gear with
eight hexagon socket bolts. It is removed by disassembling it.
z
Remove the swing motor from the slew gear, refer to section
3.9.2.1 on page 3-155. Leave the hydraulic hoses and the
slew service brake valve attached to the swing motor.
Install swivel hoist rings (M16) displaced by 180 to the

Remove the mounting bolts (Fig. 3-151, Pos. 1) at the swing

motor flange.
Remove the inner snap ring (Fig. 3-151, Pos. 2).
Remove the bearing ring (Fig. 3-151, Pos. 3) from the slew
gearbox using a crane.
Fig. 3-151
Version 2010/1
PC8000-6E
3 - 163
Slew system
Superstructure
Fig. 3-152 Slew parking brake (L&S)

z
Check the rotary shaft seal (Fig. 3-152, Pos. 16) for wear and
damage. Replace it if required.
Disconnect the pressure hose from the oil pressure port

(Fig. 3-152, Pos. 13).
NOTE: When the pressure hose is removed, the oil inside the
hose and the cylinder (Fig. 3-152, Pos. 17) will flow out.
WARNING
The piston (Fig. 3-152, Pos. 6) of the break assembly is
spring loaded.
Remove the two socket head cap bolts (Fig. 3-152, Pos. 14)
and relieve the spring load of the springs (Fig. 3-152, Pos. 9)
on the piston (Fig. 3-152, Pos. 6).
Take off the cylinder assembly (Fig. 3-152, Pos. 17).
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PC8000-6E
Version 2010/1
Superstructure
Slew system
Dismount 10 inner discs (Fig. 3-152, Pos. 3), 11 outer discs

(Fig. 3-152, Pos. 4), and 10 sinus spacer rings (Fig. 3-152,
Pos. 5) from the disc housing (Fig. 3-152, Pos. 1).
Remove the drive shaft (Fig. 3-152, Pos. 12).
Remove the thrust washer (Fig. 3-152, Pos. 2) from the disc
housing (Fig. 3-152, Pos. 1).
Check the inner discs (Fig. 3-152, Pos. 3), the outer discs
(Fig. 3-152, Pos. 4), the sinus spacer rings (Fig. 3-152,
Pos. 5), and the thrust washer (Fig. 3-152, Pos. 2) for wear
and damage. Replace if required.
Version 2010/1
PC8000-6E
3 - 165
Slew system
Superstructure
3.9.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S)

Special tools:
n/a
Crane
Hydraulic power unit (60 bar) with fitting (M18 x 1.5)
Bearing ring: 28.5 kg
Dogman/rigger

Fig. 3-153 Slew parking brake (L&S)
3 - 166
PC8000-6E
Version 2010/1
Superstructure
Slew system
NOTE: Replace all O-rings.

z
Install the thrust washer (Fig. 3-153, Pos. 2).
Install the drive shaft (Fig. 3-153, Pos. 12).
NOTE: Apply "Optimol White" to the spline shaft.

z
Install new discs according to the following order:

At first an outer disc (Fig. 3-153, Pos. 4), then an inner disc
(Fig. 3-153, Pos. 3), and then a sinus spacer ring
(Fig. 3-153, Pos. 5). Apply oil to the discs.
NOTE: Before reinstallation, apply pressure (max. 60 bar) to the

cylinder assembly (Fig. 3-153, Pos. 17), otherwise the
two socket head cap bolts (Fig. 3-153, Pos. 14) are prestressed (spring loaded).
z
Install the cylinder assembly (Fig. 3-153, Pos. 17).

WARNING
Make sure to use the specified bolts and torque for the swing
motor mounting bolts, refer to section 3.9.2.2 on page 3-158.

approx. 0.6 liters.
For the proper lubricant, refer to the Operation &
AND LUBRICANTS".
z
Check the slew parking brake for proper function. Refer to the
Service Manual.
Version 2010/1
PC8000-6E
3 - 167
Slew system
Superstructure
3 - 168
PC8000-6E
Version 2010/1
Superstructure
Slew system
3.9.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR)

Special tools:
n/a
Crane
Slew parking brake assembly: 115 kg
Dogman/rigger
6.6 on page 6-14.
z
Remove the swing motor from the slew parking brake, refer to
section 3.9.2.1 on page 3-155. Leave the hydraulic hoses and
the slew service brake valve attached to the swing motor.
Drain the oil of the brake housing, approx. 0.2 liters.
NOTE: After draining the oil of the brake housing, cap the openings with blind plugs to avoid contamination.
DANGER
removed.
Disconnect the pilot oil pressure line from the slew parking
brake.
NOTE: When the pilot oil pressure line is disconnected, the oil
inside the line will flow out. Catch it in an oil pan.
Version 2010/1
PC8000-6E
3 - 169
Slew system
Superstructure
Remove all hydraulic pipes (Fig. 3-154, Pos. 3) from the slew
parking brake (Fig. 3-154, Pos. 2) and cap the openings with
blind plugs to avoid contamination.
DANGER
Danger of parts blasting off!

Serious injury, permanent disfigurement and scarring, or
death may result!
The piston of the slew parking break assembly is spring
loaded.
It is necessary to release the brake manually (see following
procedure) before removing the mounting bolts (Fig. 3-154,
Pos. 1) attaching the complete slew parking brake (Fig. 3154, Pos. 2) to the slew gear box (Fig. 3-154, Pos. 4).
Never open the brake by removing the flange mounting bolts
(Fig. 3-155, Pos. 3) before the slew parking brake is manually
released!
Fig. 3-154
Fig. 3-155 Slew parking brake (Siebenhaar), drawn released
3 - 170
PC8000-6E
Version 2010/1
Superstructure
Slew system
Releasing the slew parking brake manually:

z
Insert two bolts (Fig. 3-156, Pos. 1) of suitable length with

nuts (Fig. 3-156, Pos. 3) into the threaded borings
(Fig. 3-155, Pos. 2) of the piston (Fig. 3-156, Pos. 2) opposed
to each other.
Tighten each nut (Fig. 3-156, Pos. 3) alternately with a half

turn, to withdraw the piston (Fig. 3-156, Pos. 2) to the flange
(Fig. 3-156, Pos. 4).
NOTE: Avoid tilting the piston!

z
Only remove the mounting bolts (Fig. 3-154 and 3-155,

Pos. 1) attaching the complete slew parking brake
(Fig. 3-154, Pos. 2) to the slew gearbox.
Fig. 3-156
DANGER
Serious injury, permanent disfigurement and scarring,
or death may result!
loaded.
released!

Remove the slew parking brake (Fig. 3-154, Pos. 2) from the
slew gearbox (Fig. 3-154, Pos. 4), using a crane.
DANGER

When removing the slew gear parking brake, make sure that
Version 2010/1
PC8000-6E
3 - 171
Slew system
Superstructure
3.9.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR)

Special tools:
n/a
Crane
Slew parking brake assembly: 115 kg
Dogman/rigger

Fig. 3-157 Slew parking brake (Siebenhaar), drawn released
3 - 172
PC8000-6E
Version 2010/1
Superstructure
Slew system
DANGER
Serious injury, permanent disfigurement and scarring, or
death may result!
loaded.
released!
z
Apply paste "Optimol White" on the spline shaft at the adapter

cover (Fig. 3-158, Pos. 4) of the gearbox.
Insert swivel hoist rings (M16) on the new pre-assembled

slew parking brake, displaced by 180 into the threads of the
swing motor mounting bolts and attach the brake assembly to
a crane.
Insert a new O-Ring (Fig. 3-158, Pos. 3).
Centre the new pre-assembled slew parking brake

(Fig. 3-158, Pos. 2) onto the adapter cover (Fig. 3-158,
Pos. 4) of the gearbox.
DANGER
Fig. 3-158

When replacing the slew parking brake, make sure that
Releasing the slew parking brake manually:

z
Insert two bolts (Fig. 3-159, Pos. 1) of suitable length with

nuts (Fig. 3-159, Pos. 3) into the threaded borings
(Fig. 3-157, Pos. 2) of the piston (Fig. 3-159, Pos. 2) opposed
to each other.
Tighten each nut (Fig. 3-159, Pos. 3) alternately with a half

turn, to withdraw the piston Fig. 3-159, Pos. 2) to the flange
(Fig. 3-159, Pos. 4).
NOTE: Avoid tilting the piston!

z
Turn the slew parking brake (Fig. 3-158, Pos. 2) until the
bores in the slew parking brake are aligned to the threads in
the adapter cover (Fig. 3-158, Pos. 4).
Insert new mounting bolts (Fig. 3-158, Pos. 1) and tighten

them crosswise.
Remove the release bolts (Fig. 3-159, Pos. 1) with nuts alternately stepwise to prevent the piston from tilting.
Version 2010/1
PC8000-6E
Fig. 3-159
3 - 173
Slew system
Superstructure

WARNING
Make sure to use the specified bolts and torques for the
swing motor mounting bolts, refer to section 3.9.2.2 on page
3-158.
Fill specified oil into the motor adapter housing, up

to level gauge marking.
Fill specified oil into the brake housing approx. 0.2
liters.
For the proper lubricant, refer to the Operation &
AND LUBRICANTS".
z
Check the slew parking brake for proper function. Refer to the
Service Manual.
3 - 174
PC8000-6E
Version 2010/1
Superstructure
Slew system
Version 2010/1
PC8000-6E
3 - 175
Slew system
3.9.4
Superstructure
DYNAMIC SLEW BRAKE
Fig. 3-160 Slew brake valve
3 - 176
PC8000-6E
Version 2010/1
Superstructure
Slew system

(1)
(2)
Check valve circuit A
(3)
Check valve circuit B
(4)
Anti-cavitation valve circuit B (check valve)
(5)
Anti cavitation valve circuit A (check valve)
(6)
Jet bore of main relief valve spool
(7)
Spring of main relief valve spool
(8)
Jet bore pilot relief valve
(9)
Valve cone of pilot relief valve
(10)
Spring of pilot relief valve
(11)
Intermediate pin
(12)
Control piston for pressure increase
(13)
Main relief valve spool
(X)
Pilot control port for pressure increase
(Y)
Leak oil, pilot valve drain
(T)
Return oil to tank / reservoir
(A)
Service line from main control valve block
(A)
(B)
Service line from main control valve block
(B)
(MA)
Check point circuit A
(MB)
Check point circuit B
Whenever a swing motion is carried out or the foot brake is used,

pilot pressure is present at port X of the pressure increase valve
(Fig. 3-160, Pos. 1). The pilot pressure preloads the relief valve.
The oil for the hydraulic motor from the main control valve block
feeds the service line port A or B depending of the slew direction
left or right. The ports A and B are internally connected to the
ports A and B and these ports in turn with the hydraulic motor.
The operating pressure at either port A or B closes the anti-cavitation valves (Fig. 3-160, Pos. 4 and 5) and opens the check valves
(Fig. 3-160, Pos. 2 and 3). That means the service lines are connected to the pressure increase valve by the check valves
(Fig. 3-160, Pos. 2 and 3).
Whenever the pressure is higher than the setting of the pressure
increase valve, the valve opens and dumps oil into the return line
T to the reservoir. If the superstructure is slewing by dynamical
momentum, the motor is driven by the slew gear and acts as a
pump. The pressure in the service lines to the motor changes.
Version 2010/1
PC8000-6E
3 - 177
Slew system
Superstructure
The low pressure return line becomes pressurized and the pressurized service line changes to suction line. The service line is
closed at the main control valve block so the oil can only circulate
through the brake valve blocks pressure increase valve.
Fig. 3-161 Pressure increase valve

Whenever a swinging motion is carried out or the foot brake is
used, pilot pressure is present at port X of the pressure increasing
valve. The pilot pressure preloads the relief valve.
By applying pilot pressure via the external port X to piston
(Fig. 3-161, Pos. 12), the pretension of the spring (Fig. 3-161,
Pos. 10) is increased by the amount of the piston stroke S which
results in a higher pressure setting for the pilot valve.
The system pressure is present at the main piston (Fig. 3-161,
Pos. 13) and via the jet bore (Fig. 3-161, Pos. 6) in the chamber
of the spring (Fig. 3-161, Pos. 7) as well. System pressure also is
present at the pressure relief valve cone (Fig. 3-161, Pos. 9) via
the jet bore (Fig. 3-161, Pos. 8).
Due to the force balance, the piston (Fig. 3-161, Pos. 13) is kept
in its position, supported by the spring (Fig. 3-161, Pos. 7).
If the system pressure is higher than the setting of the valve
(Fig. 3-161, Pos. 9) the valve opens a channel to the drain port Y.
Due to the drop of pressure, the piston (Fig. 3-161, Pos. 13) is
moved by the spring (Fig. 3-161, Pos. 7). The pressure line is
connected to the return line T.
Dampened opening and closing is obtained by the throttled volumetric change that is caused by the jet bores.
3 - 178
PC8000-6E
Version 2010/1
Superstructure
Slew system
3.9.4.1 REMOVAL OF THE SLEW BRAKE VALVE

Special tools:
n/a
Crane
Slew brake valve: 110 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Fig. 3-162
Version 2010/1
PC8000-6E
3 - 179
Slew system
Superstructure
WARNING
Hot hydraulic oil!
Disconnect the service hoses (Fig. 3-163, Pos. 2), the return
hose (Fig. 3-163, Pos. 3), the leak oil hose (Fig. 3-163,
Pos. 4), and the pilot hose (Fig. 3-163, Pos. 5) from the slew
brake valve (Fig. 3-163, Pos. 6).
NOTE: When the hydraulic hoses are removed, hydraulic oil

from inside the valve and the piping will flow out.
z
Sling the slew brake valve (Fig. 3-163, Pos. 6).
Remove the four mounting bolts (Fig. 3-163, Pos. 1) and

demount the slew brake valve (Fig. 3-163, Pos. 6) from the
swing motor (Fig. 3-163, Pos. 7), using a crane.
Fig. 3-163
DANGER
When removing the slew brake valve, make sure that nobody
Discard the O-ring from below the slew brake valve

(Fig. 3-163, Pos. 6).
NOTE: When the slew brake valve is removed, hydraulic oil from
inside the valve will flow out. Catch it in an oil pan.
3 - 180
PC8000-6E
Version 2010/1
Superstructure
Slew system
3.9.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE

Special tools:
n/a
Slew brake valve: 110 kg
Dogman/rigger

Fit new O-rings below the slew brake valve and at the
SAE-flanges.
z
NEWS No. "AH01513".
Check and adjust the slew brake valve. Refer to the Service
Manual.
Check the dynamic slew brake for proper function. Refer to

the Service Manual.
Version 2010/1
PC8000-6E
3 - 181
Slew system
3.9.5
Superstructure
SWING CIRCLE
Fig. 3-164 Swing circle
3 - 182
PC8000-6E
Version 2010/1
Superstructure
Slew system

(1)
Swing circle
(2)
Bolt
(3)
Bolt
(4)
Swing circle protection (partly shown)
(5)
Car body
(6)
Superstructure
The swing circle is the movable connection between the superstructure and the undercarriage.
The swing circle bearing is connected to the central lubrication
system. The outer ring gear is lubricated by an own lubrication
system SLS which uses a special open gear lubricant.
NOTE: For wear limits of the swing circle bearing, refer to
For additional information, refer to PARTS & SERVICE
NEWS No. "AH00511".
Version 2010/1
PC8000-6E
3 - 183
Slew system
Superstructure
3.9.5.1 REMOVAL OF THE SWING CIRCLE
Special tools:
Mounting cross, PN 329 179 40

Electro-hydraulic pump set, PN 232 613 40
2 x crane (2nd. crane for superstructure lifting)

Swing circle: 16,300 kg
Dogman/rigger

the machine, boom, and two cranes.

z
Remove the swing circle protection.
Fig. 3-165
z
Separate the superstructure from the undercarriage using

one of the two procedures:
z
For using the lifting procedure refer to section 3.15.1 on

page 3-252.
For using the removal procedure refer to section 3.15.3

on page 3-256.
NOTE: When using the removal procedure, place the superstructure on appropriate supports high enough to handle
the lifting device with mounting cross underneath the
swing circle.
3 - 184
PC8000-6E
Version 2010/1
Superstructure
Slew system
DANGER
Supports need to be substantial enough to carry total weight
of the superstructure (without counterweight, fluids and
attachment), total weight 298,000 kg.
Before removing swing circle, mark location of both slew rings

to superstructure and the car body as well for further investigations.
Disconnect all slew ring bearing lubrication hoses (Fig. 3-166,

Pos. 1) from the unions (Fig. 3-166, Pos. 3) at inner slew ring
(Fig. 3-166, Pos. 2).
Fig. 3-166
z
Position the mounting cross, PN 329 179 40 underneath the

swing circle.
Connect the the mounting cross to a crane.
NOTE: In order to avoid damage to the sling accessory, use

edge protection at all sharp edges.
The mounting cross is accessible from the centre of the
machine (Fig. 3-167, arrow).
CAUTION
Move the sling accessory carefully between the pipe work/
hoses at the manifold to prevent the pipe work from being
damaged or ripped off.
Fig. 3-167
Version 2010/1
PC8000-6E
3 - 185
Slew system
Superstructure
Lift mounting cross (Fig. 3-168, Pos. 1) to place it under the

swing circle (Fig. 3-168, Pos. 2).
Remove the mounting bolts of the inner slew ring to dismount

the swing circle (Fig. 3-168, Pos. 2) from the superstructure
(Fig. 3-168, Pos. 3).
Fig. 3-168
Lower the mounting cross with the swing circle resting on it to

the ground.
NOTE: The guides (Fig. 3-169, Pos. 2) ensure that the swing circle (Fig. 3-169, Pos. 3) is aligned accurately with the
superstructure (Fig. 3-169, Pos. 1) while it is removed
and installed respectively.
Do not remove the guides.
Fig. 3-169
z
Install four swivel hoist rings evenly distributed at the inner

slew ring and remove the swing circle from the mounting
cross using a crane.
DANGER

Death or serious injury result.
When removing the swing circle, make sure that nobody
3 - 186
PC8000-6E
Version 2010/1
Superstructure
Slew system
3.9.5.2 REPLACEMENT OF THE SWING CIRCLE
Special tools:
Mounting cross, PN 329 179 40

Measuring jaw, PN 274 703 40
8 x Measuring bolt, PN 909 004 40 or respectively 8 x Measuring bolt
(cold weather), PN 898 287 40
Test block, PN 375 795 40
2 x crane (2nd. crane for superstructure lifting)

Laser device for checking the level of bearing area
Swing circle: 16,300 kg
Dogman/rigger

z
Check the wear of the swing circle pinions at the slew gears,
refer to PARTS & SERVICE NEWS No. "AH05518".
Check the level of bearing area with a laser device before

installing a new slew ring. Refer to the PARTS & SERVICE
NEWS No. "AH00511".
Check the outer diameter of the new slew ring top surface
and compare with the outer diameter of the factory machined
surface of the superstructure. Refer to PARTS & SERVICE
NEWS No. "AH00511". Remove the shoulder by machining if
necessary.
WARNING
Shocks to the swing circle (especially radial shocks)

must be avoided.
Transport and store the new swing circle exclusively with

transport star fitted.
It is strictly forbidden to hook up the new swing circle at

the transport star.
Hang up and/or transport and store the swing circle only

horizontally. If a special attachment is available, the
transportation and storage in inclined position may be
carried out.
Only hang swing circle at four swivel hoist rings evenly

distributed in screw circle of the inner slew ring.
Version 2010/1
PC8000-6E
3 - 187
Slew system
Superstructure
NOTE: When replacing the swing circle, all fastening bolts must
also be replaced.
z
Install four swivel hoist rings evenly distributed at the inner

slew ring and lift it using a crane.
DANGER

When removing the swing circle, make sure that nobody
Place the swing circle (Fig. 3-170, Pos. 2) onto the mounting
cross (Fig. 3-170, Pos. 1).
Centre the swing circle (Fig. 3-170, Pos. 2) on the mounting

cross (Fig. 3-170, Pos. 1) with help of the transport star.
Position the mounting cross with the swing circle resting on it

under the superstructure (Fig. 3-170, Pos. 3) and connect the
mounting cross to a crane.
Fig. 3-170
NOTE: In order to avoid damage to the sling accessory, use
edge protection at all sharp edges.
The mounting cross is accessible from the centre of the
machine (Fig. 3-171, arrow).
CAUTION
Move the sling accessory carefully between the pipe work/
hoses at the manifold to prevent the pipe work from being
damaged or ripped off.
Fig. 3-171
z
Mating surfaces must be absolutely fat-free. Even the solvent

must be rinsed away before assembling.
Check flatness of the mating surfaces.
3 - 188
PC8000-6E
Version 2010/1
Superstructure
Slew system
Prepare new bolts (Fig. 3-172, Pos. 3) and washers

(Fig. 3-172, Pos. 4). Lubricate the threads and the head surface of the bolts with compound "KP2K", PN 324 969 40.
Align the "S-spots".
NOTE: The unhardened spot of race surfaces (changeover area

between beginning and end of hardening process) is
punch-marked with an "S" at the inner resp. outer side of
each slew ring (Fig. 3-172, Pos. 1 and 2).
These spots "S" must not be placed within the main load
area of the swing circle. Hence, the unhardened spot "S"
has to be turned in an angle of 90 to the main load area
refer to Fig. 3-172.
Fig. 3-172
z
Align the teeth of the outer slew ring with the lubrication pinions and the pinions of the slew gears.
Lift the swing circle (Fig. 3-173, Pos. 3) to approx. 10 mm

below the superstructure platform (Fig. 3-173, Pos. 1) by
means of the mounting cross.
Align the holes in the inner slew ring with the treads in the
superstructure platform. The guides (Fig. 3-173, Pos. 2) centre the swing circle horizontally (observe the unhardened
"S-spots").
NOTE: The guides ensure that the swing circle is aligned accurately into its mounting position.
Do not remove the guides (Fig. 3-173, Pos. 2) after
installation.
z
Install bolts (Fig. 3-172, Pos. 3) and washers (Fig. 3-172,

Pos. 4) to the inner slew ring.
Join the swing circle (Fig. 3-172, Pos. 5) on to the supporting

surface at the superstructure platform (Fig. 3-172, Pos. 6) by
tightening the bolts crosswise manually.
Remove the mounting cross.
Version 2010/1
PC8000-6E
Fig. 3-173
3 - 189
Slew system
Superstructure
Connect all slew ring bearing lubrication hoses (Fig. 3-174,

Pos. 1) to the unions (Fig. 3-166, Pos. 3) at the inner slew
ring (Fig. 3-174, Pos. 2).
Fig. 3-174
z
Check the tooth backlash between slew ring and slew pinion
with a feeler gauge.
Refer to PARTS & SERVICE NEWS No. "AH00511".
Tighten all bolts of the inner slew ring crosswise to the required torque, refer to PARTS &
SERVICE NEWS No. "AH00511".
NOTE: The procedure of tightening has to be performed twice or

three times, to ensure a setting of the bolts. Refer to
z
After tightening all bolts at the slew ring the tooth back lash
has to be checked once more at 4 points. Refer to PARTS &
If necessary adjust again.
Remount the superstructure onto the undercarriage, refer to

section 3.15.2 on page 3-255, respectively refer to section
3.15.4 on page 3-261.
DANGER

When lifting the superstructure, make sure that nobody
3 - 190
PC8000-6E
Version 2010/1
Superstructure
Slew system
Version 2010/1
PC8000-6E
3 - 191
Lubrication system
Superstructure
3.10 LUBRICATION SYSTEM

3.10.1 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL)
Fig. 3-175 Slew ring lubrication

3 - 192
PC8000-6E
Version 2010/1
Superstructure
Lubrication system

(1)
Lubrication pump station (SLS)

NOTE: A triple lubrication pump station may be
installed instead.
(2)
Lubricant supply line from pump to injector
(3)
Injectors
(4)
End of line pressure switch
(5)
Lubricant feed line from injector to lubrication pinion
(6)
Lubrication pinion
(7)
Slew ring
(8)
Lubrication pinion
(9)
Lubricant outlet
(10)
Lubrication pinion centre shaft with distributing

drillings
The swing circle lubrication system (SLS) lubricates the open

gear of the outer slew ring with special open gear lubricant.
The lubricant pump station (Fig. 3-175, Pos. 1) is identical with
the central lubrication system (CLS), refer to section 3.10.2 on
page 3-198. To apply the lubricant equably to the outer slew ring
teeth (Fig. 3-175, Pos. 7), a special lubrication pinion (Fig. 3-175,
Pos. 8) is mounted near each drive pinion of the slew gears. The
lubrication pinion (Fig. 3-175, Pos. 8) distributes the lubricant
from the injectors (Fig. 3-175, Pos. 3) evenly to the teeth. Normally two or more small SL1 injectors (Fig. 3-175, Pos. 3) are
parallel connected to supply the required amount of lubricant to
the lubrication pinion.
NOTE: The pinion centre shaft (Fig. 3-175, Pos. 10) acts as a
rotary joint and distributes lubricant through radial
drillings only to the teeth, witch are in contact with the
outer slew ring gear teeth.
Outlet bores (Fig. 3-175, Pos. 9 on different position of
the pinion gear distribute the lubricant equably to the
outer slew ring teeth (Fig. 3-175, Pos. 7).
Version 2010/1
PC8000-6E
3 - 193
Lubrication system
Superstructure
3.10.1.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY

Special tools:
n/a

Pinion cover: 1.2 kg
Lubrication pinion assembly: 15 kg

the machine, boom, and mobile working platform.
Park the machine on the prepared flat ground area with the
lubrication pinion placed between the crawler carriers, so that
the lubrication pinion can be accessed by a mobile working
platform.

z

WARNING
Before maintenance set main key switch S1 to OFF and the

maintenance safety switch S58 (Fig. 3-176, Pos. 3) to -0position to prevent starting of the electric motors during the
work. Fold up the flap
(Fig. 3-176, Pos. 2) and secure this position by inserting a
padlock into the holes (Fig. 3-176, Pos. 4) of the flap
(Fig. 3-176, Pos. 2) and the safety switch (Fig. 3-176, Pos. 1).
Assure that the system pressure of the lubrication system is
relieved before maintenance.
Fig. 3-176
z
Relieve the system pressure of the lubrication system by

actuating the vent valve (Fig. 3-184, Pos. 2) by hand, refer to
the PARTS & SERVICE NEWS No. "AH05546".
WARNING
Always wear a safety harness when working at the lubrication pinion.
NOTE: A second person is required for the work at the lubrication pinion.
3 - 194
PC8000-6E
Version 2010/1
Superstructure
Lubrication system
Fig. 3-177 Lubrication pinion assembly, removal and replacement

z
Remove the mounting bolts (Fig. 3-177, Pos. 6) with sleeves

(Fig. 3-177, Pos. 7) and remove the pinion cover (Fig. 3-177,
Pos. 1).
NOTE: A second person is required for this work.

z
Disconnect the lubrication lines (Fig. 3-177, Pos. 4).
Remove the nuts (Fig. 3-177, Pos. 5) and take the lubrication
pinion assembly (Fig. 3-177, Pos. 3) with connector plate
(Fig. 3-177, Pos. 2) off the superstructure.
Version 2010/1
PC8000-6E
3 - 195
Lubrication system
Superstructure
3.10.1.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY

Special tools:
n/a

Pinion cover: 1.2 kg
Lubrication pinion assembly: 15 kg
WARNING
Always wear a safety harness when working at the lubrication pinion.

z
After installation is complete, the swing circle lubrication system has to be activated manually, refer to the Operation &
Maintenance Manual, chapter 3, section "SWING CIRCLE
PINION LUBRICATION SYSTEM SLS.
Make sure that the end of line pressure switch B46 is pressurized and start a lubrication cycle manually with switch S26.
NOTE: There may be a time gap of up to 11 minutes until the

next manually started cycle is carried out. Refer to the
time table in the flowchart.
z
Reset the lubrication cycle counter of the slew ring lubrication

system. Refer to the Operation & Maintenance Manual, chapter 3, section "SWING CIRCLE PINION LUBRICATION SYSTEM SLS.
3 - 196
PC8000-6E
Version 2010/1
Superstructure
Lubrication system
Version 2010/1
PC8000-6E
3 - 197
Lubrication system
Superstructure
3.10.2 LUBRICATION PUMP STATION
Fig. 3-178 Lubrication pump station (old version)
3 - 198
PC8000-6E
Version 2010/1
Superstructure
Lubrication system

(1)
Coupling at the service arm for filling up the grease

container (3) of the swing circle lubrication system
(SLS)
(2)
Grease filter for swing circle pinion lubrication system (SLS)
(3)
Grease container of the swing circle pinion lubrication System (SLS)
(4)
Hydraulic motor with pump unit
(5)
Grease pressure gauge for SLS
(6)
Receiver panel at the service arm
(7)
Coupling at the service arm for filling the grease container of the central lubrication system (CLS)
(8)
Grease filter for central lubrication system
(9)
Grease container of the central lubrication system

(CLS)
(10)
Hydraulic motor with pump unit
(11)
Grease pressure gauge for CLS
(12)
Mounting bolts of the grease pump station
The lubrication pump station includes two single lubrication

pumps and a grease container for each lubrication pump. Each
lubrication pump has its own lubrication system:
One lubrication pump of the central lubrication system (CLS).
One lubrication pump of the swing circle pinion lubrication

System (SLS).
The lubrication pump is a hydraulically driven seal-free differential piston pump. The pump pumps lubricant during the up
and down stroke but sucks lubricant only during the up stroke.
The scoop piston at the pump bottom supports the main
pump with high viscosity lubricants. There is only one
dynamic seal at the piston rod on top of the pump pipe.
The lubrication pump is divided in two main components, the

pump drives hydraulic cylinder and the pump. The pump drive
and only the pump outlet are outside on top of the lubricant container, the pump itself is mounted inside and reaches into the
lubricant.
Version 2010/1
PC8000-6E
3 - 199
Lubrication system
Superstructure
Fig. 3-179 Lubrication pump station (actual version)

3 - 200
PC8000-6E
Version 2010/1
Superstructure
Lubrication system

(1)
Grease container for the superstructure lubricating

system, for swing connection bearing, and for boom
cylinder foot bearings (CLS)
(2)
Grease container for the attachment lubrication system (CLS)
(3)
Grease container of the swing circle pinion lubrication System (SLS)
(4)
Grease filter for the grease containers of the CLS
(5)
Grease filter for the grease container SLS
(6)
Hydraulic motors with pump units
(7)
Grease pressure gauges
(8)
In-line high pressure grease filters
The lubrication pump station includes three single lubrication

pumps and a grease container for each lubrication pump. Each
lubrication pump has its own lubrication system:
One lubrication pump of the attachment lubrication (CLS).
One lubrication pump of the superstructure lubricating system

for swing connection bearing and boom cylinder foot (CLS).
One lubrication pump of the swing circle pinion lubrication

System (SLS).
NOTE: The grease containers (Fig. 3-179, Pos. 1 and 2) are

linked together by an opening in the upper part of the of
the containers. This is for grease level compensation
during refilling.
Version 2010/1
PC8000-6E
3 - 201
Lubrication system
Superstructure
3.10.2.1 REMOVAL OF THE LUBRICATION PUMP STATION

Special tools:
n/a
Crane
Double lubrication pump station: 412 kg
Triple lubrication pump station: 618 kg
Dogman/rigger
NOTE: Remove the triple lubrication station analogously.

z


z

WARNING

Fig. 3-180
z
Relieve the system pressure of the lubrication system by

actuating the vent valve by hand, refer to the PARTS & SERVICE NEWS No. "AH05546".
3 - 202
PC8000-6E
Version 2010/1
Superstructure
Lubrication system
Disconnect all hydraulic and grease lines (Fig. 3-181, Pos. 1)

from the front roof plate.
Disconnect the wire harnesses from the end of line pressure

switches (B43 and B46). Clear the harnesses from the lubrication pump station.
Sling the lubrication pump station (Fig. 3-181, Pos. 3) at the

lifting eyes (arrows).
Remove the bolts (Fig. 3-181, Pos. 2) and remove the lubrication pump station from the roof using a crane.
DANGER

When removing the lubrication pump station, make sure that
Version 2010/1
PC8000-6E
Fig. 3-181
3 - 203
Lubrication system
Superstructure
3.10.2.2 REPLACEMENT OF THE LUBRICATION PUMP STATION

Special tools:
n/a
Crane
Double lubrication pump station: 412 kg
Triple lubrication pump station: 618 kg
Dogman/rigger

NOTE: Replace the triple lubrication station analogously.
z
if required, bleed the pump at the breather port

(Fig. 3-182, Pos. 1).
NOTE: Make sure that the grease hoses are filled with grease.
Therefore it may be necessary to carry out some lubrication cycles manually.
z
Make sure that the end of line pressure switch of the resp.
lubrication pump is pressurized, see following table.
Start a lubrication cycle manually with the resp. switch at the

operators console, see following table.
Fig. 3-182
Switch
Pressure
switch
Lubrication system
S24
B43
CLS
S26
B46
SLS
S99
B174
Separate attachment lubrication pump

(CLS)
NOTE: Triple pump station only
NOTE: There may be a time gap of up to 11 minutes until the

next manually started cycle is carried out. Refer to the
time table in the flowchart.
z
Adjust the lubrication pump speed and pressure. Refer to the

Service Manual.
3 - 204
PC8000-6E
Version 2010/1
Superstructure
Lubrication system
3.10.2.3 REMOVAL OF THE LUBRICATION PUMP

Special tools:
n/a
Crane
Lubrication pump: 28 kg
Dogman/rigger


z

WARNING

Fig. 3-183
z
Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-184, Pos. 1) by hand, refer to the
Disconnect the hydraulic lines (Fig. 3-184, Pos. 2) from the

lubrication pump.
Disconnect the quick coupling from the grease feeding line

(Fig. 3-184, Pos. 3).
Fig. 3-184
Version 2010/1
PC8000-6E
3 - 205
Lubrication system
Superstructure
Disconnect the grease feeding line (Fig. 3-185, Pos. 1) from

the lubrication pump.
Fig. 3-185
z
Remove the bolt (Fig. 3-186, Pos. 1).
Fig. 3-186
Sling the lubrication pump (Fig. 3-187, Pos. 1) at the installed

lifting eye (Fig. 3-187, arrow) and pull the lubrication pump
out of the grease container.
Fig. 3-187
3 - 206
PC8000-6E
Version 2010/1
Superstructure
Lubrication system
3.10.2.4 REPLACEMENT OF THE LUBRICATING PUMP

Special tools:
n/a
Crane
Lubrication pump: 28 kg
Dogman/rigger

z
After replacement, bleed the pump at the breather port

(Fig. 3-188, Pos. 1).
Fig. 3-188
z
Adjust the lubrication pump speed and pressure. Refer to the

Service Manual.
Version 2010/1
PC8000-6E
3 - 207
Operators cab
Superstructure
3.11 OPERATORS CAB
Fig. 3-189 Operators cab overview

3 - 208
PC8000-6E
Version 2010/1
Superstructure
Operators cab

A
Rear View of Operators Cab
(1)
Door handle
(2)
Door latch (with door fully opened)
(3)
Door locking pin, engages into the latch when the

cab door is fully opened
(4)
Light switch for access area lighting
(5)
Light switch for interior cab lighting
(6)
Air conditioner door
(7)
Outside mirrors with integrated heaters, both mirrors

are adjusted electrically via a control switch on the
instrument panel
(8)
Main working lights
(9)
Adapter for warning beacon
Front View of Operators Cab
(10)
Release lever for the door lock (2 - 3)
(11)
Door opener push button
(12)
Lock lever
(13)
Control levers for working attachment
(14)
Operators seat
(15)
Upper windshield wiper
(16)
Lower windshield wiper
WARNING
The operators cab is equipped with an integrated Falling
Object Protective Structure (FOPS) that meets the requirements of ISO 3449. Any modifications on the steel structure
of the cab are inadmissible. Repairs on the FOPS must only
be carried out by specialists having the authorization for
repair work on Falling Object Protective Structures and in
accordance with the manufacturers repair instructions.
Version 2010/1
PC8000-6E
3 - 209
Operators cab
Superstructure
3 - 210
PC8000-6E
Version 2010/1
Superstructure
Operators cab
3.11.1 REMOVAL OF THE OPERATORS CAB

Special tools:
n/a

Crane
Oil drain pan
Operators cab: 3785 kg
Dogman/rigger
Air condition service specialist
6.6 on page 6-14.


z

DANGER
Hazardous Voltage!

WARNING
Always wear a safety harness when working at the operators

cab.
Version 2010/1
PC8000-6E
3 - 211
Operators cab
Superstructure
Remove the grommet plate (Fig. 3-190, Pos. 1) inside the cab
base.
If the machine is equipped with harness connectors:

z
Disconnect all harness connectors at the back side of the

grommet plate.
Disconnect all other harnesses leading to the operators

cab from the X2C-board and pull it out of the grommet
plate.
If the machine is not equipped with harness connectors:

z
Disconnect all harnesses leading to the operators cab Fig. 3-190

from the X2C-board and remove the cable transfer elements.
Dismount the grommet plate (Fig. 3-191, Pos. 1) inside the

cab base.
If machine is equipped with harness connectors:

z
Disconnect all harness connectors of the manipulators at

the back side of the grommet plate.
If machine is not equipped with harness connectors:

z
Disconnect all harnesses leading to the operators cab

from the X2-board and remove the cable transfer elements.
Fig. 3-191
Remove the ground cable (Fig. 3-192, Pos. 1) in the cab base
(Fig. 3-192, Pos. 2) from the left lower fixing bolt at the
X2-board and pull it out of the grommet plate.
Fig. 3-192
3 - 212
PC8000-6E
Version 2010/1
Superstructure
Operators cab
Remove the cover (Fig. 3-193, Pos. 1) inside the cab base.
Disconnect the hose (Fig. 3-193, Pos. 2) between cab support and operators cab from the other side of the cover.
Fig. 3-193
DANGER
Danger of high pressure.
The air conditioning system is pressurized. Make sure that
the refrigerant is sucked from the system before any lines
will be removed.
WARNING
The air conditioning must be serviced by authorized service
specialists only.
Aspirate the refrigerant from the air condition system.
Disconnect the refrigerant lines (Fig. 3-194, Pos. 2) from the

air conditioning unit (Fig. 3-194, Pos. 2).
NOTE: Cap the openings with blind plugs to avoid contamination

of the air conditioning system.
z
Disconnect the condensate lines (Fig. 3-194, Pos. 3) from the

air conditioning unit (Fig. 3-194, Pos. 2).
Clear all hoses from the operators cab.
Version 2010/1
Fig. 3-194
PC8000-6E
3 - 213
Operators cab
Superstructure
Sling the operators cab (Fig. 3-195, Pos. 2) at the lifting eye
bolts (Fig. 3-195, Pos. 1) delivered with the cab.
Fig. 3-195
Fig. 3-196 Removal of the operators cab, overview
3 - 214
PC8000-6E
Version 2010/1
Superstructure
Operators cab
Remove the hose (Fig. 3-196, Pos. 7) of the operators cab

water supply.
Open the hose clips (Fig. 3-196, Pos. 5) and remove the
water hoses (Fig. 3-196, Pos. 6).
Remove the gratings (Fig. 3-196, Pos. 8) from the cab support (Fig. 3-196, Pos. 9).
Remove the bolts (Fig. 3-196, Pos. 2) and resilient sleeves

(Fig. 3-196, Pos. 3) from the viscous mounts (Fig. 3-196,
Pos. 4).
Remove the operators cab (Fig. 3-196, Pos. 1) using a

crane.
NOTE: Lift the operators cab slowly while using a second person inside the cab base to guide the harnesses through
the grommet plates.
DANGER
When removing the operators cab make sure that nobody
Version 2010/1
PC8000-6E
3 - 215
Operators cab
Superstructure
3.11.2 REPLACEMENT OF THE OPERATORS CAB

Special tools:
n/a

Crane
Dogman/rigger
Air condition service specialist
Fig. 3-197 Replacement of the operators cab, overview
3 - 216
PC8000-6E
Version 2010/1
Superstructure
Operators cab
WARNING
z
Always wear a safety harness when working at the operators cab.
Ensure that no one stands between the cabin and the cab
base during lowering.
DANGER
Hazardous Voltage!
NOTE: Use new bolts (Fig. 3-197, Pos. 2) of the grade 10.9 at
the viscous mounts (Fig. 3-197, Pos. 4). Apply Compound "KP2K", PN 324 969 40 and tighten the bolts with
(Fig. 3-197, Pos. 2): 880 Nm
NOTE: When lowering the operators cab have a second person
inside the cab base to guide the harnesses through the
grommet plates.
z
Evacuate the air conditioning system and add refrigerant.

WARNING
The air conditioning must be filled with refrigerant "R134a"

by authorized service specialists only.
Version 2010/1
PC8000-6E
3 - 217
Operators cab
Superstructure
3.11.3 VISCOUS CAB-MOUNTS

3.11.3.1 REMOVAL OF THE VISCOUS CAB-MOUNTS
Special tools:
n/a

Crane
Viscous mount: 4 kg
Absorber plate incl. 2 viscous mounts: 12 kg
Dogman/rigger


z

WARNING

cab.
Sling the operators cab (Fig. 3-195, Pos. 2) at the lifting eye
bolts (Fig. 3-195, Pos. 1) delivered with the cab.
Fig. 3-198
3 - 218
PC8000-6E
Version 2010/1
Superstructure
Operators cab
Fig. 3-199 Removal of the cab-mounts, overview

z
Remove the gratings (Fig. 3-199, Pos. 8) from the cab support (Fig. 3-199, Pos. 9).
Remove the bolts (Fig. 3-199, Pos. 2) and resilient sleeves

(Fig. 3-199, Pos. 3) from the viscous mounts (Fig. 3-196,
Pos. 4).
Raise the operators cab (Fig. 3-196, Pos. 1) only a few millimeters using a crane, just enough to clear the viscous
mounts (Fig. 3-196, Pos. 4).
Remove the bolts (Fig. 3-199, Pos. 5) from the absorber plate
(Fig. 3-199, Pos. 6) and remove the absorber plate with the
viscous mounts.
Remove the bolts (Fig. 3-199, Pos. 7) and dismount the viscous mounts (Fig. 3-196, Pos. 4) from the absorber plate
(Fig. 3-199, Pos. 6).
Version 2010/1
PC8000-6E
3 - 219
Operators cab
Superstructure
3.11.3.2 REPLACEMENT OF THE VISCOUS CAB-MOUNTS

Special tools:
n/a

Crane
Viscous mount: 4 kg
Dogman/rigger

Fig. 3-200 Replacement of the cab-mounts, overview
3 - 220
PC8000-6E
Version 2010/1
Superstructure
Operators cab
WARNING
cab.
NOTE: Use new mounting bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 to the bolts and tighten
the bolts to the specified tightening torques.
(Fig. 3-200, Pos. 7) at the cab mounts
(Fig. 3-200, Pos. 4): 108 Nm
(Fig. 3-200, Pos. 5) at the absorber plates
(Fig. 3-200, Pos. 6): 880 Nm
Tightening torque for the operators cab mounting bolts (Fig. 3-200, Pos. 2): 880 Nm
Version 2010/1
PC8000-6E
3 - 221
Operators cab
Superstructure
3.11.4 FRONT WINDOW (WINDSCREEN)

3.11.4.1 REMOVAL OF THE FRONT WINDOW
Special tools:
n/a
Suction lifters with hoist rings

Crane
Front window: 112 kg
Dogman/rigger


z

WARNING

cab.
Remove the wiper arms (Fig. 3-201, Pos. 1).
Use suction lifters with hoist rings at the front window

(Fig. 3-201, Pos. 4) to sling the front window.
Remove the bolts (Fig. 3-201, Pos. 2). Hold the nuts (Fig. 3201, Pos. 3) from inside the cab.
Remove the front window (Fig. 3-201, Pos. 4) using a crane.
Fig. 3-201
3 - 222
PC8000-6E
Version 2010/1
Superstructure
Operators cab
3.11.4.2 REPLACEMENT OF THE FRONT WINDOW

Special tools:
n/a
Suction lifters with hoist rings

Crane
Front window: 112 kg
Dogman/rigger

WARNING
cab.
NOTE: A different holes pattern is used since January 2007 for

the frame of the front window.
KOMATSU recommends to use front windows with new
holes pattern in the frame, also for shovels, delivered
before 2007.
For further information refer to the PARTS & SERVICE
NEWS No. "AH08504".
z
Check the correct end position of the wiper arm(s) after installation of the front window.
Version 2010/1
PC8000-6E
3 - 223
Operators cab
Superstructure
3.11.5 OPERATORS SEAT

3.11.5.1 REMOVAL OF THE OPERATORS SEAT
Special tools:
n/a
Crane
Operators seat: 62 kg
Dogman/rigger
2nd. person to handle the seat


z
Disconnect the wire harness connector (Fig. 3-202, Pos. 1) of

the air suspension.
Remove both control lever carriers (Fig. 3-202, Pos. 2 and 8).
Remove all mounting bolts (Fig. 3-202, Pos. 6) from the cover
plate (Fig. 3-202, Pos. 7) and remove the operators seat
(Fig. 3-202, Pos. 9) with cover plate from the heating console
(Fig. 3-202, Pos. 5).
Remove the cover plate (Fig. 3-202, Pos. 7) from the operators seat by removing all seat mounting bolts (Fig. 3-202,
Pos. 4) with lock washers (Fig. 3-202, Pos. 3).
NOTE: A second person is required to carry the operators seat

out of the operators cab.
z
Sling the operators seat and lift it off the machine using a
crane.
Fig. 3-202
3 - 224
PC8000-6E
Version 2010/1
Superstructure
Operators cab
3.11.5.2 REPLACEMENT OF THE OPERATORS SEAT

Special tools:
n/a
Crane
Operators seat: 62 kg
Dogman/rigger
2nd. person to handle the seat
z
Remove both control lever carriers from the new seat.
NOTE: A second person is required to carry the operators seat

into the operators cab.
z
Check the Seats functions after replacement.
Version 2010/1
PC8000-6E
3 - 225
Operators cab
Superstructure
3.11.6 ECS
3.11.6.1 REMOVAL OF THE ECS TEXT DISPLAY
Special tools:
n/a
n/a
Remove the keys from the battery main switches.
Open the operators console.
Disconnect the data cables (Fig. 3-203, Pos. 1 and 2) from

the ECS text display (Fig. 3-203, Pos. 4).
Remove the wing nuts (Fig. 3-203, Pos. 3) and take the ECS
text display (Fig. 3-203, Pos. 4) out of the operators console.
Fig. 3-203
3.11.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY

Special tools:
n/a
n/a
Set time, date and operating hours, refer to the Operation &
Maintenance Manual, chapter 3, section "ELECTRONIC
MONITORING AND CONTROL SYSTEM ECS".
3 - 226
PC8000-6E
Version 2010/1
Superstructure
3.12 CAB BASE (MEDIUM VOLTAGE SWITCH CABINET)

3.12.1 REMOVAL OF THE CAB BASE
Special tools:


Crane
4x swivel hoist ring (M36)
Support frame: 987 kg
Cab base: 5410 kg
Emergency ladder: 68 kg
Platform: 135 kg
Dogman/rigger

the machine, boom, elevator working platform and crane.

z

DANGER
Hazardous Voltage!

WARNING
Always wear a safety harness when working at the cab base.
Version 2010/1
PC8000-6E
3 - 227
Superstructure
Remove the operators cab (Fig. 3-204, Pos. 1),

refer to section 3.11.1 on page 3-211.
Remove the emergency ladder (Fig. 3-204, Pos. 2).
Remove the platform (Fig. 3-204, Pos. 3) with handlebar and

gratings from the cab support using a crane.
NOTE: For safety reasons, the handrails at the cab support

frame (Fig. 3-204, Pos. 4) remain mounted.
Fig. 3-204
z
Disconnect all wire harnesses leading to the cab base

(Fig. 3-205, Pos. 1) inside the cab base.
Clear all wire harnesses running under the cab base from
their cable channels.
Pull the harnesses out of the cable transfer elements at the

bottom (Fig. 3-205, Pos. 2) and at the side (Fig. 3-205,
Pos. 3) of the cab base.
If equipped with a cable clamp (Fig. 3-205, Pos. 4), clear the
wire harnesses leading to the high voltage switch cabinet
from the cab base by opening the cable clamp.
Disconnect the extinguishing agent hose of the fire suppression system between the cab base and the high voltage
switch cabinet from the socket in the transfer element
(Fig. 3-205, Pos. 3).
If equipped, disconnect the extinguishing agent hose of the

fire suppression system between the cab base and the slip
ring.
Clear the water and refrigerant hoses leading to the side of

the cab base from the support frame (Fig. 3-206, Pos. 2).
Sling the support frame.
Remove the bolts (Fig. 3-206, Pos. 1) from within the cab
base (Fig. 3-206, Pos. 3) and remove the support frame
(Fig. 3-206, Pos. 2) using a crane.
Fig. 3-205
NOTE: The bolts are secured with Loctite 222.
Fig. 3-206
3 - 228
PC8000-6E
Version 2010/1
Superstructure
Open the clamps and clear the water and refrigerant hoses
from the cab base.
Fig. 3-207
z
Insert 4 swivel hoist rings (M36) and sling the cab base
(Fig. 3-207, Pos. 1) at the hoist rings.
Remove the bolts (Fig. 3-207, Pos. 2) attaching the cab base
to the superstructure platform.
Remove the cab base using a crane.

DANGER

When moving the cab base, make sure that nobody steps
below the lifted cab base.
Fig. 3-208
Version 2010/1
PC8000-6E
3 - 229
Superstructure
3.12.2 REPLACEMENT OF THE CAB BASE

Special tools:


Crane
Compound "Epple 28", PN 592 199 40
Compound "Loctite 222", PN 414 299 40
Support frame: 987 kg
Cab base: 5410 kg
Platform: 135 kg
Dogman/rigger
WARNING
Always wear a safety harness when working at the cab base.
DANGER
Hazardous Voltage!
Insert 4 swivel hoist rings (M36) and sling the cab base at the
hoist rings.
3 - 230
PC8000-6E
Version 2010/1
Superstructure
Align the cab base (Fig. 3-209, Pos. 1) with the superstructure using a crane.
DANGER

When moving the cab base, make sure that nobody steps
below the lifted cab base.
Install the bolts (Fig. 3-209, Pos. 2) attaching the cab base to
the superstructure platform.
Fig. 3-209
NOTE: Use new mounting bolts (Fig. 3-209, Pos. 2) of grade
10.9. Apply compound "KP2K", PN 324 969 40 and
tighten the mounting bolts to the specified tightening
torque.
Tightening torque for the cab base mounting
bolts (Fig. 3-209, Pos. 2): 3100 Nm
Lead the water and refrigerant hoses through the hose

clamps at the side of the cab base.
Fig. 3-210
Version 2010/1
PC8000-6E
3 - 231
Superstructure
Apply sealing compound "Epple 28" onto the whole contact

surfaces (Fig. 3-211, arrows) of the cab base.
Install the support frame (Fig. 3-211, Pos. 2) using a crane.
Install bolts (Fig. 3-211, Pos. 1) attaching the support frame

(Fig. 3-211, Pos. 2) to the cab base (Fig. 3-211, Pos. 3).
Fig. 3-211
10.9. Apply compound "Loctite 222" on the threats of all
bolts and tighten the mounting bolts to the specified tightening torque.
Tightening torque for support frame mounting
bolts (Fig. 3-211, Pos. 1): 265 Nm
z
3 - 232
PC8000-6E
Version 2010/1
Superstructure
3.12.3 PUMP CONTROLLER

3.12.3.1 REMOVAL OF THE PUMP CONTROLLER
Special tools:
n/a
n/a

DANGER
Hazardous Voltage!

Remove the wiring harness connector X14 (Fig. 3-212,

Pos. 2) from the electronic pump controller RC4 (Fig. 3-212,
Pos. 3).
Remove four bolts and remove the pump controller RC4 from
the wall of the cab base (Fig. 3-212, Pos. 1).
Fig. 3-212
Version 2010/1
PC8000-6E
3 - 233
Superstructure
3.12.3.2 REPLACEMENT OF THE PUMP CONTROLLER

Special tools:
n/a
n/a

DANGER
Hazardous Voltage!
Check and adjust the parameters of the pump controller.

Refer to the Service Manual for further information.
3 - 234
PC8000-6E
Version 2010/1
Superstructure
Version 2010/1
PC8000-6E
3 - 235
Access ladder
Superstructure
3.13 ACCESS LADDER
Fig. 3-213 Access ladder assembly
3 - 236
PC8000-6E
Version 2010/1
Superstructure
Access ladder

(1)
Access ladder
(2)
Pin
(3)
Pin
(4)
Access ladder cylinder
(5)
Cotter pin
(6)
Washer
(7)
Union
(8)
Hydraulic hose
(9)
Hydraulic hose
(10)
Self-locking nut
(11)
Bearing
(12)
Dowel Screw
(13)
Left ladder bearing assembly
(14)
Right ladder bearing assembly
(15)
Self-locking nut
(16)
Hinged floor plate over the cylinder
Version 2010/1
PC8000-6E
3 - 237
Access ladder
Superstructure
Fig. 3-214 Access ladder removal
3 - 238
PC8000-6E
Version 2010/1
Superstructure
Access ladder
3.13.1 REMOVAL OF THE ACCESS LADDER

Special tools:
n/a

Oil drain pan
Crane
Access ladder: 162 kg
Dogman/rigger


z

Isolate the machine according to local regulations with the

access ladder (Fig. 3-214, Pos. 1) lowered to the ground.
NOTE: Relieve the remaining pressure for the ladder cylinder at

the Minimess test point M37.1 and M37.2 on the control
and filter plate at electric motor 2.
WARNING
z
Provide an adequate working platform for safe access to

the access ladder bearing.

access ladder assembly.
Secure the access ladder cylinder (Fig. 3-214, Pos. 4) in its

position.
Version 2010/1
PC8000-6E
3 - 239
Access ladder
Superstructure
Fig. 3-215 Access ladder removal
3 - 240
PC8000-6E
Version 2010/1
Superstructure
Access ladder
CAUTION
Assure that the pressure in the hydraulic system is completely relieved before removing the pin (Fig. 3-215, Pos. 2).
Remove the cotter pin (Fig. 3-215, Pos. 5) from the pin
(Fig. 3-215, Pos. 2).
Clear the access ladder (Fig. 3-215, Pos. 1) by removing the

pin (Fig. 3-215, Pos. 2) from the access ladder cylinder moving rod.
Sling the access ladder and remove the self locking nuts
(Fig. 3-215, Pos. 10 and 15) from the ladder bearing assemblies (Fig. 3-215, Pos. 13 and 14).
Remove the dowel screws (Fig. 3-215, Pos. 12) to clear the
ladder from the superstructure platform.
Remove the ladder. Rest it on the ground.
Version 2010/1
PC8000-6E
3 - 241
Access ladder
Superstructure
Fig. 3-216 Access ladder replacement
3 - 242
PC8000-6E
Version 2010/1
Superstructure
Access ladder
3.13.2 REPLACEMENT OF THE ACCESS LADDER

Special tools:
n/a

Crane
Access ladder: 162 kg
Dogman/rigger

WARNING
z


NOTE: Apply grease to the pin (Fig. 3-215, Pos. 2) at the access
ladder cylinder moving rod.
z
NOTE: Always use new self-locking nuts (Fig. 3-216, Pos. 10

and 15).
Tightening procedure for the self-locking nuts
(Fig. 3-216, Pos. 10 and 15):
z
Screw on the nuts until they have contact

with the ladder carrier frame.
Then tighten the nuts further by turning

them through an angle of 45 (1/8 turn).
Clamping torque of self locking nut
(Fig. 3-216, Pos. 10): New nut: 106 Nm
Clamping torque of Self locking nut
(Fig. 3-216, Pos. 15): New nut: 200 Nm
Version 2010/1
PC8000-6E
3 - 243
Access ladder
Superstructure
Fig. 3-217 Access ladder cylinder removal
3 - 244
PC8000-6E
Version 2010/1
Superstructure
Access ladder
3.13.3 REMOVAL OF THE ACCESS LADDER CYLINDER

Special tools:
n/a

Oil drain pan
Crane
Access ladder cylinder: 23 kg
Dogman/rigger
6.6 on page 6-14.
z


z

Isolate the machine according to local regulations with the

access ladder (Fig. 3-217, Pos. 1) lowered to the ground.
NOTE: Relieve the remaining pressure for the ladder cylinder at

the Minimess test point M37.1 and M37.2 on the control
and filter plate at electric motor 2.
z
Remove floor plate fastening bolts and open the hinged floor
WARNING


Assure that the pressure in the hydraulic system is completely relieved before removing the pins (Fig. 3-217,
Pos. 2 or 3) or disconnecting any hydraulic hoses.
Version 2010/1
PC8000-6E
3 - 245
Access ladder
Superstructure
Fig. 3-218 Access ladder cylinder installation
3 - 246
PC8000-6E
Version 2010/1
Superstructure
Access ladder
Remove the hydraulic hoses (Fig. 3-217, Pos. 8 and 9) with

the union (Fig. 3-217, Pos. 7) from the access ladder cylinder
(Fig. 3-217, Pos. 4).
NOTE: When the hydraulic hoses are removed, hydraulic oil

from inside the piping will flow out.
z
Attach the access ladder cylinder (Fig. 3-218, Pos. 4) to a

crane.
Remove the pins (Fig. 3-218, Pos. 2 and 3) and remove the
access ladder cylinder (Fig. 3-218, Pos. 4) using a crane.
3.13.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER

Special tools:
n/a

Oil drain pan
Crane
Access ladder cylinder: 23 kg
Dogman/rigger

WARNING
z


NOTE: Apply grease to the pins (Fig. 3-218, Pos. 2 and 3).
z
Version 2010/1
PC8000-6E
3 - 247
Counterweight
Superstructure
3.14 COUNTERWEIGHT
DANGER
Risk of explosion!
Blindness, serious injury, permanent disfigurement and
scarring, or death may result.
Do not weld, flame-cut, grind, or drill at the counterweight!
Follow the instructions given in the PARTS & SERVICE
NEWS No. "AH04518" for expelling the gases from the counterweight chambers!
The chambers of the counterweight are filled with a mixture of

concrete, granulated ore and steel pellets. This mixture can create explosive gases which will accumulate in the chambers of the
counterweight.
Before any welding, flame-cutting, grinding, or drilling procedures
are carried out on the counterweight, it is vital to expel these
gases from the counterweight chambers. Failure to properly expel
the gases from the counterweight chambers can result in an
explosion with serious personal injury or death. Follow the instructions given in the PARTS & SERVICE NEWS No. "AH04518" for
expelling the gases from the counterweight chambers.
3.14.1 REMOVAL OF THE COUNTERWEIGHT

Special tools:


Crane
Counterweight: 54,000 kg
Dogman/rigger

the machine, boom, and a crane.
Park the machine on the prepared flat area and position the
bucket on the ground.

3 - 248
PC8000-6E
Version 2010/1
Superstructure
Counterweight

WARNING
Always wear a safety harness when working at the counterweight.
Remove the escape ladder (Fig. 3-219, Pos. 1), the hatch
(Fig. 3-219, Pos. 2), and the covers (Fig. 3-219, Pos. 3).
Remove all additional equipment from the counterweight, if

required.
Fig. 3-219
z
Remove the gratings (Fig. 3-220, Pos. 1) from the counterweight.
Remove all additional equipment from the counterweight, if

required.
Remove the hand rails (Fig. 3-220, Pos. 2) from the counterweight.
Fig. 3-220
z
Sling the counterweight at the attached lifting eyes.
Version 2010/1
PC8000-6E
3 - 249
Counterweight
Superstructure
Fig. 3-221 Counterweight

WARNING
Make sure that the maximum rope angles depending on the
lifting situation (Fig. 3-221, Pos. 2 to 4) are not exceeded.
Remove the bolts (Fig. 3-221, Pos. 5) and the washers

(Fig. 3-221 Pos. 6).
Remove the counterweight using the crane.

DANGER

When moving the counterweight, make sure that nobody
steps below the lifted counterweight.
3 - 250
PC8000-6E
Version 2010/1
Superstructure
Counterweight
3.14.2 REPLACEMENT OF THE COUNTERWEIGHT

Special tools:


Crane
Counterweight: 54,000 kg
Dogman/rigger

WARNING
Always wear a safety harness when working at the counterweight.
NOTE: Assure that the mounting surfaces are absolutely free of

dirt, oil, fat, and paint before installation.
z

WARNING
Make sure that the maximum rope angles depending on the

lifting situation (Fig. 3-221, Pos. 2 to 4) are not exceeded.
NOTE: Apply compound "KP2K", PN 324 969 40 on heads and

threads of the bolts. Tighten the mounting bolts to the
specified tightening torque.
7500 Nm
Version 2010/1
PC8000-6E
3 - 251
Superstructure lifting
Superstructure
3.15 SUPERSTRUCTURE LIFTING

3.15.1 LIFT THE SUPERSTRUCTURE (PLATFORM, PN 910 605 40 ONLY)
Special tools:


Additional tools and aid according to the PARTS & SERVICE NEWS
No. "AH01516".
Superstructure: 298,000 kg (special procedure)
Dogman/rigger
6.6 on page 6-14.
DANGER
The below procedure is suitable for superstructure platform
910 605 40 only. With any other superstructure platform contact the KOMATSU service concerning the procedure.
Fig. 3-222 Superstructure lifting

3 - 252
PC8000-6E
Version 2010/1
Superstructure


z


DANGER
Hazardous Voltage!

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 3-223, Pos. 1) at the track tensioning
valve block (Fig. 3-223, Pos. 2) inside the car body.
Fig. 3-223
Version 2010/1
PC8000-6E
3 - 253
Superstructure
Fig. 3-224
WARNING
Always wear a safety harness when working in height.
If equipped, remove the rotating direction sensors B98 and

B99 from the swing circle protection.
Remove the slip ring unit,

Fig. 3-225
DANGER
Information not up to date.
Contact the KOMATSU service for important information concerning the next step.
Carry out the lifting procedure according to the PARTS &

Move the undercarriage away from beneath the sperstructure.
3 - 254
PC8000-6E
Version 2010/1
Superstructure
3.15.2 DUMP THE SUPERSTRUCTURE (PLATFORM, PN 910 605 40 ONLY)
Special tools:


Additional tools and aid according to the PARTS & SERVICE NEWS
No. "AH01516".
Superstructure: 298,000 kg (special procedure)
Dogman/rigger
z
Move the undercarriage underneath the superstructure.

WARNING
DANGER
Hazardous Voltage!
Carry out the dumping procedure according to the PARTS &

Install the outer slew ring to the car body. Refer to the PARTS
& SERVICE NEWS No. "AH00511" and "AH01516".
Version 2010/1
PC8000-6E
3 - 255
Superstructure
3.15.3 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE

Special tools:


2 x crane
Superstructure w.o. counterweight and attachment: 202,000 kg
Dogman/rigger
Crane operators trained in dual crane lift
6.6 on page 6-14.


z


DANGER
Hazardous Voltage!

WARNING
3 - 256
PC8000-6E
Version 2010/1
Superstructure
Fig. 3-226
z
Fig. 3-227
z

Remove the complete attachment, refer to section 5.1 on

page 5-2.
Remove the counterweight from the superstructure, refer to

Disconnect all hydraulic hoses between the superstructure

and the rotary joint from the rotary joint, refer to section
4.3.5.1 on page 4-90.
If equipped, remove the rotating direction sensors B98 and

B99 from the swing circle protection.
Fig. 3-228
Version 2010/1
PC8000-6E
3 - 257
Superstructure
3 - 258
PC8000-6E
Version 2010/1
Superstructure
Install the shackles (Fig. 3-229, Pos. 6) delivered with the

machine to the flanges of the counterweight and attach both
shackles to a crane.
Re-install the pins of both boom cylinders.
Attach the superstructure (Fig. 3-229, Pos. 4) by means of

the boom cylinders pins to a second crane.
Remove all bolts (Fig. 3-229, Pos. 1) and washers

(Fig. 3-229, Pos. 2) attaching the outer slew ring of the swing
circle (Fig. 3-229, Pos. 3) to the undercarriage (Fig. 3-229,
Pos. 5).
WARNING
Before lifting the superstructure, make sure that the crane

operators are trained in dual crane lift.
Lift off the superstructure using the two cranes and rest it on
appropriate support on the ground.
DANGER

May result in death or serious injury
When moving superstructure, make sure that all personnel
are clear.
Version 2010/1
PC8000-6E
3 - 259
Superstructure
3 - 260
PC8000-6E
Version 2010/1
Superstructure
3.15.4 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE
Special tools:


2 x crane
2 thread pins (M 36 x 500)
Superstructure w.o. counterweight and attachment: 202,000 kg
Dogman/rigger
WARNING
DANGER
Hazardous Voltage!

Version 2010/1
PC8000-6E
3 - 261
Superstructure
3 - 262
PC8000-6E
Version 2010/1
Superstructure
Clean the contact surfaces of the swing circle (Fig. 3-230,

Pos. 3) and the undercarriage (Fig. 3-230, Pos. 5) very carefully and thoroughly.
Check the level of bearing area with a laser device before

installing a new slew ring. Refer to PARTS & SERVICE
NEWS No. "AH00511".
Remove the torque support lever of the rotary joint

before installing the superstructure, refer to section 4.3.5.1 on
page 4-90.
WARNING
Before lifting the superstructure, make sure that the crane

Attach the shackles (Fig. 3-229, Pos. 6) to one crane.
Attach the superstructure (Fig. 3-229, Pos. 4) by means of

the boom cylinders pins to a second crane.
DANGER

When moving superstructure, make sure that all personnel
are clear.
NOTE: The unhardened spot of race surfaces (changeover area

between beginning and ending of hardening process) is
punch-marked with an "S" at the inner resp. outer side of
each slew ring (Fig. 3-231, Pos. 1 and 2).
z
Align the spots (Fig. 3-231, Pos. S) to each other.
Prepare new bolts, and washers. Lubricate the threads and

the head surface of the bolts with compound "KP2K",
PN 324 969 40.
Fig. 3-231
z
Align the superstructure to the undercarriage and lower the

superstructure.
To simplify the alignment of the swing circle (Fig. 3-230,

Pos. 3) to the undercarriage (Fig. 3-230, Pos. 5), install two
thread pins (M 36 x 500) displaced by 180 at the outer slew
ring (Fig. 3-231, Pos. 2).
Insert 4 bolts (Fig. 3-230, Pos. 1) with washers (Fig. 3-230,

Pos. 2) displaced by 90 and lower the superstructure.
Remove the two thread pins from the outer slew ring.
Version 2010/1
PC8000-6E
3 - 263
Superstructure
Install all remaining bolts and tight them manually.

Tighten all bolts crosswise to the required
torque, refer to PARTS & SERVICE NEWS
No. "AH00511".
NOTE: If approx. 10 bolts (front and rear) are tightened the

superstructure can be unhooked from the crane.
z
Reinstall the torque support lever of the rotary joint,refer to

WARNING
Make sure to use the specified bolts and torque for the
torque support lever mounting bolts, refer to section 4.3.5.2
on page 4-93.
3 - 264
PC8000-6E
Version 2010/1
Superstructure
3.16 HIGH VOLTAGE SWITCH CABINET
Fig. 3-232 High voltage switch cabinet, overview

(1)
(2)
(3)
Bolt
(4)
Resilient sleeve
(5)
Pin
(6)
Cable transfer element
Version 2010/1
PC8000-6E
3 - 265
Superstructure
3.16.1 REMOVAL OF THE HIGH VOLTAGE SWITCH CABINET

Special tools:


4 x Swivel hoist ring: M36
Crane
High voltage switch cabinet: 7000 kg
Platform assembly: 235 kg
Dogman/rigger


z

DANGER
Hazardous Voltage!

WARNING
Always wear a safety harness when working at the high voltage switch cabinet.
3 - 266
PC8000-6E
Version 2010/1
Superstructure
Remove the stairway (Fig. 3-233, Pos. 1).
NOTE: For safety reasons, the handrails (Fig. 3-233, Pos. 2)

should remain mounted.
Fig. 3-233
z
Remove the operators cab (Fig. 3-234, Pos. 1),

Remove the emergency ladder (Fig. 3-234, Pos. 3) from the

cab base.
Remove the cab support frame (Fig. 3-234, Pos. 2) from the
cab base, refer to section 3.12.1 on page 3-227.
Remove the platform (Fig. 3-234, Pos. 4) with handrails and

gratings from the high voltage switch cabinet using a crane.
Dismantle the upper part of the stairway (Fig. 3-234, Pos. 5)

from the high voltage switch cabinet.
Fig. 3-234
Version 2010/1
PC8000-6E
3 - 267
Superstructure
Open the hinged cover below the high voltage switch cabinet
(Fig. 3-235, Pos. 1).
Disconnect the wire harnesses between he high voltage

switch cabinet and the cab base inside the high voltage
switch cabinet.
Pull the wire harnesses out of the cable transfer element

(Fig. 3-235, Pos. 2) at the high voltage switch cabinet.
Disconnect the extinguishing agent hose of the fire suppression system between the cab base and the high voltage
switch cabinet from the socket in the transfer element
(Fig. 3-235, Pos. 2).
Disconnect the high voltage power supply cable between slip

ring and high voltage switch cabinet from the load cut-off
switch copper bars inside the high voltage switch cabinet.
Fig. 3-235
Disconnect the high voltage motor power supply cables leading to the electric motors inside the high voltage switch cabinet.
Pull the disconnected cables out of the high voltage switch

cabinet, into the front roof section next to the slew gear.
Open the brackets at the underside of the high voltage switch

cabinet and clear all cable channels, wire harnesses, and
hoses from the high voltage switch cabinet.
Remove the plates (Fig. 3-236, Pos. 1) at the threads

(Fig. 3-236, Pos. 2).
Insert 4 swivel hoist rings (M36) into the threads at the high
voltage switch cabinet.
Attach the high voltage switch cabinet to a crane.
Fig. 3-236
3 - 268
PC8000-6E
Version 2010/1
Superstructure
Remove the mounting bolts (Fig. 3-237, Pos. 2) and lift the
high voltage switch cabinet (Fig. 3-237, Pos. 1) from the
superstructure platform (Fig. 3-237, Pos. 3) using a crane.
Discard the mounting bolts (Fig. 3-237, Pos. 2).
DANGER

When moving high voltage switch cabinet, make sure that
nobody steps below the lifted high voltage switch cabinet.
Fig. 3-237
z
Dismantle the handrails and all other attached parts from the
high voltage switch cabinet.
Version 2010/1
PC8000-6E
3 - 269
Superstructure
3.16.2 REPLACEMENT OF THE HIGH VOLTAGE SWITCH CABINET

Special tools:


Crane
High voltage switch cabinet: 7000 kg
Platform assembly: 235 kg
Dogman/rigger
WARNING
Always wear a safety harness when working at the high voltage switch cabinet.
DANGER
Hazardous Voltage!

10.9 to attach the high voltage switch cabinet (Fig. 3-238,
Pos. 1) to the superstructure platform (Fig. 3-238,
Pos. 3).
Apply compound "KP2K", PN 324 969 40 and tighten the
bolts to the specified tightening torque.
Tightening torque for the high voltage switch cabinet mounting bolts (Fig. 3-238, Pos. 2): 3100 Nm
Fig. 3-238
3 - 270
PC8000-6E
Version 2010/1
Superstructure
Version 2010/1
PC8000-6E
3 - 271
Slip ring unit
Superstructure
3.17 SLIP RING UNIT
Fig. 3-239 Slip ring unit, overview
3 - 272
PC8000-6E
Version 2010/1
Superstructure
Slip ring unit

(1)
Slip ring unit
(2)
Carrier beam
(3)
Bolt
(4)
Washer
(5)
Nut
(6)
Cam
3.17.1 REMOVAL OF THE SLIP RING UNIT

Special tools:
n/a
Crane
Slip ring unit: 255 kg
Dogman/rigger


z

DANGER
Hazardous Voltage!

Remove the boom arc hoses over the slip ring unit, refer to
Version 2010/1
PC8000-6E
3 - 273
Slip ring unit
Superstructure
Fig. 3-240 Removal of the slip ring unit
3 - 274
PC8000-6E
Version 2010/1
Superstructure
Slip ring unit
Open the slip ring unit (Fig. 3-241, Pos. 1) and disconnect all
high voltage power supply cables and wirering leading into
the slip ring unit.
If equipped, disconnect the extinguishing agent hose

(Fig. 3-241, Pos. 2) of the fire suppression system between
from the slip ring unit.
Sling the slip ring unit at the installed hoist rings (Fig. 3-241,
arrows).
Fig. 3-241
z
Remove the nuts (Fig. 3-240, Pos. 5), the washers

(Fig. 3-240, Pos. 4) and the bolts (Fig. 3-240, Pos. 3) attaching the slip ring unit to the carrier beams (Fig. 3-240, Pos. 2).
Remove the slip ring unit using a crane.

DANGER

When moving slip ring assembly, make sure that nobody
steps below the lifted slip ring assembly.
Version 2010/1
PC8000-6E
3 - 275
Slip ring unit
Superstructure
Fig. 3-242 Installation of the slip ring unit
3 - 276
PC8000-6E
Version 2010/1
Superstructure
Slip ring unit
3.17.2 REPLACEMENT OF THE SLIP RING UNIT

Special tools:
n/a
Crane
Slip ring unit: 255 kg
Dogman/rigger
DANGER
Hazardous Voltage!
NOTE: Make sure that the cam (Fig. 3-242, Pos. 6) fits properly
in the slip ring unit (Fig. 3-242, Pos. 1) while mounting.
Version 2010/1
PC8000-6E
3 - 277
Slip ring unit
Superstructure
3 - 278
PC8000-6E
Version 2010/1
Undercarriage
4 UNDERCARRIAGE
Version 2010/1
PC8000-6E
4 -1
Undercarriage overview
Undercarriage
4.1
UNDERCARRIAGE OVERVIEW
Fig. 4-1
PC8000-6E, undercarriage overview
4 -2
PC8000-6E
Version 2010/1
Undercarriage
Undercarriage overview

(1)
Car body
(2)
Crawler carrier
(3)
Carrier roller
(4)
Travel gear
(5)
Travel motors
(6)
Track tensioning valve block
(7)
High pressure accumulator
(8)
Rotary joint
(9)
Travel brake valve block (overspeed valve)
(10)
Sprocket
(11)
Low pressure accumulator
(12)
Track tensioning cylinder
(13)
Guide wheel
(14)
Track roller
(15)
Cable drum assembly
(16)
High voltage power supply cable
(17)
Track group
Version 2010/1
PC8000-6E
4 -3
Travel system
Undercarriage
4.2
TRAVEL SYSTEM
4.2.1
TRACK GROUP
4.2.1.1 CHANGING OF THE TRACK GROUP

Special tools:
n/a
Personal Protective Equipment (PPE)

Dozer
Chain hoist
Slide hammer
Welding equipment
Brass drift
Track group 1900 mm: 56,000 kg
Pin track group 1900 mm: 30 kg
Track group 1500 mm: 50,000 kg
Pin track group 1500 mm: 28 kg
Dogman/rigger

NOTE: Make sure that the wear of the track group was measured according to the PARTS & SERVICE NEWS
No. "AH02521".
z
Prepare an area of flat ground twice as large to accommodate

the machine, the boom, and a dozer.

z
Remove the cover (Fig. 4-2, Pos. 1).
Relieve the pressure in the track tensioning system according

to the PARTS & SERVICE NEWS "AH06530".
Make sure that the slack in the track group is at the lower part
of the guide wheel.
NOTE: The procedure in the PARTS & SERVICE NEWS

"AH06530" prevent the track tensioning cylinders to get
pressurized when moving the excavator.
Fig. 4-2
4 -4
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Flame-cut the nuts (Fig. 4-3, Pos. 3) from the locking bolts
(Fig. 4-3, Pos. 1). Remove the locking bolts (Fig. 4-3, Pos. 1),
washers (Fig. 4-3, Pos. 2), and nuts (Fig. 4-3, Pos. 3) from
one track shoe (Fig. 4-3, Pos. 5).
WARNING
Ensure nothing flammable is in the working area during

flame-cutting and welding work.

"WELD REPAIRS".
Fig. 4-3
Weld a bolt to the pins (Fig. 4-3, Pos. 4) and attach a sliding
hammer.
Pull out two pins (Fig. 4-3, Pos. 4) to open the track group
using a sliding hammer.
NOTE: Open the track group at the guide wheel side for track
group exchange.
z
Sling the upper end of the track group using a chain and link it
to a dozer in front of the excavator.
De-isolate the machine according to local regulations.
Switch S155 to Qmin.
NOTE: Use only one engine at Qmin.

DANGER
Danger of getting overrun or squished.
Serious injury or death may result.
Make sure nobody stays in driving direction of the excavator
or the dozer.
Make sure nobody stays next to the crawler carrier.
Fig. 4-4
Drive the excavator and the dozer backwards slowly and

unroll the track group from the excavator (Fig. 4-4).
NOTE: Assure that excavator and dozer have the same speed.
z
When the upper end of the track group runs off the sprocket,
stop the excavator while driving the dozer backwards slowly
to prevent the track from knocking over.
Version 2010/1
PC8000-6E
4 -5
Travel system
Undercarriage
Align the new track group on the ground behind the old track
group.
NOTE: Observe the running direction of the new track group.

Make sure that the new track group has the correct running direction as shown in Fig. 4-5.
z
Remove the chain from the old track group.
Continue to drive the excavator backwards slowly on the new

track group until the end of the of the track group is nearly
reached.
Sling the end of the new track group at the sprocket using a
chain and link it to a dozer in front of the excavator.
DANGER

or the dozer.
Fig. 4-5
z
Drive the excavator and the dozer forward slowly and pick up
the track group with the sprocket.
Continue to drive the excavator and the dozer forward slowly

to pull up the track group (Fig. 4-6).
Fig. 4-6
z
Stop the excavator and the dozer, when the guide wheel
reaches the end of the track group (approximately 3 track
shoes away from the end of the track group).
Place the track group over the guide wheel as shown in

Fig. 4-7.
Unchain the dozer.
Fig. 4-7
4 -6
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Align the holes (Fig. 4-8, Pos. 3) in the two open track shoes
(Fig. 4-8, Pos. 2) in front of the guide wheel (Fig. 4-8, Pos. 1)
using a hoist.
Insert the pins (Fig. 4-9, Pos. 4) into the holes (Fig. 4-8,
Pos. 3).
Fig. 4-8
z
Install the locking bolts (Fig. 4-9, Pos. 1), washers

(Fig. 4-9, Pos. 2), and nuts (Fig. 4-9, Pos. 3) to the track
shoes (Fig. 4-9, Pos. 5).
Weld the nuts (Fig. 4-9, Pos. 3) to the bolts (Fig. 4-9, Pos. 1).
WARNING
Ensure nothing flammable is in the working area during

welding work.

"WELD REPAIRS".
Fig. 4-9
CAUTION
The bolts (Fig. 4-10, Pos. 1) lock the pins (Fig. 4-10, Pos. 2).
Therefore one side of the bolts head is hardened in order to
prevent wear. This hardened side must face the pin.
The hardened side (Fig. 4-10, arrow) of the bolt heads are
marked.
Fig. 4-10
Version 2010/1
PC8000-6E
4 -7
Travel system
Undercarriage
Perform the procedure given in the PARTS & SERVICE

NEWS "AH06530" in reverse order.
Switch S155 to back normal condition.
Install the cover (Fig. 4-11, Pos. 1).
Fig. 4-11
4 -8
PC8000-6E
Version 2010/1
Undercarriage
4.2.2
Travel system
SPROCKET
4.2.2.1 REMOVAL OF THE SPROCKET ASSEMBLY

Special tools:
n/a

2 x Crane
Dozer
Pulling bolts M30
Sprocket assembly: 6164 kg
Sprocket assembly oversize: 6357 kg
Hollow shaft: 790 kg
Drive shaft: 1140 kg
Dogman/rigger
NOTE: KOMATSU recommends to change the flange bearings

(Fig. 4-12, Pos. 1 + 3) and the O-rings (Fig. 4-12, Pos. 4
to 7) when changing the sprocket.
Therefore the travel gear has to be removed, refer to section 4.2.11.1 on page 4-58.
The removal and installation procedure of the inner
flange bearing (Fig. 4-12, Pos. 10) is analogously to the
removal and installation procedure of the outer flange
bearing (Fig. 4-12, Pos. 9) including the tightening
torques.
Only for removal of the sprocket (Fig. 4-12, Pos. 2) it is not necessary to remove the travel gear (Fig. 4-12, Pos. 4).
Subsequently, the removal of the sprocket without removing the
travel gear is described.
Fig. 4-12
WARNING
Ensure appropriate (PPE) Personal Protective Equipment is
used during the task.
There maybe sharp edges on the worn sprocket that is being
removed.
Version 2010/1
PC8000-6E
4 -9
Travel system
Undercarriage
Prepare an area of flat ground twice as large to accommodate

the machine, the boom, and two cranes.
attachment placed at the final drive end of the machine, counterweight above guide wheels.

z
Fig. 4-13
Drain oil of the final drive housing,

approx. 250 liters.
chapter 4, section "TRAVEL GEARS, MOTOR
ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".
z
Check the wear of the sprocket hub, refer to PARTS & SERVICE NEWS No. "AH00515".
NOTE: Make sure that the sprocket runs free after opening the
track group and it has no contact to the ground or the
track group. For example drive the excavator with the
track rollers at the respective crawler frame side onto a
knoll.
4 - 10
PC8000-6E
Version 2010/1
Undercarriage
Travel system
WARNING
Before beginning the work, block the track group to prevent
the track shoes against falling down (refer to Fig. 4-14).
Open the track group at the sprocket end (Fig. 4-14, Pos. 1),
Fig. 4-14
z
Sling the upper end of the track group using a chain and link it
to a dozer behind the excavator.

DANGER

or the dozer.
Fig. 4-15
z
Drive the excavator and the dozer forwards slowly and unroll
the track group from the excavator (refer to Fig. 4-15).
z
When the upper end of the track group is over the carrier roll
next to the sprocket, stop the excavator and the dozer.
Fasten the track group to the carrier roll to hold it in position.
NOTE: In order to avoid damage to the lifting devices, use edge

protection at all sharp edges.
z
Sling sprocket (refer to Fig. 4-16) using a crane.
NOTE: The travel parking brakes must be released to allow the

sprocket to turn slightly and find the centre of gravity.
Fig. 4-16
Version 2010/1
PC8000-6E
4 - 11
Travel system
Undercarriage
Fig. 4-17 Removal of the sprocket

z
Remove the bolts (Fig. 4-17, Pos. 11) and the cover
(Fig. 4-17, Pos. 10).
NOTE: When the cover is removed, oil may flow out.

z
NOTE: Observe the mounting position of the drive shaft

(Fig. 4-17, Pos. 6). The splines at the drive shaft have different lengths.
z
Pull the drive shaft out of the hollow shaft (Fig. 4-17, Pos. 5).
WARNING
Sling the drive shaft as soon as possible and support it using

the second crane to prevent the shaft from falling.
DANGER
When lifting the drive shaft, make sure that nobody steps
below the weight.
4 - 12
PC8000-6E
Version 2010/1
Undercarriage
Travel system
CAUTION
Make sure that the hollow shaft (Fig. 4-17, Pos. 5) is not
weight loaded before removing the flange bearing (Fig. 4-17,
Pos. 8).
Remove mounting bolts (Fig. 4-17, Pos. 1) and extract the

flange bearing (Fig. 4-17, Pos. 8) including the bush
(Fig. 4-17, Pos. 7) from the crawler carrier using pulling bolts.
Extract the hollow shaft (Fig. 4-17, Pos. 5) from the sprocket
(Fig. 4-17, Pos. 3) and remove it using a crane.
WARNING
Sling the drive shaft as soon as possible and support it using

a crane to prevent the shaft from falling.
DANGER
When lifting the hollow shaft, make sure that nobody steps
below the weight.
Lift the sprocket assembly out of the crawler carrier.

DANGER

When lifting the sprocket assembly, make sure that nobody
Discard the dual-cone seals (Fig. 4-17, Pos. 2 and Pos. 4).
NOTE: Dual-cone seals are mounted in the sprocket hub as well

as in the inner and outer flange bearing.
For further information refer to PARTS & SERVICE
NEWS No. "AH05511".
z
If required, remove the sprocket from the hub, refer to PARTS

& SERVICE NEWS No. "AH00514".
Version 2010/1
PC8000-6E
4 - 13
Travel system
Undercarriage
4.2.2.2 REPLACEMENT OF THE SPROCKET ASSEMBLY

Special tools:
Assembly tool for dual-cone seals: locally made

Hydraulic torque wrench PN 232 615 40
Electro-hydraulic pump aggregate PN 232 613 40
2 x Crane
Dozer
Paste "Optimol White", PN 999 039
Sprocket assembly: 6164 kg
Sprocket assembly oversize: 6357 kg
Hollow shaft: 790 kg
Drive shaft: 1140 kg
Dogman/rigger

Fig. 4-18 Replacement of the sprocket

z
If required, install the sprocket to the hub, refer to PARTS &

4 - 14
PC8000-6E
Version 2010/1
Undercarriage
Travel system
NOTE: For mounting the dual-cone seals (Fig. 4-18, Pos. 2 and
Pos. 4), an assembly tool has to be manufactured, refer
to PARTS & SERVICE NEWS No. "AH05511".
z
Mount new dual-cone seals (Fig. 4-18, Pos. 2 and Pos. 4)

into the flange bearing, on the gear side and into the flange
bearing (Fig. 4-18, Pos. 8) on the opposite side. Refer to
Mount new dual-cone seals (Fig. 4-18, Pos. 2 and Pos. 4)

into the sprocket hub, refer to PARTS & SERVICE NEWS
No. "AH05511".
CAUTION
Before reassembling the sprocket, the axial play has to be

determined, if necessary adjust the axial play,
refer to PARTS & SERVICE NEWS No. "AH00514".
NOTE: Observe the mounting position of the drive shaft

(Fig. 4-18, Pos. 6) when installing it. The splines at the
drive shaft have different lengths.
The longer splines must point to the gear box.
z
Apply paste "Optimol White" on the splines of the drive shaft

(Fig. 4-18, Pos. 6), the hollow shaft (Fig. 4-18, Pos. 5), and
the splines of the planet carrier inside the travel gearbox.
NOTE: Use a new O-ring (Fig. 4-18, Pos. 9).

Apply compound "KP2K", PN 324 969 40 on the sleeve
of the flange bearing (Fig. 4-18, Pos. 8) and to the flange
bearing bolts (Fig. 4-18, Pos. 1).
Tightening torque for flange bearing mounting
bolts (Fig. 4-18, Pos. 1): 1250 Nm
Tightening torque for cover mounting bolts
(Fig. 4-18, Pos. 11): 179 Nm
Refill oil in the final drive housing,
approx. 250 liters.
Version 2010/1
PC8000-6E
4 - 15
Travel system
4.2.3
Undercarriage
GUIDE WHEELS (IDLERS)
4.2.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY

Special tools:
n/a
Crane
Guide wheel assembly: 4938 kg
Dogman/rigger


z
Relieve the pressure in the track tensioning system according

to the PARTS & SERVICE NEWS "AH06530".
NOTE: If other work is carried out simultaneously, which includes

motors running, the procedure in the PARTS & SERVICE
NEWS "AH06530" prevent the track tensioning cylinders
to get pressurized and therefore falling out due to the
missing end stop.
Fig. 4-19
z
Remove the track group from the guide wheel, refer to section
4.2.1.1 on page 4-4.
4 - 16
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Remove bolts (Fig. 4-20, Pos. 1) and remove the stop plates
(Fig. 4-20, Pos. 2) from both sides of the guide wheel assembly (Fig. 4-20, Pos. 3).
Fig. 4-20
z
Sling guide wheel assembly (Fig. 4-21) and pull the guide
wheel assembly out of the crawler carrier.

WARNING
Ensure to keep hands away for the component sliding
surfaces during removal.
Fig. 4-21
z
Remove the plates (Fig. 4-22, Pos. 1) from the guide wheel
assembly.
Fig. 4-22
Version 2010/1
PC8000-6E
4 - 17
Travel system
Undercarriage
4.2.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY

Special tools:
n/a
Crane
Guide wheel assembly: 4938 kg
Dogman/rigger

z
NOTE: Observe the mounting position of the sliding blocks

(Fig. 4-23, Pos. 3):
Assure that the oil plug (Fig. 4-23, Pos. 2) at the guide
wheel (Fig. 4-23, Pos. 1) is facing the inner side of the
excavator.
Fig. 4-23
Perform the procedure given in the PARTS & SERVICE

NEWS "AH06530" in reverse order.
Install the cover (Fig. 4-24, Pos. 1).
Fig. 4-24
4 - 18
PC8000-6E
Version 2010/1
Undercarriage
4.2.4
Travel system
TRACK TENSIONING ACCUMULATORS
The hydraulic track tensioning system automatically maintains the

correct track tension. The pilot oil pressure of the travel brake
release circuit is used to pressurize the four adjusting cylinders.
The resulting force moves the guide wheels toward the front, until
the correct track tension is obtained. External forces acting upon
the guide wheels are absorbed through the pressure accumulators (Fig. 4-25, Pos. 1 and 2).
Two different types of pressure accumulators are installed:
Four high pressure (150 bar) bladder accumulators (Fig. 4-25,
Pos. 1) in the car body and a low pressure (31 bar) diaphragm
type accumulators (Fig. 4-25, Pos. 2) in each crawler carriers.
Fig. 4-25
4.2.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS

Special tools:
n/a
Oil drain pan

Low pressure accumulator: 12 kg
6.6 on page 6-14.
Fig. 4-26
Version 2010/1
PC8000-6E
4 - 19
Travel system
Undercarriage

WARNING
Hot hydraulic oil!

Fig. 4-27
DANGER
removed.
Disconnect the pressure hose (Fig. 4-28, Pos. 1).
NOTE: When the pressure hose is removed, hydraulic oil from

inside the piping and the pressure accumulator will flow
out.
z
Remove four bolts (Fig. 4-28, Pos. 4) and remove the pressure accumulator (Fig. 4-28, Pos. 3).
Remove union (Fig. 4-28, Pos. 2).
Fig. 4-28
4 - 20
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS

Special tools:
Testing and refilling device, PN 761 520 73
n/a
Low pressure accumulator: 12 kg
Fill the pressure accumulator with nitrogen gas (N2).

DANGER
Blindness, serious injury, permanent disfigurement, scaring,
or death may result.
Only fill pressure accumulators with nitrogen gas (N2).
Do not use any other gases due to explosion hazard!
Bleed the track tensioning system. Refer to the Operation &

Maintenance Manual, chapter 4, section "CRAWLER TRACK
- INSPECTION".
Check the track tensioning system and adjust if required.

For adjusting the pressure increasing valve and further information relating the pressure increasing valve refer to the
Version 2010/1
PC8000-6E
4 - 21
Travel system
Undercarriage
4.2.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS

Special tools:
n/a
n/a
High pressure accumulator: 23 kg
6.6 on page 6-14.
WARNING
Hot hydraulic oil!

Do not carry out the following work on a hot machine.
Wait until the temperature of the hydraulic oil is below
heated oil.
Fig. 4-29
DANGER
removed.
Disconnect the pressure hose assembly (Fig. 4-30, Pos. 1).
NOTE: When the pressure hose is removed, hydraulic oil from

inside the piping and the pressure accumulator will flow
out.
z
Open two clamp clips (Fig. 4-30, Pos. 2) and remove the
pressure accumulator (Fig. 4-30, Pos. 3).
Remove the socket (Fig. 4-30, Pos. 4) from the pressure

accumulator (Fig. 4-30, Pos. 3).
Fig. 4-30
NOTE: The same type of assembly is installed at the other side

of the car body for the second crawler carrier.
4 - 22
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS

Special tools:
Testing and refilling device, PN 761 520 73
n/a
High pressure accumulator: 23 kg
Fill the pressure accumulator with nitrogen gas (N2).

DANGER
Blindness, serious injury, permanent disfigurement, scaring,
or death may result.
Only fill pressure accumulators with nitrogen gas (N2).
Do not use any other gases due to explosion hazard!

- INSPECTION".

Version 2010/1
PC8000-6E
4 - 23
Travel system
4.2.5
Undercarriage
TRACK TENSIONING VALVE BLOCK
4.2.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK

Special tools:
n/a
Chain host
Oil drain pan
Track tensioning valve block: 46 kg
6.6 on page 6-14.
Fig. 4-31
WARNING
Hot hydraulic oil!
heated oil.
DANGER
removed.
The track tensioning valve block is located between the high pressure accumulators in the front in direction of travel inside the car
body.
4 - 24
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Disconnect all piping (Fig. 4-32, Pos. 2) from the track tensioning valve block (Fig. 4-32, Pos. 1).
NOTE: When the piping is removed, hydraulic oil from inside the
piping and the track tensioning valve block will flow out.
z
Find an appropriate suspension point for the chain hoist and

sling the track tensioning valve block (Fig. 4-32, Pos. 1).
Remove four mounting bolts and let down the track tensioning valve block (Fig. 4-32, Pos. 1) using the chain hoist.
Fig. 4-32
z
If required:
z
Remove the pressure increasing valve (Fig. 4-33, Pos. 1)

from the track tensioning valve block.
Remove the check valves (Fig. 4-33, Pos. 2) from the

track tensioning valve block.
NOTE:Two different types of check valves are installed at
the valve block. Do not mix up.
Remove the unions (Fig. 4-33, Pos. 3) from the track tensioning valve block.
Fig. 4-33
Version 2010/1
PC8000-6E
4 - 25
Travel system
Undercarriage
4.2.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK

Special tools:
n/a
Chain host
Track tensioning valve block: 46 kg
2.2.6 on page 2-22.

- INSPECTION".

4 - 26
PC8000-6E
Version 2010/1
Undercarriage
4.2.6
Travel system
TRACK TENSIONING CYLINDERS
4.2.6.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS

Special tools:
n/a
Crane
Oil drain pan
Track tension cylinder: 570 kg
Dogman/rigger
6.6 on page 6-14.
z


z
Remove the guide wheel assembly, refer to section 4.2.3.1 on

page 4-16.
Fig. 4-34
Version 2010/1
PC8000-6E
4 - 27
Travel system
Undercarriage
WARNING
Hot hydraulic oil!
heated oil.
DANGER
removed.
Disconnect the pressure hoses from the track tension cylinder.
NOTE: When the pressure hoses are removed, hydraulic oil from
inside the piping and the track tension cylinder will flow
out.
z
Sling the track tension cylinders (Fig. 4-35, Pos. 1) at the

retracting device (Fig. 4-35, arrow) and pull the cylinders out
of their guidance in the crawler carrier (Fig. 4-35, Pos. 2).
Fig. 4-35
4 - 28
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.6.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS

Special tools:
n/a
Crane
Track tension cylinder: 570 kg
Dogman/rigger

z

- INSPECTION".

Version 2010/1
PC8000-6E
4 - 29
Travel system
Undercarriage
4 - 30
PC8000-6E
Version 2010/1
Undercarriage
4.2.7
Travel system
SUBSTITUTE THE HYDRAULIC HOSES OF THE TRACK

TENSIONING SYSTEM
Special tools:
n/a
Oil drain pan

Hydraulic hose: 2...15 kg (depending on length)
2.2.6 on page 2-22.
6.6 on page 6-14

the machine.
WARNING
Hot hydraulic oil!

heated oil.
Fig. 4-36
DANGER
removed.
Version 2010/1
PC8000-6E
4 - 31
Travel system
Undercarriage
Fig. 4-37 Hydraulic hoses of the track tensioning system

NOTE: All hose clamps A are installed inside the car body.
All hose clamps B are installed inside the crawler carrier.
4 - 32
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.7.1 SUBSTITUTE THE HYDRAULIC HOSES INSIDE THE CAR BODY

z
Open the respective hose clamps (Fig. 4-37, A) to clear the

hydraulic hoses (Fig. 4-37, Pos. 2 to 4) from the car body.
Disconnect both ends of the hydraulic hoses (Fig. 4-37,

Pos. 1 to 5) and remove the hydraulic hoses.
NOTE: When a hose is disconnected, hydraulic oil from inside

the piping or the hose will flow out.
z
Install a new hydraulic hose in reverse order to removal.
Carry out the subsequent work, refer to section 4.2.7.4 on

page 4-36.
4.2.7.2 SUBSTITUTE THE HYDRAULIC HOSE BETWEEN CAR BODY AND CRAWLER
FRAME
z
Disconnect both ends of the hydraulic hose (Fig. 4-37,

Pos. 6).

z
Pull the hydraulic hose out completely.
Insert a new hydraulic hose from inside the car body.
Bolted undercarriage only:

Slide the hydraulic hose through the hose (Fig. 4-38, Pos. 1
and Fig. 4-37, Pos. 10) between car body and crawler carrier.
Fig. 4-38
z
Connect both ends of the hydraulic hose (Fig. 4-37, Pos. 6).

page 4-36.
Version 2010/1
PC8000-6E
4 - 33
Travel system
Undercarriage
Fig. 4-39 Hydraulic hoses of the track tensioning system

NOTE: All hose clamps A are installed inside the car body.
All hose clamps B are installed inside the crawler carrier.
4 - 34
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.7.3 SUBSTITUTE THE HYDRAULIC HOSES INSIDE THE CRAWLER FRAME

z
Fig. 4-40
z
Fig. 4-41
z
Open the respective hose clamps (Fig. 4-37, B) to clear the

hydraulic hoses (Fig. 4-37, Pos. 8 and 9) from the crawler
frame.
Disconnect both ends of the hydraulic hoses (Fig. 4-37,

Pos. 7 to 9) and remove the hydraulic hoses.

z
Install a new hydraulic hose in reverse order to removal.

page 4-36.
Version 2010/1
PC8000-6E
4 - 35
Travel system
Undercarriage
4.2.7.4 SUBSEQUENT WORK

z

- INSPECTION".

Reinstall the cover(s) (Fig. 4-42, Pos. 1, 2).
Fig. 4-42
4 - 36
PC8000-6E
Version 2010/1
Undercarriage
4.2.8
Travel system
TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE)
Fig. 4-43 Location of the travel brake valve blocks

(1)
(2)
Travel motor
(3)
Hydraulic hoses
The travel brake valve blocks (Fig. 4-43, Pos. 1) are located in the
car body. Two travel brake valve blocks are installed, one valve
block for the two travel motors of each crawler track.
At one side the travel brake valve blocks are connected to the
travel motors with hydraulic hoses (Fig. 4-43, Pos. 3) and at the
other side to the rotary joint (Fig. 4-43, Pos. 2) with hydraulic
pipes.
Version 2010/1
PC8000-6E
4 - 37
Travel system
Undercarriage
Fig. 4-44 Travel brake valve block

4 - 38
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Task:
Travel brake valves control the oil flow from the hydraulic motors
to the hydraulic oil reservoir depending on the operating pressure.
This braking action prevents the motors from over speeding.
Function:
The spring force keeps the spool in the lowest flow position.
restricted by an internal restrictor. With increasing operating pressure the opening for the return oil flow becomes larger.
On its way to the hydraulic motor the oil flows from port A to port
A1 respectively from port B to port B1, depending on the selected
travel motion (refer to Fig. 4-44).
Example:
Operating pressure at port A moves the spool (Fig. 4-44, Pos. 1)
against the force of the spring (Fig. 4-44, Pos. 2) and opens the
way for the return oil from port B1 to port B.
The check valve (Fig. 4-44, Pos. 3) prevents a direct oil flow from
port B1 to port B.
If the operating pressure decreases to an amount so that the
spring force overcomes the force of the spool, the oil flow to the
tank becomes restricted again, resulting in braking of the
machine.
Version 2010/1
PC8000-6E
4 - 39
Travel system
Undercarriage
4.2.8.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK

Special tools:
n/a
Chain hoist
Oil drain pan
Travel brake valve block: 80 kg
6.6 on page 6-14.


WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.
4 - 40
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Disconnect the pressure hoses (Fig. 4-45, Pos. 2) to the

rotary joint from the travel brake valve block (Fig. 4-45,
Pos. 4).
Disconnect the hydraulic lines (Fig. 4-45, Pos. 1) to the travel

motors from the travel brake valve block (Fig. 4-45, Pos. 4).
Disconnect the leakage oil line from the travel brake valve
block (Fig. 4-45, Pos. 4).
NOTE: When the hydraulic lines are disconnected, hydraulic oil

from inside the piping and the travel brake valve block will
flow out.
z
Sling the travel brake valve block (Fig. 4-45, Pos. 4) at the
installed hoist rings.
Remove the mounting bolts (Fig. 4-45, Pos. 3) and lift off the
travel brake valve block (Fig. 4-45, Pos. 4) using a chain
hoist.
Remove the relief valve (Fig. 4-46, Pos. 1) from the travel
brake valve block (Fig. 4-46, Pos. 2).
Fig. 4-45
Fig. 4-46
Version 2010/1
PC8000-6E
4 - 41
Travel system
Undercarriage
4.2.8.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK

Special tools:
n/a
Chain hoist
Travel brake valve block: 80 kg
NOTE: Tighten the relief valve (Fig. 4-46, Pos. 1) to the specified
tightening torque.
Tightening torque for relief valve (Fig. 4-46,
Pos. 1): 300 Nm
z

- INSPECTION".
Check the travel system and adjust if required.

4 - 42
PC8000-6E
Version 2010/1
Undercarriage
4.2.9
Travel system
TRAVEL MOTOR
The travel motor is an axial piston unit with fixed displacement.

The drive speed is proportional to the consumption capacity. The
output torque increases with the pressure drop between high and
low pressure side.
4.2.9.1 REMOVAL OF THE TRAVEL MOTORS

Special tools:
n/a
Crane
Oil drain pan
Travel motor: 161 kg each
Dogman/rigger
6.6 on page 6-14.
z


z


Drain oil of the motor adapter housing,
approx. 0.5 liters each.
Version 2010/1
PC8000-6E
4 - 43
Travel system
Undercarriage
WARNING
Hot hydraulic oil!
heated oil.
DANGER
removed.
Remove the pressure lines (Fig. 4-47, Pos. 2) and the leak oil
hoses (Fig. 4-47, Pos. 5) from the travel motor (Fig. 4-47,
Pos. 3).
NOTE: When the hoses are removed, hydraulic oil from inside
the piping will flow out.
z
Discard the O-rings of the SAE-flanges.

z
Sling the travel motor (Fig. 4-47, Pos. 3) and remove the
mounting bolts (Fig. 4-47, Pos. 4). Discard the bolts.
Remove the travel motor (Fig. 4-47, Pos. 3) by pulling it out of

the motor adapter housing of the travel gearbox using a
crane.
Fig. 4-47
DANGER
When lifting the travel motor, make sure that nobody steps
below the weight.
4 - 44
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.9.2 REPLACEMENT OF THE TRAVEL MOTORS

Special tools:
n/a
Crane
Travel motor: 161 kg
Dogman/rigger

z
Apply "Optimol White" at the spline shaft of the travel motor

before attaching the travel motor to the motor adapter housing.
NOTE: Use new mounting bolts (Fig. 4-47, Pos. 4) of grade 8.8
and tighten to the specified tightening torque.
Tightening torque for travel motor mounting
bolts: 360 Nm
z

Refill oil of the motor adapter housing,
approx. 0.5 liters.
Version 2010/1
PC8000-6E
4 - 45
Travel system
Undercarriage
4.2.10 TRAVEL PARKING BRAKE
Fig. 4-48 Travel parking brake assembly
4 - 46
PC8000-6E
Version 2010/1
Undercarriage
Travel system

(1)
Bolt
(2)
Snap ring
(3)
Control pressure port to release the brake
(4)
Oil filler plug
(5)
Outer disc carrier
(6)
Intermediate flange
(7)
Drive shaft
(8)
Inner disc carrier
(9)
Bolt
(10)
Oil drain plug
(11)
Inner and outer discs
(12
Quad rings
(13)
Bolt
(14)
Piston
(15)
Springs
(16)
Oil level plug
(17)
Retainer
Brake applied:
The outer discs (Fig. 4-48, Pos. 11) engaged to the outer disc carrier (Fig. 4-48, Pos. 5) by serration and the inner discs (Fig. 4-48,
Pos. 11) in serration connection with the inner disc carrier
(Fig. 4-48, Pos. 8) are pressed together by the springs (Fig. 4-48,
Pos. 15). This results in a fixed connection between outer disc
carrier (Fig. 4-48, Pos. 5) and drive shaft (Fig. 4-48, Pos. 7).
Brake released:
Oil pressure via the control pressure port (Fig. 4-48, Pos. 3)
forces the piston (Fig. 4-48, Pos. 14) against the spring towards
the retainer (Fig. 4-48, Pos. 17).
This function eliminates the spring force onto the discs, thus the
brake is released.
NOTE: The release pressure is 21...23 bar, the maximum permissible pressure is 50 bar.
Version 2010/1
PC8000-6E
4 - 47
Travel system
Undercarriage
4.2.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE

Special tools:
n/a
Crane
Oil drain pan
Travel parking brake assembly: 44 kg
Inner disc carrier: 3.5 kg
Dogman/rigger

z


make sure that the machine is moved to a location with
z

Place wedges at front and rear side of both crawlers and

lower the bucket onto the ground.
Drain oil of the brake housing, approx. 0.2 liters.
Refer to the PART & SERVICE NEWS
No. "AH06512".
4 - 48
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Remove the driving performance meter (Fig. 4-49, Pos. 1) if

attached at the travel parking brake (Fig. 4-49, Pos. 2).
Fig. 4-49
WARNING
Hot hydraulic oil!
heated oil.
DANGER
removed.
Fig. 4-50
Disconnect the hydraulic control pressure lines (Fig. 4-50,

Pos. 1) from the travel parking brakes.
NOTE: When the hydraulic lines are removed, hydraulic oil from
z
Attach the travel parking brake assembly to a crane.
Version 2010/1
PC8000-6E
4 - 49
Travel system
Undercarriage
Fig. 4-51 Removal of the travel parking brake
4 - 50
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Remove the mounting bolts (Fig. 4-51, Pos. 1).
Remove the travel parking brake assembly from the travel

gearbox (Fig. 4-51, Pos. 4) and lift it off.
DANGER

When lifting the travel parking brake, make sure that nobody
NOTE: When the travel parking brake is removed, a rest of

hydraulic oil from inside the brake will flow out.
Catch it in an oil pan to avoid contamination.
z
Remove the snap ring (Fig. 4-51, Pos. 2) and pull the inner
disc carrier (Fig. 4-51, Pos. 3) off the drive shaft.
NOTE: The inner disc carrier is used for the alignment of the
discs when installing the travel parking brake.
4.2.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE

Special tools:
n/a
Crane
2 x Threaded pin M12 x 250 mm (grade 8.8)
2 x Nut M12 (grade 8.0)
2 x Threaded pin M10 x 100 mm (grade 8.8)
2 x Nut M10 (grade 8.0)
Paste "Loctite 574", PN 255 239 40
Travel parking brake assembly: 44 kg
Inner disc carrier: 3.5 kg
Retainer with cover: 8.7 kg
Dogman/rigger

DANGER
For safety reasons, KOMATSU does not permit to install the
travel parking brake with pressure applied to the control
pressure port to release the brake.
NOTE: For the following procedures the brake is considered to

be pre-assembled.
Version 2010/1
PC8000-6E
4 - 51
Travel system
Undercarriage
DANGER
Risk of retainer (Fig. 4-52, Pos. 1) blasting off!
Do not apply any pressure to the control pressure port
(Fig. 4-52, Pos. 2) of the travel parking brake during the
installation process.
Clean the mating surfaces of the travel parking brake

(Fig. 4-52, Pos. A) and the travel gearbox (Fig. 4-52, Pos. B)
from old sealing agent.
Measure the protrusion (Fig. 4-52, "a") at the intermediate

flange and the protrusion (Fig. 4-52, "b") at the travel gearbox.
NOTE: The flange surface (Fig. 4-52, Pos. A) of the intermediate

flange must rest plain against the flange surface
(Fig. 4-52, Pos. B) of the gearbox.
Fig. 4-52
Machine the intermediate flange if required.
WARNING
The retainer (Fig. 4-53, Pos. 1) is spring loaded, so do not
remove the bolts (Fig. 4-53, Pos. 4) as long as the retainer is
not bolted together with at least two mounting bolts
(Fig. 4-53, Pos. 2) with nuts (Fig. 4-53, Pos. 2), displaced by
180 to prevent the retainer from blasting off.
After the travel parking brake is secured by mounting bolts

(Fig. 4-53, Pos. 2) and nuts (Fig. 4-53, Pos. 3), remove the
retainer mounting bolts (Fig. 4-53, Pos. 4).
Fig. 4-53
4 - 52
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Replace the two retainer mounting bolts by threaded pins

(Fig. 4-54, Pos. 5) M10 x 100 mm of grade 8.8.
Install nuts (Fig. 4-54, Pos. 4) of the grade 8.0 with appropriate large diameter washers and tighten the nuts hand-tight.
Remove the mounting bolts (Fig. 4-54, Pos. 1).
Apply "Optimol White" at the outer spline shaft of the inner

disc carrier (Fig. 4-54, Pos. 3) and insert the inner disc carrier
into the discs (Fig. 4-54, Pos. 2).
If it is not possible to insert the inner disc carrier, carry out the
following two steps:
z
Untighten the two nuts (Fig. 4-54, Pos. 4) alternately

stepwise to release the brake, until it is possible to insert
the inner disc carrier (Fig. 4-54, Pos. 3) into the discs
(Fig. 4-54, Pos. 2).
Retighten the two nuts alternately stepwise, with the inner

disc carrier inside the discs to lock the brake again.
Fig. 4-54
NOTE: Ensure that the inner disc carrier (Fig. 4-54, Pos. 3)
slides smoothly into the discs (Fig. 4-54, Pos. 2).
z
Remove the inner disc carrier (Fig. 4-54, Pos. 3) and reinstall
it onto the drive shaft. Reinstall the snap ring (Fig. 4-51,
Pos. 2).
NOTE: Ensure that the mating surfaces of the travel parking

brake and of the travel gearbox are clean and free of
paint and old sealing agent before reinstalling.
z
Apply "Loctite 574" at the mating surface of the travel gearbox.
Version 2010/1
PC8000-6E
4 - 53
Travel system
Undercarriage
Attach the travel parking brake assembly to a crane and align

it to the installed inner disc carrier.
DANGER

When lifting the travel parking brake, make sure that nobody
Push the travel parking brake assembly onto the inner disc
carrier (Fig. 4-55, Pos. 4).
NOTE: Make sure that the pilot oil plug (Fig. 4-55, Pos. 2) is on
top of the brake.
z
If possible (when the bores for the mounting bolts are aligned
with the threads in the travel gearbox (Fig. 4-55, Pos. 3)),
insert two threaded pins M12 x 250 mm (Fig. 4-55, Pos. 1) of
the grade 8.8 displaced by 180 into the threads in the travel
gearbox.
Carry out the following two steps only, if the bores in the travel
parking brake are not aligned to the threads in the travel gearbox and release the brake:
z
Untighten the two nuts (Fig. 4-55, Pos. 5) fixing the

retainer, alternately stepwise until it is possible to align
bores for the mounting bolts with the threads in the travel
gearbox.
Fig. 4-55
Insert two threaded pins M12 x 250 mm (Fig. 4-55,

Pos. 1) of the grade 8.8 displaced by 180 into the
threads in the travel gearbox.
Remove the nuts (Fig. 4-55, Pos. 5) (alternately stepwise if

the brake was not released) and washers.
Remove the retainer (Fig. 4-55, Pos. 8) and the two threaded
pins (Fig. 4-55, Pos. 6) fixed in the outer disc carrier.
CAUTION
Be careful!
Springs (Fig. 4-55, Pos. 7) are no longer fixed, and can fall
out of the piston.
4 - 54
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Clean the mating surfaces of retainer (Fig. 4-56, Pos. 5) and

outer disc carrier (Fig. 4-56, Pos. 3) from sealing agent.
Apply "Loctite 574" at the mating surface of the retainer and

install the retainer with oil level plug (Fig. 4-56, Pos. 4) downward.
Tighten the two nuts (Fig. 4-56, Pos. 2) alternately stepwise

until the mounting bolts of the travel parking brake can be
inserted.
NOTE: Always use new mounting bolts.

z
Pretighten the mounting bolts hand-tight.
Remove the threaded pins (Fig. 4-56, Pos. 1).
Fig. 4-56
z
Insert the last two mounting bolts (Fig. 4-57, Pos. 1).
Tighten all mounting bolts to the specified tightening torque.

(Fig. 4-57, Pos. 1) of the travel parking brake:
85 Nm
Insert the two retainer mounting bolts (Fig. 4-57, Pos. 2).
NOTE: Use new retainer mounting bolts (socket head) and

tighten them to the specified tightening torque.
Tightening torque for the retainer mounting bolts
(Fig. 4-57, Pos. 2): 49 Nm
z
Connect the hydraulic control pressure hose at the travel

parking brake.
Version 2010/1
PC8000-6E
Fig. 4-57
4 - 55
Travel system
Undercarriage
If required, reinstall the driving performance meter

(Fig. 4-58, Pos. 1) to the travel parking brake (Fig. 4-58,
Pos. 2).
Fig. 4-58
z

Fill engine oil (SAE 10) or hydraulic oil (HLP 22 or
HLP 33, ISO 51524T.2 and T3) in the travel parking
brake, approx. 0.2 liters.
Refer to PART & SERVICE NEWS No. "AH06512"
NOTE: Filling of the brake housing has to be done with the

engine stopped and the brakes applied to prevent
overfilling.
z
Perform a function check of the travel parking brake. Refer to

the Service Manual.
4 - 56
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.11 TRAVEL GEARBOX
Fig. 4-59 Travel gearbox

(1)
Crawler carrier
(2)
O-ring
(3)
Travel gearbox
(4)
Mounting bolt
(5)
Nut
(6)
Travel motor
(7)
Travel parking brake
Version 2010/1
PC8000-6E
4 - 57
Travel system
Undercarriage
4.2.11.1 REMOVAL OF THE TRAVEL GEARBOX

Special tools:
n/a

Crane
Chain hoist
Oil drain pan
Travel gearbox: 7350 kg
Dogman/rigger
6.6 on page 6-14.
z


z
Place wedges at front and rear side of both crawlers and

lower the bucket onto the ground.


Drain oil of the final drive housing,
approx. 250 liters.
Drain oil of the travel gear housing,
approx. 390 liters.
If required, remove the drive performance meter from the

travel parking brake.
4 - 58
PC8000-6E
Version 2010/1
Undercarriage
Travel system
WARNING
Hot hydraulic oil!
heated oil.
DANGER
removed.
Disconnect the hydraulic lines (Fig. 4-60, Pos. 1) from the

travel parking brakes.
Disconnect all breather hoses from the travel motor adapter

housings, the travel gearbox, and from the final drive housing.
Disconnect the hydraulic pressure hoses and the leak oil

hoses from the travel motors.
Fig. 4-60
Sling the travel gearbox (Fig. 4-61, Pos. 1).
Fig. 4-61
Version 2010/1
PC8000-6E
4 - 59
Travel system
Undercarriage
Remove the nuts (Fig. 4-62, Pos. 3) and the mounting bolts
(Fig. 4-62, Pos. 2).
Discard the bolts and the nuts.
Extract the travel gearbox (Fig. 4-62, Pos. 6) from the crawler
carrier (Fig. 4-62, Pos. 1) using a crane.
DANGER

When lifting the travel gearbox, make sure that nobody steps
below the weight.
If required, remove the travel parking brake (Fig. 4-62,

Pos. 5) from the travel gearbox, refer to section 4.2.10.1 on
page 4-48.
If required, remove the travel motors (Fig. 4-62, Pos. 4) from

the travel gearbox, refer to section 4.2.9.1 on page 4-43.
4 - 60
PC8000-6E
Fig. 4-62
Version 2010/1
Undercarriage
Travel system
4.2.11.2 REPLACEMENT OF THE TRAVEL GEARBOX

Special tools:
n/a
Hydraulic hand pump (pressure min. 25 bar max. 35 bar)

Crane
Travel gearbox: 7350 kg
Dogman/rigger

z
If required, install the travel parking brake at the travel gearbox, refer to section 4.2.10.2 on page 4-51.
If required, install the travel motors at the travel gearbox, refer

Sling the travel gearbox (Fig. 4-63, Pos. 1).

DANGER

When lifting the travel gearbox, make sure that nobody steps
below the weight.
Insert a new O-ring (Fig. 4-64, Pos. 2).
Apply "Optimol White" at the drive shaft.
Connect a hydraulic hand pump (pressure min. 25 bar

max. 35 bar) to the pressure port of the installed travel parking brake (Fig. 4-64, Pos. 5).
Loosen the brake by means of the hydraulic hand pump.
Open the hydraulic ports of the travel motors (Fig. 4-64,

Pos. 4).
Align the travel gearbox (Fig. 4-64, Pos. 6) to the drive shaft
and flange it to the crawler carrier (Fig. 4-64, Pos. 1).
Insert new mounting bolts (Fig. 4-64, Pos. 2) of grade 10.9

and new nuts (Fig. 4-64, Pos. 3).
Version 2010/1
PC8000-6E
Fig. 4-63
Fig. 4-64
4 - 61
Travel system
Undercarriage
NOTE: Remove the cover (Fig. 4-65, Pos. 1) of one travel parking brake to turn the gear drive manually while aligning
the travel gearbox or use the opening of the drive performance meter.
Fig. 4-65
z
Tighten the mounting bolts to the specified tightening torque.

Tightening torque for travel gearbox mounting
bolts (Fig. 4-64, Pos. 2): 4950 Nm

Refill oil of the final drive housing,
approx. 250 liters.
Refill oil of the travel gear housing,
approx. 390 liters.
Refill oil of the motor adapter housing,
approx. 0.5 liters each.
NOTE: Be sure to fill in the correct oil as specified, refer to section 6.2 on page 6-3.
CAUTION
The travel parking brakes are dry multiple disk brakes.
DO NOT fill the housings with oil.
4 - 62
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.12 CARRIER ROLLER

4.2.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY
Special tools:
n/a
Hydraulic jack 30 tonnes

Forklift (as the most economical device)
Chain hoist
Carrier roller assembly: 294 kg

the machine, boom, and forklift.

z
Fig. 4-66
z
Push up track shoe assembly (Fig. 4-67, Pos. 3) at the carrier

roller assembly to be removed (Fig. 4-67, Pos. 1) using
hydraulic jack (Fig. 4-67, Pos. 2).
In addition to the hydraulic jack, secure the track shoe assembly using appropriate supports.
Fig. 4-67
Version 2010/1
PC8000-6E
4 - 63
Travel system
Undercarriage
Pinned crawler carrier only:

z
Sling the carrier roller assembly (Fig. 4-68, Pos. 1) at both

sides and connect the slings to the forks (Fig. 4-68, Pos. 2) of
a forklift.

Fig. 4-68 Pinned crawler carrier

z
Remove the carrier roller assembly mounting bolts (Fig. 4-69,

Pos. 1) and lift off the carrier roller assembly (Fig. 4-69,
Pos. 2) using the forklift.
DANGER

When lifting the carrier roller, make sure that nobody steps
below the weight.
Fig. 4-69 Pinned crawler carrier
4 - 64
PC8000-6E
Version 2010/1
Undercarriage
Travel system
Bolted crawler carrier only:

z
Shove the forks (Fig. 4-70, Pos. 1) together that far, that
the carrier roller (Fig. 4-70, Pos. 2) can rest on the forks.
WARNING
If the forks can not be locked in that position, use a chain

hoist at the forks to prevent them from sliding apart.
Make sure that nobody is in the danger zone while lifting

the carrier roller assembly from the pedestal.
Fig. 4-70 Bolted crawler carrier
Remove the carrier roller assembly mounting bolts (Fig. 4-71,

Pos. 1) and lift the carrier roller assembly (Fig. 4-71, Pos. 2)
off the crawler carrier (Fig. 4-71, Pos. 3) using the forklift.
DANGER

When lifting the carrier roller, make sure that nobody steps
below the weight.
Fig. 4-71 Bolted crawler carrier
Version 2010/1
PC8000-6E
4 - 65
Travel system
Undercarriage
4.2.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY

Special tools:
n/a
Forklift (as the most economical device)

Chain hoist
Carrier roller assembly (with mounting pins): 294 kg
DANGER
Danger of crush or pinch injuries to hands and fingers!
Exercise extreme care when aligning the carrier roller
assembly to the crawler carrier.
NOTE: Observe the mounting position of the carrier roller

assembly (Fig. 4-70 and 4-71, Pos. 2). The oil plug must
face the outside of the excavator.
z
Check the oil level in the carrier roller. The following positions
of the oil level and filler plug have been defined for checking
the oil level in the carrier rollers:
z
9.00 o'clock or 3.00 o'clock position, equal to 90 angle

from TOP position of the plug to left or to the right =
MINIMUM oil level.

MAXIMUM oil level (factory filling).
For information about the proper lubricant, refer to the

"FLUIDS AND LUBRICANTS".
NOTE: Use new mounting bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 and tighten the bolts to
Tightening torque for the carrier roller mounting
bolts (bolted type / pinned type): 1770 Nm
4 - 66
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.13 TRACK ROLLER

4.2.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY
Special tools:
Safety unit for changing track rollers, PN 921 142 40

Tool for changing track rollers (optional, P&S-news in development)
Crane
Forklift (optional, instead of the tool for changing track rollers)
Track roller assembly: 925 kg
Dogman/rigger


z
Fig. 4-72
z
Jack up the machine with the work equipment.
Version 2010/1
PC8000-6E
4 - 67
Travel system
Undercarriage
Support two track rollers with the safety unit for changing
track rollers, PN 921 142 40 (Fig. 4-73, Pos. 1).
Lower the machine and place the work equipment on the

ground.
Support the track roller assembly (Fig. 4-73, Pos. 2) from the
bottom side using a forklift.
Alternatively the changing tool for track rollers can be used,
refer to Fig. 4-75.
Remove the track roller mounting bolts (Fig. 4-73, Pos. 3).
Fig. 4-73 Use of the safety unit
NOTE: The track roller mounting bolts (Fig. 4-74, Pos. 1) are
secured with lever-nuts (Fig. 4-74, Pos. 2) inside the
crawler frame.
When the bolts are removed, the nuts may slip away from
their mounting position.
z
Remove the track roller assembly using the forklift or the special tool.
DANGER

When lifting the track roller, make sure that nobody steps
below the weight.
Fig. 4-74
Changing tool for track rollers:
NOTE: Make sure that both sides of the tool are balanced (e.g.
with the new track roller assembly).
NOTE: A PARTS & SERVICE NEWS for this tool is under development.
Contact the KOMATSU service for further information.
Fig. 4-75 Optional use of the special tool
4 - 68
PC8000-6E
Version 2010/1
Undercarriage
Travel system
4.2.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY

Special tools:
Safety unit for changing track rollers, PN 921 142 40

Tool for changing track rollers (P&S-news in development)
Crane
Track roller assembly: 925 kg
Dogman/rigger

NOTE: Observe the mounting position of the track rollers. The oil
plug must face the outside of the excavator.
z
Check the oil level in the track roller. The following positions
of the oil level and filler plug have been defined for checking
the oil level in the track rollers:
z

MINIMUM oil level.

MAXIMUM oil level (factory filling).
For information about the proper lubricant, refer to the

"FLUIDS AND LUBRICANTS".

z
When inserting the track roller mounting bolts (Fig. 4-76,

Pos. 1), hold the lever-nuts (Fig. 4-76, Pos. 2) inside the
crawler frame by hand for the first convolutions.
NOTE: Use new track roller mounting bolts of the grade 10.9.
Tightening torque for the track roller mounting

bolts (Fig. 4-76, Pos. 1): 1770 Nm
Fig. 4-76
Version 2010/1
PC8000-6E
4 - 69
Car body
Undercarriage
4.3
CAR BODY
4.3.1
REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS

(TYPE WITH MOUNTING PINS)
Special tools:
n/a
2 x Crane
Dozer
Oil drain pan
Car body: 55,000 kg
Crawler carrier assembly: 46,000 kg each (without track group)
Dogman/rigger
6.6 on page 6-14.
NOTE: At first the wear of the bushes in the car body should be
checked, refer to the PARTS & SERVICE NEWS No.
"AH08508".
z
Remove the track groups from both crawler carriers, refer to

NOTE: Remove both track groups simultaneously.

This can be done using the same dozer.
z
Remove the travel gear boxes from both crawler carriers,

Lift the superstructure, refer to section 3.15.1 on page 3-252.
Attach the dozer to the car body (Fig. 4-77, Pos. 2) by means
of a chain (Fig. 4-77, Pos. 1).
Move the car body below the lifted superstructure using the
dozer.
NOTE: Move the car body over the unrolled track group.
Fig. 4-77
4 - 70
PC8000-6E
Version 2010/1
Undercarriage
Car body
Remove the pressure hoses (Fig. 4-78, Pos. 1) of the track

tensioning leading to the shut-off cocks (Fig. 4-78, Pos. 2)
and pull it out of the crawler carriers, refer to section 4.2.7.2
on page 4-33.
NOTE: When the pressure hoses are removed, the oil inside the
piping will flow out.
z
Remove the hose (Fig. 4-78, Pos. 3) between crawler carrier

and car body.
Fig. 4-78
Attach one crawler carrier to two cranes and lift it up

(Fig. 4-79).

WARNING
Before lifting, make sure that the crane operators are trained
in dual crane lift.
Fig. 4-79
z
Rest the car body on appropriate supports (also see

Fig. 4-80).
CAUTION

of both crawler carrier assembly (46,000 kg) and car body
(55,000 kg).
Version 2010/1
PC8000-6E
4 - 71
Car body
Undercarriage
Fig. 4-80 Crawler carrier removal

z
Remove all bolts (Fig. 4-80, Pos. 6) and the retainer plates
(Fig. 4-80, Pos. 7).
Remove the nuts (Fig. 4-80, Pos. 2), the inner retainer plates
(Fig. 4-80, Pos. 3), and the thread pins (Fig. 4-80, Pos. 4)
only if required (changing to a replacement car body).
Pull out the four mounting pins (Fig. 4-80, Pos. 5) just enough
to clear the crawler carrier (Fig. 4-80, Pos. 1) from the car
body as shown in (Fig. 4-80).
Remove the crawler carrier (Fig. 4-80, Pos. 1) using two

cranes.
WARNING
Before lifting the crawler carrier, make sure that the crane
DANGER
When lifting the crawler carrier, make sure that nobody steps
below the weight.
4 - 72
PC8000-6E
Version 2010/1
Undercarriage
Car body
Attach the car body to two cranes (Fig. 4-81).
Clear the other crawler carrier from the car body using the
same procedure as before.
Remove the car body using two cranes.

WARNING
Before lifting the car body, make sure that the crane operators are trained in dual crane lift.
DANGER
When lifting the car body, make sure that nobody steps
below the weight.
Fig. 4-81
Carry out the following steps only if required:

z
Remove the rotary joint from the car body, refer to section
4.3.5.1 on page 4-90.
Remove the high pressure accumulators from the car

body, refer to section 4.2.4.3 on page 4-22.
Remove the track tensioning valve from the car body,

Remove the travel brake valve blocks from the car body,
Remove all hydraulic hoses from the car body, refer to

Version 2010/1
PC8000-6E
4 - 73
Car body
4.3.2
Undercarriage
REPLACEMENT OF THE CAR BODY AND THE CRAWLER

CARRIERS (TYPE WITH MOUNTING PINS)
Special tools:
Water level gauge
AL-Compound, PN 509 623 98

2 x Crane
Dozer
Car body: 55,000 kg
Dogman/rigger

z
Carry out the following five steps only if required:

z
Install all hydraulic hoses into the new car body, refer to
Install the rotary joint in the new car body, refer to section
4.3.5.2 on page 4-93.
Install the high pressure accumulators in the new car

body, refer to section 4.2.4.4 on page 4-23.
Install the track tensioning valve in the new car body,

Install the travel brake valve blocks in the new car body,
4 - 74
PC8000-6E
Version 2010/1
Undercarriage
Car body
If required, install new inner bushings (Fig. 4-82, Pos. 5) and

new outer bushings (Fig. 4-82, Pos. 7) in the new car body.
Install the thread pins (Fig. 4-82, Pos. 4) and the inner
retainer plates (Fig. 4-82, Pos. 3) with nuts (Fig. 4-82, Pos. 2)
and washers at the four borings for the pins on the car body.
Attach the car body (Fig. 4-82, Pos. 1) to two cranes and lift it
up.
WARNING
Before lifting the car body, make sure that the crane operators are trained in dual crane lift.
DANGER
Fig. 4-82

below the weight.
Align the car body over the crawler carrier (Fig. 4-82, Pos. 10)
and let it down.
NOTE: The oil supply lines to the travel motors must be aligned
in the direction of the travel motors.
Insert the hydraulic lines for track tensioning into the
crawler carrier before installing it.
z
Align the upper borings first and insert the mounting pins
(Fig. 4-82, Pos. 6).
NOTE: Lubricate pins (Fig. 4-82, Pos. 6) with AL-Compound,

PN 509 623 98.
z
Align the lower borings and insert the mounting pins.
Install the retainer plates (Fig. 4-82, Pos. 9) at the mounting

pins and secure the retainer plates with the mounting bolts
(Fig. 4-82, Pos. 8) inclusive washers.
Tighten the mounting bolts to the specified tightening torque.

Tightening torque for mounting bolts (Fig. 4-82,
Pos. 8): 360 Nm
Version 2010/1
PC8000-6E
4 - 75
Car body
Undercarriage
For easier mounting of the second crawler carrier, support left

side of the car body with appropriate supports of approx.
1500 mm hight and lower the car body on the supports.
CAUTION

of one crawler carrier assembly (46,000 kg) and the car body
(55,000 kg).
NOTE: Assure that the track groups are parallel and the distance
"A" between track groups is:
4750 mm for track width 1900
5150 mm for track width 1500
Fig. 4-83
Fig. 4-84 Assembly of the car body

z
Install the thread pins (Fig. 4-84, Pos. 4) and the inner
retainer plates (Fig. 4-84, Pos. 3) with nuts (Fig. 4-84, Pos. 2)
and washers at the four borings for the pins on the car body.
Attach the second crawler carrier (Fig. 4-84, Pos. 1) to two

cranes, lift it up and align it to the car body.
4 - 76
PC8000-6E
Version 2010/1
Undercarriage
Car body

WARNING
DANGER
below the weight.
Align the lower borings first and insert the mounting pins
(Fig. 4-84, Pos. 5).
NOTE: Lubricate pins (Fig. 4-84, Pos. 5) with AL-compound,

PN 509 623 98.
z
Align the lower borings and insert the mounting pins.
Install the retainer plates (Fig. 4-84, Pos. 7) at the mounting

pins and secure the retainer plates with the mounting bolts
(Fig. 4-84, Pos. 6) inclusive washers.Tighten the mounting
Tightening torque for mounting bolts: 360 Nm
Lift the undercarriage as far as it is necessary to remove the

supports.
Rest the undercarriage to the ground.
Version 2010/1
PC8000-6E
4 - 77
Car body
4.3.3
Undercarriage
REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS

(TYPE WITH BOLTED CONNECTION)
Special tools:
Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73

2 x Crane
Dozer
Car body: 59,000 kg
Dogman/rigger
6.6 on page 6-14.
Remove the track groups from both crawler carriers, refer to

NOTE: Remove both track groups simultaneously.

This can be done using the same dozer.
z
Remove the travel gear boxes from both crawler carriers,

Lift the superstructure, refer to section 3.15.1 on page 3-252.
Attach the dozer to the car body (Fig. 4-77, Pos. 2) by means
of a chain (Fig. 4-77, Pos. 1).
Move the car body below the lifted superstructure using the
dozer.
NOTE: Move the car body over the unrolled track group.
Fig. 4-85
4 - 78
PC8000-6E
Version 2010/1
Undercarriage
Car body
Disconnect the pressure hoses (Fig. 4-86, Pos. 1) for the

track tensioning from the shut-off cocks (Fig. 4-86, Pos. 2).
NOTE: When the pressure hoses are removed, the oil inside the
piping will flow out.
z
Remove the hoses from both crawler carriers.
Fig. 4-86
Attach one crawler carrier (Fig. 4-87, Pos. 1) to two cranes at

the installed lifting eyes (Fig. 4-87, Pos. 2) and lift it up.
WARNING
Before lifting, make sure that the crane operators are trained
in dual crane lift.
Support the car body with appropriate supports so that all of

the track rollers are clear of the track roller path.
CAUTION

of one crawler carrier assembly (46,000 kg) and the car body
(55,000 kg).
Fig. 4-87
NOTE: Place supports between the cross-ties (Fig. 4-88, Pos. 1)

in a manner that the mounting bolts can be removed.
Fig. 4-88
Version 2010/1
PC8000-6E
4 - 79
Car body
Undercarriage
Fig. 4-89 Crawler carrier mounting bolts

z
Remove all 244 mounting bolts (Fig. 4-89, Pos. M48) and the
two measuring bolts (Fig. 4-89, Pos. 1) attaching the crawler
carrier to the car body using the hydraulic torque wrench
PN 793 374 73 + PN 793 376 73. Discard the bolts.
NOTE: The mounting bolts marked with "S" have to be removed

from inside the car body.
For hints using the torque wrench refer to section 6.3.1
on page 6-4 and refer to chapter 9 "Suppliers documentation", "AVANTI HYTORQUE".
z
Remove the crawler carrier using the two cranes.

WARNING
DANGER
When lifting the crawler carrier, make sure that nobody steps
below the weight.
Remove the car body from the other crawler carrier accordingly to Removal of the car body and the crawler carriers
(type with mounting pins) on page 70.
NOTE: Clear the second crawler carrier from the car body using
the procedure on this page.
4 - 80
PC8000-6E
Version 2010/1
Undercarriage
4.3.4
Car body
REPLACEMENT OF THE CAR BODY AND THE CRAWLER

CARRIERS (TYPE WITH BOLTED CONNECTION)
Special tools:

2 x Crane
Dozer
Car body: 59,000 kg
Dogman/rigger

z
Carry out installation in reverse order to removal and accordingly to Replacement of the car body and the crawler carriers
(type with mounting pins) on page 74.
When mounting the crawler carrier to the car body, tighten the
mounting bolts to the specified tightening torques as follows:
Version 2010/1
PC8000-6E
4 - 81
Car body
Undercarriage
Fig. 4-90 Crawler carrier mounting bolts

z
Insert 244 new bolts (Fig. 4-90, Pos. M48) and two measuring
bolts (Fig. 4-90, Pos. 1) with a resilient sleeves.
NOTE: Lubricate all bolts (Fig. 4-90, Pos. M48) with compound
"KP2K", PN 324 969 40.
Clean bottom and top surface of the resilient sleeves and
contact areas completely free of paint.
Insert the two measuring bolts (Fig. 4-90, Pos. 7) into the
upper corners.
The measuring bolts are part of the measuring device,
PN 928 476 40.
The mounting bolts marked with "S" have to be installed
from inside the car body.
z
Pretighten the mounting bolts using the hydraulic torque

wrench PN 793 374 73 + PN 793 376 73.
NOTE: For hints using the torque wrench refer to section 6.3.1
on page 6-4 and refer to chapter 9 "Suppliers documentation", "AVANTI HYTORQUE".
Pretightening torque for crawler carrier mounting bolts: 2100 Nm
z
Determine the torque and tighten the crawler carrier mounting

bolts to the determined torque, refer to section 4.3.4.1 on
page 4-84.
NOTE: Check the torque of the crawler carrier mounting bolts

after 1000 operating hours, refer to section 4.3.4.1 on
page 4-84.
4 - 82
PC8000-6E
Version 2010/1
Undercarriage
Car body
Version 2010/1
PC8000-6E
4 - 83
Car body
Undercarriage
4.3.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS

Special tools:

Measuring device, PN 928 476 40
Fig. 4-91 Tightening torque for the crawler carrier mounting bolts
4 - 84
PC8000-6E
Version 2010/1
Undercarriage
Car body
The required tightening torque for all fastening bolts has to be

determined with the 4 measuring bolts (Fig. 4-91, Pos. 7), which
dimension is analogous to the fastening bolts (Fig. 4-91,
Pos. M48). The required axial tension force of the bolts depends
on the elongation of the fastening bolts.
NOTE: The tightening torque must be determined at the first
assembly of the excavator at the operation site, for the
first inspection, and after 1000 operation hours, or after
replacing either crawler carrier or car body.
The required measuring device, PN 928 476 40 is delivered with
the excavator. To determine the tightening torque, 4 specially prepared measuring bolts are supplied besides the normal fastening
bolts. The measuring bolts can be recognized by the machined
area at the end of the bolt.
The measuring device (Fig. 4-91, Pos. 1 - 6) is composed of the
following items and will be delivered with each new machine.
Refer to Fig. 4-91:
Pos.
Part name
Part number
Qty.
(1)
Angle bar
928 475 40
(2)
Dial gauge
092 706 40
(3)
Screw M5x16
502 515 98
(4)
Feeler
477 172 40
(5)
Bolt M10x25
307 777 99
(6)
Washer
517 122 98
(7)
Measuring bolt
(installed)
933 613 40
WARNING
Pre-condition:
Crawler carrier is assembled and bolts tightened to 2100 Nm
Loosen all 4 measuring bolts (Fig. 4-91, Pos. 7). Do not lubricate the measuring bolts again.
Tighten the 4 measuring bolts (Fig. 4-91, Pos. 7) to

150 Nm.
Install the measuring device (Fig. 4-91, Pos. 1 - 6).
Set the dial gauge (Fig. 4-91, Pos. 2) to zero.
Install the special hydraulic torque wrench,

PN 793 374 73 + PN 793 376 73, refer to section 6.4.2 on
page 6-13.
Version 2010/1
PC8000-6E
4 - 85
Car body
Undercarriage
Fig. 4-92 Tightening torque for the crawler carrier mounting bolts
4 - 86
PC8000-6E
Version 2010/1
Undercarriage
Car body
Adjust the pressure at the hydraulic torque wrench to

2100 Nm and tighten the measuring bolt (Fig. 4-92, Pos. 7).
List the pressure and the changed bolt length in a table.
Increase the pressure in steps of 10 bar until the measuring

bolts have the required elongation of 1.22 mm.
List the corresponding hydraulic pressure in a table.
Repeat this procedure for all 4 measuring bolts.
Add all 4 determined hydraulic pressures and then divide by 4

to obtain an average value.
Loosen one mounting bolt (Fig. 4-92, Pos. M48) and tighten
the bolt with the calculated average pressure.
CAUTION
Do not lubricate the bolts again.

Do not loosen more than one bolt at a time.
Repeat this procedure step by step for all the other bolts.
Version 2010/1
PC8000-6E
4 - 87
Car body
4.3.5
Undercarriage
ROTARY JOINT
Fig. 4-93 Rotary joint
4 - 88
PC8000-6E
Version 2010/1
Undercarriage
Car body

(1)
Rotary joint
(2)
Torque support lever
(3)
Resilient sleeve
(4)
Mounting bolt
(5)
Car body
(6)
Support plate
(7)
Center of the rotary joint (hollow-bore)
(8)
Cam at the superstructure
Ports:
A-D
Service lines
Grease
Leak (case drain) oil
ST
Control oil (pilot oil)
K1 / K2
Return oil to tank
The rotary distributor (rotary joint) permits a hydraulic connection

between the superstructure and the undercarriage. That means
there is an unrestricted hydraulic connection installed between
the rotating and stationary part which allows free rotation in both
slew directions.
During operation the superstructure and the undercarriage rotate
towards each other. The travel motors must be supplied with
hydraulic oil in each position in which the superstructure is slewed
against the undercarriage.
The rotary joint is hollow-bored, so the main power cable to the
slip ring runs through the center of the rotary joint.
Version 2010/1
PC8000-6E
4 - 89
Car body
Undercarriage
4.3.5.1 REMOVAL OF THE ROTARY JOINT

Special tools:
n/a
Crane
Rotary joint: 261 kg
Dogman/rigger
6.6 on page 6-14.
z

the machine, boom, and a crane.

z

Fig. 4-94
4 - 90
PC8000-6E
Version 2010/1
Undercarriage
Car body
valve between suction oil reservoir and main oil reservoir.
Fig. 4-95
DANGER
Hazardous Voltage!


Pull the high voltage power supply cable out of the rotary joint
and the support plate.
WARNING
Hot hydraulic oil!

heated oil.
Mark and disconnect all hydraulic hoses and pipes from the
rotary joint. Discard the O-rings of the SAEflange connections, refer to Fig. 4-93.
z
Disconnect the lines of the central lubrication system from the

rotary joint.
Version 2010/1
PC8000-6E
4 - 91
Car body
Undercarriage
Sling the rotary joint.
NOTE: The rotary joint is accessible from above, from between

the pipe work at the manifold at the centre of the machine
(Fig. 4-96, arrow).
CAUTION
Move the sling carefully between the pipe work/hoses at the
manifold to prevent the pipe work from being damaged or
ripped off.
Fig. 4-96
z
Remove the mounting bolts (Fig. 4-97, Pos. 1) and remove

the torque support lever (Fig. 4-97, Pos. 2) from the rotary
joint (Fig. 4-97, Pos. 3).
Remove mounting bolts (Fig. 4-97, Pos. 4) and lift the rotary
joint (Fig. 4-97, Pos. 3) off the support plate (Fig. 4-97,
Pos. 5) in the car body using a crane.
DANGER

When lifting the rotary joint, make sure that nobody steps
below the weight.
Fig. 4-97
4 - 92
PC8000-6E
Version 2010/1
Undercarriage
Car body
4.3.5.2 REPLACEMENT OF THE ROTARY JOINT

Special tools:
n/a
Crane
Rotary joint: 261 kg
Dogman/rigger

Place the new rotary joint (Fig. 4-98, Pos. 3) at the support
plate (Fig. 4-98, Pos. 5) using a crane.
DANGER

When lifting the rotary joint, make sure that nobody steps
below the weight.
NOTE: Insert new mounting bolts (Fig. 4-98, Pos. 4) of grade

10.9. Apply compound "KP2K", PN 324 969 40 and
tighten the bolts to the specific tightening torque.
Tightening torque for rotary joint mounting bolts
(Fig. 4-98, Pos. 4): 265 Nm
z
Install the torque support lever to the new rotary joint

(Fig. 4-98, Pos. 3). Make sure that the torque support lever
fits into the cam at the superstructure.
Fig. 4-98
NOTE: Use new mounting bolts (Fig. 4-98, Pos. 1) of grade 10.9.
Tightening torque for torque support lever
mounting bolts (Fig. 4-98, Pos. 1): 265 Nm
z
Lead the high voltage power supply cable through the support
plate (Fig. 4-98, Pos. 5) and the center of the rotary joint
(Fig. 4-98, Pos. 3).
Version 2010/1
PC8000-6E
4 - 93
Cable drum assembly
4.4
Undercarriage
CABLE DRUM ASSEMBLY
Fig. 4-99 Cable drum, overview

(1)
Mounting flange
(2)
Connection box
(3)
Cable drum brake motor
(4)
Power cable guiding tube
(5)
Carrier
(6)
Cable guide mechanism
(7)
Cable drum
(8)
Brake motor resistor
(9)
Maintenance access ladder
4 - 94
PC8000-6E
Version 2010/1
Undercarriage
4.4.1
Cable drum assembly
REMOVAL OF THE CABLE DRUM ASSEMBLY
Special tools:
n/a
Crane
2 x Chain hoist (carrying capacity: 5000 kg, each)
Cable drum assembly (empty): 10,000 kg
Dogman/rigger


z
Turn the superstructure 45 degrees to the right, i.e. in the

position where the corner with the hydraulic cooler is located
above the centre of the cable drum.
Unroll the high voltage power supply cable from the cable
drum til the end using the manual switch of the unit.

DANGER
Hazardous Voltage!

Disconnect the high voltage power supply cable at the power

station.
If the electric supply has been switched off from the power
plant, loosen the brake of the drum motor, refer to the Operation & Maintenance Manual of the cable drum assembly.
Open the man hole of the cable drum.
Disconnect the high voltage power supply cable coming from

the power station inside the drum, and pull the cable out of
the drum.
Version 2010/1
PC8000-6E
4 - 95
Cable drum assembly
Undercarriage
Disconnect all cables and wires leading from the car body
(Fig. 4-100, Pos. 1) to the cable drum assembly, and put them
down on the machine.
Sling the cable drum assembly at the carrier (Fig. 4-100,

Pos. 2) using a crane and two chain hoists (for balancing).
Remove the mounting bolts (Fig. 4-100, Pos. 3) and resilient

sleeves (Fig. 4-100, Pos. 4) at the flanges (Fig. 4-100, Pos.
5).
DANGER

When removing the mounting bolts, make sure that nobody
steps below the cable drum assembly.
Move the cable drum assembly away from the machine carefully, and put it down on the ground.
Fig. 4-100
DANGER

When lifting the cable drum assembly, make sure that
4 - 96
PC8000-6E
Version 2010/1
Undercarriage
4.4.2
Cable drum assembly
REPLACEMENT OF THE CABLE DRUM ASSEMBLY
Special tools:
n/a
Crane
2 x Chain hoist
Cable drum assembly (empty): 10,000 kg
Dogman/rigger

DANGER
Hazardous Voltage!
NOTE: Ensure that the mating surfaces are free of grease and
rust, and that the surfaces are plane.
z
Sling the cable drum assembly (Fig. 4-101, Pos. 2) using a

crane and two chain hoists (for balancing).
Bring the cable drum assembly into mounting position at the

car body (Fig. 4-100, Pos. 1).
DANGER

When lifting the cable drum assembly, make sure that
Install the mounting bolts (Fig. 4-100, Pos. 3) with resilient

sleeves (Fig. 4-100, Pos. 4) at the mounting flanges
(Fig. 4-100, Pos. 5).
NOTE: Always use new mounting bolts of grade 10.9.

Apply compound "KP2K", PN 324 969 40 on heads and
threads of the bolts and tighten them to the specified
tightening torque:
Fig. 4-101
Tightening torques for the cable drum assembly
mounting bolts: 880 Nm
Version 2010/1
PC8000-6E
4 - 97
Cable drum assembly
Undercarriage
Reconnect all cables and wires leading from the machine to

the cable drum and the connection box of the cable drum
assembly.
Open the manhole of the cable drum.
Reconnect the high voltage power supply cable from the

power station inside the cable drum.
Change the dryer pack according to the Operation & Maintenance Manual of the cable drum assembly.
Clean the inside of the cable drum.
NOTE: Dirt, water, oil or other contamination is not permissible

inside the cable drum.
z
Carry out further installation in reverse order to removal
NOTE: For the initial operation of the cable drum assembly, refer
to the Operation & Maintenance Manual of the cable
drum assembly, delivered with the machine.
4 - 98
PC8000-6E
Version 2010/1
Attachment
5 ATTACHMENT
Version 2010/1
PC8000-6E
5 -1
Face Shovel (FSA)
Attachment
5.1
FACE SHOVEL (FSA)
5.1.1
FSA OVERVIEW
Fig. 5-1
Face shovel attachment, overview
(1)
Lip with installed ground engaging tools (GET)
(2)
Bull clam bucket (clam)
(3)
Bull clam bucket (wall)
(4)
Stick
(5)
Boom
(6)
Boom cylinder
(7)
Stick cylinder
(8)
Bucket cylinder
5 -2
PC8000-6E
Version 2010/1
Attachment
5.1.2
Face Shovel (FSA)
USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS
Designated use:
Each hydraulic cylinder has a groove (Fig. 5-2, arrow) at each
end of the cylinder body (Fig. 5-2, Pos. 1). Clamp the installation
tool (Fig. 5-2, Pos. 2) on the hydraulic cylinder using the groove.
Fig. 5-2
The tools are designed to handle the attachments hydraulic cylinders vertically in combination with a forklift. Thereby, the forks of
the forklift are inserted between the cylinder body and the scorpers (Fig. 5-3, Pos. 2). The tools extensions (Fig. 5-3, Pos. 1)
rest on the forks of the forklift.
This is the tools main direction of stress, indicated by "F".
DANGER
Use the installation tools in the proper way shown only!
Cylinders may only be handled vertically when using these
tools.
Misuse may result in death, serious injury, or damage to the
tools.
Version 2010/1
PC8000-6E
Fig. 5-3
5 -3
Face Shovel (FSA)
5.1.3
Attachment
BOOM
5.1.3.1 REMOVAL OF THE BOOM
Fig. 5-4
Boom removal
(1)
Boom
(2)
Stripper
(3)
Bush
(4)
Pin boom/superstructure
(5)
Cover
(6)
Bolt
(7)
Pin boom cylinder/superstructure
(8)
Chain hoist
(9)
5 -4
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Special tools:
n/a

2 x Crane
4 x Chain hoist
Oil drain pan
Boom with attached stick and boom cylinders: 71,020 kg
Pin boom/superstructure: 339 kg
Pin boom cylinder/superstructure: 243 kg
Dogman/rigger
6.6 on page 6-14.
WARNING
z

attachment.


bucket on the ground with the stick and the bucket cylinders
in vertical position (Fig. 5-5).

Fig. 5-5
z

Remove the stick, refer to section 5.1.4 on page 5-22.
NOTE: Leave the stick cylinders retracted and fixed to the boom.
Secure them under the boom using chain hoists.
Version 2010/1
PC8000-6E
5 -5
Face Shovel (FSA)
Fig. 5-6
Attachment
Boom removal
For safety reasons tie the piston rods to the stick cylinder
bodies with a wire rope.
Fully retract the boom cylinders.

Fix the boom cylinders at the boom (Fig. 5-6, Pos. 1) using
chain hoists (Fig. 5-6, Pos. 8).
5 -6
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
DANGER
removed.
Disconnect the boom arc hoses incl. grease feeding lines

from the boom, refer to section 5.1.7.1 on page 5-68.

z
Disconnect all electric wires from the boom.
Remove the bolts (Fig. 5-6, Pos. 6) and the covers

(Fig. 5-6, Pos. 5) securing the pins (Fig. 5-6, Pos. 4 and 7).
Attach the front part of the boom to a crane.
Remove the pins (Fig. 5-6, Pos. 7) attaching the boom cylinders to the superstructure.
WARNING
Sling the pin as soon as possible and support it using a

crane to prevent the pin from falling.
Lift the booms front side.
For safety reasons tie the piston rods to the boom cylinder
body with a wire rope.
Attach the rear part of the boom to another crane.
Remove the pins (Fig. 5-6, Pos. 4) attaching the boom to the
superstructure.
WARNING

Version 2010/1
PC8000-6E
5 -7
Face Shovel (FSA)
Attachment
Remove the boom with attached stick cylinders and boom

cylinders using two cranes, refer to Fig. 5-6.
Place it on appropriate supports.
WARNING
Make sure that the crane operators are trained in dual crane
lift.
DANGER
When moving the boom, make sure that nobody steps below
the lifted boom.
Carry out the next steps with the boom placed on the ground:
z
Remove the pins of the boom cylinders, refer to section

5.1.3.3 on page 5-14 and remove the boom cylinders
from the boom.
Remove the pins of the stick cylinders, refer to section

5.1.4.3 on page 5-30 and remove the stick cylinders from
the boom.
Remove all provided parts and the hydraulic piping from

the boom.
5 -8
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
5.1.3.2 REPLACEMENT OF THE BOOM

Special tools:
n/a

2 x Crane
4 x Chain hoist
Boom with attached stick and boom cylinders: 71,020 kg
Pin boom/superstructure: 339 kg
Dogman/rigger
WARNING
z

attachment.

NOTE: When performing the installation procedures, comply to

the following:
Always discard used seals and install new seals.
Apply the appropriate grease on every bush and pin on
assembly!
z
Install new bushes (Fig. 5-7, Pos. 2) into the boom (Fig. 5-7,
Pos. 1) if required, and insert new seals (Fig. 5-7, Pos. 3) into
the bushes.
CAUTION
There is a tolerance gap between bush and seal so that the

seal can move freely within the groove.
In order to avoid damage to the seals stick the seals into the
grooves of the bushes with grease and center the seals in
Fig. 5-7
Version 2010/1
PC8000-6E
5 -9
Face Shovel (FSA)
Fig. 5-8
z
Attachment
FSA boom installation
Install all provided parts and the hydraulic piping to the boom.
NOTE: For safety reasons tie the piston rods to the cylinder bodies with wire ropes.
z
Install the boom cylinders to the boom in reverse order to

removal, refer to section 5.1.3.4 on page 5-19.
Install the stick cylinders to the boom in reverse order to

removal, refer to section 5.1.4.4 on page 5-35.
NOTE: Make sure that the hydraulic hoses are already connected to the cylinders at this state.
z
Fix the cylinders at the boom using chain hoists (Fig. 5-8,
Pos. 8).
5 - 10
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Install new bushes (Fig. 5-8, Pos. 3), if required and insert
new seals (Fig. 5-8, Pos. 2) into the bushes.
CAUTION

Attach the boom to two cranes.

WARNING
Before lifting the boom, make sure that the crane operators
are trained in dual crane lift.
Lift the boom (Fig. 5-8, Pos. 1) with the boom and stick cylinders attached using two cranes.
NOTE: Lift the front part of the boom higher than the back part.
DANGER
When moving the boom, make sure that nobody steps below
the lifted boom.
Align the boom (Fig. 5-8, Pos. 1) with the superstructure.

DANGER
Never put hands into the holes when aligning the boom to
the superstructure.
Insert both pins (Fig. 5-8, Pos. 4) connecting the boom to the
superstructure.
Detach the rear crane.
Install the covers (Fig. 5-8, Pos. 5), and bolts (Fig. 5-8,
Pos. 6) to secure the pins (Fig. 5-8, Pos. 4).
Connect the boom arc hoses incl. the grease feeding lines to
the boom, refer to section 5.1.7.1 on page 5-68.
Switch S155 to Qmin and retract the boom cylinders fully.
Version 2010/1
PC8000-6E
5 - 11
Face Shovel (FSA)
Fig. 5-9
Attachment
FSA boom installation
Remove the wire ropes from the boom cylinders.

Align the boom cylinders to superstructure.

Move the boom up and down using the crane. Use the chain
hoist (Fig. 5-9, Pos. 8) to align the boom cylinders to the
superstructure.
DANGER
Never put hands into the holes when aligning the boom to
the superstructure.
5 - 12
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Insert the pins (Fig. 5-9, Pos. 7) connecting the boom cylinders to the superstructure.
Lower the boom completely and detach the front crane.
Install the covers (Fig. 5-9, Pos. 5) and the bolts (Fig. 5-9,
Pos. 6) to secure the pin (Fig. 5-9, Pos. 7).
Connect the electric wires to the boom.
Perform the bleeding procedure for the boom cylinders.


Check for leaks and the cylinders operation.
Check the hydraulic oil level again and add oil if required.
Version 2010/1
PC8000-6E
5 - 13
Face Shovel (FSA)
Attachment
5.1.3.3 REMOVAL OF THE BOOM CYLINDERS
Fig. 5-10 Boom cylinder, removal and installation
5 - 14
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Boom cylinder
(2)
Boom
(3)
Catch
(4)
Pin
(5)
Cover
(6)
Bolt
(7)
Seal
(8)
Bush
(9)
Seal
(10)
Bush
(11)
O-ring
(12)
Hydraulic hose
(13)
Bolt
(14)
Cover
(15)
Bush
(16)
Pin
(17)
(18)
Stripper
(19)
Bolt
(20)
Bush
Special tools:
Installation tool, PN 934 606 40

Crane
Chain hoist
Forklift 10 t
Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan
Boom cylinder: 7500 kg
Pin boom cylinder/boom: 255 kg
Dogman/rigger
6.6 on page 6-14.
Version 2010/1
PC8000-6E
5 - 15
Face Shovel (FSA)
Attachment
NOTE: At first the wear of the bushes in the hydraulic cylinder

should be checked, refer to the PARTS & SERVICE
NEWS No. "AH08508".
WARNING
z

attachment.


Park the machine on the prepared flat area with the superstructure turned by 90 and position the bucket on the ground
as shown (Fig. 5-11).

z

Disconnect the grease feeding line (Fig. 5-12, Pos. 1) from

the cover (Fig. 5-12, Pos. 2) of the boom cylinder pin at the
union (Fig. 5-12, Pos. 3).
Disconnect the grease feeding lines from the boom cylinder(s) to be removed.
Fig. 5-11
Fig. 5-12
5 - 16
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Sling the lower end of the boom cylinder (Fig. 5-13, Pos. 1)
and fix it to the boom (Fig. 5-13, Pos. 2) using a chain hoist
(Fig. 5-13, Pos. 6).

(Fig. 5-13, Pos. 4) securing the pin (Fig. 5-13, Pos. 5).
Remove the pin (Fig. 5-13, Pos. 5) attaching the boom cylinder to the superstructure.
WARNING

Fig. 5-13
z

z
For safety reasons tie the piston rod to the boom cylinder


WARNING
Hot hydraulic oil!

DANGER
removed.
Version 2010/1
PC8000-6E
5 - 17
Face Shovel (FSA)
Attachment
Disconnect the hydraulic hoses from the boom cylinder, refer


inside the piping and the hoses will flow out. Catch it in an
oil pan.
z
Lower the boom cylinder using the chain hoist until the cylinder is in vertical position.
Install the installation tool, PN 934 606 40 at the boom cylinders upper side, refer to section 5.1.2 on page 5-3.
Hold the boom cylinder by means of the installation tool using

the forklift.
Remove the bolts (Fig. 5-14, Pos. 1) and the cover (Fig. 5-14,
Pos. 2).
Remove the pin (Fig. 5-14, Pos. 4) with the catches

(Fig. 5-14, Pos. 5).
Check the bushes (Fig. 5-14, Pos. 3) and replace if required.

WARNING

Fig. 5-14
z
Remove the boom cylinder with the forklift.
NOTE: Use a crane to lift the cylinder from the forklift.

DANGER
When moving the boom cylinder, make sure that nobody
steps below the lifted cylinder.
If required, remove the pipe work, the connecting blocks, and

the seals from the removed cylinder(s). Discard the seals and
fit caps to the cylinder(s) openings to avoid environmental
contamination.
5 - 18
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
5.1.3.4 REPLACEMENT OF THE BOOM CYLINDERS

Special tools:

Chain hoist
Crane
Fork lift 10 t
Boom cylinder: 7500 kg
Pin boom cylinder/boom: 255 kg
Dogman/rigger

WARNING
z

attachment.


the following:
Always discard used seals and install new seals.
assembly!
z
Insert new bushes (Fig. 5-15, Pos. 3) into the boom cylinder
(Fig. 5-15, Pos. 1) if required, refer to the PARTS & SERVICE
NEWS No. "AH06545".
If required, install the pipe work, the connecting blocks, and

the seals at the cylinder(s).
Insert new seals (Fig. 5-15, Pos. 2) into the bushes

(Fig. 5-15, Pos. 3) of the boom cylinder (Fig. 5-15, Pos. 1).
CAUTION

Fig. 5-15
For safety reasons tie the piston rod to the boom cylinder
Version 2010/1
PC8000-6E
5 - 19
Face Shovel (FSA)
Attachment
Install the installation tool, PN 934 606 40 at the upper end of

the new boom cylinder, refer to section 5.1.2 on page 5-3.
Place the boom cylinder on the forklift in a vertical position so

that the cylinder is supported by means of the installation tool.
DANGER

When moving the boom cylinder, make sure that nobody
steps below the lifted boom.
Align the upper end of the boom cylinder with the boom using
the forklift.
DANGER
Never put hands into the holes when aligning the boom
cylinder to the boom.
Insert the pin (Fig. 5-16, Pos. 4) with the catches (Fig. 5-16,
Pos. 5).
Install the cover (Fig. 5-16, Pos. 2), and the bolts (Fig. 5-16,
Pos. 1).
Remove the installation tool from the boom cylinder.
Fig. 5-16
z
Sling the piston rod side of the boom cylinder (Fig. 5-17,
Pos. 1) and fix it to the boom (Fig. 5-17, Pos. 2) using a chain
hoist (Fig. 5-17, Pos. 6).
Hoist the boom cylinder to a position in which the hydraulic

hoses can be connected.
Connect the hydraulic lines to the boom cylinder, refer to section 5.1.7.2 on page 5-72.
NOTE: Always use new O-rings at the SAEflange connections.

z

z
Remove the wire ropes from the boom cylinders.
5 - 20
PC8000-6E
Fig. 5-17
Version 2010/1
Attachment
Face Shovel (FSA)
Extend and retract the boom cylinder (Fig. 5-17, Pos. 1)

slowly at Qmin 2...3 times as far as possible to partly bleed the
cylinder.
WARNING
The air in the cylinder will result in slightly jerky movements

of the cylinder.
Operate the boom cylinder slowly at Qmin and use the chain
hoist to align the boom cylinders to the superstructure.
DANGER
Never put hands into the holes when aligning the boom cylinder to the superstructure.
Insert the pin (Fig. 5-17, Pos. 5).

Install the covers (Fig. 5-17, Pos. 4), and the bolts (Fig. 5-17,
Perform the bleeding procedure for the boom cylinders.

Version 2010/1
PC8000-6E
5 - 21
Face Shovel (FSA)
5.1.4
Attachment
STICK
5.1.4.1 REMOVAL OF THE STICK
Fig. 5-18 Stick, removal and installation
5 - 22
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Boom
(2)
Stick
(3)
Bush
(4)
Seal ring
(5)
Catch
(6)
Pin
(7)
Ring
(8)
Cover
(9)
Bolt
(10)
Seal
(11)
Ring (welded to the stick)
(12)
Flange bush
(13)
Bush
(14)
Pin
(15)
Shackle
(16)
Bolt
(17)
Bush
Special tools:
n/a

Crane
2 x Chain hoist
Stick: 25,170 kg
Pin stick/boom: 373 kg
Pin stick cylinder/stick: 98 kg
Dogman/rigger
6.6 on page 6-14.
WARNING
z

attachment.

Version 2010/1
PC8000-6E
5 - 23
Face Shovel (FSA)
Attachment


z
Remove the bull clam bucket, refer to section 5.1.5.1 on page

5-40.
Hook up both stick cylinders (Fig. 5-20, Pos. 1) using chain

hoists (Fig. 5-20, Pos. 2).
Remove the bolts (Fig. 5-20, Pos. 7) and the shackles

(Fig. 5-20, Pos. 4) securing the pins (Fig. 5-20, Pos. 3) from
the stick cylinders.
Remove the pins (Fig. 5-20, Pos. 3) from both cylinders.
Fig. 5-19
WARNING
Remove the seals (Fig. 5-20, Pos. 5) from the bushes

(Fig. 5-20, Pos. 6) in the stick. Discard the seals.
Check the bushes (Fig. 5-20, Pos. 6) in the stick and replace
them if required.
Switch S155 to Qmin and retract the stick cylinders

(Fig. 5-20, Pos. 1) fully.
Fig. 5-20

z

5 - 24
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
DANGER
removed.
Disconnect all hydraulic hoses and the grease feeding line

from the stick leading to the boom, refer to section 5.1.7.3 on
page 5-76.
Disconnect all electric wires from the stick.
Sling the stick (Fig. 5-21, Pos. 1) and lift it using a crane.

(Fig. 5-21, Pos. 3).
Remove the pins (Fig. 5-21, Pos. 4) with the catches

(Fig. 5-21, Pos. 5).
WARNING
Sling the pins as soon as possible and support them using a

crane to prevent the pins from falling.
Remove the stick and rest it on the ground using a crane.

Place it on appropriate supports.
Fig. 5-21
DANGER
When moving the stick, make sure that nobody steps below
the lifted stick.
Remove all provided parts and the hydraulic piping from the
stick (Fig. 5-21, Pos. 1).
Version 2010/1
PC8000-6E
5 - 25
Face Shovel (FSA)
Attachment
5.1.4.2 REPLACEMENT OF THE STICK

Special tools:
n/a

Crane
2 x Chain hoist
Stick: 25,170 kg
Pin stick/boom: 373 kg
Dogman/rigger

WARNING
z

attachment.


the following:
Always discard used seals and install new seals!
Put the appropriate grease in every bush on assembly!
z
Check the bushes (Fig. 5-22, Pos. 2) at the boom side of the
stick (Fig. 5-22, Pos. 1) and replace if required.
Insert new seals (Fig. 5-22, Pos. 3) into the grooves of the
bushes (Fig. 5-22, Pos. 2).
CAUTION

Fig. 5-22
5 - 26
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Check the bushes (Fig. 5-23, Pos. 1) at the boom (Fig. 5-23,
Pos. 2) and replace if required.
Fig. 5-23
z
Install all provided parts and hydraulic piping to the stick

(Fig. 5-24, Pos. 1).
Sling the stick (Fig. 5-24, Pos. 1) and align it to the boom
using a crane.
DANGER

When moving the stick, make sure that nobody steps below
the lifted stick.
DANGER
Never put hands into the holes when aligning the stick to the
boom.
Install the pins (Fig. 5-24, Pos. 4) attaching the stick

(Fig. 5-24, Pos. 1) to the boom.
Install the catches (Fig. 5-24, Pos. 5), the covers (Fig. 5-24,
Pos. 3), and the bolts (Fig. 5-24, Pos. 2) to secure the pins
(Fig. 5-24, Pos. 4).
Version 2010/1
PC8000-6E
Fig. 5-24
5 - 27
Face Shovel (FSA)
Attachment
Bring the stick to the position shown in Fig. 5-25 using the
crane.
Install new seals (Fig. 5-25, Pos. 5) into the bushes

(Fig. 5-25, Pos. 6) in the stick.
CAUTION

Switch S155 to Qmin and extend the stick cylinders to align

the stick cylinders with the stick horizontally. Use the chain
hoists (Fig. 5-25, Pos. 2) to align the stick cylinders with the
stick vertically.
Fig. 5-25

DANGER
Never put hands into the holes when aligning the stick cylinders to the stick.
Install the pins (Fig. 5-26, Pos. 3).
Install the shackle (Fig. 5-26, Pos. 4) and the bolts (Fig. 5-26,
Pos. 7) to secure the pins (Fig. 5-26, Pos. 3).
5 - 28
PC8000-6E
Fig. 5-26
Version 2010/1
Attachment
Face Shovel (FSA)
Version 2010/1
PC8000-6E
5 - 29
Face Shovel (FSA)
Attachment
5.1.4.3 REMOVAL OF THE STICK CYLINDERS
Fig. 5-27 Stick cylinder, removal and installation
5 - 30
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Stick cylinder
(2)
Boom
(3)
Stick
(4)
Seal
(5)
O-ring
(6)
Connecting block
(7)
Pipe
(8)
Pin
(9)
Seal
(10)
Bush
(11)
Bolt
(12)
Shackle
(13)
Pin
(14)
Catch
(15)
Bolt
(16)
Cover
(17)
Ring
Special tools:
n/a

2 x Chain hoist
Crane
Forklift 6 t
Oil drain pan
Stick cylinder: 4007 kg each
Pin stick cylinder/boom: 225 kg
Dogman/rigger
6.6 on page 6-14.
WARNING
Always wear a safety harness when working at the attachment.
Version 2010/1
PC8000-6E
5 - 31
Face Shovel (FSA)
Attachment
WARNING
NOTE: At first the wear of the bushes in the hydraulic cylinders

NEWS No. "AH08508".
z


Fig. 5-28
z

Remove the grease feeding lines from the stick cylinder(s) to

be removed.
Secure the stick cylinder (Fig. 5-29, Pos. 1) to be removed

under the boom using one chain hoist at each side of the cylinder.
Remove the pin connecting the stick cylinder piston rod to the
stick, refer to section 5.1.4.1 on page 5-22.
WARNING

crane to prevent the pin from falling when it is pulled out
completely.
Fig. 5-29
z
Switch S155 to Qmin and retract the stick cylinders


z
For safety reasons tie the piston rod to the cylinder body with
a wire rope.
5 - 32
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)


WARNING
Hot hydraulic oil!

DANGER
removed.
Disconnect the hydraulic hoses from the stick cylinder, refer


oil pan.
z
Remove the bolts (Fig. 5-30, Pos. 1), the cover (Fig. 5-30,
Pos. 2), the ring (Fig. 5-30, Pos. 3), and the catches
(Fig. 5-30, Pos. 5), securing the pin (Fig. 5-30, Pos. 4).
Pull out the pin (Fig. 5-30, Pos. 4) connecting the stick cylinder to the boom.
NOTE: Pull out the pin just far enough to clear the left stick cylinder if only this cylinder needs to be removed.
Only pull out the pin completely, if both cylinders need to
be removed.
WARNING
crane to prevent the pin from falling when it is pulled out
completely.
Fig. 5-30
z
Check the bushes (Fig. 5-30, Pos. 6) in the boom and replace
the bushes if required.
Version 2010/1
PC8000-6E
5 - 33
Face Shovel (FSA)
Attachment
Lower the stick cylinder in horizontal position using the chain

hoists simultaneously.
Use the Forklift to take over the stick cylinder.
DANGER

When moving the stick cylinder, make sure that nobody
If required, remove the pipe work, the connecting blocks, and

the seals from the removed cylinder(s).
Discard the seals and fit caps to the cylinder(s) openings to
avoid environmental contamination.
5 - 34
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
5.1.4.4 REPLACEMENT OF THE STICK CYLINDERS

Special tools:
n/a

2 x Chain hoist
Crane
Forklift 6 t
Stick cylinder: 4007 kg each
Pin stick cylinder/boom: 225 kg
Dogman/rigger

WARNING
z

attachment.


the following:
assembly!
z
Install new bushes (Fig. 5-31, Pos. 3) into the stick cylinder
(Fig. 5-31, Pos. 1) if required, refer to the PARTS & SERVICE
NEWS No. "AH06545".
Insert new seals (Fig. 5-31, Pos. 2) into the bushes.

CAUTION

Fig. 5-31
z
If required, install the pipe work, the connecting blocks, and

the seals at the cylinder(s).
For safety reasons tie the piston rod to the cylinder body with
a wire rope.
Version 2010/1
PC8000-6E
5 - 35
Face Shovel (FSA)
Attachment
Lift the stick cylinder beneath the boom using a forklift.

WARNING

When moving the stick cylinder, make sure that nobody
Hook up two chain hoists to the underside of the boom.
Connect the two chain hoists to the stick cylinder bodies

using one chain hoist at each side of the cylinder.
Pull up the stick cylinder using the chain hoists and align the
stick cylinder to the boom.
DANGER
Never put hands into the holes when aligning the stick cylinders to the boom.
NOTE: Insert the pin just far enough to hold right stick cylinder if
this or both cylinders were removed.
Insert the pin completely if the left stick cylinder is in
mounting position.
z
Install the catches (Fig. 5-32, Pos. 5), the ring (Fig. 5-32,
Pos. 3), the cover (Fig. 5-32, Pos. 2), and the bolts (Fig. 5-32,
Fig. 5-32
5 - 36
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Connect the hydraulic hoses to the stick cylinder (Fig. 5-33,

Pos. 1), refer to section 5.1.7.4 on page 5-82.
Switch S155 to Qmin and retract the stick cylinder (Fig. 5-33,
Pos. 1) fully.

z
Remove the wire ropes from the stick cylinder (Fig. 5-33,
Pos. 1).
Extend and retract the stick cylinder (Fig. 5-33, Pos. 1) slowly
at Qmin 2...3 times as far as possible to partly bleed the cylinder.
Fig. 5-33
WARNING
of the cylinder.
Operate the stick cylinder slowly at Qmin and use the chain
hoist to align the stick cylinder to the stick.
DANGER
Never put hands into the holes when aligning the stick cylinder to the stick.
Install the pin connecting the stick cylinder to the stick, refer

Perform the bleeding procedure for the stick cylinders.

Version 2010/1
PC8000-6E
5 - 37
Face Shovel (FSA)
5.1.5
Attachment
BULL CLAM BUCKET
Fig. 5-34 Bull clam bucket, removal and installation
5 - 38
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Bull clam bucket
(2)
Bush
(3)
Ring (welded to the bucket)
(4)
Pin
(5)
Axle stirrup
(6)
Catch (welded to the bucket)
(7)
Shackle
(8)
Bolt
(9)
Bush
(10)
Pin
(11)
Axle stirrup
(12)
Catch (welded to the bucket)
(13)
Shackle
(14)
Bolt
(15)
Bucket cylinder
(16)
Seal
(17
Stick
(18)
Seal fixing ring
(19)
Seal
Version 2010/1
PC8000-6E
5 - 39
Face Shovel (FSA)
Attachment
5.1.5.1 REMOVAL OF THE BULL CLAM BUCKET

Special tools:
n/a
Crane
Oil drain pan
Bucket: 63,316 kg
Pin bucket cylinder/bucket: 238 kg
Pin bucket/stick: 365 kg
Dogman/rigger
6.6 on page 6-14.


Fig. 5-35
z

Disconnect the grease feeding lines leading to the bucket.
Remove the cover plate (Fig. 5-36, Pos. 2) from inside the
bucket (Fig. 5-36, Pos. 1) to gain access to the assembly
opening.
Fig. 5-36
5 - 40
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
WARNING
Hot hydraulic oil!
DANGER
removed.
Disconnect the hydraulic hoses from the clam cylinder distributor blocks, refer to section 5.1.7.6 on page 5-92.

z
Remove the seal fixing rings (Fig. 5-37, Pos. 1) from the pin
(Fig. 5-37, Pos. 4) located on both sides of the bucket cylinder respectively the stick (Fig. 5-37, Pos. 3).
NOTE: Always use new seals (Fig. 5-37, Pos. 2).
Fig. 5-37
Version 2010/1
PC8000-6E
5 - 41
Face Shovel (FSA)
Attachment
Fig. 5-38 Bull clam bucket removal

z
Sling the bucket cylinders (Fig. 5-38, Pos. 15) to prevent

them from swinging when the pins (Fig. 5-38, Pos. 10) are
removed.
Remove the bolts (Fig. 5-38, Pos. 14) with washers and the
shackle (Fig. 5-38, Pos. 13).
5 - 42
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Push the pin (Fig. 5-38, Pos. 10) inwards just enough to
remove the axle stirrups (Fig. 5-38, Pos. 11) from the catches
(Fig. 5-38, Pos. 12).
NOTE: The catches (Fig. 5-38, Pos. 12) are welded to the bucket
(Fig. 5-38, Pos. 1).
z
Remove the pin (Fig. 5-38, Pos. 10) to clear the bucket cylinder (Fig. 5-38, Pos. 15).
Remove the seals (Fig. 5-38, Pos. 16) when removing the
pin.
WARNING

Remove the bolts (Fig. 5-38, Pos. 8) with washers and the
shackle (Fig. 5-38, Pos. 7).
Push the pins (Fig. 5-38, Pos. 4) inwards just enough to

remove the axle stirrups (Fig. 5-38, Pos. 5) from the catches
(Fig. 5-38, Pos. 6).
NOTE: The catches are welded to the bucket.

Use the assembly opening (refer to Fig. 5-36) to push the
pin.
z
Push the pins (Fig. 5-39, Pos. 1) out of the inner pin bearing
(Fig. 5-39, Pos. 2) outwards until the stick is cleared from the
bucket.
Remove the seals (Fig. 5-37, Pos. 2) when removing the pin.
NOTE: When the stick is cleared, the pins can remain in the
outer pin bearings (Fig. 5-39, Pos. 3).
Fig. 5-39
z
Check the bushes (Fig. 5-38, Pos. 2 and 9) for wear or damage and replace if required.
Lift the boom, and move the excavator away.
Version 2010/1
PC8000-6E
5 - 43
Face Shovel (FSA)
Attachment
5.1.5.2 REPLACEMENT OF THE BULL CLAM BUCKET
Fig. 5-40 Bull clam bucket replacement
5 - 44
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Special tools:
n/a
n/a
Bucket: 63,316 kg
Pin bucket/stick: 365 kg
Dogman/rigger

the following:
Insert new bushes into the stick (Fig. 5-40, Pos. 17) if
required!
assembly!
z
Attach the seals (Fig. 5-40, Pos. 16 and 19) to the flange of
the steel bushes (Fig. 5-40, Pos. 2 and 9) installed in the
bucket (Fig. 5-40, Pos. 1).
NOTE: During the installation of the stick resp. the cylinder, there
is not enough space to insert the seals.
z
Perform the bleeding procedure for the clam cylinder.

Version 2010/1
PC8000-6E
5 - 45
Face Shovel (FSA)
Attachment
5.1.5.3 REMOVAL OF THE BUCKET CYLINDERS
Fig. 5-41 Bucket cylinders, removal and installation
5 - 46
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Bucket cylinder
(2)
Stick
(3)
Boom
(4)
Axle stirrup
(5)
Pin
(6)
Ring
(7)
Cover
(8)
Bolt
(9)
Bull clam bucket
(10)
Bush
(11)
Seal fixing ring
(12)
Seal
(13)
Catch
(14)
Shackle
(15)
O-ring
(16)
SAEflange
(17)
Flange
(18)
Bush
Version 2010/1
PC8000-6E
5 - 47
Face Shovel (FSA)
Attachment
Special tools:

Crane
Forklift 8 t
Oil drain pan
Bucket cylinder: 5358 kg
Pin bucket cylinder/boom: 209 kg
Dogman/rigger
6.6 on page 6-14.
WARNING
z

attachment.

NOTE: At first the wear of the bushes in the hydraulic cylinder

NEWS No. "AH08508".
z

as shown (Fig. 5-42), bucket cylinders in vertical position.

z

Disconnect the grease feeding lines from the bucket cylinder(s) to be removed.
Install the installation tool, PN 923 828 40 at the piston rod

side of the bucket cylinder, refer to section 5.1.2 on page 5-3.
Support the bucket cylinder by means of the installation tool

using the forks of a forklift.
5 - 48
PC8000-6E
Fig. 5-42
Version 2010/1
Attachment
Face Shovel (FSA)
Remove the bolts (Fig. 5-43, Pos. 1), the cover (Fig. 5-43,
Pos. 2), and the ring (Fig. 5-43, Pos. 3).
Remove the pin (Fig. 5-43, Pos. 4) with the catches

(Fig. 5-43, Pos. 5) to clear the bucket cylinder from the boom.
WARNING

Fig. 5-43
z
Switch S155 to Qmin and retract the bucket cylinder


z
For safety reasons tie the piston rod to the bucket cylinder


WARNING
Hot hydraulic oil!

DANGER
removed.
Disconnect the hydraulic hoses from the bucket cylinder, refer


oil pan.
Version 2010/1
PC8000-6E
5 - 49
Face Shovel (FSA)
Attachment
Remove the seal fixing rings (Fig. 5-44, Pos. 1) from the pin
(Fig. 5-44, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-44, Pos. 3).
NOTE: Always use new seals (Fig. 5-44, Pos. 2).
Fig. 5-44
z
Remove the bolts (Fig. 5-45, Pos. 5) and the shackle

(Fig. 5-45, Pos. 4) securing the pin (Fig. 5-45, Pos. 1).
Pull out the pin (Fig. 5-45, Pos. 1).

Thereby remove the axle stirrups (Fig. 5-45, Pos. 2) from the
catches (Fig. 5-45, Pos. 3).
NOTE: The catches are welded to the bucket.
Fig. 5-45
z
Remove the bucket cylinder using the forklift.
NOTE: Use a crane to lift the cylinder from the forklift.

WARNING
When moving the bucket cylinder, make sure that nobody
5 - 50
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
5.1.5.4 REPLACEMENT OF THE BUCKET CYLINDERS

Special tools:

Crane
Forklift 8 t
Bucket cylinder: 5358 kg
Pin bucket cylinder/boom: 209 kg
Dogman/rigger

the following:
assembly!.
z
Check the following bushes and replace them if required:

z
Bushes in the boom (Fig. 5-41, Pos. 18).
Bushes in the bucket cylinder (Fig. 5-46, Pos. 1) and in

the bucket (Fig. 5-41, Pos. 10).
For replacement of the cylinders bushes refer to the
Insert new seals (Fig. 5-46, Pos. 2) into the bushes in the piston rod.
CAUTION

Fig. 5-46
Attach the seals (Fig. 5-46, Pos. 3) to the flange of the steel
bushes installed in the bucket.
NOTE: During the installation of the cylinder, there is not enough

space to insert the seals.
Version 2010/1
PC8000-6E
5 - 51
Face Shovel (FSA)
Attachment
WARNING
z

attachment.

Install the installation tool, PN 923 828 40 at the piston rod

side of the new bucket cylinder.
Sling the bucket cylinder to a crane at the piston rod side,

using the installation tool as a stop for the wire rope.
WARNING
Do not sling the wire rope to the installation tool.
Lift the bucket cylinder until it is in upright position.
Take over the bucket cylinder with a forklift, supporting the

cylinder at the installation tool with the forks of the forklift.
DANGER

When moving the bucket cylinder, make sure that nobody
Align the bucket cylinder with the bucket using the forklift.
DANGER
Never put hands into the holes when aligning the bucket cylinder to the bucket.
NOTE: Install the bucket cylinder so that the hydraulic ports at

the piston rod point outward and the hydraulic ports at
cylinder point to the superstructure, refer to Fig. 5-49.
5 - 52
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

Secure the pin with the axle stirrups (Fig. 5-47, Pos. 2) in the
catches (Fig. 5-47, Pos. 3).
NOTE: Take care of the seals sticking on the cylinder.

z
Install the shackle (Fig. 5-47, Pos. 4) and insert the bolts
(Fig. 5-47, Pos. 5) with washers.
Remove the installation tool.
NOTE: The cylinder furthermore must be held uprightly by the

forklift.
Fig. 5-47
z
Install the seal fixing rings (Fig. 5-48, Pos. 1) at the pin
(Fig. 5-48, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-48, Pos. 3) to fix the seals (Fig. 5-48, Pos. 2).
Fig. 5-48
z
Connect the hydraulic lines (Fig. 5-49, Pos. 2 and 3) to the

bucket cylinder (Fig. 5-49, Pos. 1), refer to section 5.1.7.5 on
page 5-86.
NOTE: Always use new O-rings at the SAEflange connections.
Fig. 5-49
Version 2010/1
PC8000-6E
5 - 53
Face Shovel (FSA)
Attachment

z
Extend and retract the bucket cylinder slowly at Qmin 2...3

times as far as possible to partly bleed the cylinder.
WARNING

of the cylinder.
Operate the bucket cylinder slowly at Qmin and align the

bucket cylinder to the boom vertically. Use the forks of the
forklift to align the stick cylinders with the boom horizontally.
DANGER
Never put hands into the holes when aligning the bucket
cylinder to the boom.
Insert the pin (Fig. 5-50, Pos. 4) with the catches

(Fig. 5-50, Pos. 5).
Install the ring (Fig. 5-50, Pos. 3), the cover (Fig. 5-50,
Pos. 2), and the bolts (Fig. 5-50, Pos. 1).

Perform the bleeding procedure for the bucket cylinders.

5 - 54
PC8000-6E
Fig. 5-50
Version 2010/1
Attachment
Face Shovel (FSA)
Version 2010/1
PC8000-6E
5 - 55
Face Shovel (FSA)
Attachment
5.1.5.5 REMOVAL OF THE CLAM CYLINDERS
Fig. 5-51 Clam cylinders, removal and installation
5 - 56
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Clam cylinder
(2)
Clam
(3)
Seal
(4)
Pin
(5)
Cover
(6)
Bolt
(7)
Bush
(8)
Seal
(9)
Bush
(10)
Hydraulic hose
(11)
O-ring
(12)
Pin
(13)
Bolt
(14)
Plate
(15)
Catch
Special tools:
n/a
Crane
Oil drain pan
Clam cylinder: 1475 kg
Clam cylinders upper pin: 72 kg
Clam cylinders lower pin: 95 kg
Dogman/rigger
6.6 on page 6-14.

the machine boom and crane.
bucket horizontally on the ground (Fig. 5-52).

Fig. 5-52
Version 2010/1
PC8000-6E
5 - 57
Face Shovel (FSA)
Attachment

Support the clam cylinder with appropriate blocks (Fig. 5-53,

arrows) to fix it in its position.
Disconnect the grease feeding lines from the clam cylinder.
Fig. 5-53
z

(Fig. 5-54, Pos. 2) to access the pin connecting the clam cylinder to the clam.
Fig. 5-54
z

(Fig. 5-55, Pos. 4).
Pull out the pin (Fig. 5-55, Pos. 3) to clear the clam cylinder
(Fig. 5-55, Pos. 2) from the clam (Fig. 5-55, Pos. 1).
Switch S155 to Qmin and retract the clam cylinder fully.
Fig. 5-55
WARNING
Both clam cylinders are connected to the same hydraulic
line, so when the cleared cylinder is fully retracted, the
other cylinder will start to retract and the clam will open.
Do not open the clam.
5 - 58
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)


WARNING
Hot hydraulic oil!

DANGER
removed.
Disconnect the hydraulic hoses from the clam cylinder, refer


Discard the O-rings.
Sling the clam cylinder at both ends.
Remove the bolt (Fig. 5-56, Pos. 1) and the plate (Fig. 5-56,
Pos. 2).
Pull out the pin (Fig. 5-56, Pos. 3) using pulling bolts.
Remove the clam cylinder from the bucket using a crane.

DANGER

When moving the clam cylinder, make sure that nobody
Version 2010/1
PC8000-6E
Fig. 5-56
5 - 59
Face Shovel (FSA)
Attachment
5.1.5.6 REPLACEMENT OF THE CLAM CYLINDERS

Special tools:
n/a
Crane
Clam cylinder: 1475 kg
Clam cylinders upper pin: 72 kg
Clam cylinders lower pin: 95 kg
Dogman/rigger

the following:
assembly!
z
Insert new bushes (Fig. 5-57, Pos. 1) into the clam cylinder if
required, refer to the PARTS & SERVICE NEWS No.
"AH06545".
Install new seals (Fig. 5-57, Pos. 2) into the bushes

(Fig. 5-57, Pos. 1).
CAUTION

Fig. 5-57
z
Insert the clam cylinder into the bucket using a crane and
align the cylinder with the bucket to insert the lower pin.
DANGER
Never put hands into the holes when aligning the clam
cylinder to the bucket.
NOTE: For easier alignment it is recommended to support the

clam cylinder with appropriate blocks (Fig. 5-58, arrows)
to fix it in its position.
Fig. 5-58
5 - 60
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Insert the pin (Fig. 5-59, Pos. 3) and install the seals. Fix the
pin with the plate (Fig. 5-59, Pos. 2).
Secure the plate with the bolt (Fig. 5-59, Pos. 1).
Fig. 5-59
z
Connect the hydraulic hoses to the clam cylinder, refer to section 5.1.7.6 on page 5-92.
NOTE: Use new O-rings at the SAEflange connections.

z

z
Extend and retract the clam cylinder slowly at Qmin 2...3 times
as far as possible to partly bleed the cylinder.
WARNING

of the cylinder.
Operate the clam cylinder slowly at Qmin and align the cylinders piston rod to with the clam.
WARNING
Never put hands into the holes when aligning the clam
cylinder to the clam.
Version 2010/1
PC8000-6E
5 - 61
Face Shovel (FSA)
Attachment
Insert the pin (Fig. 5-60, Pos. 3) connecting the clam cylinder
(Fig. 5-60, Pos. 2) and the clam (Fig. 5-60, Pos. 1).

Install the cover (Fig. 5-60, Pos. 4) and the bolts (Fig. 5-60,
Pos. 5).
Fig. 5-60
z
Perform the bleeding procedure for the clam cylinders.

5 - 62
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Version 2010/1
PC8000-6E
5 - 63
Face Shovel (FSA)
5.1.6
Attachment
GROUND ENGAGING TOOLS (GET)
Fig. 5-61 GET
5 - 64
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Shroud
(2)
Toplok boss
(3)
Wedge
(4)
Point (tooth)
(5)
Wedge
(6)
Tooth adapter (centre/corner)
(7)
Pin
(8)
Wear plate
(9)
Base plate
(10)
Wear cap
(11)
Spool
As ground engaging tools, the ESCO POSILOK Tooth System is

used.
Up to now, there is no approval for other tooth systems by
KOMATSU.
Version 2010/1
PC8000-6E
5 - 65
Face Shovel (FSA)
Attachment
5.1.6.1 REMOVAL AND REPLACEMENT OF THE GET

Special tools:
POSILOK Pin removal tool: PN 793 502 73

POSILOK Lifting tool: PN 793 503 73
ESCO POSILOK Tooth System S145

Forklift (if no lifting tool is available)
Point (tooth): 362 kg (ESCO)
Shroud: 245 kg (ESCO)
Tooth adapter: 91 kg (ESCO)
Dogman/rigger

CAUTION
Hazard of injuries from splinters!
When working on the locking pins, always wear hard hat,
safety glasses, steel-toed shoes, and gloves. To avoid injury
to others, keep people not directly involved well out of the
way.

the machine, bucket and a forklift.
Park the machine on the prepared flat ground area and position the bucket in an appropriate height for work.

z
For removing and installing the ESCO Tooth System, refer to

NOTE: Use a forklift to remove and install the GET.
5 - 66
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Version 2010/1
PC8000-6E
5 - 67
Face Shovel (FSA)
5.1.7
Attachment
HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT
5.1.7.1 SUBSTITUTE THE BOOM ARC HOSES
Fig. 5-62 Boom arc hoses, removal and installation
5 - 68
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Hose clamp
(2)
Clamp line
(3)
Nut
(4)
Distribution block
(5)
Hydraulic pipe (to manifold)
(6)
Hydraulic hose (boom arc hose)
(7)
Bolt
(8)
O-ring
(9)
Hydraulic pipe (on boom)
(10)
Chain
Special tools:
n/a

Crane
Oil drain pan
Boom arc hose (depending on type): 25...30.5 kg
Dogman/rigger
2.2.6 on page 2-22.
6.6 on page 6-14.
WARNING
Version 2010/1
PC8000-6E
5 - 69
Face Shovel (FSA)
Attachment

Park the machine on the prepared flat area with the stick cylinder fully retracted and position the bucket horizontally on
the ground (Fig. 5-63).

Fig. 5-63
Fig. 5-64 Boom arc hoses, removal and installation
5 - 70
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

Open the hose clamps (Fig. 5-64, Pos. 1) and clear the
hydraulic hose (Fig. 5-64, Pos. 6) to be removed from the
clamp lines (Fig. 5-64, Pos. 2).
WARNING
Hot hydraulic oil!

DANGER
removed.
Sling the hydraulic hose (Fig. 5-64, Pos. 6) to be removed.
Remove the bolts (Fig. 5-64, Pos. 7) and disconnect the

SAEflanges from the hydraulic tube (Fig. 5-64, Pos. 5) at the
distributor block (Fig. 5-64, Pos. 4) and from the hydraulic
tube (Fig. 5-64, Pos. 9) at the boom.

z
Remove the hydraulic hose using a crane.
Replace the boom arc hoses by new ones and carry out
installation in reverse order to removal.
NOTE: Always replace the O-rings (Fig. 5-64, Pos. 8) at the

SAEflange connections.
z
Substitute the other boom arc hoses if required, using the

same procedure.
Perform the bleeding procedure for all cylinders.

Check hydraulic oil level again and add oil if required.
Version 2010/1
PC8000-6E
5 - 71
Face Shovel (FSA)
Attachment
5.1.7.2 SUBSTITUTE THE BOOM CYLINDER HOSES
Fig. 5-65 Boom cylinder hoses, removal and installation
5 - 72
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Bolt
(4)
O-ring
(5)
Ring
(6)
Boom cylinder
Special tools:
n/a

Crane
Oil drain pan
Boom cylinder hose: 24 kg (each)
Dogman/rigger
2.2.6 on page 2-22.
6.6 on page 6-14.
WARNING
z

attachment.


Fig. 5-66

Version 2010/1
PC8000-6E
5 - 73
Face Shovel (FSA)
Attachment
Fig. 5-67 Boom cylinder hoses, removal and installation
5 - 74
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)


WARNING
Hot hydraulic oil!

DANGER
removed.
Sling the hydraulic hose (Fig. 5-67, Pos. 1 or 2) to be

removed.

SAEflanges from the boom cylinder (Fig. 5-67, Pos. 6) and
from the hydraulic tube at the boom.

z
Replace the boom cylinder hoses by new ones and carry out
NOTE: Always replace the O-rings (Fig. 5-67, Pos. 4) and the
rings (Fig. 5-67, Pos. 5) at the SAEflange connections.
z
Substitute the other boom cylinder hoses if required, using

the same procedure.
Perform the bleeding procedure for the boom cylinder(s).

Version 2010/1
PC8000-6E
5 - 75
Face Shovel (FSA)
Attachment
5.1.7.3 SUBSTITUTE THE STICK ARC HOSES
Fig. 5-68 Stick arc hoses, removal and installation
5 - 76
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Hydraulic hose
(2)
Hose clamp line
(3)
Bolt
(4)
O-ring
(5)
Ring
(6)
Hydraulic tube
Special tools:
n/a

Crane
Oil drain pan
Stick arc hose: 30...31 kg
Dogman/rigger
2.2.6 on page 2-22.
6.6 on page 6-14.
WARNING
z

attachment.

NOTE: In case that two hose clamp lines (Fig. 5-68, Pos. 2) are
installed, KOMATSU recommends the replacing of the
hydraulic lines on the stick and the boom and the hydraulic hoses between stick and boom (stick arc hoses).
NEWS No. "AH08516" resp. No. "AH08532".
Version 2010/1
PC8000-6E
5 - 77
Face Shovel (FSA)
Attachment
Fig. 5-69 Stick arc hoses, removal and installation
5 - 78
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

Park the machine on the prepared flat area with the stick
cylinder fully retracted and position the bucket horizontally on

z

Remove the hose clamp lines (Fig. 5-69, Pos. 2).
Fig. 5-70
WARNING
Hot hydraulic oil!
DANGER
removed.

SAEflanges from the hydraulic tubes (Fig. 5-69, Pos. 6).

z
Replace the stick arc hoses by new ones and carry out installation in reverse order to removal.
Version 2010/1
PC8000-6E
5 - 79
Face Shovel (FSA)
Attachment
Substitute the other stick arc hoses if required, using the

same procedure.
Perform the bleeding procedure for the bucket and clam cylinders.
5 - 80
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Version 2010/1
PC8000-6E
5 - 81
Face Shovel (FSA)
Attachment
5.1.7.4 SUBSTITUTE THE STICK CYLINDER HOSES
Fig. 5-71 Stick cylinder hoses, removal and installation

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Bolt
(4)
O-ring
(5)
Ring
5 - 82
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Special tools:
n/a

Forklift
Oil drain pan
Stick cylinder hose (depending on length): 18.5 kg
Dogman/rigger
2.2.6 on page 2-22.
6.6 on page 6-14.
WARNING
z

attachment.



Fig. 5-72
z

Version 2010/1
PC8000-6E
5 - 83
Face Shovel (FSA)
Attachment
Fig. 5-73 Stick cylinder hoses, removal and installation
5 - 84
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

removed using a forklift.
WARNING
Hot hydraulic oil!

DANGER
removed.

SAEflanges.

z
Remove the hydraulic hose using a forklift.
Replace the stick cylinder hoses by new ones and carry out
z
Substitute the other stick cylinder hoses if required, using the

same procedure.
Perform the bleeding procedure for the stick cylinder(s).

Version 2010/1
PC8000-6E
5 - 85
Face Shovel (FSA)
Attachment
5.1.7.5 SUBSTITUTE THE BUCKET CYLINDER HOSES
Fig. 5-74 Bucket cylinder hoses, removal and installation

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Bolt
(4)
O-ring
(5)
Ring
(6)
Intermediate flange
(7)
Bucket cylinder
(8)
Stick
5 - 86
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Special tools:
n/a

Crane
Oil drain pan
Bucket cylinder hose (depending on length): 31...34 kg
Dogman/rigger
2.2.6 on page 2-22.
6.6 on page 6-14.
WARNING
z

attachment.

NOTE: In case that two hose clamp lines (Fig. 5-68, Pos. 2) are
installed, KOMATSU recommends the replacing of the
hydraulic lines on the stick and the boom and the hydraulic hoses between stick and boom (stick arc hoses).
NEWS No. "AH08516" resp. No. "AH08532".
z


Fig. 5-75
Version 2010/1
PC8000-6E
5 - 87
Face Shovel (FSA)
Attachment
Fig. 5-76 Bucket cylinder hoses, removal and installation

z

5 - 88
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

removed.
WARNING
Hot hydraulic oil!

DANGER
removed.

SAEflanges.
z
Remove the intermediate flange (Fig. 5-76, Pos. 6) from

the cylinder when removing the bucket cylinder hose
(Fig. 5-76, Pos. 1) on the piston rod side of the bucket
cylinder (Fig. 5-76, Pos. 7).

z
Remove the hydraulic hose using a crane and replace the

bucket cylinder hose by a new one.
Version 2010/1
PC8000-6E
5 - 89
Face Shovel (FSA)
Attachment
Connect the hydraulic lines (Fig. 5-77, Pos. 2 and 3) to the

bucket cylinder (Fig. 5-77, Pos. 1).
NOTE: When connecting the hydraulic hose (Fig. 5-77, Pos. 2)

at the piston rod observe the next step.
Fig. 5-77
z
The SAEflange at the piston rod of the bucket cylinder must

be mounted in an angle of 45.
Fig. 5-78
z
Substitute the other bucket cylinder hoses if required, using

the same procedure.
Perform the bleeding procedure for the bucket cylinder(s).

5 - 90
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Version 2010/1
PC8000-6E
5 - 91
Face Shovel (FSA)
Attachment
5.1.7.6 SUBSTITUTE THE CLAM CYLINDER HOSES

The clam cylinder hose set contains two hydraulic hoses at the
stick and four (two for each cylinder) hydraulic hoses at the clam
cylinders.
Substitute the clam cylinder hoses at the stick
Fig. 5-79 Clam cylinder hoses at stick, removal and installation

(1)
Hydraulic hose
(2)
Bolt
(3)
O-Ring
(4)
Ring
5 - 92
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
Special tools:
n/a

Forklift
Oil drain pan
Clam cylinder hose: 30 kg
Dogman/rigger
2.2.6 on page 2-22.
6.6 on page 6-14.
WARNING
z

attachment.



Fig. 5-80
z

Version 2010/1
PC8000-6E
5 - 93
Face Shovel (FSA)
Attachment
Fig. 5-81 Clam cylinder hoses at stick, removal and installation

WARNING
Hot hydraulic oil!
DANGER
removed.
5 - 94
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

SAEflanges.

z
Remove the hydraulic hose using a forklift.
Replace the clam cylinder hose by a new one and carry out
z
Substitute the other clam cylinder hose if required, using the

same procedure.
If required, substitute the clam cylinder hoses at the clam

cylinders as described in the next section on on page 5-96.
Perform the bleeding procedure for the clam cylinders.

Version 2010/1
PC8000-6E
5 - 95
Face Shovel (FSA)
Attachment
Substitute the clam cylinder hoses at the cylinders
Fig. 5-82 Clam cylinder hoses, removal and installation
5 - 96
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Hydraulic hose
(4)
Hydraulic hose
(5)
Bolt
(6)
O-ring
(7)
Distributor block
(8)
Clam cylinder
Special tools:
n/a
Oil drain pan

Clam cylinder hose (depending on length): 9 ...14 kg
Dogman/rigger
2.2.6 on page 2-22.
6.6 on page 6-14.

the machine.

z

Fig. 5-83
Version 2010/1
PC8000-6E
5 - 97
Face Shovel (FSA)
Attachment
Fig. 5-84 Clam cylinder hoses, removal and installation

WARNING
Hot hydraulic oil!
5 - 98
PC8000-6E
Version 2010/1
Attachment
Face Shovel (FSA)
DANGER
removed.

SAEflanges from the distributor block (Fig. 5-84, Pos. 7) and
from the clam cylinder (Fig. 5-84, Pos. 8).

z
Replace the hydraulic hoses (Fig. 5-84, Pos. 1 to 4).
Replace the clam cylinder hoses by a new one and carry out
NOTE: Always replace the O-rings (Fig. 5-84, Pos. 6) at the

SAEflange connections.
z
Perform the bleeding procedure for the clam cylinder(s).

Version 2010/1
PC8000-6E
5 - 99
Metering valves (grease injectors) at the attachment
5.2
Attachment
METERING VALVES (GREASE INJECTORS) AT THE

ATTACHMENT
Fig. 5-85 Position of the grease injectors at the FSA attachment
5 - 100
PC8000-6E
Version 2010/1
Attachment

(1)
Indicator stem
(2)
Output adjusting screw
(3)
Boom
(4)
Stick
(5)
Bucket
(6)
Metering valve group on the boom
(7)
Metering valves on the bucket
(8)
Metering valve group on the stick
5.2.1
CHECK THE OPERATION OF THE METERING VALVES (GREASE

INJECTORS)
Check the operation of all metering valves (Fig. 5-85, Pos. 6...8)
on the attachment visually, by watching the cycle indicator stem
(Fig. 5-85, Pos. 1) while operating the central lubrication system
manually. The stem must move in and out one time in a complete
lubrication cycle.
NOTE: Remember the timing setting which may cause a delay of
up to 11 minutes, before a manual lubrication loop may
start after its release. If in doubt, refer to the relating timing diagram in your flowchart.
If any indicator stem does not move during a lubrication cycle, the
grease supply to the lubrication point of the respective valve is
interrupted or clogged.
NOTE: There are two types of metering valves installed:
type "SL1 and type SL11.
Version 2010/1
PC8000-6E
5 - 101
5.2.2
Attachment
REMOVAL OF THE METERING VALVES (GREASE INJECTORS)
Special tools:
n/a

WARNING
z

attachment.
The work requires the use of men safety cages on elevator working platforms.

the machine and mobile elevator working platform.
attachment in the "defined position" (Fig. 5-86).

z

Fig. 5-86
NOTE: It is described how to remove metering valves at the

boom exemplarily, all other metering valves at the attachment are removed analogously.
z
Disconnect all grease lines (Fig. 5-87, Pos. 2) from the metering valve assembly (Fig. 5-87, Pos. 5).
Disconnect the grease feeding line at the union (Fig. 5-87,

Pos. 3).
Remove the bolts (Fig. 5-87, Pos. 4) and remove the metering valve assembly (Fig. 5-87, Pos. 5) from the boom
(Fig. 5-87, Pos. 1).
Fig. 5-87
5 - 102
PC8000-6E
Version 2010/1
Attachment
Remove the adapter bolt (Fig. 5-88, Pos. 2) and remove the
valve housing (Fig. 5-88, Pos. 1) from the metering valve
assembly (Fig. 5-88, Pos. 4).
Fig. 5-88
5.2.3
REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS)
Special tools:
n/a

WARNING
z

attachment.
The work requires the use of men safety cages on elevator working platforms.
Use new seals (Fig. 5-88, Pos. 3) at the valve housing

(Fig. 5-88, Pos. 1) and at the adapter bolt (Fig. 5-88, Pos. 2).
Check the metering valves at the attachment for proper operation, refer to section 5.2.1 on page 5-101.
NOTE: Remember the timing setting which may cause a delay of

up to 11 minutes, before a manual lubrication loop may
start after its release. If in doubt, refer to the relating timing diagram in your flowchart.
Version 2010/1
PC8000-6E
5 - 103
Cylinder bypass test
5.3
Attachment
CYLINDER BYPASS TEST
Special tools:
n/a
Infrared thermometer
Oil drain pan
Hydraulic hose with 2" 6000 PSI SAEflange
The SAEflange size depends on the cylinder flange size, the hose
should be long enough to lead from the respective cylinder to an oil
pan.
6.6 on page 6-14.
The cylinder bypass test can be performed to check if a hydraulic
cylinder has an internal leakage.
NOTE: A cylinder with an internal leakage also has a higher temperature (at working temperature of the machine) than a
hydraulic cylinder which has no internal leakage.
WARNING
NOTE: First check the hydraulic cylinder temperature using an

infrared thermometer if an internal leakage is assumed. If
the temperature is not higher than the temperature of the
other cylinders, another reason e.g. leakage of a valve
may be the reason for loosing pressure.
If the temperature is higher than the temperature of the
other cylinders, perform the following steps:
z


WARNING
Hot hydraulic oil!

5 - 104
PC8000-6E
Version 2010/1
Attachment
DANGER
Danger of hydraulic pressure.
May result in blindness, serious injury, permanent disfigurement, or scaring.
pressure is relieved before any hydraulic lines will be
removed.
Disconnect the hydraulic hose from the piston rod side of the
respective cylinder (Fig. 5-89, Pos. 2).

Cap the hydraulic hose with a blind plug to avoid contamination.
z
Connect a hydraulic hose (Fig. 5-89, Pos. 1) to the piston rod

side of the cylinder.
Put the open end of the hose into an oil pan.
Fig. 5-89

WARNING
Make sure that nobody is at close range of the hydraulic
hoses open end when extending the cylinder.
Fully extend the hydraulic cylinder at Qmin.
NOTE: The oil inside the cylinder will flow out of the hydraulic
hose (Fig. 5-89, Pos. 1) connected to the piston rod side
of the cylinder. Catch it in the oil pan.
z
When the piston of the cylinder reaches its mechanical stop,

continue to extend the cylinder.
If the cylinder has an internal leakage, some oil will continuously

flow out of the hydraulic hose (Fig. 5-89, Pos. 1) connected to the
piston rod side of the cylinder.
If the cylinder has no internal leakage, oil will stop flowing out of
the hydraulic hose (Fig. 5-89, Pos. 1).
Version 2010/1
PC8000-6E
5 - 105
Attachment
5 - 106
PC8000-6E
Version 2010/1
Service information
6 SERVICE INFORMATION
Version 2010/1
PC8000-6E
6 -1
Fluids and lubricants
6.1
Service information
FLUIDS AND LUBRICANTS
Due to extremely different environmental and working conditions

for the excavator as well as special customized approvals for
lubricants it is not possible to get a general conclusion about the
used fluids and lubricants.
Therefore, no lubrication or other fluids are listed at this point in
this R&R-Manual.
NOTE: For proper fluids and lubricants refer to the Service Manual of your machine.
6 -2
PC8000-6E
Version 2010/1
Service information
6.2
Filling capacities
FILLING CAPACITIES
NOTE: Capacities listed below are approximate values.

For proper checking use level plugs, dipsticks, and
inspection openings, provided for this purpose and refer
to the service manual of the excavator.
Units or system
Liters (approximate)
8350
Complete hydraulic system
11500
Pump distributor gear (PTO), each
*1
1.5*1
Main hydraulic pumps, drive shaft housing

Slew gear (L&S), each
42
Motor adapter housing
0.6
Slew gear (Siebenhaar), each
60
*1
Brake housing
0.2
390*1
Travel gearbox
0.5*1
Travel brake housing
0.2*1
250*1
Final drive housing

Carrier rollers
*2
Track rollers
*2
Guide wheel
3.2
NOTE: *1) Fill up to level gauge marking, do not overfill!

*2) Fill up to the specified level, refer to section 4.2.12 on
page 4-63.
Version 2010/1
PC8000-6E
6 -3
Work instructions
Service information
6.3
WORK INSTRUCTIONS
6.3.1
REMOVE / INSTALL THE CRAWLER CARRIER
Special tools:

NOTE: Fig. 6-1 shows the following:

(Fig. 6-1, Pos. 1) Hydraulic wrench PN 793 374 73.
(Fig. 6-1, Pos. 2) Special wrench socket PN 793 376 73.
(Fig. 6-1, Pos. 3) Electro-hydraulic pump set
PN 795 922 73 (picture as example).
For information about the Electro-hydraulic pump set, refer to
chapter 9 "Suppliers documentation", "AVANTI HYTORQUE".
Fig. 6-1
6 -4
PC8000-6E
Hydraulic torque wrench
Version 2010/1
Service information
Weight tables
6.4
WEIGHT TABLES
6.4.1
SUPERSTRUCTURE
Part or assembly
Weight
Service crane MKG
2050 kg
Roof plate "cooling air intake"
175 kg
Roof plate "motor"
85 kg
Roof plate "PTO"
165 kg
Roof plate "main pumps"
175 kg
Front roof plate
162 kg
Front roof frame
310 kg
Front wall (front roof)
136.5 kg
Battery
62 kg
Electric motor
5600 kg
Capacitor assembly
50 kg
Coupling assembly
38 kg
Cover ring
94 kg
Main pump assembly with flanged gear pump
524 kg
PTO oil pump (auxiliary pump)
34 kg
Oil circulation pump (auxiliary pump)
34 kg
PTO (pump distributor gearbox)
2450 kg
Control- and filter plate assembly
237 kg
Hydraulic oil cooler fan drive pump
74 kg
Additional hydraulic oil cooler fan assembly
104 kg
Additional hydraulic oil cooler fan
17 kg
Additional hydraulic oil cooler fan adapter
3 kg
Additional hydraulic oil cooler fan cross-head
44 kg
Additional hydraulic oil cooler fan motor
10 kg
Additional hydraulic oil cooler
230 kg
Additional hydraulic oil cooler frame
1300 kg
Hydraulic oil cooler fan assembly
262 kg
Hydraulic oil cooler fan
78 kg
Hydraulic oil cooler fan mounting assembly
262 kg
Hydraulic oil cooler fan motor
49 kg
Hydraulic oil cooler fan support assembly
61 kg
Version 2010/1
PC8000-6E
Remark
each
each
each element
6 -5
Weight tables
Service information
Part or assembly
Weight
Remark
Hydraulic oil cooler fan bar
74 kg
Hydraulic oil cooler
230 kg
Hydraulic oil cooler frame incl. Hydraulic oil coolers
7320 kg
Pilot oil pump
34 kg
Main gate valve
54 kg
Hydraulic oil reservoir incl. Back pressure valve
7170 kg
Main control valve block incl. ACVs & SRVs
683 kg
High pressure filter
50 kg
Single anti cavitation valve on manifold
32 kg
Double anti cavitation valve on manifold
50 kg
Throttle check valve on manifold (long version)
31 kg
Throttle check valve on manifold (short version)
28 kg
Manifold incl. ACVs & SRVs
1925 kg
Manifold without ACVs & SRVs
725 kg
Slew gear
1700 kg
Siebenhaar
Slew gear
1880 kg
L&S
Swing motor
120 kg
Swing motor with attached slew service brake valve
330 kg
Bearing ring of the slew parking brake assembly
28.5 kg
L&S
Slew parking brake
115 kg
Siebenhaar
Slew brake valve
110 kg
Swing circle
16,300 kg
Pinion cover
1.2 kg
Lubrication pinion assembly
15 kg
Double lubrication pump station
412 kg
Tripple lubrication pump station
618 kg
Lubrication pump
28 kg
Operator's cab
3785 kg
Viscous mount
4 kg
Absorber plate incl. 2 viscous mount
12 kg
Absorber plate incl. 3 viscous mounts
18 kg
Front window
112 kg
Operator's seat
62 kg
5410 kg
6 -6
PC8000-6E
each element
FSA
Version 2010/1
Service information
Weight tables
Part or assembly
Weight
Emergency ladder
68 kg
Platform
135 kg
Support frame
987 kg
Access ladder
162 kg
Access ladder cylinder
23 kg
Counterweight
54,000 kg
Superstructure complete with swing circle
298,000 kg
Superstructure without counterweight and attachment
202,000 kg
7000 kg
Platform assembly at the high voltage switch cabinet
235 kg
Slip ring unit
255 kg
Version 2010/1
PC8000-6E
Remark
Special
6 -7
Weight tables
Service information
6.4.1.1 UNDERCARRIAGE
Part or assembly
Weight
Remark
Track group 1500 mm
50,000 kg
Pin between track shoes (track group 1500 mm)
28 kg
Track group 1900 mm
56,000 kg
Pin between track shoes (track group 1900 mm)
30 kg
Sprocket assembly
6164 kg
6357 kg
Hollow shaft
790 kg
Drive shaft
1140 kg
Guide wheel assembly
4938 kg
Low pressure accumulator
12 kg
High pressure accumulator
23 kg
Track tensioning valve block
46 kg
Hydraulic hoses of the track tensioning system
2...15 kg
80 kg
Track tensioning cylinder
570 kg
Travel motor
161 kg
Travel parking brake
44 kg
Travel gearbox
7350 kg
Carrier roller assembly
294 kg
Track roller assembly
925 kg
Car body without crawler carrier
55,000 kg
Mounting pins
Crawler carrier assembly without track group
46,000 kg
Mounting pins
Car body without crawler carrier
59,000 kg
Bolted type
Crawler carrier assembly without track group
55,000 kg
Bolted type
Rotary joint
261 kg
Cable drum assembly (empty)
10,000 kg
6 -8
PC8000-6E
Standard
Oversize
depending on
type
Version 2010/1
Service information
Weight tables
6.4.1.2 FACE SHOVEL ATTACHMENT (FSA)

Part or assembly
Weight
Remark
Boom with attached stick and boom cylinders
71,020 kg
Boom
48,600 kg
Pin boom/superstructure
339 kg
Pin boom cylinder/boom
255 kg
Pin boom cylinder/superstructure
243 kg
Boom cylinder
7500 kg
Stick
25,170 kg
Pin stick/boom
373 kg
Stick cylinder
4007 kg
Pin stick cylinder/stick
98 kg
Pin stick cylinder/boom
225 kg
Bucket
63,316 kg
Pin bucket cylinder/bucket
238 kg
Pin bucket/stick
365 kg
Bucket cylinder
5358 kg
Pin bucket cylinder/boom
209 kg
Clam cylinder
1475 kg
Upper pin at clam cylinder
72 kg
Lower pin at clam cylinder
95 kg
Point (tooth) (ESCO)
362 kg
Shroud (ESCO)
245 kg
Tooth adapter (ESCO)
91 kg
Boom arc hose
25...30.5 kg
depending on
type
Boom cylinder hose
24 kg
each
Stick arc hose
30...31 kg
Stick cylinder hose
18.5 kg
each
Bucket cylinder hose
31...34 kg
depending on
length
Clam cylinder hose at stick
30 kg
each
Clam cylinder hose at clam cylinder
9 ...14 kg
depending on
length
Version 2010/1
PC8000-6E
6 -9
Torque charts according to ISO
Service information
6.5
TORQUE CHARTS ACCORDING TO ISO
6.5.1
METRIC STANDARD THREAD
Bolt
diameter
Wrench size
[mm]
Tightening torque
[Nm]
Bolt quality grades
Metric regular
8.8
10.9
12.9
M 8
13
21
31
36
M 10
17
43
63
73
M 12
19
10
74
108
127
M 14
22
12
118
173
202
M 16
24
14
179
265
310
M 18
27
14
255
360
425
M 20
30
17
360
510
600
M 22
32
17
485
690
810
M 24
36
19
620
880
1030
M 27
41
19
920
1310
1530
M 30
46
22
1250
1770
2080
M 33
50
24
1690
2400
2800
M 36
55
27
2170
3100
3600
M 39
60
2800
4000
4700
M 42
65
3500
4950
5800
M 45
70
4350
6200
7200
M 48
75
5200
7500
8700
M 52
80
6700
9600
11200
M 56
85
8400
12000
14000
M 60
90
10400
14800
17400
M 64
95
12600
17900
20900
M 68
100
15200
21600
25500
32
35
41
46
NOTE: Threads and bolts must be greased carefully with grease

KP2K. Contact surfaces which should be screwed
together must be free of grease.
6 - 10
PC8000-6E
Version 2010/1
Service information
6.5.2
METRIC FINE THREAD
Bolt
diameter
Wrench size
[mm]
Tightening torque
[Nm]
Bolt quality grades
Metric
fine
8.8
10.9
12.9
M 8 x 1.0
13
23
33
39
M 10 x 1.0
17
48
70
82
M 12 x 1.25
19
10
81
119
139
M 14x1.5
22
12
127
187
219
M 16 x 1.5
24
14
191
280
330
M 18 x 2.0
27
14
270
385
450
M 20 x 2.0
30
17
380
540
630
M 22 x 2.0
32
17
510
720
850
M 24 x 2.0
36
19
680
960
1130
M 27 x 2.0
41
19
990
1410
1650
M 30 x 2.0
46
22
1380
1960
2300
M 33 x 2.0
50
24
1850
2650
3100
M 36 x 3.0
55
27
2300
3250
3850
M 39 x 3.0
60
3000
4200
4950
M 42 x 3.0
65
3750
5300
6200
M 45 x 3.0
70
4600
6600
7700
M 48 x 3.0
75
5700
8100
9500
M 52 x 3.0
80
7300
10400
12100
M 56 x 4.0
85
8900
12600
14800
M 60 x 4.0
90
11000
15600
18300
M 64 x 4.0
95
13300
19000
22200
M 68 x 4.0
100
16100
22900
27000
32
35
41
46
NOTE: Threads and bolts must be greased carefully with grease

KP2K. Contact surfaces which should be screwed
together must be free of grease.
CAUTION
Bolts at the slew rings have different torques, refer to Service
NEWS No. "AH00511" last edition!
Version 2010/1
PC8000-6E
6 - 11
Service information
6.5.3
SAE FLANGE CONNECTIONS
Fig. 6-2
Torques for SAEflange connections
6 - 12
PC8000-6E
Version 2010/1
Service information
Version 2010/1
PC8000-6E
6 - 13
Blind plugs
Service information
6.6
BLIND PLUGS
6.6.1
DUMMY PLATES FOR SAEFLANGES
Fig. 6-3
Forms / types of dummy plates for SAEflanges

Up to 3000 PSI
6 - 14
SAE size
Form / type
according to
Fig. 6-36-3
PN
DN
(hose / pipe)
1/2"
506 521 98
12
3/4"
506 583 98
20
1 1/4"
506 584 98
32
1 1/2"
506 522 98
40
2"
506 523 98
50
2 1/2"
506 585 98
65
3"
512 570 98
80
3/4"
516 826 98
20
1 1/4
517 479 98
32
1 1/2"
506 528 98
40
2"
506 529 98
50
2 1/2"
506 530 98
65
3"
512 571 98
80
PC8000-6E
Version 2010/1
Service information
Blind plugs
Up to 6000 PSI
SAE size
Form / type
according to
Fig. 6-36-3
PN
DN
(hose / pipe)
3/4"
506 580 98
20
1"
506 519 98
25
1 1/4"
506 520 98
32
1 1/2"
506 581 98
40
2"
506 582 98
50
1"
506 524 98
25
1 1/4"
506 525 98
32
1 1/2"
506 526 98
40
2"
506 527 98
50
1 1/4"
516 499 98
32
1 1/2"
509 375 98
40
2"
509 376 98
50
Version 2010/1
PC8000-6E
6 - 15
Blind plugs
6.6.2
Service information
CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH

Heavy class
(up to 6000 PSI)
Light class
(up to 3000 PSI)
Size
Ra
DN
Ra
DN
M 12 x 1.5
M 14 x 1.5
M 16 x 1.5
10
M 18 x 1.5
10
12
10
M 20 x 1.5
12
M 22 x 1.5
14
10
15
12
M 24 x 1.5
16
12
M 26 x 1.5
18
16
M 30 x 1.5
M 30 x 2
20
16
22
20
M 36 x 2
25
20
28
25
M 38 x 1.5
M 42 x 2
30
25
M 45 x 1.5
M 45 x 2
35
32
M 52 x 1.5
M 52 x 2
38
32
42
40
M 65 x 2
Method of using the above table to find an appropriate plugs and

fittings according to Table 6.6.3 on page 17:
EXAMPLE:
To cover up a hose / tube with a diameter of 25 mm, for a pressure up to 3000 PSI perform the following steps:
z
Locate the 25 in the column "DN" in the category "up to 3000

PSI".
Check the digit in the column "Ra" next to DN 25 in the same

row and category.
For this example the proper plug and fitting is BUZ 28-L and
ROV 28-L, refer to Table 6.6.3 on page 17.
NOTE: The column "Size" indicates the thread-size for the

ROV-fittings.
6 - 16
PC8000-6E
Version 2010/1
Service information
6.6.3
Blind plugs
PLUGS AND FITTINGS ACCORDING TO EN ISO 84 34-1

Up to 3000 PSI
BUZ (plugs)
PN
ROV (fittings)
PN
8-L
501 692 98
8-L
518 113 98
10-L
371 852 99
10-PL
513 789 98
12-L
371 854 99
12-PL
513 547 98
15-L
371 855 99
15-PL
507 051 98
18-L
371 856 99
18-PL
513 787 98
22-L
371 857 99
22-PL
513 788 98
28-L
371 858 99
28-PL
509 377 98
35-L
371 859 99
35-PL
516 770 98
42-L
371 860 99
42-PL
513 790 98
Up to 6000 PSI
BUZ (plugs)
PN
ROV (fittings)
PN
8-PS
515 921 98
10-PS
507 023 98
12-PS
507 022 98
16-S
371 866 99
20-S
371 853 99
20-PS
512 005 98
25-S
371 867 99
25-PS
508 033 98
30-S
371 868 99
30-PS
507 021 98
38-S
371 869 99
38-PS
507 020 98
Version 2010/1
PC8000-6E
6 - 17
Conversion table
Service information
6.7
CONVERSION TABLE
6.7.1
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple

conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE:
Method of using the Conversion Table to convert from millimeters
to inches.
Convert 55 mm into inches:
z
Locate the number 50 in the vertical column at the left side,

take this as (A), then draw a horizontal line from (A).
Locate the number 5 in the row across the top, take this as
(B), then draw a perpendicular line down from (B).
Take the point where the two lines cross as (C). This point (C)
gives the value when converting from millimeters to inches.
Therefore, 55 millimeters = 2.165 inches.
Convert 550 mm into inches:

z
The number 550 does not appear in the table, so divide by 10

(move the decimal one place to the left) to convert it to 55
mm.
Carry out the same procedure as above to convert 55 mm to

2.165 inches.
The original value (550 mm) was divided by 10, so multiply

2.165 inches by 10 (move the decimal one place to the right)
to return to the original value. This gives 550 mm = 21.65
inches.
6 - 18
PC8000-6E
Version 2010/1
Service information
6.7.2
Conversion table
MILLIMETER - INCH & KILOGRAM - POUND
Version 2010/1
PC8000-6E
6 - 19
Conversion table
6.7.3
6 - 20
Service information
LITER - U.S. GALLON & LITER - U.K. GALLON
PC8000-6E
Version 2010/1
Service information
6.7.4
Conversion table
NM- FT.LB
0
0.74
1.47
2.21
2.95
3.69
4.42
5.16
5.90
6.63
10
7.37
8.11
8.84
9.58
10.32
11.06
11.79
12.53
13.27
14.00
20
14.74
15.48
16.21
16.95
17.69
18.43
19.16
19.90
20.64
21.37
30
22.11
22.85
23.58
24.32
25.06
25.80
26.53
27.27
28.01
28.74
40
29.48
30.22
30.95
31.69
32.43
33.17
33.90
34.64
35.38
36.11
50
36.85
37.59
38.32
39.06
39.80
40.54
41.27
42.01
42.75
43.48
60
44.22
44.96
45.69
46.43
47.17
47.91
48.64
49.38
50.12
50.85
70
51.59
52.33
53.06
53.08
54.54
55.28
56.01
56.75
57.49
58.22
80
58.96
59.07
60.43
61.17
61.91
62.65
63.38
64.12
64.86
65.59
90
66.33
67.07
67.80
68.54
69.28
70.02
70.75
71.49
72.23
72.96
100
73.70
74.44
75.17
75.91
76.65
77.39
78.12
78.86
79.60
80.33
110
81.07
81.81
82.54
83.28
84.02
84.76
85.49
86.23
86.97
87.70
120
88.44
89.18
89.91
90.65
91.39
92.13
92.86
93.60
94.34
95.07
130
95.81
96.55
97.28
98.02
98.76
99.50
100.23
100.97
101.71
102.44
140
103.18
103.92
104.65
105.39
106.13
106.87
107.60
108.34
109.08
109.81
150
110.55
111.29
112.02
112.76
113.50
114.24
114.97
115.71
116.45
117.18
160
117.92
118.66
119.39
120.13
120.87
121.61
122.34
123.08
123.82
124.55
170
125.29
126.03
126.76
127.50
128.24
128.98
129.71
130.45
131.19
131.92
180
132.66
133.40
134.13
134.87
135.61
136.35
137.08
137.82
138.56
139.29
190
140.03
140.77
141.50
142.24
142.98
143.72
144.45
145.19
145.93
146.66
200
147.40
148.14
148.87
149.61
150.35
151.09
151.82
152.56
153.30
154.03
1 Nm = 0.737 FT.LB
Version 2010/1
PC8000-6E
6 - 21
Conversion table
6.7.5
Service information
BAR - PSI - KPA - MPA

1...200 Bar
205...400 Bar
Bar
PSI
kPa
MPa
Bar
PSI
kPa
MPa
1
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
14.5037
72.52
145.03
217.55
290.07
362.58
435.1
507.62
580.13
652.65
725.17
797.68
870.2
942.71
1015.23
1087.75
1160.26
1232.78
1305.3
1377.81
1450.33
1522.85
1595.36
1667.88
1740.4
1812.91
1885.43
1957.95
2030.46
2102.98
2175.5
2248.01
2320.53
2393.04
2465.56
2538.08
2610.59
2683.11
2755.63
2828.14
2900.66
100
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
9500
10000
10500
11000
11500
12000
12500
13000
13500
14000
14500
15000
15500
16000
16500
17000
17500
18000
18500
19000
19500
20000
0.1
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
8
8.5
9
9.5
10
10.5
11
11.5
12
12.5
13
13.5
14
14.5
15
15.5
16
16.5
17
17.5
18
18.5
19
19.5
20
205
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
2973.18
3045.69
3118.21
3190.73
3263.24
3335.76
3408.28
3480.79
3553.31
3625.83
3698.34
3770.86
3843.37
3915.89
3988.41
4060.92
4133.44
4205.96
4278.47
4350.99
4423.51
4496.02
4568.54
4641.06
4713.57
4786.09
4858.61
4931.12
5003.64
5076.16
5148.67
5221.19
5293.7
5366.22
5438.74
5511.25
5583.77
5656.29
5728.8
5801.32
20500
21000
21500
22000
22500
23000
23500
24000
24500
25000
25500
26000
26500
27000
27500
28000
28500
29000
29500
30000
30500
31000
31500
32000
32500
33000
33500
34000
34500
35000
35500
36000
36500
37000
37500
38000
38500
39000
39500
40000
20.5
21
21.5
22
22.5
23
23.5
24
24.5
25
25.5
26
26.5
27
27.5
28
28.5
29
29.5
30
30.5
31
31.5
32
32.5
33
33.5
34
34.5
35
35.5
36
36.5
37
37.5
38
38.5
39
39.5
40
1 Bar = 14.5037 PSI
6 - 22
PC8000-6E
Version 2010/1
Service information
6.7.6
Conversion table
BASIC VALUES IN OHM ACCORDING TO DIN 4376 / IEC 751
Conversion Table - Ohm to Centigrade of PT100 sensors

C
-0
-1
-2
-3
-4
-5
-6
-7
-8
-9
-50
80.31
79.91
79.51
79.11
78.72
78.32
77.92
77.52
77.13
76.73
-40
84.27
83.88
83.48
83.08
82.69
82.29
81.89
81.50
81.10
80.70
-30
88.22
87.83
87.43
87.04
86.64
86.25
85.85
85.46
85.06
84.67
-20
92.16
91.77
91.37
90.98
90.59
90.19
89.80
89.40
89.01
88.62
-10
96.09
95.69
95.30
94.91
94.52
94.12
93.73
93.34
92.95
92.55
100.00
99.61
99.22
98.83
98.44
98.04
97.65
97.26
96.87
96.48
100.00
100.39
100.78
101.17
101.56
101.95
102.34
102.73
103.12
103.51
10
103.90
104.29
104.68
105.07
105.46
105.85
106.24
106.63
107.02
107.40
20
107.79
108.18
108.57
108.96
109.35
109.73
110.12
110.51
110.90
111.28
30
111.67
112.06
112.45
112.83
113.22
113.61
113.99
114.38
114.77
115.15
40
115.54
115.93
116.31
116.70
117.08
117.47
117.85
118.24
118.62
119.01
50
119.40
119.78
120.16
120.55
120.93
121.32
121.70
122.09
122.47
122.86
60
123.24
123.62
124.01.
124.39
124.77
125.16
125.54
125.92
126.31
126.69
70
127.07
127.45
127.84
128.22
128.60
128.98
129.37
129.75
130.13
130.51
80
130.89
131.27
131.66
132.04
132.42
132.80
133.18
133.56
133.94
134.32
90
134.70
135.08
135.46
135.84
136.22
136.60
136.98
137.36
137.47
138.12
100
138.50
138.88
139.26
139.64
140.02
140.39
140.77
141.15
141.53
141.91
110
142.29
142.66
143.04
143.42
143.80
144.17
144.55
144.93
145.31
145.68
120
146.06
146.44
146.81
147.19
147.57
147.94
148.32
148.70
149.07
149.45
130
149.82
150.20
150.57
150.95
151.33
151.70
152.08
152.45
152.83
153.20
140
153.58
153.95
154.32
154.70
155.07
155.45
155.82
156.19
156.57
156.94
150
157.31
157.69
158.06
158.43
158.81
159.18
159.55
159.93
160.30
160.67
Version 2010/1
PC8000-6E
6 - 23
Conversion table
6.7.7
Service information
TEMPERATURE
The figures in the table below refer to the temperature in either

degree Fahrenheit or degree Celsius.
If it is desired to convert from degree Fahrenheit to degree Celsius, consider the centre column as a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the
column at the left.
If it is desired to convert from degree Celsius to degree Fahrenheit, consider the centre column as a table of Celsius values, and
read the corresponding Fahrenheit temperature on the right.
6 - 24
PC8000-6E
Version 2010/1
Service information
Tools
6.8
TOOLS
6.8.1
STANDARD TOOL CASE
Komatsu provides a standard tool case, PN 232 709 40.
Qty
1
Part name
Part number
Measuring tape 3 m long
470 615 40
Hammer 500 g
232 130 40
Sliding caliper, 200 mm long
232 107 40
Reamer (countersink, stem diameter 10 mm; reamer diameter 20 mm)
232 690 40
Socket wrench - set (WS 10 - 32)
232 691 40
Internal hexagon socket, - set (WS 5 - 17)
232 570 40
Double ended open wrench - set (WS 6 - 32)
232 692 40
Combination wrenches - set, (WS 10 - 32)
232 693 40
Twist drill - set (1 - 13 mm)
232 207 40
Needle files - set
232 199 40
Tool bag
232 694 40
Toolbox (460 x 170 x 310)
232 695 40
Socket wrench - set (WS 3 - 13)
232 696 40
Drift punch (3 - 8 mm)
232 697 40
Socket wrench with ball head - set (1.5 - 10 mm)
232 698 40
Side cutter insulated up to 1000 Volt, 190 mm
232 401 40
Combination pliers insulated up to 1000 Volt, 185 mm
232 400 40
Bent nose pliers, Knipex
232 403 40
Water pump pliers 250 mm long
232 139 40
Cable stripping knife 4 - 16 mm
232 699 40
Screwdriver for slotted screws 11 x 300 mm
232 120 40
Screwdriver for slotted screws 13 x 390 mm
232 121 40
Crosstip screwdriver size 0
232 111 40
232 112 40
232 113 40
Infrared thermometer IR 1
232 665 40
LCD-Digital Multimeter VC 444
232 688 40
VDE Screwdriver, WERA
232 689 40
Hydraulic mini testing kit
232 591 40
Pressure gauge 400 bar
793 363 73
Measuring hose 2.5 m
896 483 40
Pressure gauge fitting G
232 501 40
Set Screwdriver
907 696 40
Side cutting pliers, Knipex
232 700 40
Stripping- and cutting tool Stripax for PVC-isolation up to 6 mm, 20 mm
232 663 40
Crimp pliers, crimp capacity 0.5 - 4 mm
232 661 40
Crimp pliers HTN 21
232 701 40
Testing wire 4mm Type 410 (red)
232 702 40
Testing wire 4mm Type 410 (black)
232 703 40
Version 2010/1
PC8000-6E
6 - 25
Tools
Service information
Qty
Part name
Part number
Testing tip "Hirschmann Prf 2" (red)
232 704 40
Testing tip "Hirschmann Prf 2" (black)
232 705 40
Clip terminal "Hirschmann Ak 2 S" (red)
232 706 40
Clip terminal "Hirschmann Ak 2 S" (black)
232 707 40
Fluke 179 Digital-Multimeter
232 708 40
Rollbox K 412 (740 x 365 x 375)
232 711 40
Manual non-contact revolution counter (digital)
232 551 40
Magnet-stick
232 712 40
Electric set with pliers
793 265 73
Software (Bodem 24)
796 726 73
Bodem connection cable
896 791 40
Crimp-pliers for revolved contacts
793 729 73
Cable set
796 443 73
Prostat Cable VL 3 (X27 -PC)
659 820 40
Prosyd Cable VL 12 (PLC-PC)
926 503 40
TazETM Cable VL 10 (ETM-PC)
891 175 40
Cable VL 9a
891 176 40
Cable VL 9b
891 177 40
PC4000-6 VHMS download-cable (new for 08156 and up)
894 580 40
Converter, cable, and software as set
796 442 73
Converter
796 439 73
USB extension wire
796 440 73
UMG diagnostic software (CD)
796 441 73
6 - 26
PC8000-6E
Version 2010/1
Service information
6.8.2
Tools
USED SPECIAL TOOLS (OVERVIEW)
Component
Part number
Part name
Qty
PN 232 386 40
Universal grounding short-circuting

device
PN 232 390 40
Measuring rod
3...6 kV
PN 232 389 40
Measuring rod
5...10 kV
PN 232 267 40
55 mm hexagon
impact socket
wrench
PN 232 615 40
Hydraulic torque
wrench (7800 Nm)
PN 232 613 40
Electro-hydraulic
pump set
PN 793 374 73 +
PN 793 376 73
Hydraulic torque
wrench + Wrench
socket with supporting bar
PN 795 922 73
Electro-hydraulic
pump set
PN 928 476 40
Measuring device
PN 274 703 40
Measuring jaw
PN 909 004 40
Measuring bolt
PN 898 287 40
Measuring bolt
(cold weather)
PN 375 795 40
Test block
Safety unit for

changing track
rollers
Removal and installation of the track

rollers
PN ???
(P&S-news under
development)
Tool for changing

track rollers
Removal and installation of the track

rollers
PN 761 520 73
Testing- and refilling

device
Refilling pressure accumulators
PN 923 828 40
Installation tool
Removal and installation of the

bucket cylinders FSA
PN 923 824 40
Installation tool
Removal and installation of the stick

cylinders FSA
PN 934 606 40
Installation tool
Removal and installation of the boom

cylinders FSA
High voltage switch

cabinet
Car body/crawler
carrier
Swing circle
mounting
PN 921 142 40
Nature of work, remarks
Grounding procedure
Removal and installation of the high

voltage switch cabinet
Removal and installation of the car

body/crawler carrier
Installation of the crawler carriers
Installation of the swing circle.

Assembly of superstructure onto
undercarriage
Track rollers
Pressure accumulators of the track

tensioning system
Attachment
Version 2010/1
PC8000-6E
6 - 27
Tools
Service information
Component
Part number
Part name
Qty
PN 793 502 73
POSILOK pin
removal tool
PN 793 503 73
POSILOK lifting tool
Sprocket
locally made
(refer to PARTS &
SERVICE NEWS
No. "AH05511")
Assembly tool for

dual-cone seals
Installation of new dual-cone seals
Hydraulic system
(general)
PN 232 591 40
Hydraulic testing kit
Measurements of hydraulic pressures
PN 793 788 73
Rotational speed
infrared probe
DS03s
Measurements of rotation fan speed
PN 232 269 40
75 mm hexagon
impact socket
wrench
PN 232 615 40
Hydraulic torque
wrench (7800 Nm)
PN 232 613 40
Electro-hydraulic
pump set
PN 232 267 40
55 mm hexagon
impact socket
wrench
PN 232 615 40
Hydraulic torque
wrench (7800 Nm)
PN 232 613 40
Electro-hydraulic
pump set
PN 232 267 40
55 mm hexagon
impact socket
wrench
PN 232 615 40
Hydraulic torque
wrench (7800 Nm)
PN 232 613 40
Electro-hydraulic
pump set
PN 232 265 40
46 mm
hexagon impact
socket wrench
PN 232 615 40
Hydraulic torque
wrench (7800 Nm)
PN 232 613 40
Electro-hydraulic
pump set
GET
Hydraulic cooler fan

drive pump
Hydraulic cooler fan
assembly
Counterweight
Superstructure
Cab base
Hydraulic oil
reservoir
6 - 28
PC8000-6E
Removal and installation of the GET
Removal and installation of the counterweight

superstructure
Removal and installation of the cab

base

hydraulic oil reservoir
Version 2010/1
Service information
Component
Tools
Part number
Part name
Qty
PN 232 713 40
Laser alignment set
PN 232 714 40
Bracket set
Alignment procedure for the electric

motors
Electric motor
Version 2010/1
PC8000-6E
6 - 29
Tools
Service information
6 - 30
PC8000-6E
Version 2010/1
Tools catalogue
7 TOOLS CATALOGUE
Version 2010/1
PC8000-6E
7 -1
Tools catalogue
7 -2
PC8000-6E
Version 2010/1
Tools and Accessories

Werkzeuge und Zubehr
Release: March 09th, 2010

Ausgabe: 09. Mrz 2010
Content / Inhalt
Page No.
Seite
Section 1
Assembly Tools for Screws and Nuts
Gruppe 1
Schraubwerkzeuge
Section 2
Pliers
19
Gruppe 2
Zangen
19
Section 3
Metal Working Tools
22
Gruppe 3
Werkzeuge fr die Metallbearbeitung
22
Section 4
Measuring Tools
25
Gruppe 4
Messwerkzeuge
25
Section 5
Data Transfer and IT Tools
34
Gruppe 5
Datenbertragung und IT-Zubehr
34
Section 6
Others
37
Gruppe 6
Sonstiges
37
Section 7
Paint and Accessories
43
Gruppe 7
Lackiermaterialien
43
Section 8
Auxiliaries, Cleaner, Adhesive & Sealant
45
Gruppe 8
Hilfsstoffe, Reiniger, Kleber
45
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Combination wrenches, single

Gabelringschlssel, einzeln
232 001 40
232 002 40
232 002 40
232 003 40
232 004 40
232 005 40
232 006 40
232 007 40
232 008 40
232 009 40
232 010 40
232 011 40
232 012 40
323 013 40
232 014 40
232 015 40
232 016 40
232 017 40
232 018 40
232 019 40
232 557 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
6
7
7
8
9
10
11
12
13
14
15
17
19
22
24
27
30
32
36
41
46
232 693 40
Combination wrenches, set SW 10 - 32

Gabelringschlssel, Satz SW 10 - 32
Combination wrenches, single
Gabelringschlssel, einzeln
232 432 40
232 433 40
232 434 40
232 435 40
232 436 40
232 437 40
232 438 40
232 439 40
232 440 40
232 441 40
232 442 40
232 443 40
232 444 40
232 445 40
232 446 40
232 447 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
1/4
5/16
3/8
7/16
1/2
9/16
5/8
11/16
3/4
13/16
7/8
15/16
1
11/16
11/8
11/4
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
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Continued / Fortsetzung
3
4
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Special ring wrench open

Spezial-Ringschlssel offen
232 305 40
232 306 40
232 307 40
232 308 40
SW
SW
SW
SW
41
46
50
60
Double ended open wrenches, single

Doppelgabelschlssel, einzeln
232 020 40
232 021 40
232 022 40
232 023 40
232 024 40
232 025 40
232 026 40
232 027 40
232 028 40
232 029 40
232 030 40
232 031 40
232 032 40
232 033 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
6x7
8x9
10 x 11
12 x 13
14 x 15
16 x 17
18 x 19
20 x 22
21 x 23
24 x 27
25 x 28
30 x 32
36 x 41
50 x 55
Single ended open wrenches, single

Einfachgabelschlssel, einzeln
232 361 40
232 211 40
232 212 40
232 213 40
232 214 40
232 215 40
232 362 40
232 216 40
232 363 40
232 217 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
41
46
50
55
60
65
70
75
80
85
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
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4
5
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Hook wrenches, single

Hakenschlssel, einzeln
232 275 40
232 276 40
232 277 40
232 278 40
232 279 40
232 280 40
120 130 mm
155 165 mm
180 195 mm
205 220 mm
260 270 mm
280 300 mm
Push-pull ratchet
Knarre
232 337 40
232 047 40
232 562 40
232 563 40
1/4
1/2
3/4
1
Reversible ratchet
Umschaltknarre 1 x 660 mm (26)
232 380 40
232 218 40
3/4 x 620 mm
1 x 660 mm (26)
Torque wrench
Drehmomentschlssel
232 262 40
232 285 40
232 477 40
232 478 40
232 379 40
232 304 40
232 220 40
232 221 40
7 32 mkp
30 75 mkp
50 130 mkp
80 200 mkp
3/4 x 200 mm
3/4 x 430 mm
1 x 250 mm (8)
1 x 405 mm (16)
70 320 Nm
300 750 Nm
500 1300 Nm
800 2000 Nm
991-1010
Tools
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5
6
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 285 40
March 09th, 2010

09. Mrz 2010
Torque wrench with scale

DSG-5S, measuring range: 300 - 750Nm
Drehmomentschlssel mit Skala
DSG-5S, Messbereich: 300 - 750 Nm
232 477 40

DSG-6S, measuring range: 500 - 1300 Nm
232 478 40

DSG-7S measuring range: 800 - 2000 Nm
232 681 40
Elbow socket, 28/5 - 3/4 x 70

Einsteck-Winkelstck, 28/5 - 3/4 x 70
232 682 40
Elbow socket, 28/6 - 7; 1 x 70

Einsteck-Winkelstck, 28/6 - 7; 1 x 70
232 574 40
Reducer socket, 1 1/2 - 1

Reduzierstck, 1 1/2 - 1
232 577 40
Extension socket, 1 1/2 - 1

Vergrerungsstck, 1 1/2 - 1
Sliding & tommy bar
Griff mit Gleitstck
232 339 40
232 050 40
232 303 40
232 219 40
1/4
1/2 x 290 mm (12)
3/4 x 500 mm (20)
1 x 640 mm (25)
991-1010
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7
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Universal joint
Kardangelenk
232 051 40
1/2
Socket wrench 1/4", single
Stecknuss, 1/4, einzeln
232 326 40
232 327 40
232 328 40
232 329 40
232 330 40
232 331 40
232 332 40
232 333 40
232 334 40
232 335 40
232 336 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
4
4,5
5
5,5
6
7
8
9
10
11
13
Socket wrench, 1/2, single

Steckschlsseleinsatz, 1/2, einzeln
232 034 40
232 035 40
232 036 40
232 037 40
232 038 40
232 039 40
232 040 40
232 041 40
232 042 40
232 340 40
232 043 40
232 044 40
232 045 40
232 046 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
9
10
11
12
13
14
15
17
19
21
24
27
30
32
991-1010
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7
8
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010

232 448 40
232 449 40
232 450 40
232 451 40
232 452 40
232 453 40
232 454 40
232 455 40
232 456 40
232 457 40
232 458 40
232 459 40
232 460 40
232 461 40
232 462 40
232 463 40
232 464 40
232 465 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
3/8
13/32
7/16
1/2
9/16
19/32
5/8
11/16
3/4
25/32
13/16
7/8
15/16
1
1 1/16
1 1/8
1 3/16
1 1/4

232 369 40
232 370 40
232 371 40
232 372 40
232 373 40
232 374 40
232 375 40
232 376 40
232 377 40
232 378 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
22
24
27
30
32
36
38
41
46
50
991-1010
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9
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Socket wrench, 1, single

Steckschlsseleinsatz, 1, einzeln
232 223 40
232 224 40
232 225 40
232 226 40
232 227 40
232 228 40
232 229 40
232 230 40
232 231 40
232 232 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
36
41
46
50
55
60
65
70
75
80
232 569 40
Extra deep socket wrench for grease nipple of grease cylinder

1/2, long, SW 27
Steckschlsseleinsatz fr Schmiernippel am
Schmierzylinder 1/2, lang, SW 27
Internal hexagon socket, 1/2 , single

Innensechskant Steckschlsseleinsatz, 1/2, einzeln
232 052 40
232 053 40
232 054 40
232 055 40
232 056 40
232 057 40
232 058 40
232 059 40
232 060 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
5
6
7
8
9
10
12
14
17
Internal hexagon socket, 1/2", single

Innensechskant Steckschlsseleinsatz, 1/2, einzeln
232 423 40
232 424 40
232 425 40
232 426 40
232 427 40
232 428 40
232 429 40
232 430 40
232 431 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
3/16
7/32
1/4
9/32
5/16
3/8
1/2
9/16
5/8
991-1010
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10
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Internal hexagon socket, 1/2, single

Innensechskant-Steckschlsseleinsatz, 1/2, einzeln
232 341 40
232 342 40
232 343 40
232 344 40
232 345 40
232 346 40
SW
SW
SW
SW
SW
SW
5 x 180 mm
6 x 90 mm
8 x 120 mm
10 x 140 mm
12 x 140 mm
14 x 140 mm
Internal hexagon socket, 3/4

Innensechskant Steckschlsseleinsatz, 3/4
232 347 40
232 348 40
232 349 40
232 350 40
SW
SW
SW
SW
14
17
19
22
Internal hexagon socket,1

Innensechskant Steckschlsseleinsatz, 1
232 351 40
232 352 40
232 353 40
SW 19
SW 22
SW 24
Internal Torx socket
Innen-Torx Steckschlsseleinsatz
232 597 40
232 598 40
232 599 40
232 600 40
232 601 40
232 602 40
232 603 40
SW
SW
SW
SW
SW
SW
SW
45
4,5 5
4,5 5 6
67
78
8 10
10
991-1010
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11
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
External Torx socket

Auen-Torx Steckschlsseleinsatz
232 604 40
232 605 40
232 606 40
232 607 40
232 608 40
232 609 40
232 610 40
SW
SW
SW
SW
SW
SW
SW
4
5
6
67
8
10
12
Reducing socket
Reduzierstck
232 573 40
232 096 40
232 574 40
1 3/4
3/4 1/2
1 1/2 1
Expansion socket
Vergrerungsstck
232 575 40
232 576 40
232 577 40
1/2 3/4
3/4 1
1 1 1/2
232 146 40
Strap wrench (fuel-water filter)

Bandschlssel (Kraftstoff-Wasserfilter)
232 511 40
Torque multiplier max. 2700 Nm (2000 lbf-ft)

Drive 3/4
Reduction 1 : 5
Drehmomentvervielfltiger max. 2700 Nm
Antrieb 3/4
Untersetzung 1 : 5
232 611 40
High-power pneumatic torque drive wrench, 900 - 4.200 Nm

Square tool socket 1''
Including reaction arm (long type),
torque adjustment and service unit,
pneumatic hose 6m, torque certificate,
and silencer
Hochleistungs-Pneumatik-Getriebeschrauber, 900 - 4.200 Nm
Antriebsvierkant 1''
Inklusive Reaktionsarm (lange Ausfhrung),
Drehmomenteinstell- und Wartungseinheit,
Druckluftschlauch 6m, Drehmomentzertifikat
und Schalldmpfer
991-1010
Tools
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Section / Gruppe 1
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11
12
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 612 40
March 09th, 2010

09. Mrz 2010
High-power pneumatic torque drive wrench, 1.500 - 7.100 Nm

Square tool socket 1 ''
Including reaction arm (long type),
torque adjustment and service unit,
pneumatic hose 6m, torque certificate,
and silencer
Hochleistungs-Pneumatik-Getriebeschrauber, 1.500 - 7.100 Nm
Antriebsvierkant 1 ''
Inklusive Reaktionsarm (lange Ausfhrung),
Drehmomenteinstell- und Wartungseinheit,
Druckluftschlauch 6m, Drehmomentzertifikat
und Schalldmpfer
232 614 40
High-power hydraulic torque wrench

Torque range 390 - 3,934 Nm
incl. reaction arm
Hochleistungs-Hydraulik-Drehmomentschrauber
Drehmomentbereich 390 - 3.934 Nm
Antriebsvierkant 1'' mit Reaktionsarm
232 615 40
High-power hydraulic torque wrench

Square tool socket 1 '' incl. reaction arm
Hochleistungs-Hydraulik-Drehmomentschrauber
mit Reaktionsarm
793 374 73
High-power hydraulic torque wrench for side member

assembly*
Torque range 1,049 - 10,671 Nm
Square tool socket 1 '' incl. reaction arm
* For mounting of crawler carriers the supplemental
extended reaction arm 793 376 73 is required
Hochleistungs-Hydraulik-Drehmomentschrauber fr die
Seitentrgermontage*
Drehmomentbereich 1.049 - 10.671 Nm
Antriebsvierkant 1 '' mit Reaktionsarm
* Fr die Seitentrgermontage wird zustzlich der verlngerte
Reaktionsarm 793 376 73 bentigt
991-1010
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13
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Electro-hydraulic pump aggregate, 220 Volt/800 bar

Elektro-hydraulisches Pumpenaggregat, 220 Volt/800 bar
232 613 40
5 bar
232 269 40
232 366 40
232 367 40
232 097 40
SW 75
SW 80
SW 85
3 15 mkp
232 759 40
High-power hydraulic torque wrench & aggregate, set

30 150 Nm
The set contains:

High-power hydraulic torque wrench (232 614 40)
incl. reaction arm
High pressure hydraulic aggregate with hoses (793 375 73)
Supply voltage 230 V
3-stages-delivery
Setting range up to 700 bar
incl. digital manometer, oil, and 5 m remote control
incl. safety couplings
High pressure twin-hose NS 6 x 5 m (795 923 73)
Welded
Burst pressure 2,800 bar
Transportation box (232 719 40)
Hochleistungs-Hydraulik-Drehmomentschrauber & Aggregat, Satz
Der Satz beinhaltet:
Hochleistungs-Hydraulik-Drehmomentschrauber (232 614 40)
Antriebsvierkant 1''
mit Reaktionsarm
Hochdruck-Hydraulikaggregat mit Schluchen (793 375 73)
Versorgungsspannung 230 V
3-Stufen-Frderleistung
Einstellbereich bis 700 bar
inkl. Digital-Manometer, l und 5 m Fernbedienung
inkl. Sicherheitskupplungen
Hochdruck-Zwillingsschlauch NW 6 x 5 m (795 923 73)
Verschweit
Berstdruck 2.800 bar
Transportkiste (232 719 40)
991-1010
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13
14
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 758 40
March 09th, 2010

09. Mrz 2010

The set contains:
incl. reaction arm
3-stages-delivery
Welded
mit Reaktionsarm
Verschweit
232 757 40

for mounting crawler carriers
Torque range 1,049 - 10,671 Nm
The set contains:
incl. reaction arm
3-stages-delivery
Welded
Torque wrench accessory
Extended reaction arm with tool drive unit M48
suitable for torque wrench 793 374 73,
for bolts with resilient sleeve
991-1010
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15
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 757 40
March 09th, 2010

09. Mrz 2010

fr die Seitentrgermontage
Drehmomentbereich 1.049 - 10.671 Nm
mit Reaktionsarm
Verschweit
Drehmomentschrauber-Zubehr
Verlngerter Reaktionsarm mit Antriebseinheit M48
passend fr den Drehmomentschrauber 793 374 73,
fr Schrauben mit Dehnhlse
232 718 40
Electro-hydraulic pump set, assy

Hydraulikaggregat, Satz
793 375 73
Electro-hydraulic pump
Hydraulikaggregat
232 719 40
Transportation box
Transportbox
793 376 73
Extended reaction arm for crawler carrier mounting

(in combination with high-power hydraulic torque wrench
793 374 73)
Verlngerter Reaktionsarm fr die Seitentrgermontage
(in Verbindung mit Hochleistungs-Hydraulik-Drehmomentschrauber
793 374 73)
795 923 73
High pressure hose DN6 x 10000

Hochdruckschlauch DN6 x 10000
991-1010
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15
16
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Additional equipment / Zusatzteile

232 749 40
Reaction arm
Reaktionsarm
232 750 40
Fixing screw for the reaction arm

Fixierschraube fr den Reaktionsarm
232 687 40
Electro-hydraulic aggregate, 230 Volt, for servicing

undercarriage and slew ring.
Max. pressure output 700 bar (10000 psi), double acting, with
wired remote control for the motor
Elektro-hydraulisches Aggregat, 230 Volt, fr die Fahrwerks- und
Zahnkranzwartung.
Max. Betriebsdruck 700 bar, doppelt wirkend, mit
Kabelfernsteuerung fr den Motor
Not applicable for high-power impact wrenches
Nicht fr Hochleistungs-Kraftschrauber geeignet
Impact socket wrench, 1, single
Kraftschrauberstecknuss 1, einzeln
232 264 40
232 515 40
232 516 40
232 265 40
232 266 40
232 267 40
232 494 40
232 268 40
SW
SW
SW
SW
SW
SW
SW
SW
36
38
41
46
50
55
60
65
Impact socket wrench, 1 "

Kraftschrauberstecknuss 1 1/2
232 517 40
232 518 40
232 519 40
232 520 40
232 521 40
SW
SW
SW
SW
SW
46
50
55
60
65
Impact internal hexagon socket, 1", single

Kraftschrauberstecknuss Innensechskant, 1 ", einzeln
232 765 40
232 766 40
232 767 40
232 768 40
232 769 40
232 770 40
SW
SW
SW
SW
SW
SW
19
22
24
27
32
36
991-1010
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16
17
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Screwdriver for slotted screws

Schraubendreher fr Schlitzschrauben
232 120 40
232 121 40
11 x 300 mm
13 x 390 mm
Screwdriver, insulated up to 1000 Volt
Schraubendreher, isoliert bis 1000 Volt
232 391 40
232 764 40
232 392 40
232 393 40
232 394 40
232 395 40
2,5 x 75 mm
3,0 x 100 mm
3,5 x 100 mm
4 x 100 mm
5,5 x 125 mm
6,5 x 150 mm
Crosstip screwdriver, insulated up to 1000 Volt
Kreuzschlitzschraubendreher, isoliert bis 1000 Volt
232 397 40
232 398 40
232 399 40
Gre / size 0
Gre / size 1
Gre / size 2
232 208 40
Screw extractor kit with spiral drills to remove damaged or

broken screws
Schraubenausdrehersatz mit Spiralbohrern zum Entfernen
beschdigter oder abgebrochener Schrauben
Allen head wrench L type, single

Innensechskantschlssel, einzeln
232 066 40
232 067 40
232 068 40
232 069 40
232 070 40
232 071 40
232 072 40
232 073 40
232 074 40
232 075 40
232 076 40
232 077 40
232 078 40
232 079 40
232 080 40
232 081 40
232 082 40
232 354 40
232 355 40
232 356 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
2
2,5
3
4
5
6
7
8
9
10
12
14
17
19
22
24
27
30
32
36
991-1010
Tools
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Section / Gruppe 1
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17
18
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Allen head wrench L type

Innensechskantschlssel
232 414 40
232 415 40
232 416 40
232 417 40
232 418 40
232 419 40
232 420 40
232 421 40
232 422 40
SW
SW
SW
SW
SW
SW
SW
SW
SW
3/16
7/32
1/4
5/16
3/8
1/2
9/16
5/8
3/4
Allen head wrench L type, with spherical head

Innensechskantschlssel, mit Kugelkopf
232 582 40
232 583 40
232 584 40
232 585 40
232 586 40
232 587 40
232 588 40
232 589 40
SW
SW
SW
SW
SW
SW
SW
SW
2
3
4
5
6
8
10
12
232 698 40
Allen head wrenches "L" type, with spherical head,

set 1.5 - 10 mm
Innensechskantschlssel, mit Kugelkopf, Satz 1.5 - 10 mm
232 666 40
Pneumatic impact wrench (Bosch)

Druckluft-Schlagschrauber (Bosch)
232 667 40
Pneumatic impact wrench (Bosch)

Druckluft-Schlagschrauber (Bosch)
793 828 73
Cordless impact wrench

Torque 150 Nm, tool fitting 1/2'', including exchange
accumulator 14.4V 3.3Ah in a tool case
Akku-Schlagschrauber
Drehmoment 150 Nm, Werkzeugaufnahme 1/2'',
inkl. Wechselakku 14,4V 3,3Ah im Transportkoffer
991-1010
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18
19
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 139 40
March 09th, 2010

09. Mrz 2010
Water pump pliers 250 mm long

Wasserpumpenzange 250 mm lang
232 140 40
Grip pliers 250 mm long

Gripzange 250 mm lang
232 141 40
Stork beak pliers, straight, 200 mm long

Storchschnabelzange, gerade, 200 mm lang
232 142 40
Telephone pliers, 200 mm long, bent jaws

Storchschnabelzange, abgewinkelt, 200 mm lang
232 143 40
Wire strippers 160 mm long

Abisolierzange 160 mm lang
232 663 40
Stripping- and cutting tool Stripax

for PVC-isolation up to 6 mm, 20mm
Abisolier- und Schneidewerkzeug Stripax
fr PVC-Isolation bis 6 mm, 20 mm
232 401 40
Side cutter insulated up to 1000 Volt, 190 mm

Seitenschneider isoliert bis 1000 Volt, 190 mm
232 400 40
Combination pliers insulated up to 1000 Volt, 185 mm

Kombizange isoliert bis 1000 Volt, 185 mm
232 147 40
Pipe wrenches, angeled jaws, with adjusting nut, 350 mm long

Eckrohrzange abgewinkelt, mit Stellmutter, 350 mm lang
232 404 40
Flat nose pliers, insulated up to 1000 Volt, 185 mm

Flachzange, isoliert bis 1000 Volt, 185 mm
232 405 40
Round nose pliers, insulated up to 1000 Volt, 185 mm

Rundzange, isoliert bis 1000 Volt, 185 mm
991-1010
Tools
Pliers
Werkzeug
Zangen
Section / Gruppe 2
Page / Seite
19
20
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Circlip pliers, straight, for external circlips

Sicherungsringzange, gerade, fr Auenringe
232 150 40
232 151 40
232 152 40
19 60
40 100
85 140
Circlip pliers, 90, for external circlips
Sicherungsringzange, gewinkelt, fr Auenringe
232 156 40
232 157 40
232 158 40
19 60
40 100
85 140
Circlip pliers, straight, for internal circlips
Sicherungsringzange, gerade, fr Innenringe
232 159 40
232 160 40
232 161 40
19 60
30 100
85 130
Circlip pliers, angled, for internal circlips
Sicherungsringzange, gewinkelt, fr Innenringe
232 153 40
232 154 40
232 155 40
19 60
31 100
85 140
232 281 40
Circlip pliers, straight, for external circlips

122 300 mm
Seegerringzange, gerade, fr Auenringe
122 300 mm
232 282 40
Circlip pliers, angled, for external circlips

122 300 mm
Seegerringzange, gewinkelt, fr Auenringe
122 300 mm
232 283 40
Circlip pliers, straight, for internal circlips

122 300 mm
Seegerringzange, gerade, fr Innenringe
122 300 mm
232 284 40
Circlip pliers, angled, for internal circlips

122 300 mm
Seegerringzange, gewinkelt, fr Innenringe
122 300 mm
991-1010
Tools
Pliers
Werkzeug
Zangen
Section / Gruppe 2
Page / Seite
20
21
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 662 40
March 09th, 2010

09. Mrz 2010
Crimp set
Crimp pliers, crimp capacity 0,5 - 4,0 mm
Crimp-Set
Crimpzange, Crimpbereich 0,5 - 4,0 mm
232 661 40
Crimp pliers
Crimp capacity 0,5-4 mm
Crimpzange
Crimpbereich 0,5-4 mm
793 729 73
Crimp-pliers for revolved contacts

Crimpzange fr gedrehte Kontakte
232 209 40
Crimp pliers with cable lugs, set in a metal box

Crimpzange im Kasten mit Kabelschuhsortiment
991-1010
Tools
Pliers
Werkzeug
Zangen
Section / Gruppe 2
Page / Seite
21
22
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Hammer
Handhammer
232 129 40
232 130 40
232 131 40
300 g
500 g
1000 g
232 310 40
Sledge hammer, 5 kg
Vorschlaghammer, 5 kg
232 579 40
Plastic hammer, 450 g

Plastikhammer, 450 g
Flat chisel
Flachmeiel
232 135 40
232 136 40
16 x 165 mm
19 x 180 mm
232 137 40
Cape chisel, 6 x 165 mm

Kreuzmeiel, 6 x 165 mm
232 138 40
Center punch, 4 x 130 mm

Krner, 4 x 130 mm
Drift punch
Durchtreiber
232 132 40
232 133 40
232 134 40
5 x 150 mm
6 x 160 mm
8 x 180 mm
Cotter pin drive
Splintentreiber
232 099 40
232 100 40
232 101 40
232 102 40
232 103 40
232 104 40
3 mm
4 mm
5 mm
6 mm
8 mm
10 mm
232 122 40
Hack saw with blade

Metallbgelsge mit Sgeblatt
991-1010
Tools
Metal Working Tools
Werkzeug
Section / Gruppe 3
Page / Seite
22
23
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 123 40
March 09th, 2010

09. Mrz 2010
Three square scraper (hollow), 250 mm long

Dreikanthohlschaber, 250 mm lang
232 124 40
Flat scraper, 250 mm long

Flachschaber, 250 mm lang
Adjustable tap wrench for taps
Verstellbares Wendeisen fr Gewindebohrer
232 164 40
232 165 40
232 235 40
Gr. 1 M 1 10
Gr. 4 M 10 27
Gr. 6 M 20 42
Tap
Gewindebohrer
232 166 40
232 167 40
232 168 40
232 169 40
232 170 40
232 171 40
232 172 40
232 173 40
232 174 40
232 357 40
232 175 40
232 240 40
232 241 40
232 242 40
232 243 40
M3
M4
M5
M6
M8
M 10
M 12
M 14
M 16
M 18
M 20
M 24
M 30
M 36
M 42
Tap
Gewindebohrer
232 244 40
232 245 40
232 246 40
232 247 40
232 248 40
232 236 40
232 237 40R
232 238 40
232 239 40
M8x1
M 10 x 1
M 14 x 1,5
M 20 x 1,5
M 24 x 1,5
R 1/8
R 3/8
R 1/4
R 1/2
991-1010
Tools
Metal Working Tools
Werkzeug
Section / Gruppe 3
Page / Seite
23
24
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Thread restorer
Gewindefeile
232 162 40
232 163 40
Whitworth
Metric
Holder for threading dies
Schneideisenhalter fr Schneideisen
232 176 40
232 177 40
232 178 40
232 179 40
232 180 40
232 359 40
232 249 40
232 250 40
232 364 40
232 365 40
232 358 40
M3/M4
M5/M6
M 8 / M 8 x 1,0
M 10 / M 10 x 1
M 12 / M 14
M 16 / M 18 / M 20
M 24
M 30 / M 36
M 14 x 1,5 / R 1/8 / R 1/4
M 24 x M 1,5
R 3/8 / R 1/2
20 x 5 mm
20 x 7 mm
25 x 9 mm
30 x 11 mm
38 x 14 mm
45 x 18 mm
55 x 22 mm
65 x 25 mm
38 x 10 mm
55 x 16 mm
45 x 14 mm
Threading die
Schneideisen
232 181 40
232 182 40
232 183 40
232 184 40
232 185 40
232 186 40
232 187 40
232 188 40
232 189 40
232 360 40
232 190 40
232 261 40
232 260 40
232 259 40
232 255 40
232 256 40
232 257 40
232 258 40
232 251 40
232 252 40
232 253 40
232 254 40
M3
M4
M5
M6
M8
M 10
M 12
M 14
M 16
M 18
M 20
M 24
M 30
M 36
M8x1
M 10 x 1
M 14 x 1,5
M 24 x 1,5
R 1/8
R 1/4
R 3/8
R 1/2
947 173 40
Auxiliary tool 1 for threaded pins M12

Hilfswerkzeug 1 fr Gewindestift M12
947 178 40
Auxiliary tool 2 for threaded pins M16

Hilfswerkzeug 2 fr Gewindestift M16
991-1010
Tools
Metal Working Tools
Werkzeug
Section / Gruppe 3
Page / Seite
24
25
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 194 40
March 09th, 2010

09. Mrz 2010
Inside caliper, 200 mm long

Lochtaster, 200 mm lang
232 195 40
Outside caliper, 200 mm long

Dickentaster 200 mm lang
232 107 40
Sliding caliper, 200 mm long

Schieblehre, 200 mm lang
232 108 40
Measuring tape, 2000 mm long

Rollbandma, 2000 mm lang
232 590 40
Metal rule, 1000 mm long

Stahlma, 1000 mm lang
232 109 40
Feeler gauge set

Fhlerlehrenset
232 110 40
Thread gauge, metric & whithworth

Gewindeschablone, metrisch & Whitworth
232 668 40
Micrometer gauge
Measuring range: 0 - 150 mm
Bgelmessschraube
Messbereich: 0 - 150 mm
232 669 40
Micrometer gauge
Measuring range: 150 - 300 mm
Bgelmessschraube
Messbereich: 150 - 300 mm
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
25
26
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 591 40
March 09th, 2010

09. Mrz 2010
Hydraulic mini testing kit, consisting of:

1 pressure gauge 0 25 bar
1 pressure gauge 0 60 bar
2 pressure gauges 0 400 bar
2 instrument hoses 3 m each
1 hose 5 m
and diverse adapters
Hydraulik Mini-Messbox, bestehend aus:
1 Manometer 0 25 bar
2 Messschluche je 3 m
1 Messschlauch 5 m
und diverse Anschlsse
79453773
Digital dial gauge, 0 - 12,5 mm

Digitalmessuhr, 0 - 12,5 mm
232 673 40
Magnetic articulated stand, 390 mm, 60 x 50 x 55 mm

Magnet-Gelenkstativ, 390 mm, 60 x 50 x 55 mm
232 720 40
Digital pressure manometer SPG-DIGI

Digitales Druckmanometer SPG-DIGI
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
26
27
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 708 40
March 09th, 2010

09. Mrz 2010
Digital Multimeter Fluke 179 True-RMS-DMM

Features:
True-RMS for precise measurement of non linear signals
0,09% basic accuracy
6000 count resolution
Large, easy-to-read display with analog bargraph and backlight
for work in dimly lit areas
Manual and automatic ranging
Display Hold and Auto Hold
Smoothing mode allows filtering of rapidly changing inputs
Easy battery exchange without opening the case
Closed case calibration through front panel
Measuring frequency and capacity
Resistance, continuity and diode check
Measuring temperature
Min/Max/Avg recording
EN 61010-1 CAT III 1000 V/CAT iV 600 V
Digitales Multimeter Fluke 179 True-RMS-DMM
Ausstattung:
TrueRMS Echt-Effektivwert (AC)
0,09% Grundabweichung
6000 Digits Anzeigeumfang
Balkenanzeige und Hintergrundbeleuchtung
Bereichsautomatik; abschaltbar
Display-Hold und Auto-Hold
Filter-Modus zur Glttung sehr instabiler Signale
Leichter Batteriewechsel, ohne das Gehuse zu ffnen
Kalibrierung bei geschlossenem Gehuse ber das Bedienfeld
Frequenz- und Kapazittsmessung
Widerstand, Durchgangs- und Diodenprfung
Temperaturmessung
Min-/Max-/Mittelwerterfassung
EN 61010-1 CAT III 1000 V/CAT iV 600 V
232 753 40
Fuse 440 mA
Sicherung 440 mA
232 754 40
Fuse 11 A
Sicherung 11 A
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
27
28
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 619 40
March 09th, 2010

09. Mrz 2010
Autorange digital multimeter incl. fuse set and temperature

sensor
Specification:
V = : 100 V 1 KV accuracy 0,3% + 2 Dig.
V ~ : 100 V 1 KV accuracy 0,5% + 3 Dig.
A = : 100 nA 20 A accuracy 1% + 5 Dig.
A ~ : 100 nA 20 A accuracy 1% + 5 Dig.
Resistance: 100 mOhm 40 MOhm Genauigkeit 0,5% + 3 Dig.
Frequenz (Hz): 1 Hz 200 kHz accuracy 0,2% + 2 Dig.
Diode test: Test voltage (open) below 3 V
Acust. continuity tester: sounds below 100 Ohm
Voltage supply: 1 x 9 V block battery
Autorange Digital-Multimeter inkl. Sicherungssatz und
Temperatursensor
Technische Daten:
V = : 100 V 1 KV Genauigkeit 0,3% + 2 Dig.
V ~ : 100 V 1 KV Genauigkeit 0,5% + 3 Dig.
A = : 100 nA 20 A Genauigkeit 1% + 5 Dig.
A ~ : 100 nA 20 A Genauigkeit 1% + 5 Dig.
Widerstand: 100 mOhm 40 MOhm Genauigkeit 0,5% + 3 Dig.
Frequenz (Hz): 1 Hz 200 kHz Genauigkeit 0,2% + 2 Dig.
Diodentest: Prfspannung (offen) unter 3 V
akust. Durchgangsprfer: ertnt unter 100 Ohm
Spannungsversorgung: 1 x 9 V Block-Batterie
232 670 40
SUBITO Internal gauge, 280 - 510 mm,

in a case without dial
SUBITO Innenmessgert, 280 - 510 mm,
im Etui ohne Uhr
232 671 40
SUBITO Measuring depth extension

Pipe 18mm, 2000 mm long
SUBITO Messtiefenverlngerung
Rohr 18mm, 2000 mm lang
232 384 40
Flow meter gauge incl. Accessories

Volumenstrom-Messgert inkl. Zubehr
793 787 73
Measuring turbine RE4

Measuring range: 16,0 up to 600 l/min
Messturbine RE4
Messbereich: 16,0 bis 600 l/min
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
28
29
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 593 40
March 09th, 2010

09. Mrz 2010
Shock pulse measuring instrument

Stossimpuls-Messgert
232 665 40
Infrared thermometer
Infrarot-Thermometer
694 944
Electric thermometer with temp. probe tip

Temperaturmessgert mit Temperaturfhler
793 788 73
Infrared revolution counter DS03,

Measuring range : 1 to 9999 min-1
Infrarot-Drehzahlmesser DS03
Messbereich: 1 bis 999 min-1
793 789 73
Magnetic holder for DS03

Magnethalter fr DS03
232 551 40
Manual non-contact revolution counter (digital)

Berhrungsloser Drehzahlmesser (digital)
232 756 40
Clamp-on ammeter AC/DC, Fluke 336

incl. carrying case, test lead, 2 batteries (AAA), user manual
Technical data:
Measurement range A/AC & A/DC: 0 - 600 A
Measurement range V/AC & V/DC: 0 - 600 V
Frequency range: 10 - 400 Hz
Measurement range resistance: 0 6000
Strommesszange AC/DC, Fluke 336
inkl. Tragetasche, Messleitung, 2 Batterien (AAA),
Bedienungsanleitung
Technische Daten:
Messbereich A/AC & A/DC: 0 - 600 A
Messbereich V/AC & V/DC: 0 - 600 V
Frequenzbereich: 10 - 400 Hz
Messbereich Widerstand: 0 6000
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
29
30
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 496 40
March 09th, 2010

09. Mrz 2010
Cable set for part no. 232 323 40

Kabelset fr ET-Nr. 232 323 40 (s.o.)
Test manometer, incl. accessories

Prfmanometer, inkl. Zubehr
770 466 73
769 150 73
770 464 73
770 465 75
0 - 60 bar
0 - 400 bar
0 -16 bar
0 - 25 bar
Pressure gauge
Druckmanometer
793 361 73
793 362 73
793 363 73
0-25 bar (1 Stck / pc.)

0-60 bar (1 Stck / pc.)
0-400 bar (2 Stck / pcs.)
232 501 40
Pressure gauge fitting (4 pcs.)

Anschluss fr Druckmanometer (4 Stck)
Measuring hose
Messschlauch
792 283 73
792 284 73
3200 mm lg (2 Stck / pcs.)

5000 mm lg (1 Stck / pc.)
761 520 73
Filling and testing device for piston, diaphragm and bladder

accumulators
0 100 bar (with pressure reducer)
Fll- und Prfvorrichtung fr Kolben-, Membran- und Blasenspeicher
0 100 bar (mit Druckminderer)
232 752 40
Tool case (without tools)

Koffer (ohne Inhalt)
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
30
31
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 382 40
March 09th, 2010

09. Mrz 2010
Filling and testing device for piston and diaphragm and

accumulators
0 25 bar
Fll- und Prfvorrichtung fr Kolben- und Membranspeicher
0 25 bar
Thread reducing fitting (manometer)

Gewindereduzierung (Manometer)
232 506 40
232 507 40
232 508 40
R 1/4
R 3/8
R 1/2
232 385 40
Voltage tester 25 kV
Spannungsprfer 25 kV
232 386 40
Universal grounding short-circuiting device

95/35, mm2
Universale Erdungs- und Kurzschlievorrichtung
95/35, mm2
232 387 40
Insulation tester . . . 500 V

Isolationsmesser . . . 500 V
232 713 40
ALIGNEO laser set, for the alignment of horizontal mounted

machines
ALIGNEO Laser-Set, fr die Ausrichtung horizontal verbauter
Maschinen
232 714 40
ALIGNEO Bracket set

ALIGNEO Halterungssatz
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
31
32
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 388 40
March 09th, 2010

09. Mrz 2010
Phase-sequence indicator 100 . . . 600 V

Drehfeldrichtungsanzeiger 100 . . . 600 V
Electronical unipolar voltage meter

Elektronischer einpoliger Spannungsprfer
232 389 40
232 390 40
5 10 kV
3 6 kV
232 594 40
Shock pulse transducer

Stoimpulsaufnehmer
232 595 40
Shock pulse transducer

Stoimpulsaufnehmer
232 596 40
Head receiver for shock pulse measuring instrument

Kopfhrer fr Stoimpulsmessgert
232 762 40
Test box for electrical components with Deutsch connectors

Test-Box fr elektrische Bauteile mit Deutsch-Steckern
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
32
33
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
766 138 73
March 09th, 2010

09. Mrz 2010
System diagnostic for lubrication system

Systemdiagnose fr Schmieranlage
966 225
Crack detection testing kit, consisting of:

Test-Set Rissprfung, bestehend aus:
966 229
Permanent magnet
Permanentmagnet
966 226
Magnetic powder
Magnetpulver
996 228
Cleaner, spray can, 500 ml

Reiniger, Sprhdose, 500 ml
966 227
Contrasting agent
Kontrastmittel
232 723 40
Universal box
Universalkoffer
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
33
34
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
793 780 73
March 09th, 2010

09. Mrz 2010
Hand-held measuring unit MH 3020, 3 channels, USB interface,

ISDS
Memory: max. 1 million readings
incl. power supply unit, USB cable and software
Handmessgert MH 3020, 3 Kanle, USB-Schnittstelle, ISDS
Speicher: max. 1 Million Messwerte
inkl. Netzgert, USB-Kabel und Software
793 781 73
Pressure sensor (2 pcs), 0 - 400 bar, ISDS

Druckaufnehmer (2 Stck.), 0 - 400 bar, ISDS
793 783 73
Direct connector for pressure sensor no. 1620 (2 pcs)

Direktanschluss fr Drucksensor Nr. 1620 (2 Stck.)
793 784 73
Screw-in temperature sensor no. 1620 (2 pcs) -50C up to 200C,

ISDS
Temperatur-Einschraubfhler Nr. 1620 (2 Stck.) -50C bis 200C,
ISDS
793 785 73
Rev counter sensor DS 03, incl. 25 reflection foils

Drehzahlsonde DS 03, inkl. 25 Reflexionsfolien
793 787 73
Measuring cable (2 pcs), 5.0 m

Messkabel (2 Stck.), 5,0 m
793 786 73
Measuring extension cable, 5.0 m

Messkabel-Verlngerung, 5,0 m
793 782 73
Carrier box
Transportkoffer
991-1010
Tools
Werkzeug
Section / Gruppe 5
Page / Seite
34
35
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
796 440 73
March 09th, 2010

09. Mrz 2010
USB extension wire

USB-Kabel
793 796 73
Data communication cable USB

Datenbertragungskabel USB
796 441 73
UMG diagnostic software (CD)

UMG-Diagnosesoftware (CD)
796 439 73
Converter
Konverter
796 443 73
Cable set
Kabel-Set
873 570 40
Content:
Inhalt:
Cable VL3
Cable VL12
Cable VL10
Cable VL9a
Cable VL9b
Kabel VL3
Kabel VL12
Kabel VL10
Kabel VL9a
Kabel VL9b
Data transfer, grease, memory ETM, ECS, 1 set

Datenbertragung, Fett, Speicher ETM, ECS, 1 Satz
796 726 73
Bodem PC software
Bodem PC-Software
896 791 40
Bodem connection cable

Bodem Verbindungskabel
991-1010
Tools
Werkzeug
Section / Gruppe 5
Page / Seite
35
36
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 684 40
March 09th, 2010

09. Mrz 2010
Vibrotip-Set Trend
Engine analyzer and data collector
Vibrotip-Paket Trend
Maschinen-Analysator und Datensammler
232 686 40
Drill for Vibrotip

Bohrer fr Vibrotip
232 685 40
Sensor with quick coupling

Aufnehmer mit Schnellkupplung
232 747 40
LAN card, USB 2.0, 10/100 Mbit/s

This USB-RJ45-adapter is a high-performance network
converter for the USB 2.0 port
LAN-Karte, USB 2.0, 10/100 Mbit/s
Dieser USB-RJ45-Adapter ist ein leistungsstarker Netzwerkkonverter
fr die USB 2.0-Schnittstelle
232 748 40
CAT-5 Crossover adapter

For fast direct PC connection via LAN (RJ45)
CAT-5 Crossover-Adapter
Fr die schnelle PC-Direktverbindung ber LAN (RJ45)
232 755 40
Crossover cabel, for CAT-5 Crossover adapter, double shielded,

1 meter
Crossover-Patchkabel, fr CAT-5 Crossover-Adapter, doppelt
geschirmt, 1 Meter
991-1010
Tools
Werkzeug
Section / Gruppe 5
Page / Seite
36
37
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 621 40
March 09th, 2010

09. Mrz 2010
Cordless headphone intercom

Sprechfunkanlage
232 623 40
Vacuum pump + adaptor

Vakuumpumpe + Adapter
Puller, grip width/depth

Abzieher, Spannweite/Spanntiefe
232 300 40
232 301 40
232 302 40
120 mm/100 mm
200 mm/150 mm
350 mm/200 mm
232 287 40
Grease gun, hand-lever type, with couplings, 400 bar

Handhebelfettpresse, mit Anschlssen, 400 bar
232 288 40
Fitters tub
Montagewanne
232 000 40
Tool box, 5 trays

420 x 200 x 210 mm
Werkzeugkasten, 5-teilig
420 x 200 x 210 mm
232 761 40
Tool chest
With 3 wide & 3 small drawers and 1 removable element
Width 663 mm, height 364 mm, depth 308 mm, weight 25.5 kg
Delivery without tools
Werkzeugtruhe
Mit 3 groen & 3 kleinen Schubladen und 1 Trageeinsatz
Breite 663 mm, Hhe 364 mm, Tiefe 308 mm, Gewicht 25,5 kg
Lieferung ohne Werkzeuge
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
37
38
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 763 40
March 09th, 2010

09. Mrz 2010
Universal tool box

Outside:
Width 600 mm, height 330 mm, depth 400 mm, weight 4.5 kg
Inside:
Width 550 mm, height 310 mm, depth 350 mm, capacity 60
Universalbox
Auen:
Breite 600 mm, Hhe 330 mm, Tiefe 400 mm, Gewicht 4.5 kg
Innen:
Breite 550 mm, Hhe 310 mm, Tiefe 350 mm, Volumen 60
232 299 40
Pinch bar with pointed and claw ends, 1000 mm long

Brechstange mit Klaue und Spitze, 1000 mm lang
793 639 73
Removal tool for double-level terminals

Lsewerkzeug fr Doppelstockklemmen
232 542 40
Oil analysis
l-Analyse
232 622 40
Suction pump, extracting oil for testing

Pumpe zur Entnahme einer lprobe
Flat-link chain hoist

Hubzug mit Gelenkkette
232 368 40
232 289 40
???
Lifting capacity 0,75 t

324460 40
Cable suspension, 5 t
Tragkraft 0,75 t
Tragkraft 1,5 t
Tragkraft 3,0 t
Drahtseilgehnge, 5 t
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
38
39
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
792 005 73
March 09th, 2010

09. Mrz 2010
Edge protector
Kantenschoner
792 006 73
Edge protector
Kantenschoner
232 616 40
4-hook chain
WMH S6
A = 1500 mm
4-Strang-Kette
WM 1401
A = 1500 mm
232 617 40
Nylon lifting belt, AL 4

Width 75 mm, length 3500 mm
1500 kg
Nylon Hebegurt, AL 4
Breite 75 mm, Lnge 3500 mm
1500 kg
232 618 40
Nylon lifting belt

Width 25 mm, length 1500 mm
1000 kg
Nylon Hebegurt, AL 5
Breite 25 mm, Lnge 1500 mm
1000 kg
Lifting bolt
Ringschraube
941 650 40
941 651 40
906 519 40
906 780 40
906 782 40
906 783 40
906 421 40
906 233 40
M8
M10
M12
M16
M20
M24
M30
M36
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
39
40
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Pin-driving press, complete set for crawler chassis

Bolzenpresse, komplett fr Traktorenlaufwerk
232 313 40
100 t, for all excavators up to H 121

100 t, fr alle Bagger bis H 121
232 381 40
150 t, for all excavators up to H 185

150 t fr alle Bagger bis H 185
232 626 40
Mounting bushing set for cylinder repair.

When ordering tools, please always state the identification
number of the cylinder.
Montage-Buchsensatz fr Zylinder-Reparatur.
Bei Bestellung der Werkzeuge unbedingt die Ident-Nr. des Zylinders
angeben.
999 860 73
5 finger gloves, with textile extension, with lining

5-Finger-Handschuhe mit Strickbund, gefttert
999 861 73
Rubber gloves, size F3 and F4

Gummi-Handschuhe, Gre F3 und F4
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
40
41
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
999 925 73
March 09th, 2010

09. Mrz 2010
Working gloves, pork leather, with lining

Arbeits-Handschuhe, Schweinsleder mit Futter
950 642
Canister 10 l (plastics)
Kanister 10 l (Kunststoff)
950 643
Canister 25 l (plastics)
Kanister 25 l (Kunststoff)
232 683 40
Combination angle set

Satz Kombinationswinkel
232 717 40
Stud welding unit for threaded pins, with welding gun

Bolzenschwei-Kompaktanlage, mit Schweipistole
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
41
42
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 712 40
March 09th, 2010

09. Mrz 2010
Magnet-Stick
Magnetfeldprfer
232 715 40
Hydro-pump, type IPV 3-8 101

Hydropumpe, Typ IPV 3-8 101
232 716 40
Coupling
Kupplung
766 307 73
766 308 73
766 309 73
766 310 73
766 311 73
766 312 73
766 313 73
766 314 73
766 315 73
766 316 73
766 317 73
766 318 73
766 319 73
766 320 73
766 321 73
766 322 73
766 323 73
768 881 73
797 549 73
Mounting tools for dual cone seal rings at the undercarriage

Montagewerkzeuge fr Gleitdichtringe am Unterwagen
For detailed information refer to

PARTS & SERVICE NEWS AH05511
Ausfhrliche Informationen siehe
PARTS & SERVICE NEWS AH05511
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
42
43
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
767 566 73
March 09th, 2010

09. Mrz 2010
Thinner, 10 kg
Verdnner, 10 kg
767 567 73
Primer, lemon yellow, 1 kg

Grundierung, zitronengelb, 1 kg
083 026
Paint yellow, RAL 1007

Spray can, 400 ml
Farbe gelb, RAL 1007
Spraydose, 400 ml
501 415 98
Paint sky-blue, RAL 5015

Can, 2,5 kg
Farbe himmelblau, RAL 5015
Dose, 2,5 kg
767 568 73
Paint black, RAL 9005

Can, 1 kg
Farbe Schwarz, RAL 9005
Dose, 1 kg
991-1010
Tools
Paint and accessories
Werkzeug
Lackiermaterialien
Section / Gruppe 7
Page / Seite
43
44
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
767 569 73
March 09th, 2010

09. Mrz 2010
Paint yellow = DEMAG KOMATSU colour

Can, 1 kg
Farbe gelb = DEMAG KOMATSU-gelb
Dose, 1 kg
767 570 73
Paint grey = KOMATSU colour

Can, 1 kg
Farbe grau = KOMATSU-grau
Dose, 1 kg
999 019
Nickel spray can, Metaflux 70-81

Nickelspray, Metaflux 70-81
991-1010
Tools
Paint and accessories
Werkzeug
Lackiermaterialien
Section / Gruppe 7
Page / Seite
44
45
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
592 199 40
March 09th, 2010

09. Mrz 2010
Liquid sealing compound (Epple blue, No. 28), 250 ml

Flssigdichtung (Epple blau, Nr. 28), 250 ml
461 798 40
Adhesive Sicomet 85, in tubes,

for sealing the rotary joint (with rollers or balls)
Klebstoff Sicomet 85, in Tuben,
fr die Abdichtung der Rollendrehverbindung,
Kugeldrehverbindung
390 905
Teflon tape
Teflonband
464 814
Insulating tape, 33-19 Tesa PVCd

Isolierband, 33-19 Tesa PVCd
691 959
Filler bottle Startpilot

Fllflasche Startpilot
989 967
Oil binding agent (paper sacks, 8 kg each)

lbindemittel (Papierscke 8 kg)
993 528 73
Cleaning agent
Bio Pent E, for steam blasting cleaners
Reinigungsmittel
Bio Pent E, fr Dampfstrahler
993 529 73
Cleaning agent
Bio Versal, for steam blasting cleaners
Reinigungsmittel
Bio Versal fr Dampfstrahler
999 926 73
Cleaning rags (fleece rags)

35 x 35 cm, bale of 30 kg
Paket Putzlappen (Vliestcher)
35 x 35 cm, in 30 kg-Ballen
991-1010
Tools
Auxiliaries, cleaners, adhesive & sealant
Werkzeug
Hilfsstoffe, Reiniger, Kleber & Dichtungsmittel
Section / Gruppe 8
Page / Seite
45
46
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
March 09th, 2010

09. Mrz 2010
Loctite products
Loctite-Produkte
414 299 40
Loctite No. 222 E, bolt lock fluid, 50 ml

low stability, up to M36
Loctite Nr. 222 E, Schraubensicherung, 50 ml
niedrigfest, bis M 36
973 125
Loctite No. 241, bolt lock fluid, 50 ml

medium stability, up to M12
Loctite Nr. 241, Schraubensicherung, 50 ml
mittelfest, bis M 12
973 130

255 242 40

170 470 40

mittelfest, bis M80
158 856 40

high stability, up to M20
hochfest, bis M20
167 644 40
Loctite No. 307, 50 ml

metal adhesive (only in conjunction with 7471)
Loctite Nr. 307, 50 ml
Metallkleber (nur in Verbindung mit 7471)
288 906 40
Loctite No. 330, bonding set

bonds nearly all materials (except Gi)
Loctite Nr. 330, Klebeset
verbindet nahezu alle Materialien (auer Gi)
461 798 40
Loctite No. 401, 20 g, Cyanacrylat

bonds Kn, rubber, paperboard, leather, wood, and many more
Loctite Nr. 401, 20 g, Cyanacrylat
zum Verkleben von Kn, Gummi, Pappe, Leder, Holz, u.v.m.
991-1010
Tools
Werkzeug
Section / Gruppe 8
Page / Seite
46
47
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
255 238 40
March 09th, 2010

09. Mrz 2010
Loctite No. 511, fluid sealing, 50 ml

low stability, sealing threaded connections up to R2
Loctite Nr. 511, Flssigdichtung, 50 ml
niedrigfest, zum Abdichten von Verschraubungen bis R2
232 554 40
Loctite No. 511, fluid sealing, 250 ml

low stability
niedrigfest
083 399 40
Loctite Nr. 586, fluid sealing, 50 ml

high stability, up to R 2
hochfest, bis R 2
255 239 40
Loctite 574, sealant for surfaces, 50ml

gap size up to 0,5 mm
Loctite Nr. 574, Flchendichtung, 50 ml
Spaltgre bis 0,5 mm
255 237 40
Loctite No. 603, for join connections, 50 ml

high stability
Loctite Nr. 603, Fgeverbindung, 50 ml
hochfest
288 907 40
Loctite No. 706, fast cleaner, 400 ml

Loctite Nr. 706, Schnellreiniger, 400 ml
321 32240
Loctite, removal of adhesives and sealants

spray can, 300 ml
Loctite, Klebstoff- u. Dichtungsentferner
300 ml-Sprhdose
083 376 40
Loctite Nr. 7471, activator, 500 ml

(for hardening of 307 and for the acceleration of the hardening
process)
Loctite Nr. 7471, Aktivator, 500 ml
(zur Aushrtung von 307 und zur Beschleunigung des
Aushrtevorgangs)
991-1010
Tools
Werkzeug
Section / Gruppe 8
Page / Seite
47
48
Parts & Service News
8 PARTS & SERVICE NEWS
Version 2010/1
PC8000-6E
8 -1
Parts & Service News
Contents of this chapter:

SB-No.
Subject
AH00511
AH00514
AH00515
Final drive: Wear and tear measurements Mounting procedures
AH00519
AH01513
AH01516
Lift off the superstructure platform from the undercarriage for instance to change the swing circle
(slew ring)
AH01523
AH01531
Hydraulic accumulators - testing and refilling
AH02513
AH02521
AH03506
AH03510
AH03528
AH04518
AH05501
AH05510
Bearing flushing of the A4VS variable displacement axial piston pump
AH05511
AH05518
Swing circle pinion
AH05525
Suction elbows of the main Pumps
AH05535
Hints for replacing by the slewing gear of an other manufacturer
AH05546
AH06512
Travel gears - Brake and motor adapter housings - Oil Change
AH06524
Hydraulic cylinder
AH06530
AH06544
AH06545
AH08504
Windscreen
AH08507
Steel structure
AH08508
AH08516
AH08532
The numbers of the PARTS & SERVICE NEWS do not label the
latest edition. Ensure that the latest edition is always filed to the
binder of this manual.
8 -2
PC8000-6E
Version 2010/1
COMPONENT CODE:
2500
REF NO.
AH00511f
PARTS & SERVICE NEWS
DATE
February 12, 2009

Page 1 of 20
This PARTS & SERVICE NEWS supersedes the previous issue No. AH00511e
which should be discarded.
SUBJECT:
PURPOSE:
Revision
APPLICATION:
From H185S (06078) up to PC8000
FAILURE CODE:
2500Z9
DESCRIPTION:
Content
Page
1.
2.
3.
4.
5.
6.
List of swing circle types

Safety instructions
General
Measurements
Determination of tightening torques
Mounting of a swing circle
Adjustment: Unhardened spot s
Tooth back lash
Hints for rotating the slew ring
7.
Checking of fastening bolts
8.
Lubrication and maintenance
8.1 Races of roller bearings
8.2 Outer toothing
8.3 General
1.
Type
H 185S
H 255S / PC3000
H 285S
PC4000
H 455S / PC5500
H 485S
H 655S / PC8000 ( - 12036)
PC8000 (12037 - )
H 685SP
H 685SX (12030)
Slew ring
Weight
[t]
3,5
3,5
6,0
6,7
9,0 / 10,0
14,0
14,0
16,3
14,0
16,3
01
02
03
04
06
08
11
12
14
16
16
16
18
20
Mounting cross
P/N
Tooth back lash

[mm]
379 383 40
379 383 40
379 128 40
379 128 40
477 577 40
379 129 40
379 129 40
379 129 40
379 129 40
379 129 40
0.4 0.8
0.4 0.8
0.6 1.0
0.6 1.0
0,6 1,0
0.5 0.9
0.5 0.9
0.5 2.5
0.5 0.9
0.5 2.5
AH00511f
Page 2 of 20
2. Safety Instructions
Assign trained or well-instructed personnel only, and clearly define the respective
spheres of responsibility for the repair work.
Inform the operating personnel prior to the commencing special and regular
maintenance work.
Secure the maintenance area amply enough, as far as required.
Carry out repair and maintenance work only with the machine standing on firm and level
ground and secured against rolling away and sinking in.
During exchange action, fix and secure individual parts and assemblies carefully to the
lifting devices so that they cannot become dangerous in any way. Use exclusively
suitable lifting devices consistent with sound engineering and load-lifting elements with
sufficient load-bearing capacity! Never stay or work beneath suspended loads!
Entrust experienced personnel only with fastening and securing of loads and guiding
crane operators! The guide has to be within the operator's visual range or have voice
contact with him.
In case of assembly work exceeding body height, use suitable and otherwise secure
means of access and working platforms. Never step on machine parts as an access!
For maintenance work at higher levels, use the appropriate safety devices! Keep all
handles, steps, handrails, landings, working platforms, ladders, etc. free from dirt, snow
and ice!
Retighten immediately all bolted connections loosened during repair and maintenance
work!
If disassembly of safety devices is required for rigging, maintenance, and repair,

reassembly and checking of such safety devices has to be carried out immediately after
having finished the respective work.
Strictly observe all safety instructions and warnings in the country of destination.
AH00511f
Page 3 of 20
3. General
Before removing swing circle mark location of both slew rings to superstructure
and the carbody as well for further investigations.
Shocks to the swing circle, especially radial ones, must be avoided.
Transport and store exclusively with transport star fitted. It is strictly forbidden to
hook up the SR (Slew Ring) at the transport star.
Hang up and/or transport and store swing circle only horizontally. If a special
attachment is available, the transportation and storage in oblique position may be
carried out.
Only hang SR at four/three eyebolts evenly distributed in screw circle of the upper
ring.
Prior to mounting the SR clean all supporting surfaces and the toothing, if
necessary clean those areas with fat solvents, methylene chloride, cold cleaners.
The cleaning agents must not enter the races. Hence, the swing circle has to be
thoroughly lubricated before and after cleaning.
With each replacement swing circle and each new machine, fastening bolts,
measuring bolts, a measuring device and mounting compound
P/N. 324 969 40 will be delivered. If this parts delivery is not complete, please get
immediately in contact with KOMATSU MINING GERMANY, because a proper
mounting may not be possible in case of missing items.
AH00511f
Page 4 of 20
4. Measurements
Check the level of bearing area (only center section undercarriage) with a laser device
before installing a new slew ring.
To prevent incorrect measuring results caused by partial sun radiation onto the pedestal
/carbody it is recommended that the whole area be protected from the direct sunlight.
Legend
ID
= Inner diameter slewring (mm)
OD = Outer diameter slewring (mm)
= 3.14
P
= Maximum Deviation (deflection) (mm)
P = (OD ID) 1000
Example: OD = 4000 mm
ID = 3600 mm
P=
P=
P=
(4000mm 3600mm) 1000
400mm 1000
0.4 mm
If the measured value exceeds the calculated value P, the

surface has to be remachined.
AH00511f
Page 5 of 20
Check the outer diameter of the new slewring top surface and compare with the outer
diameter of the factory machined surface of the superstructure.
Remove the shoulder by machining if necessary.
A shoulder exists only at some excavators.
AH00511f
Page 6 of 20
5. Determination of tightening torque

The required tightening torque for all fastening bolts (inner and outer) has to be
determined with the measuring bolts, which dimension is analogous to the outer
fastening bolts mounted to carbody / swing circle.
The required axial tension force of the bolts is determined by means of the
elongation of the fastening bolts, carbody and swing circle.
The tightening torque must be determined each time the SR (Slew Ring) is
replaced as well as at the first assembling of the excavator at the operation site
and for the first and final inspection after 1000 operation hours.
The required measuring device is delivered with the excavator or with the SR (Slew
Ring)
(see ill.).
To determine the tightening torque, eight specially prepared test bolts are
supplied besides the normal fastening bolts. The test bolts can be recognized at
the centering (Z) in the bolt head and in the end of the threads.
The measuring device is composed of the following items and will be delivered with
each replacement swing circle and each new machine:
(1) Measuring jaw

(2) Test block
1pce.
1pce.
(3) Measuring bolt

(4) Washer
8pcs.
1pce.
For the determination of the tightening torque, the eight measuring bolts have to
be mounted one by one to the measuring device as illustrated. Then the bolt has
to be tightened in steps to the prescribed elongation (see table page 05). The
needed tightening torque will be determined as a result of average of eight
tightening torque's. For the exactly procedure refer to the following pages.
AH00511f
Page 7 of 20
For the determination of the torque / or pressure (hydr. torque multiplier) for the
elongation of the test bolts proceed according to illustration on page 03 and the
following description.
Before the mounting of the measuring bolts (3) to the jaw, the bearing surface of
head, threads and washers have to be applied with compound P/N. 324 969 40.
Screw test bolt (3) with washer (4) in test block (2) and tighten manually.
Fit jaw (1) and micrometer gauge into the centering "Z" of the bolt and set
gauge to zero.
Increase tightening torque of test bolts by steps of app. 200 Nm until the
required elongation of the bolt according to the table is reached.
Measuring bolts
Type
Analogous to the
dimension of the outer
fastening bolts (8)
Quality
grade
Wrench size
Elongation [mm]
H 185S
M 30 x 230
10.9
46 mm
0.55 0.015
H 255S / PC3000/1
M 30 x 230
10.9
46 mm
PC3000/6
M 30 x 230
10.9
46 mm
0.55 0.015
0.5500.015
PC3000/6
M 30 x 190
10.9
46 mm
0.4420.013
H 285S
M 36 x 220
10.9
55 mm
0.61 0.020
PC4000
M 36 x 220
10.9
55 mm
0.61 0.020
H 455S / PC5500
M 36 x 230
10.9
55 mm
0.58 0.020
H 485S (to 12010)

H 485S (12011 up)
M 36 x 230
M 36 x 270
10.9
10.9
55 mm
55 mm
0.58 0.020
0.65 0.020
M 36 x 270
10.9
55 mm
0.65 0.020
M 36 x 295
10.9
55 mm
0.71 0.020
H 685SP
M 36 x 270
10.9
55 mm
0.65 0.020
H 685SX (12030)
M 36 x 295
10.9
55 mm
0.71 0.020
H 655S
PC8000 (to 12036)
PC8000 (12037 up)
Note down the tightening values in Nm, ft. lbf. resp. bar.
Repeat this procedure with all eight test bolts.
Add all 8 tightening values and than divide by 8.
Tighten bolts (7) and (8) to the calculated value
(refer to the drawing at the next page).
AH00511f
Page 8 of 20
6. Mounting of a Swing circle (refer to ill. pages 06/08)
Depending on the model, bushes (11) or washers (10) have to be mounted.
AH00511f
Page 9 of 20
When replacing the swing circle, all fastening bolts must also
be replaced.
The eight measuring bolts have to be mounted equally distributed on the outer ring
of the swing circle.
If scratches are found at supporting surfaces of washers or bushes, they must be
reworked or replaced.
Replacement swing circles has to be mounted without dowel pins.
If the mounted SR (Slew Ring) was fixed to the platform with dowel pins, remove
these ones.
Clean fat-free supporting surfaces (A) carbody and platform.
Supporting surfaces (A) must be absolutely fat-free. Even the solvent must be rinsed
away before assembling.
Check surface evenness (A).
The swing circles (5/6) must have good contact to the carbody and superstructure
platform.
Check mating surfaces with feeler gauge.
Check lube lines for correct condition and grease passage.
Check accordance of tapped and through holes in SR (Slew Ring) with those in
carbody and platform. Discordance's may easily cause distortions of SR.
AH00511f
Page 10 of 20
For removal and assembly always use a mounting cross (M).

Fabricate mounting cross (M) according to the drawing or
order it under giving the corresponding P/N. The construction
drawing of the mounting cross has to be ordered from the
Parts Department if necessary.
Swing circle weight
Mounting cross
[t]
P/N
H 185S
3.5
379 383 40
H 255S / PC3000
3.5
379 383 40
H 285S
6.0
379 128 40
PC4000
6.7
379 128 40
9.0 / 10.0
477 577 40
14.0
379 129 40
14.0
379 129 40
16.3
379 129 40
H685SX (12030)
16.3
379 129 40
H 685SP
14.0
379 129 40
Type
H 455S / PC5500
H 485S
H 655S
PC8000 ( - 12036)
PC8000 (12037 - )
AH00511f
Page 11 of 20
Deposit and center SR with transport star (T, see page 07) on mounting cross (M).
Check length of threads in platform and SR, if necessary retap.
Place SR at its fastening position under the jacked-up platform.
Adjustment: Unhardened spot S

For the adjustment of the Unhardened spot "S", see illustration.
The Unhardened spot of race surfaces (changeover area between beginning and
ending of hardening process) is punch marked with a "S" at the inner resp. outer side
of each race ring (5 and 6), see illustration.
These spots "S" must not be placed within the main load area of the swing circle.
Hence, the unhardened spot "S" has to be turned in an angle of 90 to the main load
area as illustrated.
AH00511f
Page 12 of 20
Lift SR until approx. 10 mm below the platform (observe unhardened spot "S").
Screw fastening bolts (7) with washers (10) through swing circle into the
platform. Slightly treat bolt heads, threads and washers with Compound,
P/N 324 969 40.
Lift SR to the supporting surface by screwing in the bolts crosswise.
Lower mounting cross.
Remove transport cross.
Tooth back lash
The tooth back lash is the play measured by a

feeler gauge in point D if tooth A press on the
reference circle (B) against tooth C.
On swing circle where you find a green
color marking on 3 teeth, rotate the lower ring
(6) until the 3 green marked teeth are mating
with the teeth of a slew pinion.
Type
Tooth
back lash
[mm]
H 185S
H 255S/PC3000
H 285S
PC4000
H 455S/PC5500
H 485S
H 655S/PC8000 ( -12036)
PC8000 (12037 - )
H685SX (12030)
H 685SP
0.4 0.8
0.4 0.8
0.6 1.0
0.6 1.0
0.6 1.0
0.5 0.9
0.5 0.9
0.5 2.5
0.5 2.5
0.5 0.9
Note:
The green teeth indicate the point of the SR
having the greatest circularity deviation of
the reference circle (positive deviation).
At this narrowest spot, a tooth backlash
clearance according to the chart should be
measured.
On machines without green color marking
at the teeth, adjust backlash at 4 points
evenly distributed according to the following
dimensions.
AH00511f
Page 13 of 20
Before lowering the platform with SR on center section of the undercarriage:
1. Mark 4 teeth(1; 2; 3; 4 - refer to illustration) displaced by 90 .
The slew gears are marked gear 1, gear 2 and gear 3 (if so present).
2. Rotate the slew ring so far that tooth 1 is engaged at pinion of slew gear 1.
3. Measure play between A and D. Note value in the table below.
C means tooth 1 and must have contact at point B.
4. Rotate superstructure further until tooth 1 is engaged at pinion of slew gear 2.
Measure play as described under step 3.
5. Rotate superstructure further until tooth 1 is engaged at pinion of slew gear 3.
Measure play as described under step 3.
6. Rotate superstructure further that tooth two is engaged at pinion of slew gear 1.
Measure play and note value in table.
7. Carry out same measuring procedure as described for the other teeth.
At the end for every slew gear, four dimensions are noted in the table.
8. If necessary, adjust the backlash by displacement of the SR. For the correct
backlash, refer to chart above.
9. Hints for the three slew gear version:
Adjust an equal play at pinion of slew gear 1 and 3 by shifting the slew ring.
For this use the installed adjusting bolts.
Afterwards adjust play at slew gear 2 to the same value before adjusted at 1 and 3.
Tooth backlash
Slew gear
gear 1
gear 2
gear 3
Play nominal value
Tooth 1 Tooth 2 Tooth 3 Tooth 4
refer to table
at page 10
AH00511f
Page 14 of 20
Hints for rotating the slew ring
1. Remove the slew motor.
2. If the excavator is equipped with more than one slew motor:
Remove the hoses at the other slew motor(s).
3. Loosen the slew brake(s) by applying external pressure (25 - 60 bar).
4. Use the below shown tool in place of the removed slew motor for rotating
the slew ring (drive: 36 mm).
36 mm
The shown tool can be used for Series:

PC3000; PC4000; PC5500; PC8000.
Toothed shaft:
DIN 5480
W 60x2x30x28x9g
Part no.: 864 501 40
AH00511f
Page 15 of 20
Tighten all SR fastening bolts with the torque determined. Use the
same torque multiplier you have used for the determination.
Before mounting the bearing surface of bolt head, threads

and washers have to be applied with compound
P/N 324 969 40.
Fasten crosswise fastening bolts (7) with the previously determined tightening torque
(see page 05). This has to be performed twice or three times, to ensure a setting of the
bolts.
During tightening check permanently toothed outer ring (6) for easy running. For this
purpose unscrew hydraulic lines of slew motor and loosen all slew brakes by applying
external pressure (25 - 60 bar).
Check for easy motion in all ranges by turning the outer ring (6).
After tightening of all bolts (7) from SR to the superstructure, the tooth backlash
has to be checked once more at 4 points, if necessary adjust again.
Lower platform with SR on center section of the undercarriage. Watch position of

not hardened spot "S" of the ring (6) according to illustration on page 09. If
necessary turn ring (6).
Screw in 8 measuring bolts with washers resp. bushings (11) evenly distributed
and the other fastening bolts (8) with washers (10), and bushings (11).
Tighten crosswise all fastening bolts (7/8) with the previously determined
tightening torque. This has to be performed twice or three times, to ensure a
setting of the bolts.
AH00511f
Page 16 of 20
7. Checking of bolts
To compensate settling between SR and parts connected to it the bolts must be
checked after 1000 operation hours. If necessary retighten bolts with the
determined torque (refer to page 05).
Unscrew the eight test bolts (4) of the connection SR / carbody.

Determine the required torque with these eight test bolts (4) in the test block (2).
For the procedure, refer to the pages 03 - 05.
Retighten all bolts (4/7/8) with the same torque multiplier you have used for the
determination.
On the models H 285 - H 685 for the retightening of the bolts of the connection SR
/ platform you need an extension, Part-No. 232 511 40.
8. Lubrication and maintenance (RDV)

8.1.
Races of roller bearings
Races must be lubricated regularly using high quality brands of lubricants.

This is particularly important before and after longer interruptions of operation (e.g.
winter intermission).
The grease content in the race system is intended to avoid friction, to seal and to
prevent corrosion. Greasing must be done abundantly until a continuous collar of
grease pours out of the entire circumference of the upper seal "L" and the lower
bearing gap "G".
When greasing check visually the upper bearing seal "L" and, if necessary, replace
immediately in order to prevent dirt and/or water to penetrate into the race system.
Avoid cleaning agents to enter the race system when

cleaning the excavator with high-pressure water or with vapor
blast apparatuses. Before and after each cleaning grease
thoroughly. The even distribution of grease requires slewing
of the superstructure during greasing.
AH00511f
Page 17 of 20
Lubricating by central lube systems use

With central lube systems, the lubricating intervals are controlled by the time control
unit and the grease quantity is controlled by the adjustable metering valves / distributor
valves in order to meet the local requirements.
Manual greasing
The lubrication intervals can be found in the Lubrication and Maintenance Manual.
Before greasing clean grease nipples.
Shorter intervals must be selected in tropical climate, in high humidity, under important
effects of dust and dirt, considerable changes of temperature and continuous slewing
motions e.g. during material transfer.
Lubricants
For greasing only use high quality grease which meets the requirements of the
KOMATSU MINING GERMANY Lubricant Specification 011 597 99 (published in July
1995) section A.
When choosing the grease, consider the ambient temperature range.
Exchange of the lip type seal "L" (see ill., page 06)
If a damage of the seal is determined while greasing operation, it has to be exchanged
immediately, to avoid damages, caused by contamination.
The exchange has to be performed as follows:
Remove the complete lip type seal.

Clean groove fat-free, remove lip remainder completely
Insert new lip type seal (P/N, refer Parts Catalogue). The seal must not be
stretched during pushing in.
Finally, the seal has to be cut to the needed length and the ends has to be glued
together. The gluten is available under P/N 989 965.
AH00511f
Page 18 of 20
8.2.
Outer toothing
Adhesive lubricants may be applied by means of an automatic swing circle gear lubrication
system or manually by a spatula, a brush or a spray tin.
Lubrication with automatic lubrication system
Spray lube system
Drop lube system
Swing circle gear lubrication system
The most important requirement of a swing circle gear lubricant, besides the extreme
pressure resistance, is its optimum adhesion to the tooth flanks, which can only be obtained
by using the recommended lubricants in the prescribed temperature ranges. The following
table includes several adhesive lubricants providing excellent results on several machines
under different working conditions.
The use of other lubricants is not recommended before consultation of Dept. 8151.
AH00511f
Page 19 of 20
The following table includes several adhesive lubricants providing excellent results on several
machines under different working conditions.
Note: Use these Greases for Swing Circle open Gear Lubrication only
Ambient Temperature
C
F
Supplier
-50
-58
-40
-40
-30
-22
-20
-4
-10
14
0
32
10
50
20
68
30
86
40
104
50
122
60
140
Castrol Molub-Alloy 936 SF Heavy NG

BP /
Castrol
Industrie
GmbH
Castrol Molub-Alloy 936 SF Heavy

Castrol Molub-Alloy
958 SF
Castrol Molub-Alloy 936 SF Arctic
BERULIT GA 2500 / BERUGEAR W4000
BECHEM
BERULIT GA 800
BERUGEAR
W 3000
Beru Gear FG 34 (Biodegradable)
Molub unee lubricant 7059
Molub Gear Tac 6895
BEL RAY
Molub Gear Tac
6894 / 6899
ESSO
Dynagear Extra
Ceplattyn KG 10 HMF
FUCHS
LUBRITECH
Ceplattyn KG 10 HMF LT
URETHYN HG O *1)
MOLYBOND
TSG Heavy
Malleus GL 500
SHELL
Malleus GL 400
Malleus GL 25
TEXACO
LUBRITENE
*1)
*2)
Crater 2X Fluid *2)

Lubrene Multi ServOGL
The URETHYN HG O Grease should only be used in Arctic climates where the ambient temperatures fall
to 50 C. In regions where the ambient temperatures do not fall below 40 C,
a grease of the temperature range to 40 C should be used.
Use the Crater 2X Fluid for Spray systems only.
AH00511f
Page 20 of 20
Lubrication: Manual
The manually lubrication has to be carried out with the following adhesive
lubricants.
Those lubricants are suitable for all temperature ranges.
Company Product
Komatsu Voler Compound
2000 E
Mining
Germany Spray (0,625kg)
Voler Compound
2000 E
Special
Adhesive lub
grease
(indicate quantity
in kg)
T1
-5C +60C
+23F +140F
T2
-20C +10C
-4F +10F
T3
-40C -10C
-40F +14F
P/N 500 893 98
P/N 006 057 98
8.3 General
The adhesive lubricants protect the tooth profile against dust, dirt, and damage
resulting from driving or braking actions. However, this protection is effective only
when the adhesive greases have been applied to clean surfaces where it can form a
continuous coating.
When bright spots show up at the tooth profile the toothing must be sprayed or laid on
immediately with the special adhesive grease.
When visiting customers, the service staff or dealers should also check the machine
equipment and stock of lubricant and advise the exchange, if necessary, to prevent
premature wear of the toothing.
The adhesive lubricants provide totally different features

compared to the Bearing greases / MPG (e.g. used in the central
lubrication system). Hence, those lubricants must not be
replaced against each other or mixed.
Example: This may happen when grease pressed out of the upper
sealing system of the races forms too big collar at the
swing circle and penetrates into the toothing. This
eventuality must be avoided by removing the excess
grease.
If tooth profiles of the slewing connection have been damaged

due to one of the above mentioned reasons they do not fall
under our warranty.
AH00511f
COMPONENT CODE:
3000
REF NO.
AH00514
DATE
08162000
Page 1 of 11
This PARTS & SERVICE NEWS supercedes the previous issue No. 21 251c
dated May 2000 which should be discarded.
SUBJECT:
PURPOSE:
Sprocket exchange in case of normal wear
APPLICATION:
H 185S; H 241; H 285; H 285S; PC4000; H 485;

H 485S; H 685S/SX; H 655S; PC8000
FAILURE CODE:
3000CA
DESCRIPTION:
1. Sprocket types
1.1 Standard sprocket
1.2 Oversize sprocket
2. Part no.
2.1 Sprockets with hub
2.2 Sprockets without hub / shaering pins
3. Removal sprocket
4. Conversion of the hub
5. Preparing the shearing pins
6. Determination of the Axial Play
7. Remachining
8. Assembly
9. Torque Data for Standard Application
AH00514
Page 2 of 11
1. Sprocket types
1.1 Standard sprocket
The standard sprocket has to be used in case of assembling new machine or
regenerating the track group in connection with new track pads.
1.2 Oversize sprocket
The oversize sprocket has to be used to compensate chain elongation, wear on
sprocket diameter and wear in the roller path on track pads, caused by the wear of
the chain, if the X-dimension / circular pitch, comes up to 0.5 mm
(see Service Bulletin 21-205 latest edition).
This retrofitting assures assembly condition of the X dimension of a new machine,
furthermore the service life of the track group will be increased.
The oversize sprocket is available without a sprocket hub, if the old one is reuseable.
For the part no. of sprockets and the mounting procedure, refer to the following
pages.
The conversion of the sprockets is very time- and cost-intensive, so it is
recommended to exchange the final-drive bearings at the same time if the
dimensions have reached the wear tolerances, to avoid a standstill of the machine for
the final-drive bearing exchange only.
Before placing the order, pay attention to Service News AH00515 and Parts
Catalogue for correct choice of the bush type.
Basically, all seals (4; 5; 6; 10, see page 04) according to Parts Catalogue have be
replaced.
The difference between the standard version (NT) and the very
low temperature version (TT) are only the bolts. The sprocket
and the shearing pins are the same.
AH00514
Page 3 of 11
2. Part no.
2.1 Standard sprocket (T) with hub
Oversize sprocket with hub (T)
Type
H 185S
H 241
H 285
H 285S
PC4000
H 485
H 485S
H 685S/SX
H 655S/ PC8000
Type
H 185S *
H 241
H 285
H 285S
Part No.
429 206 40
261 678 40
352 433 40
643 940 40
643 936 40
313 343 40
643 930 40
643 930 40
643 930 40
Part No.
448 943 40
425 656 40
425 654 40
643 936 40
PC4000
643 940 40
H 485
426 016 40
H 485S
643 926 40
H 685S/SX
643 926 40
H 655S/ PC8000
643 926 40
* Oversize sprocket for H 185S
is available only with hub
AH00514
Page 4 of 11
2.2 Oversize sprocket without hub (R) /

Shearing pins (O)
Type
H 241
H 285
H 285S
PC4000
H 485
H 485S
H 685S/SX
H 655S/ PC8000
Sprocket (R)
Part No.
425 655 40
448 961 40
887 105 40
887 105 40
448 969 40
643 923 40
643 923 40
887 115 40
Pin
numbers
4
6
6
6
8
8
8
8
Pin (O)
Part No.
429 638 40
429 691 40
429 691 40
429 691 40
429 640 40
429 692 40
429 692 40
429 692 40
AH00514
Page 5 of 11
3. Removal sprocket
Suspend travel gear (1) to a crane, remove mounting bolts.

Remove travel gear by using the pulling bolts, put aside.
Remove cover (2).
Underpin sprocket (T/R) from below, suspend to a crane.
Pull out drive shaft (8).
Remove mounting bolts in flange bearing (7), loosen by using the pulling bolts,
extract.
Extract hollow shaft (9) to cover side (2), lift sprocket (T/R) out.
Remove mounting bolts in flange bearing (3), loosen by using the pulling bolts,
extract.
14
22
50
34
AH00514
Page 6 of 11
4. Conversion of the hub
Loosen bolts and bore into

shearing pins.
Pin
Do not drill
through !
Model
H 241
H 285/ H 285S
PC4000
H 485/ H 485S
H 685S/SX
H 655/ PC8000
Pin dia. (mm)

standard
42
50
50
55
55
55
Drill dia. (mm)

36
44
44
49
49
49
Pin dia. (mm)

oversize
44
52
52
57
57
57
Drill dia. (mm)

36
44
44
49
49
49
Pull out shearing pins.

Separate hub and sprocket, if necessary heat up sprocket to approx. 100C.
Insert hub into the new sprocket and align corresponding to the existing holes.
Insert bolts and tighten.
AH00514
Page 7 of 11
Drill holes on a vertical boring machine. The sprocket has to be on top. Use Shell
counterbores of high speed steel.
Model
H 241
H 285/ H 285S
PC4000
H 485/ H485S
H 685S/SX
H 655/ PC8000
Holes for the shearing pins

4 x 43.5 mm
6 x 51.5 mm
6 x 51.5 mm
8 x 56.5 mm
8 x 56.5 mm
8 x 56.5 mm
Ream the holes for the shearing pins.

Model
H 241
H 285/ H 285S
PC4000
H 485/ H485S
H 685S/SX
H 655/ PC8000
Holes for the shearing pins

4 x 44 H7
6 x 52 H7
6 x 52 H7
8 x 57 H7
8 x 57 H7
8 x 57 H7
After reaming bur the holes carefully.

5. Preparing the shearing pins
A
sprocket
hub
B
By means of a 3 point inside micrometer measure the diameter A and B at the
spots as shown in the illustration.
Add 0.04 mm to the larger diameter and grind the oversize sharing pin to this
dimension.
Repeat this procedure separately for all pins.
Example:
A = 57.01 mm
B = 57.02 mm
B is bigger.
The diameter of the pin has to be :

57.02 mm
+ 0.04 mm
= 57.06 mm
Shearing pins have to be deep-freezed by using liquid nitrogen (-196C/-320F and

pushed into the reamed holes.
AH00514
Page 8 of 11
29
50
29
AH00514
Page 9 of 11
6. Determination of the Axial Play

After removal, all seals have to be renewed.
Slide O-ring (5) over flange bearing (3).

Mount flange bearing (3) without dual-cone seal (29).
Pay attention to the lubrication-grooves position, they have to be displaced by
22.5 to the vertical line.
Mount all bolts (50) and tighten according to tightening torques on the last page.
Suspend sprocket (T/R) to a crane , insert without dual-cone seals(29).
Mount hollow shaft (9) and slide against collar B. By this, the sprocket (T/R) is
moved against the collar of the bushing.
Mount flange bearing (7) with 3 bolts (22) without dual-cone seal (29).
Measure dimension X.
Slide sprocket (T/R) to direction C until the hollow shaft (9) rests against the
collar D of the flange bushing.
Measure dimension Y.
The axial play result in X Y .
7. Remachining
If the amount of axial play exceeds 0.9 mm (H 241 > 0.5mm). area E has to be
remachined until the original dimension, is reached.
If the amount of axial play is less than 0.2 mm, area F has to be remachined until the
original dimension, is reached.
Type
H 185S
H 241
H 285/ H 285S
PC4000
H 485/ H485S
H 685S/SX
H 655S/ PC8000
Original
0.2 0.9
0.2 0.5
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
Wear limit
2.75
2.00
2.75
2.75
2.75
2.75
2,75
Suspend sprocket (T/R) to crane, pull out hollow shaft (9), lift sprocket (T/R) out.
AH00514
Page 10 of 11
29
29
50
AH00514
Page 11 of 11
8. Assembly
Mount dual-cone seal (29) according to SB 10-33 into flange bearing (3).
Mount dual-cone seals (29) according to SB 10-33 into sprocket (T/R).
Place sprocket (T/R) into the side frame by using a crane, align and underpin
sprocket in mounting position.
Mount hollow shaft (9).
Mount dual-cone seal (29) according to SB 21-558 into flange bearing (7).
Mount flange bearing (7). The lubrication grooves of the bushing(4) have to be
displaced by 22.5 to the vertical line.
Tighten bolts (22), according to the tightening torques below.
Insert O-ring(6) in cover (2). Mount cover (2) with bolts (14).
Insert O-ring (10).
Suspend travel gear (1) to a crane and mount to side frame.
Refill oil and check levels.
When selecting tightening torques, observe size and quality

grade of the bolts.
9. Torque Data for Standard Application
Bolt
dia.
[mm]
M 10
M 12
M 14
M 16
M 18
M 20
M 22
M 24
M 27
M 30
M 33
M 36
Wrench
size
[mm]
17
19
22
24
27
30
32
36
41
46
50
55
8.8
43/32
74/54.6
118/87
179/132
255/188
360/265
485/358
620/457
920/679
1250/922
1690/1246
2170/1600
Tightening torque
Nm/lbs.ft.
Quality grades
10.9
63/47
108/80
173/128
265/196
360/265
510/376
690/509
880/649
1310/966
1770/1305
2400/1770
3100/2286
12.9
73/54
127/94
202/149
310/229
425/313
600/443
810/597
1030/760
1530/1128
2080/1534
2800/2065
3600/2655
Insert all bolts lubricated with MPG, KP2K type lubricant.
AH00514
COMPONENT CODE:
30
REF NO.
AH00515c
DATE
July 5, 2006
Page 1 of 10
This PARTS & SERVICE NEWS supersedes the previous issue No. AH00515b
SUBJECT:
Final drive:
Wear and tear measurements

Mounting procedures
PURPOSE:
Revision
APPLICATION:
H 185S; H 285; H 285S; PC4000; PC5500 (#15026 and up);

H 485; H485S; H 685S/SX; H 655S; PC8000
FAILURE CODE:
3000CA
DESCRIPTION:
1. Wear and tear measurements
1.1 Radial wear determination
a) Preparation
b) Measuring procedure Method A
c) Measuring procedure Method B
d) Determination of wear depending on the Bushing version Old or New
1.2. Axial play determination of the hollow shaft
a) Measuring procedure
b) Reducing the axial play by remachining
2. Mounting procedures
2.1 Mounting of drive shaft
a) Gap between drive shaft and cover plate
b) Measuring procedure
c) How to establish the recommended gap
2.2 Exchange bushings
a) Freeze shrinking bush
b) Flange Assy. with freezed in bush
3. Final works

The wear- and tear-measurements on the bearing bushings in mounted condition
inform quickly and exactly about the axial and parallel abrasion, without quickly a
time and cost-intensive disassembly of the final drive.
It is recommended to perform the measurements every 5000 working hours to
avoid consequential damages as a result of a too high abrasion amount.
The wear- and tear-measurements are described and illustrated on the following
pages.
AH00515c
Page 2 of 10

1.1. Radial wear determination
a) Preparation
For the measurements proceed according to the following sequence:
Place suitable oil pan for outflowing oil and remove cover (H).
Operate travel gear that the bores (B) in the hollow shaft are placed in vertical
position (see illustration).
Turn the superstructure to the illustrated position.
Hoist the sprocket side by using the attachment, until a wooden plank can be
placed under the track (middle of sprocket).
Lift attachment until the bucket no longer touches the ground.
AH00515c
Page 3 of 10
b) Measuring procedure Method A
Place dial gauge bracket with magnet (1), dial gauge (2) and bolt (3) as shown in
illustration below.
Set dial gauge (2) to 0 when attachment is lifted. Wooden plank must lie under
the sprocket.
Hoist the sprocket side by using the attachment until the wooden plank is free.
Take reading of dial gauge.
c) Measuring procedure Method B
Check by using a feeler gauge between hollow shaft and bearing bush.
AH00515c
Page 4 of 10
d) Determination of wear depending on the Bushing version Old or New
Because of technical development the bushings (P/N 429 649 40 for H 485; H485S;
H 685S/SX; H 655S; PC8000) and (P/N 429 652 40 for PC4000) are made of a new
material and have spiral grooves instead of radial grooves of the former version.
Type
H 485; H485S; H 685S/SX;
H 655S; PC8000
H 285; H 285S; PC4000
PC5500 (#15026 and up)
Bearing assy.*
(outside)
old
new
Bearing assy.*
(inside)
old
new
Bushings *
old
new
31335540
91159540
31335640
92298040
42964940
92298440
36103640
----
92253840
93360240
36103740
---
92253940
93360440
42965240
---
92253740
93360040
* Refer to the respective Parts Catalogue of the machines.
Old bushing version
The radial play after new machine assembly amounts to 0.35 mm to

0.45 mm *.
If the maximum permissible parallel play comes up to 2 mm, the
bushings have to be changed *.
* H 485; H485S; H 685S/SX; H 655S; PC8000 only up to S/N 12041.
PC4000 only up to S/N 08155.
New bushing version
For machines with the new bushings (P/N 922 984 40) the radial
play after installation amounts to 0.74 mm to 0.85 mm.
If the maximum permissible parallel play comes up to 2.0 mm,
the bushings have to be changed.
AH00515c
Page 5 of 10
1.2. Axial play determination of the hollow shaft

a) Measuring procedure
Make bracket (1) as shown in the illustration. The bores dia. have drilled
respectively to the thread diameter (see table).
Screw threaded rods (4) into the hollow shaft.
Mount nuts (3), bracket (1) and bolts (2) as shown in the illustration.
Hoist the sprocket side by using the attachment until the sprocket no longer
touches the ground.
Slide hollow shaft in by using nuts (3) until it comes against the final stop.
Place dial gauge with bracket, set dial gauge to 0.
Slide hollow shaft out by nuts (3) until it comes against the final stop.
Take reading of dial gauge.
When the maximum values (see table) are reached, the play can be reduced to
the new machine value by remachining according to page 5.
Type
H 185 / S
H 285 / S
PC4000
PC5500
H 485 / S
H 685S / SX
H 655S/PC8000
Mounting
bolt (2)
Threaded
shaft (mm)
M 12
M 16
M 16
M 12
M 16
M 16
M 16
M 16
M 20
M 20
M 20
M 20
M 20
M 20
Gauge (S)
(mm)
316
360
360
435
460
460
460
Axial play
new (mm)
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
Max.
permissible
axial play
(mm)
2.75
2.75
2.75
2.75
2.75
2.75
2.75
AH00515c
Page 6 of 10
b) Reducing the axial play by remachining
When the axial play comes up to the maximum value according to the table on page
4, flange (2) can be remachined in area (E) , to bring the axial play to the new
machine condition.
Underpin sprocket, suspend to a crane.

Remove bolts (S) (see page 06), remove flange (2) by means of puller bolts.
Remachine flange (2) in area (E), until the axial play (new value) is reached.
For the mounting , proceed in inverse sequence of the removal.
AH00515c
Page 7 of 10
2. Mounting procedures
2.1 Mounting of drive shaft
a) Gap between drive shaft and cover plate
Install drive shaft (12)
The drive shaft has a multi-spline shaft at both ends.

The correct mounting position is when the longer toothing
faces the gear.
b) Measuring procedure
Check if the drive shaft rests completely against the stop in the gear by means of
a hit with a mounting bar and a metallic click is audible.
Measure dimension A at the cover plate (7).
Measure dimension B according to the illustration by mean of measuring
device (1).
Calculate the existing play with formula:
B minus A = 2 mm.
c) How to establish the recommended gap

Play too much, machine cover plate at surface C.
Play too low, machine cover plate at surface D.
C
Cover
(Drawing
enlarged)
D
B
12
A
AH00515c
Page 8 of 10
2.2 Exchange bushings
The removal of the travel gear is described in Service News

AH00514 (latest version), the mounting of the dual-cone seals
(4) is described in Service Bulletin AH05511 (latest version).
Exchange bushings are available in the following types:

a) Freeze shrinking bush
Exchange bush (3) has to be fixed by freeze- shrinking according to Service Bulletin
21 62a. Afterwards, it has to be remachined to the final dimension according to
table below. Parts (3; 4; 5 and 6) have to be ordered for the conversion. For the part
no. refer to the respective Part Catalogue of the machines.
Type
Dnew (mm)
H 185 / S
355.35+0.07
H 285 / S
400.56+0.06
PC4000
PC5500
400.56+0.06
480.67+0.06
H 485 / S
520.74+0.07
H 685S / SX
520.74+0.07
H655S/PC8000 520.74+0.07
AH00515c
Page 9 of 10
b) Flange Assy. with freezed in bush
If the remachining of the flange under consideration of the tolerances and diameters
is not possible, it is recommended to order the flanges with freezedin and machined
bushings , to shorten the standstill of the machine.
For conversion, the parts shown below (3; 4; 5; 6 and 7) have to be ordered
according to the respective Parts Catalogue of the machines.
AH00515c
Page 10 of 10
3. Final works
(For detailed informations refer to the respective Maintenance Manual of the
machines.)
1. Fill in new oil up to the MAX marking on oil level gauge (3).
2. After short operating period check oil level and gear for leaks.
AH00515c
COMPONENT CODE:
25
REF NO.
AH00519e
DATE
January 15, 2007

Page 1 of 4
This PARTS & SERVICE NEWS supercedes the previous issue AH00519d
SUBJECT:
PURPOSE:
Revision
APPLICATION:
All types
FAILURE CODE:
2500Z9
DESCRIPTION:
The transmission of a torque from the slew pinion to the toothing of the slew ring
causes the slewing of the superstructure. The existing extreme force in this section
requires the separating of the engaged gears by means of grease film, to ensure a
proper damping of shocks and to prevent metallic abrasion.
Adhesive lubricants may be applied by means of an automatic slew ring gear
lubrication system or manually by a spatula, a brush or a spray tin. Automatically
tooth lubrication systems provides the upper most protection because of the
continuously uninterrupted lubrication, permanent checks are not required.
AH00519e
Page 2 of 4
Independent of the lubricant and lubrication system, the

toothing should be visually checked approx. every 500 working
hours. If the check is not possible because of applied lubricant,
the toothing has to be cleaned at several points equally
distributed on the circumference of the slew ring. In case of
wear or damages, Dept. 8151 has to be informed to discuss
suitable remedies.
These adhesive lubricants provide totally different features

compared to the Bearing greases / MPG (e.g. used in the
central lubrication system). Hence, those lubricants must not
replace against each other or mixed.
Example: This may happen when grease (1) pressed out of the
upper sealing system of the races forms too big collar at
the slew ring and penetrates into the toothing (2).
This eventuality must be avoided by removing the excess
grease.
AH00519e
Page 3 of 4
The following table includes several adhesive lubricants providing excellent results on
several machines under different working conditions.
Note: Use these Greases for Swing Circle open Gear Lubrication only
Ambient Temperature
C
F
Supplier
-50
-58
-40
-40
-30
-22
-20
-4
-10
14
0
32
10
50
20
68
30
86
40
104
50
122
60
140
Castrol Molub-Alloy 936 SF Heavy NG

Castrol
Industrie
GmbH
Castrol Molub-Alloy 936 SF Heavy

Castrol Molub-Alloy
958 SF
Castrol Molub-Alloy 936 SF Arctic
BERULIT GA 2500 / BERUGEAR W4000
BECHEM
BERULIT GA 800
BERUGEAR
W 3000
Beru Gear FG 34 (Biodegradable)
Molub unee lubricant 7059
Molub Gear Tac 6895
BEL RAY
Molub Gear Tac
6894 / 6899
ESSO
Dynagear Extra
Ceplattyn KG 10 HMF
FUCHS
LUBRITECH
Ceplattyn KG 10 HMF LT
URETHYN HG O *1)
MOLYBOND
TSG Heavy
Malleus GL 500
SHELL
Malleus GL 400
Malleus GL 25
TEXACO
LUBRITENE
*1)
*2)
Crater 2X Fluid *2)

Lubrene Multi ServOGL
The URETHYN HG O Grease should only be used in Arctic climates where the ambient temperatures fall
to 50 C. In regions where the ambient temperatures do not fall below 40 C,
a grease of the temperature range to 40 C should be used.
Use the Crater 2X Fluid for Spray systems only.
AH00519e
Page 4 of 4
The manually lubrication has to be carried out with the following adhesive lubricants.
Those lubricants are suitable for all temperature ranges.
Company
Product
T1
-5C +60C
+23F +140F
T2
-20C +10C
-4F +10F
T3
-40C -10C
-40F +14F
Voler Compound
KOMATSU
2000 E
Spray
(0,625kg)
P/N 500 893 98
Voler Compound
Special
grease
2000 E
Adhesive lub
(indicate
quantity in kg)
P/N 006 057 98
What has to be done in case of grease exchange according to

the chart on page 03 ?
The new adhesive grease may directly be changed without a
complete cleaning of the toothing. An increased grease supply
after the exchange is recommended until the toothing is
completely applied.
AH00519e
COMPONENT CODE:
K1; J1
REF NO.
AH01513
DATE
06252001
Page 1 of 4
This PARTS & SERVICE NEWS supercedes the previous issues No.: 21491 which
should be discarded.
SUBJECT:
PURPOSE:
Avoiding of cavitation
APPLICATION:
All types
FAILURE CODE:
J100PH; K100PH
DESCRIPTION:
The bleeding of the hydraulic pumps (Axial piston and Gear pumps) and the complete
filling of the suction oil reservoir and the suction lines has strictly be done, to prevent
damages caused by air in the suction system (cavitation). If the oil level decreases in the
suction oil reservoir or the pump flows empty in case of commissioning or repairs the
bleeding of the system is momentous and has to carried out as follows.
The bleeding procedure has to be carried out on all pumps !
Hydraulic
pump
PTO
Suction
line
Hydraulic oil
reservoir
Cock
closed
AH01513
Page 2 of 4
Hydraulic pumps at the Pump Distributer gear (Example PC4000)
3; 4
Gear pumps
1; 2
Axial piston pump (bent axis design)
I; II; III; IV
Axial piston pump (swashing plate design)
AH01513
Page 3 of 4
1. Gear pump
5
4
Cock
closed
Precondition
Hydraulic oil reservoir (1)
filled
Cock (2) closed
Suction oil reservoir (3)
totally empty or decreased
level
Suction line (4) empty
Hydraulic pump (5) empty
3
2
5
outflowing
oil
Measure
Place oil pan for out coming
oil.
Loosen suction line (4)
Open cock (2), when oil
runs out, reconnect suction
line (4)
Cock
opened
3
2
The a.m. precondition has also be observed for the
axial piston pumps.
2.a Axial piston pump (bent axis design)
Precondition (see above)

Measure
Remove plug (6)
Open cock (2)
When oil flows out of the
bore, insert plug (6) tighten.
Cock
opened
The bleeding plug (6) may be placed different, it depends on
the design and mounting position.
AH01513
Page 4 of 4
2.a Axial piston pump (swashing plate design)

The pump housings has to be filled up with hydraulic oil before installation and after
repairs via the special bore (A) or via the leak oil connection (B).
The suction lines of the Axial piston pumps (swashing plate
design) have to be bled via plug C.

For that open the plug and wait until oil is coming out.
After the bleeding procedure, the hydraulic oil reservoir has to be refilled to the
permissible level.
AH01513
COMPONENT CODE:
2500
REF NO.
AH01516a
DATE
09062001
Page 1 of 7
This PARTS & SERVICE NEWS supersedes the previous issue No. AH01516
SUBJECT:
Lift off the superstructure platform from the undercarriage for

instance to changing the swing circle (slew ring)
PURPOSE:
Description of the method for preparing the repair works
APPLICATION:
H 485; H 685; H655; PC8000-1

(from serial number 12001 up)
FAILURE CODE:
2500CA
DESCRIPTION:
1. Preparation
1.1 Park the excavator at a smooth, solid and big enough mounting place.
1.2 Make available the following tools and aids (see Fig. Z 21169):
Two cranes 40t for disassembly and assembly with various rigging materials
(for a time)
Forklift
Four hydraulic jacks (200t)
4 chain hoists for the cylinder assembly and cylinder securing respective
1 hydraulic torque wrench
Lifting brackets (3)* for lifting up the superstructure at the front lever arms
2 concrete blocks (1) - 150/400/200 cm - and 4 concrete blocks (2)
- 100/150/50 cm - all blocks with reinforcing and pull eyes; the upper sides and the
undersides have to be even.
For the statics of the concrete blocks contact our Department Service Information
(8151.30).
2 wedges(5) for the compensation of the slope of the girder at the back of the
superstructure
2 metal sheets(6) 300/300/30 for power allocation
Dummy flanges for closing of the pipes and hoses (part of the excavator delivery).
* Excavators with serial numbers 12001 to 12011: You can borrow 2 lever arms from
the Komatsu Service Department.
* Excavators with serial numbers from 12012 up
Special device must be prepared

according the attached drawing.
AH01516a
Page 2 of 7
2. Weights (bullclam attachment)

Boom with 4 cylinders
approx. 55.000 kg
Stick with cylinders
approx. 32.000 kg
Counterweight
approx. 2 x 30.000 kg or 1 x 50.000 kg
Swing circle with mounting cross approx. 18.000 kg
3. Working sequence (see illustration Z 21169)

Removal of the bullclam bucket; close all pipes and hoses.
Removal of the stick
Loosen the stick cylinders at the stick and secure by means of a chain hoist.
Retract the cylinder and secure against extending.
Remove the stick.
Removal of the boom
Remove and close the hoses at the boom.
Loosen the boom cylinder at the superstructure and secure it by means of a chain hoist.
Remove the boom.
Remove the Counter weights
(only at excavators with serial numbers 12001 to 12011)
Preparation for the excavator disassembly
Put the 2 big concrete blocks (1) in the middle beside the crawlers.
Put on every big concrete block 2 little concrete blocks (2) with a distance of about 1 m.
Turn the superstructure for about 90.
Mount the lifting brackets (3) with the boom cylinder pins to the superstructure.
Line up 2 little concrete blocks, 2 hydraulic jacks and 2 metal sheets under the lifting
brackets (the lifting height has to be approx. 80 mm).
Line up the other 2 little concrete blocks, 2 hydraulic jacks and 2 metal sheets at the
back site of the excavator under the longitudinal girders of the superstructure.
Put the metal wedges for compensating of the slope between metal sheets and carrier;
tack weld the wedges with longitudinal welding seams.
Remove the collector ring
Remove the swivel joint; close the pipes
Disconnect the swing circle (slew ring) from the undercarriage by removing the
outer bolts of the swing circle.
Before removing the lube lines from the swing circle number line and respective
injector with the same number.
Extend the 4 hydraulic jacks so far that they touch the lever arms and superstructure.
Disconnect the high pressure hoses from the ports (manifold) at the travel motors of
the excavator.
Temporarily reconnect the flow and return line hoses to prevent unnecessary loss of
system hydraulic oil.
Connect the supply and return lines of the foreign hydraulic system to the excavator
travel motors by means of long hoses.
Use small diameter hoses e.g. inner dia. 16 or 20 mm, because even under pressure
these ones are easier to handle (more flexible).
AH01516a
Page 3 of 7
Check these hoses for suitability for pressure up to 350 bar.
To connect these hoses to the travel motors make use of the plug flanges that are
used to plug the ports when the excavator is shipped from factory. Drill a hole into
these and weld on a welding - flange.
Release the parking brakes by means of manual pump (pressure among 26 and 50
bar). Connect both brake pressure lines by a T-union and connect this to the manual
pump. Release pressure: 26 bar.
Connect the leakage lines of the excavator travel motors to the hydraulic tank of the
foreign hydraulic system. It is vital to check the hydraulic oil level of the foreign
hydraulic continuously.
Lift up the superstructure for about 80 mm and secure it against lowering.
Travel out the undercarriage backwards.
Install a mounting cross and remove the slew ring downwards by using of a crane.
Assembly of the new swing circle
Carry out the preparation and the assembly corresponding to the Service Bulletin
AH00511.
Note that the superstructure is turned for 90!
Therefore the unhardened spot S of the inner and the outer
ring of the swing circle have to be turned in an angle of 90 to
each other for installation (Z22137).
After finishing of replacement of the swing circle both
punchmarked unhardened spots S are at the same place.
Assembly of the removed components.
After removing of the wedges at the back of the superstructure smooth the girder.
Bleed all hydraulic cylinders carefully after the assembly,

otherwise serious damages are possible (see service bulletin
21-531).
AH01516a
Page 4 of 7
AH01516a
Page 5 of 7
For the statics of the concrete blocks please

contact our Department Service Information
(8151.30).
AH01516a
Page 6 of 7
AH01516a
Page 7 of 7
Special device for excavators with serial number 12012 up
AH01516a
COMPONENT CODE:
10
REF NO.
AH01523c
DATE
July 28, 2006

Page 1 of 3
This PARTS & SERVICE NEWS supersedes the previous issue No.AH01523b which
SUBJECT:
PURPOSE:
Revision (Addition of a new model)
APPLICATION:
H 185SE (06099 and up); H 255SE (06122 and up);

H 285SE (78137 and up); H 655SE; PC3000; PC4000;
PC5500; PC8000
FAILURE CODE:
1000FA
DESCRIPTION:
The above mentioned excavators are equipped with highly flexible couplings.
The inspection for the indicated tightening torques and the visual inspection for cracks
have to be carried out in the following intervals (refer also to the Maintenance Manual of
your excavator):
250 working hours after commissioning

Every 2000 working hours or every 6 month
When should the elastic elements be changed?
In case of cracks in the marked area (arrows in illustration A and B)

After 15.000 working hours or after 10 years.
In case of new installation or exchange, the following alignment tolerances have to be

checked by using a gauge and, if necessary, corrected.
Excavator
Type
H 185 SE
H 255 SE
H 285 SE
H 655 SE
PC3000 E
PC4000 E
PC5500 E
Clutch
Part-No.
551 980 40
655 615 40
896 479 40
902 215 40
655 615 40
Radial (x)*
misalignment
1,0 mm
1,0 mm
1,0 mm
0,35 mm
1,0 mm
0,35 mm
1,0 mm
Axial (y)*
misalignment
2,0 mm
2,0 mm
2,0 mm
2,0 mm
2,0 mm
2,0 mm
2,0 mm
907 174 40
655 615 40
902 215 40
0,35 mm
2,0 mm
PC8000-E
907 174 40
* Explanation refers to illustrations at the next page.
Angular (z)*
misalignment
0,5
0,5
0,5
0,5
0,5
0,5
0,5
Installation
Dimension (a)
477 2 mm
527 2 mm
645 2 mm
866 2 mm
527 2 mm
866 2 mm
527 2 mm
0,5
866 2 mm
AH01523c
Page 2 of 3
axial
radial
angular
Inspection of the coupling elements

1. Move the cover ring(3) to the left (refer to the removing procedure)
2. Inspect the surface of the rubber elements visually (If there are 2 rubber elements
illustration B - use a small mirror)
Removing of the coupling element/s
1. Remove nuts (1) and bolts (2).
2. Move the cover ring (3) to the left.
3. Remove the bolts (4).
4. Move the rubber element/s(5) to the right and remove it/them.
5. Remove the screws (6) and the ring (7).
Installing of the new coupling element/s
1. Bolt ring (7) and the rubber element (5) together with the screws (6).
2. Further installation reverse order to the removal.
Excavator type
H 185SE
Tightening torques Tightening torques Tightening torques

A (Nm)*
B (Nm)*
C (Nm)*
215.0
560.0
H 255SE; PC3000;
480.0 + 50
175.0 +20
PC5500; H 285 SE
H 655SE; PC8000;
250.0 +30
960.0 +110
PC4000
* Threads and bolt heads must be greased carefully with engine oil.
86.0
70.0 +
960.0 +110
AH01523c
Page 3 of 3
3
Illustration A
2
A
5
B
7
gearbox side
C
6
motor side
Illustration B
3
1
2
A
B
4
C
motor side
gearbox side
5b
5a
AH01523c
COMPONENT CODE:
30; 63
REF NO.
AH01531A
DATE
06122002
Page 1 of 9
This PARTS & SERVICE NEWS supersedes the previous issues No. 21-426; 21-549 and
AH01531 which should be discarded.
SUBJECT:
Hydraulic accumulators testing and refilling
PURPOSE:
Regular check
APPLICATION:
All types
FAILURE CODE:
307EPB; 6347PB
DESCRIPTION:
The testing and refilling of the hydraulic accumulators have to be performed
by testing- and refilling device Part no. 761 520 73.
When ordering this particular device, please always indicate country of destination.
1. Testing of existing gas

pressure at piston and
diaphragm accumulators
For testing of existing gas
pressure at bladder accumulators,
refer to page 7 9.
Stop engine.
Allow pressure relief of the

system to be checked.
Remove protective cap from accumulator.
Unscrew a union of the feeding line in order

to allow the hydraulic oil to pour out.
AH01531A
Page 2 of 9
The testing- and refilling device includes following pressure gauges:
0 to 25 bar
0 to 100 bar
0 to 250 bar
Screw the pressure gauge with

the correct pressure range into
the testing and refilling device.
Screw home screw (14) at the

filling device.
Loosen the socket-head screw

of the gas valve by turn
with a hex key 6 mm.
Screw filling device without

hose carefully by hand onto
accumulator.
Observe correct position of

the o-ring.
Check valve in hose connection is operative only if hose is not

connected.
Turn T-handle (12) several

times in both directions
until it is engaged in
socket head of gas filler screw (11).
By means of the T-handle unscrew

gas filler screw (11) by 4 to 5 turns
until pressure gauge indicates the
existing gas pressure.
AH01531A
Page 3 of 9
For the specified gas pressure of the piston-diaphragm and bladder

type accumulator, refer to the circuitry diagrams in the Operation Manual.
Compare the pressure reading on the gauge with the specified gas pressure.
If the pressure reading is too low, the accumulator has to be refilled.

To fill the accumulator, a pressure reducing valve must
be used.
Only nitrogen must be used to fill the accumulator.
2. Filling of the accumulator
Close shut-off valve (5) at the bottle pressure reducing valve. Turn
in completely outlet screw (14) of filling device and install the hose.
AH01531A
Page 4 of 9
Open valve (8) of nitrogen

bottle and check bottle pressure.
The bottle pressure must always be
higher than the pressure specified
for the accumulator.
adjust specified accumulator

pressure with pressure-reducing
valve (6).
Turn out the filling screw (11)

by means of the T-handle of the
filling device.
Open slowly shut-off valve at

bottle pressure reducing valve
and let nitrogen flow into
accumulator, until pressure gauge
on filling device indicates the
specified pressure. Then close
shut off valve.
AH01531A
Page 5 of 9
Wait for temperature to be

equalized (approx. 5 min.)
and open outlet screw (14)
to let the pressure drop to
the specified value.
Close outlet screw (14).
Screw in tightly screw (11) by

means of T handle (12).
Open outlet screw to let

nitrogen escape from filling
device.
Disconnect hose connection and

unscrew filling device.
Fasten O - ring (13) to the

testing device.
Tighten the screw (11) by means

of a hex key 6 mm.
AH01531A
Page 6 of 9
Reinstall protective card and

retighten union in feeding line.
Close bottle valve (8).
Turn out completely the

T handle at the pressure
reducing valve (6).
AH01531A
Page 7 of 9
3. Testing of existing gas pressure bladder accumulators

The testing- and refilling device includes
pressure gauges:
0 to 25 bar
0 to 100 bar
0 to 250 bar.
Screw the pressure gauge with the correct

pressure range in the testing- and refilling
device.
Shut down the engine.
Allow pressure relief of the system to be
checked.
Unscrew the feeding line in order to allow the
hydraulic oil to pour out.
Remove cap (1) and nut (2).
Do not remove O - ring (3).
Check valve in hose connection is

operative only when hose is not connected.
Turn the socket head screw (4)

installed in the adapter (2) a little bit.
Mount testing- and refilling device to adapter
(2).
Install adapter (2) to testing connection (3).
Turn in completely outlet screw of the filling
device.
Turn T handle (12) several times in both
directions until it is engaged in the screw (4) of
the adapter (2).
By means of the T handle (12) turn in the
screw so far that the existing gas pressure is
indicated by the pressure gauge.
Do not turn in the screw any further; the gas
valve may be destroyed.
AH01531A
Page 8 of 9
If the pressure reading does not correspond with the nominal filling pressure,
the accumulator has to be refilled.
4. Filling of the bladder accumulator

To fill the accumulator, a pressure reducing valve must be
used.
Only nitrogen must be used to fill the accumulator.
Close the shut off valve (5)

on the pressure-reducing valve.
Turn in completely the outlet

screw (14), see illustration on page 5.
By means of the T-handle (12), turn

out the screw (4) of the adapter (2)
until the gas valve in the testing
connection (3) of the accumulator is
closed. After that, install connecting hose.
Open the valve (8) at the nitrogen

bottle and check the gas pressure of
the bottle.
The gas pressure of the nitrogen bottle
must always be higher than the specified
filling pressure of the accumulator.
Adjust the specified filling pressure

by means of setting screw (6) of the
pressure reducing valve.
Open the gas valve in the testing
connection (3) of the accumulator ba
turning in screw (4).
Slowly open the shut off valve (5) at

the pressure reducing valve and fill
the accumulator until the pressure
gauge (7) of the testing and refilling
device indicates the specified filling
pressure.
Then close the shut-off valve (5).
AH01531A
Page 9 of 9
Wait for temperature to be

equalized (approx. 5 min) and,
if necessary, reduce pressure
with outlet screw (14) or let
the pressure reach the specified
value according to page o4.
Close outlet screw (14).
By means of T-handle (12) turn

out screw (4) from the adapter (2)
till the gas valve in the testing
connection (3) is closed.
Open outlet screw (14) that the

nitrogen can escape from the
filling and testing device.
Close the nitrogen bottle and
remove the filling- and testing
device, filling hose and pressure
reducing valve.
Turn out completely screw (6) of
the pressure-reducing valve.
By doing so, the spring-reducing
valve is discharged.
Re-install protection cap in the

testing connection.
Re-tighten the hydraulic line.
AH01531A
COMPONENT CODE:
25
REF NO.
AH02513b
DATE
January 4, 2005
Page 1 of 4
This PARTS & SERVICE NEWS supersedes the previous issue No. AH02513a
SUBJECT:
PURPOSE:
In time ordering of a new swing circle

in order to prevent unexpected downtime
APPLICATION:
All types
FAILURE CODE:
2500CA
DESCRIPTION:
For assessing the condition of the swing circle bearing, we recommend that its normal
wear rate is determined.
The first measurement must be performed when the excavator is put into operation in order to
obtain a base value for subsequent repeat measurements.
The following measurements have to be effected:
1. Period of the first 10.000 h:
2. Period more than 10.000 h:
every 5.000 working hours;

every 2.500 working hours.
After finishing the measurements, record the values obtained in a tabular form.
The diagram shows the principle of bearing wear progression.
If the increased wear situation is reached, prepare the changing of the swing circle.
We recommend to turn the swing circle (180) after 20 000

working hours.
normal wear
increased extrem wear

wear
Axial movement/wear
mm
Base value
Working hours
h
AH02513b
Page 2 of 4
Measurement procedure
1. Park the machine on level ground.

2. Slew the attachment to the normal working position (idler wheel in front).
3. Remove cover as shown in the photos (Illust. 7 and 8).
4. Clean the center slew gear tooth and the contact point on the superstructure.
5. Install the dial gauge* as shown in the photos.
6. Turn the swing brake switch in the on position.
7. Straighten the attachment fully (lmax) and raise the shovel approx. A=3 m over the
ground (Illust. 1, 3 or 5).
8. Set measuring instrument (dial gauge*) to zero.
Make sure the area below and around the excavator is clear of
all persons before you start operating.
9. Move the attachment in the shown position (Illust. 2, 4 or 6).

Lower the attachment until the track lift off the ground up to the sprocket (B).
Use for all measurements the same distances A and B.
10. Move the attachment in the normal parking position.

11. Read measurement M 1 (out of the memory) and record in the table (page 4).
12. Repeat the measuring procedure at the same point for a 2nd value (M 2).
13. Remove the dial gauge, swing the superstructure 180 degrease and repeat the
measuring procedure two times.
* We recommend to use a digital dial gauge with min. / max. measuring value
memory (Part No. 794 537 73).
Photo only as example
AH02513b
Page 3 of 4
AH02513b
Page 4 of 4
Excavator Typ:
Planned
h
0
Actual
h
Date
Serial number:
Front
M1
Front
M2
Mfront =
(M1 + M2)/2
Rear
M1
Rear
M2
Mrear =
(M1 + M2)/2
5 000
10 000
12 500
15 000
17.500
20 000
22.500
25 000
27.500
30 000
32.500
35 000
37.500
40.000
AH02513b
COMPONENT CODE:
75
REF NO.
AH02521d
DATE
August 18, 2009

Page 1 of 10
This PARTS & SERVICE NEWS supersedes the previous issue Number AH02521c which
SUBJECT:
PURPOSE:
Revision
APPLICATION:
H 185 to PC8000
FAILURE CODE:
752DCA
DESCRIPTION:
1.
2.
3.
4.
5.
6.
7.
Preconditions for the measurements

Adjusting range for guide wheels
Chain elongation / measured over three track pads (4 pins)
Circular pitch (Sprocket / Track pad)
Wear of track pads (Roller contact surface)
Conditions for changing to oversize sprockets
Tables
The professional and regular inspection increases the service life of the track group and
can avoid early and very expensive repairs, including unforeseen standstill of the machine.
It is recommended to perform the inspections every 3 month or 1500 working hours
according to the description and to fill in the measured values to the table on page 10.
The measurements are described in detail and illustrated on the following pages.
To prevent unnecessary problems and standstills and to assure fast help when wear limits
are reached, it is recommended to send the filled-in tables in the mentioned intervals to
Komatsu Mining Germany, Service Department 8151.
Illustration 1
AH02521d
Page 2 of 10
1.
Preconditions for the measurements:
1.1.
Cleaning of the track group, according to the Maintenance Manual
Illustration 2
1.2
Track sag (A):

On Machines without the hydraulic track - tensioning system
H 185S
up to max. 230 mm
H 285 - H 285S
up to max. 300 mm
H 485 - H 485S
up to max. 420 mm
1.3
Track sag (A):

On Machines with hydraulic track - tensioning system
No specification, since self-regulating
Illustration 3
AH02521d
Page 3 of 10
2.
Adjusting range for guide wheels
Illustration 4
Legend
(1)Guide wheel
(2)Slide block
(3)Stop plate
X Adjusting range for track tension
The adjusting range for track tension is the distance X between guide wheel slide block
(2) and stop plate (3). Depending on the stretching of the track the slide block (2) may
come in contact with stop plate (3). In such a case, it must be ensured that the track does
not become too loose. Depending on track condition; the removal of one track pad will
restore the adjusting range X. If necessary contact our Service Department for more
information.
AH02521d
Page 4 of 10
3.
Chain elongation / measured over three track pads (4 pins)
This wear check has to be carried out in 4 equally distributed areas of the track chain
(L1 to L4 - l.h. and R1 to R4 - r.h.).
Turn superstructure 90 to the travel direction.
Retract attachment and lower bucket on the ground until the chain has no longer
contact with the ground.
Block the machine against inadvertent lowering with suitable
devices.
Turn sprocket until the first measuring area (L1) is located at the deepest point of sag T).
To measure the areas L2 - L4 turn the chain always forward

until point T is reached.
To obtain a comparable measuring result, stop the main drive motor/engine of short
duration, so that the track tensioning system is released to pilot pressure.
Place the points of the dividers into the centre bores of pins 1 and 4 of the measuring
area L1 / R1, determine the distance and record in the table on page 10.
Repeat measuring procedure at measuring areas L2 / R2 to L4 / R4.
Illustration 5
AH02521d
Page 5 of 10
4.
Circular pitch (Sprocket / Track pad)
For this inspection, the excavator has to be placed on an even surface and only one chain
has to be moved, like turning.
Diesel engine:
Electric motor:
Operate at low idle.

Operate joy-stick slightly.
Move l.h. track group forward (Sprocket rotation F = forward), until the contact area of
the sprocket tooth (0) and the track-pad lug (0) is in the uppermost position without
loosing contact, (Refer to illustration 6 A, page 6 as example).
Measure gaps (X1). Measure inside and outside of the sprocket between the sprocket
teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain.
Sprocket tooth (7) has to be used irrespective of the numbers

of teeth of the sprocket (possible 14 or 15 teeth).
Record the values into table -circular pitch A- on page 10.

Repeat the measurements on the r.h. track group.
Move l.h. track group back (Sprocket rotation R = backwards), until the contact area of
the sprocket tooth (0) and the track-pad lug (0) is in the lowest position,
(Refer to illustration 6 B, page 6 as example).
Measure gaps (X2). Measure inside and outside of the sprocket between the sprocket
teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain.
Record the values to the table -circular pitch B- on page 10.
Repeat the measurements at the r.h. track group.
5.
Wear of track pads (Roller contact surface)
Stop the engine/motor and secure the machine against unintentional movement.
Mark 3 track pads of each track group (l.h. track group and r.h. track group) to make
repeated measurements in the future comparable.
Take a ruler to measure the wear of the roller contact surface. The ruler needs an even
contact surface, if not exist, prepare the track pad as necessary.
(Refer to illustration 6 C, page 6).
Record the measuring results in the form sheet on page 10.
For wear limits of individual parts please refer to

P&S News AH06507 Undercarriage wear limit values.
AH02521d
Page 6 of 10
)
The real position
of the sprocket
lug (0) might
deviate from
these
illustrations.
Illustration 6
AH02521d
Page 7 of 10
6.
Conditions for changing to oversize sprockets
1.
If the connection point of Roller path depth and Elongation is in the oversize
sprocket area* and all X dimension (X1 and X2) becomes zero, only then change
to oversize sprocket.
2.
If the connection point of Roller path depth and Elongation is in the oversize
sprocket area* but not all X dimension (X1 and X2) becomes zero, run further with
the standard sprockets as long as X1 or X2 reaches zero.
3.
If the connection point of Roller path depth and Elongation is in the standard
sprocket area* run further with the standard sprockets as long as you reach the
oversize sprocket area and all X dimension (X1 and X2) becomes zero.
* refer to illustrations 7 to 10
For the exchange of the oversize sprockets, refer to Service Bulletin AH00514.
AH02521d
Page 8 of 10
Minimum wear for oversize sprocket PC 3000-6

1145
Elongation over 4 pins [mm]
1144
Condition: X1 and X2 becomes zero

1143
1142
1141
1140
1139
1138
1137
1136
1135
10
11
12
13
14
15
16
17
Roller path depth [mm]
Illustration 7

1212
1211
1210
1209
1208
1207
1206
1205
1204
1203
1202
1201
1200
1199
1198
1197
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Illustration 8
AH02521d
Page 9 of 10

1421
1420
1419
1418
1417
1416
1415
1414
1413
1412
1411
1410
1409
1408
1407
1406
1405
1404
1403
1402
1401
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Illustration 9

1472
1471
1470
1469
1468
1467
1466
1465
1464
1463
1462
1461
1460
1459
1458
1457
1456
1455
1454
1453
1452
1451
1450
1449
1448
1447
1446
1445
1444
1443
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Illustration 10
AH02521d
Page 10 of 10
7.
Tables for measurements
Machine-Type :
Customer :
Oversize sprocket ? :
(left hand side)
Oversize sprocket ? :
(right hand side)
NO
Serial-No. :
Location :
Date of installation:
...................
at operating hours:
.....................
Date of installation:
...................
at operating hours:
.....................
YES
NO
YES
Chain elongation (Illustration 5):

Measuring area
W-dimension [mm] via 4 pins
Left hand crawler track L

L1
L2
Chain elongation (Illustration 5):

Measuring area
W-dimension [mm] via 4 pins
Operating hours :
Date of measurement :
Part-No. of track pad :
L3
L4
Right hand crawler track R
R1
R2
R3
R4
Circular pitch:
Illustration 6 A
3 points (equally distributed on the chain)

1
Sprocket side
inside
2
outside
inside
3
outside
inside
outside
X1-dimension [mm] L.H

X1-dimension [mm] R.H
Illustration 6 B
3 points (equally distributed on the chain)

1
Sprocket side
inside
2
outside
inside
3
outside
inside
outside
X2-dimension [mm] L.H

X2-dimension [mm] R.H
Wear of Track pads (Illustration 6 C):

Track pad
Side
No.1
No.2
L.H.
L.H.
No.3
No.4
No.5
No.6
L.H.
R.H.
R.H.
R.H.
Dimension D
[mm]
Number of cracked track pads

left hand crawler track
right hand crawler track
AH02521d
COMPONENT CODE:
03
REF NO.
AH03506b
DATE
October 25, 2003

Page 1 of 5
This PARTS & SERVICE NEWS supersedes the previous issue AH03506a which should
be discarded.
SUBJECT:
PURPOSE:
Replacement of the bearings
APPLICATION:
PC4000; PC5500; PC8000
FAILURE CODE:
0373CA
DESCRIPTION:
Two types of bearing units are used for the cooler fans at the above mentioned excavator
models:
1. Grease lubricated bearings
2. Gear oil lubricated bearings
We recommend to replace these bearings to avoid

consequential damages according to the following table:
Bearing unit
Replacing time after:
Grease lubricated bearings
8 000 working hours
Gear oil lubricated bearings 10 000 working hours *
* or if damage or a leak has occurred.
The hydraulic motors for the fans should be replaced

preventively every 10.000 working hours.
AH03506b
Page 2 of 5
Hints for replacement:

1. Grease lubricated bearings
1 Bearing retainer
2 Shaft
3 Hydraulic motor
4 Fan
5 Bearing
6 Grease nippel
7 Circlip
8 Bolt
9 Bolt
10 Locking plate
1. Remove the hydraulic and the grease lines; the fan; and then the motor.
2. Remove the bearings and the fan shaft.
3. Clean all parts carefully.
4. Install the first bearing (5) and fill the chamber between the bearings to 50% with
grease.
5. Install the shaft with the first bearing (5) and the grease into the bearing retainer.
6. Install the second bearing and fix it with the circlip (7).
(Install also the sleeve between the bearings if applicable.)
7. Grease the hydraulic motor drive shaft with Optimol paste white T and fill the
chamber in the fan shaft to 50% with normal grease according to the drawing above.
8. Reinstall the bearing hub, the fan and the motor.
9. Reconnect all lines.
Grease the bearings every 500 working hours with maximal 2
strokes with the hand greasing pump.
AH03506b
Page 3 of 5

1 Bearing retainer
2 Shaft
3 Circlip
4 Bearing
5 Shaft grommet
6 Shaft seal
7 Plug
Fill the chamber at the
lip type seal with grease.
1. Remove the hydraulic lines; the fan, then the complete unit.
2. Drain off the gear oil and remove the motor, the bearings, the fan shaft, the shaft
grommet and the shaft seal.
3. Clean all parts carefully.
4. Check the dia. d according to drawing and table at the next page.
5. Install a new shaft grommet with the flanged end at first (press it into depth a see
next page).
6. Do not remove the seam of the shaft grommet.
7. Install the 1st bearing and the shaft seal into the bearing retainer.
8. Grease the shaft and install it.
9. Mount the 2nd bearing(4) and the circlip.
10. Check the spline and grease the hydraulic motor drive shaft with
Optimol paste white T.
11. Reinstall the motor by using a new O ring and mount then the fan.
12. Fill in the bearing retainer gear oil according to the Maintenance Manual.
13. Reconnect the hydraulic lines.
AH03506b
Page 4 of 5
PC4000
PC5500
PC8000
Oil
cooler
Water
cooler
Oil
cooler
Water
cooler
Oil
cooler
Water
cooler*
Part no.
Part no.
Part no.
Part no.
Part no. Part no.**
Part no.
Fan mounting
89590740 90202640 91091140 90479140 90389040 93394140 90968540b
(assy.)
Repair kit ***
Press depht
"a" (mm)
Shaft dia. "d"
(mm)
79296573 79296673 79296573 79296673 79296773 79484873 79296873
4 -0,5
3,7 +0,2
4 -0,5
3,7 +0,2
80 0,05
110 0,05
80 0,05
110 0,05
4 -0,5
6,4 0,8
1000,05 1300,025
4,3 0,8
85 0,05
* Serial No. 12040 up see drawing next page

** Serial No. 12048/12049 only
*** The Repair kit includes: 2 bearings; 1 shaft seal; 1 shaft grommet; 1 O-ring
Fill the chamber at the lip type seal with grease.
AH03506b
Page 5 of 5
PC8000-6 Water cooler fan bearings
Intermediate ring
AH03506b
COMPONENT CODE:
71
REF NO.
AH03510
DATE
2nd June 2003

Page 1 of 18
SUBJECT:
PURPOSE:
Hints for handling
APPLICATION:
PC4000; PC5500 (15012 - ); PC8000
FAILURE CODE:
7168Z9
DESCRIPTION:
At our excavators PC4000; PC5500 (15012-) and PC8000 the new bucket tooth system
POSILOK is used. In the following is showed how to handle the parts of this system.
Page
2
1.
Overview
1.1
1.2
Komatsu standard version

Optional version
2.
The Points
2.1
2.2
Removing the points

Installing the points
4
5
2
2
3.
The Adapters
3.1
3.2
3.2.1
3.2.2
3.2.3
3.3
3.4
Adapter removal
Nose rebuild
Nose end and sides rebuild
Nose flats rebuild
Rear corner rebuild
Adapter installation
Retighten Sidewinder Pin
6
8
8
9
9
10
11
4.
Wear Caps
11
4.1
4.1.1
4.1.2
4.2
11
11
12
13
4.2.1
4.2.2
Lock style wear caps (PC4000)

Removal
Installation
Non lock style wear caps
(Option PC4000; PC5500; PC8000)
Removal
Installation
5.
The Shrouds
14
5.1
5.2
5.2.1
5.2.2
5.2.3
5.3
5.4
Removal the shrouds

Installing the shrouds
Prepare the surface
Position the bosses
Welding the bosses
Inspecting Worn Shrouds
Installing (Shrouds and Pins)
14
15
15
16
17
17
18
13
13
AH03510
Page 2 of 18
1.
1.1
Overview
Komatsu standard version
Additional wearcap for plate

lips version (PC4000)
Wearcap
1.2
Optional version
For changing to optional version new points, new adapters and

the wearcaps are required.
AH03510
Page 3 of 18
Classification of the Tooth Systems to the Excavator Types
Type of Excavator
PC4000
PC5500
PC8000
- ( 12030)
- ( 12034)
Shovel Version
S 110
S 130
S 145
S 130
S 130
Backhoe Version
S 95
S 130
S 145
-
Component Preparation
Prior to installing the new tooth system components:
Thoroughly clean all bearing surfaces on the tooth base, adapter and pin.
Visually inspect top and bottom of tooth base for wear, refer to following sections.
Replace all damaged components.
2.
The points
4
2
5
1
1
Point
Posilok Locking Pin
Integral rubber lock
Adapter
Mating rails between point and adapter
Stabilizing flats
AH03510
Page 4 of 18
2.1
Removing the points
All persons performing maintenance work should wear a

approved hard hat, safety glasses, steel-toed shoes and
gloves.
To avoid injury to others, keep people not directly involved well
out of the way.
1. Removal
tool between the
(PART
NO. 79350273)
Posilok Pin and the lock
2. Drive the Posilok Pin out

using a removal tool
(Part No.
793 502 73)
Use this end to start

the Posilok Pin out.
Use this end to

drive it through.
Remove the vertical drive-through pin using a hammer and a pin removal tool
(Part No. 79350273).
Make sure to insert the tip of the removal tool between the Posilok Pin and the rubber
lock.
In order to loosen the point for removal from the adapter, it may be necessary to tap
the sides of the point to loosen fines.
AH03510
Page 5 of 18
2.2
Installing the points
Preparation
Prior to point replacement, make sure adapters are clean and free of damage.
Carefully inspect adapters for excessive wear.
If the nose is worn or if insufficient wear metal remains to see adapters through their work
cycle, they should be replaced with new ones.
Vertical locking pins: Locking pins may be reused provided they do not show signs of
significant wear, damage or distortion.
Points: If you are going to install new points, make sure the rubber lock is installed so the
arrows embossed on the surface of the lock are pointing forward (toward the tip of the
point).
Position the locking

pin and drive it in.
Vertical
locking pin
Point
Install the points onto the adapters.

After positioning a point onto its adapter, drive in the vertical locking pin using an
4 kg (8lb) hammer.
The rubber lock keeps the
Posilok Pin securely in place.
Posilok Pin engages the lock.
Topside and
forward
Drive in the Posilok Pin until it engages the lock.

When the Posilok Pin is correctly in place, the rubber lock fits
into the slot of the Posilok Pin to secure it.
AH03510
Page 6 of 18
3.
The adapters
3.1
Adapter removal
Prior to using an adapter tool be sure that the following safety
precautions are followed at all times:
Always wear proper safety equipment including hardhat, gloves,
safety glasses and steel-toed shoes.
Never exceed the lifting capacity of the tool.
Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb)
- for the S145 tooth system.
Tool is intended for vertical lift only.
Always stand clear of the raised adapter.
Never allow anyone to work under the adapter until it is secured to
the lip by the appropriate locking mechanism.
Always use the safety features (lock and safety pin) as indicated.
Never use hand tools or other fastener to secure the sleeve. Never
use anything other than the sleeve provided to support the adapter.
Replace the tool when it becomes visibly damaged or distorted. Do
not attempt to repair a damaged tool.
Position the bucket with the nose tilted slightly upward.

Clean debris from adapter Sidewinder Pin head slot and remove cap from Sidewinder
Pin head.
(The fastening Sidewinder Pin may become frozen in the nose hole by cemented fines.
In this event, use either a hammer and drift or a porta-power, applied directly against
the end of the Sidewinder Pin sleeve, to force the Sidewinder Pin out. Use a striking
plate, as needed, to avoid hammering the end of the Sidewinder Pin base.
With body completely retracted, insert drift that fits inside hex recess and hammer
Sidewinder Pin through nose hole.
Alternately, drift can be placed against outer sleeve. Avoid hammering over hex recess
and thereby peening over the edges of this recess.)
AH03510
Page 7 of 18
Insert Allen hex bit (14; 17 or 19 mm) into the head of Sidewinder Pin and turn
counterclockwise (only for S 95 clockwise) until the Sidewinder Pin body is fully
retracted. Do not continue to turn after stop is felt.
The Sidewinder Pin is designed for operation with a ratchet wrench and should not
normally require use of an air-impact wrench.
For removing the adapter the Sidewinder Pin need not to

remove out off the adapter base if it is in good condition.
If the Sidewinder Pin have to be removed the end opposite the
hex socket must be removed at first.
Lifting tools (refer to drawing next page):

122K (793 503 73):
(for S145)
- Remove the safety pin of the adapter tool and slide the
sleeve off the arm.
- Guide the arm through the square hole in the nose of
the adapter.
- Arm must be pointed towards rear of the adapter.
- Slide the sleeve onto the arm, align the holes in the arm
and sleeve and install safety pin.
112K (793 504 73):

(for S130)
- Guide the lug on the end of the arm through the

D-shaped hole in the nose of the adapter.
- Rotate the arm towards the rear of the adapter until the
tool is aligned with the adapter 90 and slide the lock
down through the D-shaped hole and insert the safety pin.
AH03510
Page 8 of 18
Part No. 793 503 73 (for S145)

Part No. 793 504 73 (for S130)
Rotate the arm 90 for fixing
Safety pin of the adapter tool

Sleeve
Using a boom rated at 270 kg (600 lb) or greater (PC5500 and PC8000)
or a boom rated at 230 kg (500 lb) or greater (PC4000), hook into the shackle at the
top of the arm and remove the adapter.
3.2
Nose rebuild
Nose fit: This tooth system is designed to operate with movement of the adapter on the
nose. However, movement may become excessive over long term service because of
nose wear. In this event, the nose can be rebuilt in the indicated areas with welding and
grinding.
3.2.1 Nose end and sides rebuild
AH03510
Page 9 of 18
Place the nose side template on the centerline of nose.

Nose side template
Size
S 95
S 110
S 130
S 145
Nose Side
Template
79350573
79350773
79350973
79400373
Nose Flats
Template
79350673
79350873
79351073
79400473
Weldrebuild nose end surface and grind flat until gage ends align with front edge of
pin hole. Weld stringer beads should run parallel to the nose width.
Rebuild nose end radii as necessary.
3.2.2 Nose flats rebuild
Place the nose flats template over the nose as shown.

Weld buildup nose flats and radii and grind flat until template contacts nose end.
Nose flat template
3.2.3 Rear corner rebuild
Weld rebuild rear corners of nose.

Chalk or paint weld buildup areas, place adapter as far as possible on nose and then
remove. High spots will be indicated by missing chalk or paint.
Grind weld buildup areas until a new adapter has a little or no movement up and down.
Grind blend smoothly into rear shoulders.
AH03510
Page 10 of 18
3.3
Adapter installation
Prior to using an adapter tool be sure that the following safety
precautions are followed at all times:
Always wear proper safety equipment including hardhat, gloves,
safety glasses and steel-toed shoes.
Never exceed the lifting capacity of the tool.
Tool is intended for vertical lift only.
Always stand clear of the raised adapter.
Never allow anyone to work under the adapter until it is secured to
the lip by the appropriate locking mechanism.
Always use the safety features (lock and safety pin) as indicated.
Never use hand tools or other fastener to secure the sleeve. Never
use anything other than the sleeve provided to support the
adapter.
Replace the tool when it becomes visibly damaged or distorted.
Do not attempt to repair a damaged tool.
The Sidewinder Pin must be fully retracted in the adapter base.

Sidewinder Pin can be inserted from either side of base. Recommend corner positions
be installed from inside.
Position the bucket with the nose tilted slightly upward.
Use a lifting tool and a lifting boom for the movement of the adapter as described in
section 3.1. Test lift the adapter to check for satisfactory adapter tilt angle.
The adapter should tilt downwards at the rear for easy

installation onto the nose.
Lower the adapter and reposition the shackle as needed to achieve appropriate tilt
angle.
Lift the adapter and slide it onto the nose. With the lifting boom still holding the
adapter, install the adapter locking pin:
For applications where soil fines pack and harden, it is

recommended that the outer sleeve of the pin be covered in
grease.
AH03510
Page 11 of 18
Using hex bit and socket drive, turn hex socket end of Sidewinder Pin clockwise
to extend the pin into the pin hole in the opposite side of the adapter.
Tighten to the specified torque value shown below.
Size
S 95
S 110
S 130
S 145
3.4
Allen type wrench size

14 mm
17 mm
19 mm
19 mm
Recommended pin torque

160-200 Nm (120-150ft-lb)
200-260 Nm (150-190ft-lb)
260-390 Nm (190-290 ft-lb)
260-390 Nm (190-290 ft-lb)
Insert the Sidewinder Pin cap to prevent the pin hex socket from filling with soil fines.
Cap should snap into place.
Retighten Sidewinder Pin
Retighten the Sidewinder Pin every 600 to 1200 hours of operating service depending on
the severity of application.
Some loosening of pin - turns is normal. It is not

necessary to keep it tightened to the recommended torque.
4.
Wear Caps
4.1
Lock style wear caps (PC4000)
4.1.1 Removal
Clean debris from the gaps around the wearcap lock.

Do not strike corners or edges with hammer!
Rotate Lock : Use a drift and a 2-4 kg/4-8 lb hammer to rotate the lock to the unlocked
position.
It may be necessary to partially rotate the lock in both directions to break loose soil
fines, before fully rotating it.
Lock must be rotated completely (180 degrees) to release the

wearcap.
Lock can rotate either way.
AH03510
Page 12 of 18
Remove Wearcap:
Slide wearcap out of adapter slots. Use appropriate lifting devices to support and remove
wearcap. It may be necessary to place a pry bar between the adapter and the rear inside
face of the wearcap to lift and free it from soil fines.
4.1.2 Installation
Wearcap tabs, adapter tab slots, and lock recesses must be

thoroughly cleaned. Inspect all components for damage.
Replace any damaged parts.
Position Wearcap Lock

First place the lock flat side down against the inside of the wearcap, adjacent to the
lock opening. Slide it toward the wearcap lug. One of the lock shafts will enter the hole
in the lug. Push the lock up tight against the lug. Then, using a drift placed in one of
the lock pockets, tap the drift with a hammer to cause the lock to rotate halfway
around, until the flat side of the lock is facing you and is lined up with the inside face of
the wearcap.
Wearcap Installation
Place the wearcap on the adapter. The tabs on the inside of the wearcap fit into the
tab slots in the adapter.
Lock Wearcap
Use an suitable tool and hammer to rotate the lock to the locked position. If lock resists
rotation, this indicates more cleaning of the adapter slots is required. When flat is
facing out, the lock is in a locked position.
AH03510
Page 13 of 18
4.2
Non lock style wear caps (Option PC4000; PC5500; PC8000)
For using of these kind of wear caps special points and special
adapters are required.
4.2.1 Removal
Drive out the point pin and remove the point.

Slide the worn wearcap off the adapter.
If soil packs tightly between the wearcap and the adapter, it

may be necessary to strike the flat sides of the wearcap several
times with a hammer, to loosen it for removal.
Do not strike corners or edges with hammer!
4.2.2 Installation
Inspect all components for damage. Replace any damaged parts.

Slide wearcaps onto the adapter top and bottom surfaces, so that the wearcap rear
central and two forward side tabs insert fully into the respective slots of the adapter.
Install and pin the point.
AH03510
Page 14 of 18
5.
5.1
The Shrouds
Removal the shrouds
The Toplok shroud system is engineered to make change-out easy. Before following these
simple steps shown to the Figures, its important to clean fines from pin area by tapping
the shroud to loosen them, then scraping them using a chisel or needle gun (if fines are
heavily packed).
Use a small bar with flat end (19 mm wide maximum) to retract the latch and lift the
pin out.
Pins can be reused if not worn below the locator flange and the insert latch rubber is
fully bonded to the steel tip and fully seated in the pin body.
Place a pry bar or pinch bar behind the

latch as shown, as a lever to compress it.
Lift out and remove the lock. Slide the

shroud off the lip base.
In severe applications assist removal by inserting a pry bar

under the lock from the rear of the shroud and lifting up the
latch end of the pin while prying as shown.
AH03510
Page 15 of 18
5.2
Installing the shroud
5.2.1 Prepare the surface
In order to provide sufficient support for the boss as well as its pin, the mounting surface
must:
Be relatively smooth and free of debris, weld spatter, and other irregularities.
Have a profile that produces a gap no greater than 3 mm or 1/16" at the boss weld.
Any gap greater than 3 mm or 1/16" must be shimmed.
Checking the Fit Pad Areas
The fit pad surface (1) & (2) should be perpendicular to each other.
Make sure 70% of the fit pad surfaces (1) & (2) are in contact with the gauge.
After achieving this, the fit pad surface (3) should be checked.
Use a straight edge to help check the surface consistency.
Plate lips (PC4000)
Cast lips (PC5500 and PC8000)
Templates Part numbers for checking and preparation the lips

Type of Excavator
PC4000
PC5500
PC8000
Shovel Version
Lip Shroud
Template
654 547 40
654 548 40
794 005 73
655 867 40 or
907 281 40
907 006 40
794 007 73
Backhoe
Lip Shroud
654 627 40
654 628 40
654 629 40
655 867 40
Version
Template
794 008 73
907 448 40 On request
794 006 73
794 007 73
AH03510
Page 16 of 18
5.2.2 Position the bosses

Checking the Boss Position
To insure the boss is located correctly, the gap between the gauge and the boss rails
should not exceed 1mm/.04in. If the gap exceeds 1mm/.04in.,the boss has to be removed
and a new boss installed (see below).
The back of the boss should line up with the back of the gauge rail.
If the boss does not line up with the back of the gauge rail, then two repair options are
possible:
(A) If the gap does not exceed 1.5mm/.06in., build up the back of the boss; or
(B) Weld build the leading edge fit pad (2). This may result in the ramp fit pad (3) also
requiring weld build up.
Weld Rebuilding Fit Pads

When weld rebuilding fit pads ensure the weld surface is clean and free of any
contamination that might prevent a good weld. Follow the preheat, interpass and post heat
guidelines below.
Summary of Welding Specifications
Electrodes: E7016 or E7018 low hydrogen (keep dry!)
Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas.
Preheat: 200F/95C (350-400F/175-205C if air temperature is 40F/5C or lower.)
Interpass: Maintain interpass temperature less than 500F/260C.
Postheat: If air temperature is 40F or lower, postheat 350-400F, then let air cool.
Remove slag after each pass and peen each bead.
New Boss installation
Set the boss onto the gauge rails and locate the back of the boss with the back of the
gauge rails. If no gauge is available, use a new shroud to locate the boss.
Move the gauge onto the lip, making sure the gauge is centered between the nose
bases and the gauge is in contact with fit pad surfaces (1) & (2).
Practice has shown, that the boss will suck down 1/16" during welding. To equalize this
use a 1/16" shim under the boss, even if there is no gap between the fit pad (1) and the
boss. This will ensure the boss height is correct after welding.
If there is a gap between the fit pad surface (1) and the boss, use a thicker shim
accordingly.
AH03510
Page 17 of 18
5.2.3 Welding the bosses
The weld surface must be clean and free of any contamination that might prevent a good
weld. Follow the preheat interweld and post heat guidelines below.
Summary of Welding Specifications
Electrodes: E7016 or E7018 low hydrogen (keep dry!)
Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas.
Preheat: 200F/95C (350-400F/175-205C if air temperature is 40F/5C or lower.)
Interpass: Maintain interpass temperature less than 500F/260C.
Postheat: If air temperature is 40F or lower, postheat 350-400F, then let air cool.
Remove slag after each pass and peen each bead.
Weld the boss to the lip. Make sure that the boss is shimmed, so that the height of the
boss will be correct after welding.
Weld area (A) completely before welding areas (B) & (C).
Welding Guide
Weld
Location
Boss
TAB
TBB
TCB
(A)
Depth of
weld plug holes
mm/in
Plug Weld 10/.38
Plug Weld 13/.50
Plug Weld 16/.62
(B)
Size of fillet
weld-on ends
mm/in
Fillet 10/.38
Fillet 13/.50
Fillet 13/.50
(C)
Size of fillet
weld-on ends
mm/in
Fillet 3/.19
Fillet 6/.25
Fillet 6/.25
5.3
Inspecting Worn Shrouds
Toplok shrouds protect the bucket lip and wings from abrasive wear. Use of ESCO 12S
abrasion resistant alloy assures long life before change out.
Periodic inspection should be made to determine when to replace a shroud.
Monitor high wear surfaces of the Toplok shroud for wear.
Special wear indicators are special panels that will open up to alert the user of the
need for changing shrouds.
AH03510
Page 18 of 18
5.4
Installing
Installing the shroud
Slide the shroud over the lip and boss to install the pin. If installing a new shroud, the
pin must have contact with the back of the boss and with the back of the shroud without
losing contact at the leading edge.
Installing the pin
Position the pin in the shroud cavity as shown.
A light blow with a hammer will engage the pin.
The shroud is now securely attached.
AH03510
COMPONENT CODE:
63
REF NO.
AH03528
DATE
Sept. 29, 2003

Page 1 of 1
SUBJECT:
PURPOSE:
Prevention of serious injury or death through high voltage

system
APPLICATION:
PC8000-6 Electric Drive
FAILURE CODE:
6300Z9
DESCRIPTION:
The pilot line of the above mentioned excavators is a vital safety equipment.
This line controls the security of the following components:
Fire suppression system (9K3);
Flaps at slip ring unit (OS4 and OS4B);
HT switch cabinet (OS10; OS11);
Emergency switch at the cable drum (OS15);
Flaps at the cable drum (OS17; OS18);
Flap at the terminal box of the cable drum (OS19).
If all these components are in normal working order the pilot line is closed.
If one component is not in normal working order this line will be interrupted and the power
supply of the excavator will be shut off in the external transformer station.
Make sure that the pilot line is always in proper working order.
A defective or missing pilot line can cause serious injury or
death.
AH03528
COMPONENT CODE:
46
REF NO.
AH04518a
DATE
June 29, 2005

Page 1 of 2
This PARTS & SERVICE NEWS supersedes the previous issue AH04518 which
SUBJECT:
PURPOSE:
Emphasize the importance of expelling the accumulate gases from

the counterweight chambers before welding
APPLICATION:
H 255; PC3000; PC5500(SN15011 and up); PC4000;

PC8000(SN12037 and up)
FAILURE CODE:
4621Z9
DESCRIPTION:
Avoid injury or death!

Do not perform welding operation before expelling the
accumulated gases from the counterweight chambers!
The gases may explode!
The welded counterweights are filled with a mixture of iron ore and breech blocks.
They are not fully filled.
It is possible that in the separate chambers explosive gases have collected.
There is a risk of explosion during welding, grinding, cutting and drilling without coolant.
The following outlines the proper gas expelling procedure from counterweight
(Illustrations 1 and 2)
1. Counterweights with a thread connection point(1):
Connect a hose to this point and blow compressed air toward the inside.
At these counterweights all chambers are connected to each other.
2. Counterweights without thread connection point:
Make the holes (2) larger by means of a 10 mm drill.
Blow out carefully all chambers separately through the holes (2).
AH04518a
Page 2 of 2
(1)
(2)
Illustration 2
AH04518a
COMPONENT CODE:
6A
REF NO.
AH05501a
DATE
September 15, 2006

Page 1 of 1
This PARTS & SERVICE NEWS supersedes the previous issue AH05501 which should be
discarded.
SUBJECT:
PURPOSE:
Reduction of stress on the pipes
APPLICATION:
All types
FAILURE CODE:
6A00GB
DESCRIPTION:
To reduce the stress on hydraulic pipes and the flange bolts install a pair* of metal half
clamps (weight approx. 5 kg).
Start in the middle of the line and check the effect by laying on a hand. Try to optimize the
effect by shifting the clamps. Mark the optimal position.
*if required two pairs of half clamps can be used
Description
Pipe 50x6 (PN)
Pipe 65x8 (PN)
Modification kit (assy.)
938 578 40
938 581 40
AH05501a
COMPONENT CODE:
K1
REF NO.
AH05510
DATE
February 16, 2005

Page 1 of 1
SUBJECT:
Bearing flushing of the A4VS variable displacement axial piston

pump
PURPOSE:
Activate the external flushing of bearing by mounting a new pump
APPLICATION:
PC4000 (SN08151 up);

PC5500 (SN15011 up); H 455S (SN15007; 15009);
PC8000 (SN12037 up); H685SP (SN12020; 12030)
FAILURE CODE:
K100FA
DESCRIPTION:
The installed main pumps are provided with an external cooling and lubrication system for
flushing of drive shaft bearing and shaft seal.
Oil supply is provided from the X4-pressure circuit.
To direct the external cooling oil to the bearing and shaft seal it is necessary to turn in the
throttle screw all the way.
Observe also the information plate fixed at the pump.
Drawing and photos as example
AH05510
COMPONENT CODE:
30
REF NO.
AH05511
DATE
March 23, 2005

Page 1 of 4
This PARTS & SERVICE NEWS supersedes the previous issue No. 21-558 which should
be discarded.
SUBJECT:
PURPOSE:
Mounting hints
APPLICATION:
all types
FAILURE CODE:
3047AA
DESCRIPTION:
Leaky dual cone seal rings must be replaced, in order to prevent damages through "dry
running".
Dual cone seals have also to be replaced in case of component repairs.
Dual cone seals are precision parts made from chilled cast iron. Therefore, sharp knocks
and blows should be avoided.
The correct way to install dual cone seals is as follows:
Only remove the seal (1) from its original
wrapping just before installing. This
protects the super - finished seal faces (2)
from damage and contamination.
Seal housing (3) must be free of dirt and
machining residues; all edges in the
housing bore must be rounded.
The illustration shows the preloaded seal (1).
Install the face seal by means of the
assembly tool (4). Pressure is applied
directly via the O-ring (5).
For easier assembly, moisten the housing
bore and O-rings with spirit (no oil or grease!).
Order number for assembly tool (4), refer
to the table on page 2.
For the machining dimensions of the
assembly tool, refer to the illustration and
Fig. on page 3.
The illustration shows the dual cone seal
(1) before mounting it with tool (4) into
housing (3).
AH05511
Page 2 of 4
Press the seal ring (1) with the special tool
like a push button into the housing (3).
Take care that afterwards the housing
surface (6) lies parallel to the seal face (2).
The O-ring (1) must not sit wave-like in
the housing bore or bulge partially
looped out of the bore.
C = correct
W = wrong
Before the seal rings (1) are clamped to

the installation dimensions, apply a
thin grease or oil film to the seal faces
(2), preferably with a soaked chamois
leather cloth.
Fig.
1
2
3
4
5
6
Description
Seal ring
Seal face
Seal housing
Tool
O ring
Housing surface
Table for selection of the assembly tool (other tools on inquiry)

Part No.
Dual Cone Seal
145 800 40
180 472 40
180 624 40
202 986 40
226 424 40
226 425 40
255 058 40
269 454 40
270 460 40
Order-No.
Assembly tool
766 311 73
766 308 73
766 312 73
766 315 73
766 322 73
766 317 73
766 314 73
766 312 73
766 316 73
Part No.
Dual Cone Seal
323 823 40
324 067 40
461 627 40
461 628 40
696 523 73
696 525 73
804 595 73
963 754
Order-No.
Assembly tool
766 323 73
766 309 73
766 318 73
766 307 73
766 310 73
766 311 73
766 313 73
766 321 73
AH05511
Page 3 of 4
Assembly tool (locally made)
The assembly tool consists of two half-shells that are closed around the seal ring. The two
halves are joined by a hinge.
Step (d) grips between the O-ring (5) and the land of the seal ring. The pressure required
to insert the seal is then applied directly via the O-ring (5).
Measure dimension "b" at the dual cone seal.
Determine the machining dimensions "a", "b", "c" and "d" according to this measured
dimension in the chart.
The dimension "X" can be chosen freely.
b
mm
95
99
104
110
111
112
121
127
126
139
142
141,5
143
146
157
162
175
159
174,5
177
169
172,5
169
171
170
176
182
194
a
mm
100
107
118
115
118
120
128
131
134
148
150
149
150
153
163
169
182
166
181,5
185
176
180
175
177
176
183
190
201
c
mm
89,5
92,5
98
104
105
107
115
121
120
133
135
133
137
137,7
150,5
155
169
153,5
162
168
161
166,5
165
168
165
167,5
177
182,5
d
mm
1,8
3,5
3
2,5
4
3
4
3,5
3
3
4
3
4
4
4
3
4,5
3
4
4
2,8
3,5
2
2,5
4
3,5
3
4
b
mm
191
200
202
213
217
231
229,5
242
254
270,5
282,8
295,5
326
343,5
348
377,5
397
418
458
503
536,5
563
593
611
703
626
753
890
a
mm
198
208
209
220
225
238
236,5
249
261
279
292
302,5
334
350,5
357
384,5
407
426
468
518
545
578
608
620
710
642
768
898
c
mm
185
192
196
201
210
220
220,5
232
242,5
258,5
269
282
321
335
342
369
385
410
446
495
528,4
555
585
603
694
618
745
878
d
mm
4
4
4
4
4
4
4
4
4
4
4
4
4
4
7
4
4
5
4
7
5
7
7
5
5
7
7
10
AH05511
Page 4 of 4
Assembly tools for mounting of dual cone seal
AH05511
COMPONENT CODE:
25
REF NO.
AH05518
DATE
June 27, 2005

Page 1 of 2
This PARTS & SERVICE NEWS supersedes the previous issue 21 - 503 which should be
discarded.
SUBJECT:
Swing circle pinion
PURPOSE:
Wear check every 5000 Operating hours
APPLICATION:
PC3000; PC4000; PC5500; PC8000
FAILURE CODE:
2518CA
DESCRIPTION:
All swing pinions are surface hardened to ensure a long service life.
If the depth of the wear reaches the hardening depth, the wear of the pinion will be rapid.
The increased tooth back-lash and the different tooth meshing, could decrease the service
life of the slew ring and the swing gear box(es).
By means of regular wear check , every 5000 operating hours, the depth of the wear
should be compared to the original shape.
AH05518
Page 2 of 2
The following table shows the machines with the pertaining swing gear box(es) and the
corresponding hardening depth:
Type
PN Swing gear box
Hardening depth
PC3000
898 100 40
917 915 40
924 352 40
926 795 40
898 100 40
925 864 40
926 795 40
898 100 40
917 915 40
925 864 40
926 795 40
917 915 40
924 325 40
926 325 40
2.0
2.0
2.0
2.0
2.0
1.8 +0.4
2.0
2.0
2.0
1.8 +0.4
2.0
2.0
2.0
2.0
PC4000
PC5500
PC8000
If the depth of the wear reaches the hardening depth, the slew
pinion should be replaced, to ensure a proper function of the
machine.
AH05518
COMPONENT CODE:
K1
REF NO.
AH05525
DATE
September 20, 2005

Page 1 of 3
SUBJECT:
Suction elbows of the Main Pumps
PURPOSE:
Hints for sealing
APPLICATION:
PC3000-1; PC4000-6 (to # 08156) PC5500 (to # 15019);

PC8000 (to # 12042)
FAILURE CODE:
K1T3AA
DESCRIPTION:
1.
2.
PC3000-1
PC4000; PC5500; PC8000
AH05525
Page 2 of 3
1. PC3000-1
1
2
3
4
Seal
Intake
Remachining surface
Bolt
Illustration 1
as example
In case of leakiness disassemble the suction elbow (2) and remachine the
sealing surface (3).
Then reassemble the suction elbow (2) by using a new seal (1).
Install the 4 bolts (4) crosswise and evenly.

Final torque: maximum 179 Nm!
Replace the intake (2) by a new one if necessary.
Check the surface (3) for evenness also of the new intake (2)
before installing. Even it out if necessary.
AH05525
Page 3 of 3
2. PC4000; PC5500; PC8000
Type
PC4000-6
PC5500-6
PC8000-6
In case of leakiness replace the old suction elbow (2) by a new one with an
other sealing system (1)(O-ring).
Intake (old)
Intake (new)
O - ring
891 451 40
928 335 40
517 582 98
624 085 40
928 706 40
517 582 98
624 085 40
928 706 40
517 582 98
894 317 40
928 287 40
517 582 98
894 321 40
928 285 40
517 582 98
894 322 40
928 288 40
517 582 98
894 323 40
928 289 40
517 582 98
624 085 40
928 706 40
517 582 98
Screw in the 4 bolts

(4) crosswise and
evenly.
Final torque:
maximum 179 Nm!
Illustration 2
as example
AH05525
COMPONENT CODE:
26
REF NO.
AH05535f
DATE
December 15, 2008

Page 1 of 24
This PARTS & SERVICE NEWS supersedes the previous issue AH05535e which should
be discarded.
SUBJECT:
Hints for replacing the slew gear of a different manufacturer
PURPOSE:
Revision
APPLICATION:
PC3000 (#06193 and up); PC4000 (#08152 and up);

PC5500 (#15018 and up); PC8000 (#12041 and up)
FAILURE CODE:
2600CA
DESCRIPTION:
New swing gears will be delivered without gear oil.
After replacing the swing gear, fill in oil according to the
Maintenance Manual.
REMARK
The machines can be equipped either with a swing machinery of manufacturer
"L&S"
Part No. 926 795 40 or of manufacturer
"Siebenhaar"
Part No. 925 864 40; 936 560 40 or 944 872 40.
Refer to the data plate on each swing machinery housing to find out the manufacturer of
the swing machinery.
Both swing gears are replaceable by using of a special modification kit.
Lubricants
Filling Capacities (liters)
AH05535f
Page 2 of 24
1.
Description (general)
2.
Overview
2.1 Swing Machinery manufactured by "L&S"
2.2 Swing machinery manufactured by Siebenhaaar
2.3 Overview lubrication lines
3.
Modification kits
3.1 Modification kit PC3000-6
3.1.1
Replacing L+S gear by Siebenhaar gear
3.1.2
Replacing Siebenhaar gear by L+S gear

3.2.1
3.2.2

3.3.1
3.3.2

3.4.1
3.4.2
AH05535f
Page 3 of 24
1.
Description (general)
1. Remove the bolts at the hydraulic motor.

2. Remove the motor with connected hoses and place it beside or if this it not possible,
disconnect the hydraulic lines and block the ports.
3. Disconnect the lubrication lines below the gearbox.
4. Remove all fastening bolts from the gearbox.
5. Install 2 eye bolts to lift the gearbox assy.
6. Remove the gearbox from the superstructure frame.
7. Clean the flange area at the superstructure free of grease, oil, dust and paint.
8. Insert the new gearbox and mount it with the new bolts and the washers to the
superstructure.
9. Cover the bolt heads with plugs.
10. Swap the drain valves and the breather filters from the old to the new gearbox and
install the dip sticks.
11. Remove the cover below the gearbox and connect the lubrication lines.
12. Reinstall the cover with bolts.
13. Reinstall the motor with bolts.
14. Reconnect all hydraulic lines.
15. Fill in oil to the max. oil level markings*.
16. Install the cover plates (PC3000; PC4000*).
* If the slew gear PN 944 872 40 (Siebenhaar) will be delivered for first installation in a PC4000-6,
the pinion cover PN 939 460 40 (right) or
the pinion cover PN 939 455 40 (left) has to be installed also or these covers have to be modified according
to the PSN AH08518a.
* "L&S" gear (Part No. 926 795 40)

2 oil chambers: (gear housing; motor adapter housing);
"Siebenhaar" (Part No. 925 864 40; 936 560 40 or 944 872 40)
Three oil chambers: (gear housing; motor adapter housing, brake housing)
AH05535f
Page 4 of 24
2.
Overview
2.1
Swing Machinery manufactured by "L&S"
Legend for illustration 1

Swing gears
(1) Oil level gauge
(2) Oil filler plug
(3) Breather filter
(10) Drain couplings or evacuation nozzles for Wiggins system Motor
Adapter Housing
(4) Oil level gauge and filler opening.
(5) Breather filter
(6) Oil drain plug
Illustration 1
AH05535f
Page 5 of 24
2.2
Swing machinery manufactured by Siebenhaaar
Legend for illustration 2

(1) Swing machinery
(2) Brake housing
(3) Compensator oil tank for swing machinery
(4) Oil level gauge for swing machinery
(5) Oil drain plug for motor adapter housing
(6) Oil level gauge for motor adapter housing
(7) Breather filter for brake housing
(8) Oil level gauge for brake housing
(9) Oil drain plug for brake housing
(10) Breather filter
(11) Drain coupling or evacuation nozzle for Wiggins system
For avoiding overheating of the disks inside the brake a correct adjustment
of the brake oil level (8) is necessary.
Too high oil level reduces the life time of the brake.
AH05535f
Page 6 of 24
Swing machinery manufactured by Siebenhaaar
Illustration 2
AH05535f
Page 7 of 24
2.3
Overview lubrication lines
AH05535f
Page 8 of 24
3.
3.1
Modification kits
Modification kit PC3000-6
3.1.1 Replacing L+S gear by Siebenhaar gear (PC3000-6; illustration 3)

Modification Kit: PN 794 853 73
Pos.
Part No.
Qty.
Description
10
323 460 40
Bleeder valve
11
517 676 98
34
Bolt
12
516 920 98
34
Washer
15
507 037 98
Nut
16
340 465 99
Washer
22
907 142 40
34
Plug
30
307 824 99
Bolt
31
374 428 99
Union
32
517 905 98
Hose assy.
33
500 141 98
Union
34
372 174 99
Union
35
334 601 99
Nut
36
340 469 99
Washer
37
0443452511
Clip
38
340 467 99
Washer
934 351 40
Thread tube
0443451810
Clip
0443451910
Clip
307 777 99
Bolt
AH05535f
Page 9 of 24
Illustration 3
AH05535f
Page 10 of 24
3.1.2 Replacing Siebenhaar gear by L+S gear (PC3000-6; illustration 4)
Pos.
Part No.
Qty.
Description
10
323 460 40
Bleeder valve
11
517 013 98
34
Bolt
20
872 200 40
Union
30
925 833 40
Pipe 157 mm
31
517 489 98
Socket
32
906 868 40
Olive
33
371 264 99
Union nut
34
517 490 98
Union
35
907 568 40
Dipstick
36
921 815 40
Cover
37
319 159 99
Bolt
38
504 149 98
Washer
39
517 073 98
Union
40
371 273 99
Union nut
41
906 346 40
Olive
42
215 627 99
Pipe
43
517 074 98
Union
44
371 258 99
Union nut
45
907 228 40
Union
AH05535f
Page 11 of 24
Illustration 4
AH05535f
Page 12 of 24
3.2
3.2.1 Replacing L+S gear by Siebenhaar gear (PC4000-6)

Modification Kit: PN 797 345 73 (l.h.) (Illustration 5)
Pos.
Part No.
Qty.
Description
11
517 612 98
34
Bolt
12
516 920 98
34
Washer
15
374 428 99
Union
16
507 037 98
10
Nut
17
512 545 98
10
Washer
18
507 488 98
10
Pin bolt
19
506 129 98
10
Washer
22
904 614 40
Cover plate rear l.h.
23
904 617 40
Cover plate front r.h.
24
307 827 99
Bolt
26
907 142 40
34
Plug
27
939 455 40
Pinion cover l.h.
29
510 213 98
Thread pin
30
340 112 99
Washer
31
512 545 98
Washer
32
334 600 99
Nut
308 639 99
Bolt
510 730 98
Resilient sleeve
AH05535f
Page 13 of 24
Modification Kit: PN 797 349 73 (r.h.) (Illustration 5)

Pos.
Part No.
Qty.
Description
11
517 612 98
34
Bolt
12
516 920 98
34
Washer
15
374 428 99
Union
16
507 037 98
10
Nut
17
512 545 98
10
Washer
18
507 488 98
10
Pin bolt
19
506 129 98
10
Washer
20
945 988 40
Cover plate rear r.h.
21
938 534 40
24
307 827 99
Bolt
26
907 142 40
34
Plug
28
939 460 40
Pinion cover r.h.
29
510 213 98
Thread pin
30
340 112 99
Washer
31
512 545 98
Washer
32
334 600 99
Nut
308 639 99
Bolt
510 730 98
Resilient sleeve
AH05535f
Page 14 of 24
Illustration 5
AH05535f
Page 15 of 24
3.2.2 Replacing Siebenhaar gear by L+S gear (PC4000-6; illustration 6)
Modification Kit: 794 869 73
Pos.
Part No.
Qty.
Description
15
872 200 40
Union
20
922 584 40
Cover plate rear l.h.
21
922 583 40
Cover plate front l.h.
22
922 586 40
23
922 587 40
Cover plate rear r.h.
25
516 919 98
34
Bolt
28
921 815 40
Cover
29
319 159 99
Bolt
30
517 073 98
Union
31
371 273 99
Union nut
32
906 346 40
Olive
33
215 627 99
Pipe 400 mm
34
517 074 98
Union
35
371 258 99
Union nut
36
906 346 40
Olive
37
907 228 40
Union
38
371 257 99
Union nut
39
907 080 40
Olive
40
922 580 40
Cover pinion l.h.
41
922 578 40
Cover pinion r.h.
42
517 489 98
Socket
43
517 490 98
Union
44
906 868 40
Olive
45
371 264 99
Union nut
46
925 833 40
Pipe 157 mm
47
907 568 40
Dipstick
49
339 907 99
Seal ring
AH05535f
Page 16 of 24
Illustration 6
AH05535f
Page 17 of 24
3.3

Pos.
Part No.
Qty.
Description
10
323 460 40
Bleeder valve
12
308 639 99
Screw
15
339 907 99
Seal ring
24
516 920 98
34
Washer
25
517 612 98
34
Bolt
26
907 142 40
34
Plug
510 730 98
Resilient sleeve
516 159 98
Union
515 362 40
Oil drain coupling
AH05535f
Page 18 of 24
Illustration 7
AH05535f
Page 19 of 24
3.3.2 Replacing Siebenhaar gear by L+S gear (PC5500-6; Illustration 8)
Pos.
Part No.
Qty.
Description
17
921 815 40
Cover
18
907 131 40
Union
19
214 140 99
Pipe 85 mm
20
374 460 99
Socket
21
872 200 40
Union
22
371 279 99
Union nut
23
906 979 40
Olive
24
516 920 98
34
Washer
25
517 889 98
34
Bolt
26
907 142 40
34
Plug
27
907 228 40
Union
28
517 074 98
Union
29
371 258 99
Union nut
30
906 346 40
Olive
31
517 073 98
Union
32
371 273 99
Union nut
33
906 346 40
Olive
34
215 627 99
Pipe 200mm
35
319 159 99
Bolt
36
504 149 98
Washer
50
517 489 98
Socket
51
517 490 98
Union
52
906 868 40
Olive
53
371 264 99
Union nut
54
925 830 40
Pipe 350 mm
55
907 569 40
Dipstick
AH05535f
Page 20 of 24
Illustration 8
AH05535f
Page 21 of 24
3.4
Pos.
Part No.
Qty.
904 613 40
Cover plate r.h.
904 618 40
Cover plate l.h.
517 612 98
34
Bolt
516 920 98
34
Washer
907 142 40
34
Plug
10
323 460 40
Bleeder valve
12
308 636 99
Bolt
510 730 98
Resilient sleeve
374 428 99
Union
13
Description
AH05535f
Page 22 of 24
Illustration 9
AH05535f
Page 23 of 24
3.4.2 Replacing Siebenhaar gear by L+S gear (PC8000-6, illustration 10)
Pos.
Part No.
Qty.
Description
11
516 919 40
34
Bolt
13
898 288 40
Cover plate
14
914 737 40
Cover plate
20
872 200 40
Union
21
374 460 99
Screwed socket
22
371 279 99
Union nut
23
906 979 40
Olive
24
914 736 40
Pipe 85 mm
25
907 131 40
Union
26
517 489 98
Socket
27
906 868 40
Olive
28
371 264 99
Union nut
29
925 830 40
Pipe 350 mm
31
517 490 98
Union
32
907 569 40
Dipstick
33
921 815 40
Cover
34
319 159 99
Bolt
35
517 073 98
Union
36
371 273 99
Union nut
37
906 346 40
Olive
38
215 627 99
Pipe 200 mm
39
371 258 99
Union nut
40
517 074 98
Union
41
907 228 40
Union
AH05535f
Page 24 of 24
Illustration 10
AH05535f
COMPONENT CODE:
8D
REF NO.
AH05546
DATE
December 6, 2005
Page 1 of 2
SUBJECT:
PURPOSE:
Hints for trouble shooting
APPLICATION:
All types with Lincoln Lubrication System
FAILURE CODE:
8D00ME
DESCRIPTION:
Manual actuation
(Vent valve: PN 769 879 73)
FUNCTION:
The solenoid gets energized when the lubrication starts.
The connection from A to B gets closed, thus a pressure build-up is possible.
The solenoid gets de-energized, as soon as the lubrication cycle is finished.
This causes opening of the connection A to B, thus the supply line to the
lubricant barrel is open. The lubricant flows from A to B.
TASK (Refer to illustration next page):
By the function of the vent valve (7) the lubricant supply line gets pressure released,
after the lubrication cycle is finished. The injector pistons can move into their initial
position.
AH05546
Page 2 of 2
Troubleshooting:
The solenoid valve (7) sometimes is blocked by dirt and causing that the pumping
pressure will be not built correctly due to bypassed pressure back to grease barrel. On the
monitor in the operators cab any failure in lubrication system will be indicated.
Manual actuation
To make easy troubleshooting the 2/2 Directional valve (7)

is equipped with the possibility of manual actuation.
The valve had a push button on the top to verify whether the
electric problem or the vent valve itself causing the lubrication
pressure bypassed.
For manual actuating of the valve (7) push down the pin on
top of the valve e.g. with a screwdriver.
AH05546
COMPONENT CODE:
2C
REF NO.
AH06512
DATE
February 23, 2006

Page 1 of 1
SUBJECT:
Travel gears Brake and motor adapter housings Oil Change
PURPOSE:
Improvement of the oil change Avoiding of overfill the brake

housings
APPLICATION:
H 485S; H 655S; PC8000
FAILURE CODE:
2C4LZ9
DESCRIPTION:
Regular oil level checking of the brake housings is carried out with the engine at standstill,
brakes applied.
For draining the oil at the 3000 h maintenance the brakes must be released in order to
remove the oil between the brake disks, this requires the engine running.
However, filling of the brake housings has to be done with the engine stopped and the
brakes applied to prevent overfilling.
Attached you will find new pages of the Maintenance Manual. Please replace them in the
existing machine Service Literature.
COMPONENT CODE:
REF NO.
DATE
AH06524
September 6, 2006
Page 1 of 2
This PARTS & SERVICE NEWS supersedes the previous issue 21 199b which should
be discarded.
SUBJET:
Hydraulic cylinder
PURPOSE:
Hints for bleeding
APPLICATION:
All types
FAILURE CODE:
H100BJ
DESCRIPTION:
To avoid damages to the hydraulic system caused by air in the cylinders, a bleeding
procedure has to be carried out after each opening or cylinder exchange.
Read the safety instruction in the Operation and Maintenance
Manual carefully, before starting any work on the excavator.
1. Standard procedure for bleeding of hydraulic cylinder

1. Run the engine at low idle.
PC5500 and PC8000: Start for the bleeding procedure only one engine.
Electric driven excavators: Set the service switch S155 (X2 main
board) to position 2 for QMIN control of the main pumps.
2. Extend and retract each cylinder 4 or 5 times without going to the end of
its stroke (stop approx. 100 mm before the end of the stroke).
At first there can be a large amount of air inside the cylinders, so the
cylinder may not move for the first ten seconds. In such cases, do not
operate the joy stick to the end of its travel. Be carefully!
3. Keep the engine running at low idle/or QMIN* and operate each cylinder
from a point 100 mm from the end of its stroke slowly (take at least 10
seconds) to the end of its stroke (fully extended) and hold the work
equipment joy stick at the full stroke position for 3 minutes.
AH06524
Page 2 of 2
4. Next run the engine at high idle/or QMAX* and operate each cylinder
from a point 100 mm from the end of its stroke slowly (take at least 10
seconds) to the end of its stroke (fully extended) and hold the work
equipment joy stick at the full stroke position for 1 minutes.
5. Repeat steps 2 4 if necessary.
6. Make sure that the switch S155 is set to the 0 position as soon as the
bleeding procedure of the hydraulic cylinders is finished.*
* Electric driven excavator
After bleeding the cylinders check oil level in the hydraulic tank
according to the Maintenance Manual and add oil if necessary.
AH06524
COMPONENT CODE:
32
REF NO.
AH06530
DATE
July 24, 2006

Page 1 of 2
SUBJET:
PURPOSE:
Hints for working at the crawler unit
APPLICATION:
PC3000; PC4000; PC5500; PC8000
FAILURE CODE:
3200FA
DESCRIPTION:
Read the safety instruction in the Operation and Maintenance

Manual carefully, before starting repair works.
For avoiding damages at the travel brakes (4) the following procedure should be used:
Turn the superstructure (90) and lift the machine.
Shut off the engine.
Open cock (2) for releasing the pressure.
Close cocks (1) and cock (3) if installed.
Close cock (2) (important!).
Now the engine can be started and the sprocket can be turned to the working
position. The travel brake is released by pilot pressure.
Illustration as example
AH06530
Page 2 of 2
AH06530
COMPONENT CODE:
REF NO.
AH06544
November 23, 2006
DATE
Page 1 of 11
This PARTS & SERVICE NEWS supersedes the previous issue 21 435a which should
be discarded.
SUBJECT:
PURPOSE:
Revision
APPLICATION:
All types with hydraulic track tension system
FAILURE CODE:
3000PB
DESCRIPTION:
1. Overview (as example for PC8000)
** Not available at all excavators.
2. Purpose of the pressure increasing valve
3. Function of the Pressure increasing valve
4. Adjustments / Checks
4.1 Pre-conditions
4.2 Basic Adjustments
4.3 Setting procedure, high pressure stage
10
4.4 Setting procedure, low pressure stage
10
4.5 Final works
10
5. Functional Test
11
AH06544
Page 2 of 11
1. Overview (as example for PC8000)
AH06544
Page 3 of 11

(59)
Rotary distributor (joint).
(ST)
Supply line, pilot pressure from travel parking brake circuit
(118.1)
Supply line shut-off cock**.
(118.2 + 118.3) Service shut-off cocks.
(118.4)
Main shut-off cock.
(119.1 + 119.2) Membrane accumulator, 1.3 liter (pre-charge pressure 31bar)
(120.1 120.4) Bladder accumulator, 5 liter (pre-charge pressure 150bar)
(121.1 + 121.2) Check valves (prevents feedback pressure to pilot pressure)
(124.1 124.4) Track tensioning cylinders
(125.1 + 125.2) Check valves (prevents a cross-over flow)
(141)
Pressure increasing valve.
"O" = open
"C" = closed
** Not available at all excavators.
2. Purpose of the pressure increasing valve

The two system pressures
35 bar with engine stopped

310 bar with engine running
are controlled by the pressure increasing valve as follows.
With stopped motor and switched off ignition there is no pilot pressure at
pressure increasing valve (141) and only the lowest adjusted pressure of 35 bar
remains in the system.
As soon as the motor has been started, the pilot pressure acts on the pressureincreasing valve. As a result, the system pressure can rise to the adjusted
pressure of 310 bar.
AH06544
Page 4 of 11
AH06544
Page 5 of 11
(1)
(2)
Valve poppet
(3)
Compression spring
(4)
(5)
Main piston
(6)
Closing spring
(7)
Set screw - low pressure
(8)
(9)
Piston
(10)
Pin
(11+12) Jet bore
(13+14) Lock nut
35 bar
310bar
3. Function of the Pressure increasing valve

The valve poppet (2) is connected via the jet bores (11) and (12) with the
P port.
If static pressure increases above the set pressure value, the valve poppet
(2) opens and allows oil to flow freely to tank (T1). This oil generates a
pressure drop in the spring chamber of the main spool, the closing force of
the spring (6) is cancelled, and the main piston (5) opens to allow the pump
flow to flow to tank (T2).
port X, the pre-tensioning of the pressure spring (3) is increased by the
amount of the piston stroke "S" and system pressure is increased
correspondingly.
of the screw ~ 150 bar.
AH06544
Page 6 of 11
AH06544
Page 7 of 11
4. Adjustments / Checks
(1)
Piston
(2)
Lock nut
(3)
(4)
Lock nut
(5)
Set screw - low pressure
(P)
Plug
(X)
Pilot pressure port
(141)
(118.1)
(118.3)
(118.4)
(119.2)
(120.3 / .4)
(124.3 / .4)
(M11.1)
(M29.2)
(M29.4)
(MRV)
310bar
35 bar

Service shut-off cock supply line*
Service shut-off cock in the side frame
Main shut-off cock
Membrane accumulator 31 bar
Bladder accumulators 150 bar
Pressure check point (Main control block II)
Pressure check point at the track tensioning cylinders L.H.-side
Pressure check point at the bladder accumulators L.H.-side
Main relief valve Operating pressure of main control block
* Not available at all excavators.

4.1 Pre-conditions
Correct MRV (Main Relief Valves), SRV (Secondary Relief Valves)

and pilot pressure setting and the system must be free of air.
The description is only for the R.H. track. The same procedure applies
also for the L.H. side.
4.2 Basic Adjustments

1.
2.
3.
4.
Connect a pressure gauge to check point M 11.1

Start the motors.
Increase the concerning MRV-setting, to ~ 330 to 340 bar.
Switch OFF the motors, open cock valve (118.4) to allow pressure
relieves of track cylinders, and close it again.
AH06544
Page 8 of 11
Hydraulic circuit diagram (partly) for the right hand track tensioning system
AH06544
Page 9 of 11
5.
6.
Move the pressure gauge from M11.1 to M29.4

For the adjustment, two pressure check unions have to be modified as
follows and exchanged against the pressure checkpoints M11.1 and
M29.2.
- Remove cap.
- Drill, until the ball and spring are removable.
7.
Connect pressure checkpoint M11.1 with pressure checkpoint M29.2,

using a long pressure gauge hose (required for the oil supply).
8. Disconnect the pilot pressure line at port X of the pressure-increasing
valve (141) and close the hose with a plug (P).
9. Loosen lock nut (4) of the pressure-increasing valve and screw in set
sleeve (5) until piston (1) comes to stop (substitution of 35bar pilot
pressure).
11. Stall the hydraulic with the clam opening function (clam cylinders
completely retracted) and observe pressure at checkpoint M29.4.
A pressure of 310 + 5 bar has to be reached within a time of
10 15 minutes and must remain at this value.
The maximum pressure will be shown only after the

accumulators are completely filled with oil.
When the pressure reaches the pre-charge gas pressure

(31 bar and 150 bar), the gauge pointer moves slower
depending on the gas compression.
If the gauge shows a lower or higher value, the pressure-increasing

valve must be adjusted.
AH06544
Page 10 of 11
4.3 Setting procedure, high pressure stage

a)
b)
c)
d)

Adjust pressure with setscrew (3).
Secure adjustment by tightening lock nut (2).
The low-pressure setting of the pressure-increasing valve must now be reset

(with the pilot pressure line at port X still disconnected):
4.4 Setting procedure, low pressure stage

a)
b)
c)
d)
completely retracted) and observe pressure at checkpoint M29.4.
Loosen lock nut (4) and turn setscrew (5) ccw until gauge at
checkpoint M29.4 shows 35 bar.
Tighten lock nut (4).
4.5 Final works

a)
b)
c)
d)
e)
Switch OFF the motors and open cock (118.4) to allow pressure
relieve.
Re-connect the pilot pressure line to port X of the pressureincreasing valve (141).
Remove the pressure gauge hose between pressure checkpoint
M11.1 and pressure check point M29.2.
Close the cock (118.4).
Re-set MRV (Block IV) to 310 + 5 bar after the check / adjustment is
finished.
AH06544
Page 11 of 11
5. Functional Test
After all adjustments are finished, do the following:
a)
b)
Bleed all air from the system

Place shutoff and pressure relief cocks into correct operating
position.
Connect pressure gauge to check point (M29.4).
Start motors.
Travel approx. 10 m with the shovel.
Stop the motors.
The pressure must drop to 35 bar.
c)
d)
e)
f)
g)
If the pressure remains at a higher or lower pressure*, re-adjust the low

pressure setting at the pressure increasing valve (141).
The pressure may drop below 35 bar after a longer time.

This is O.K. because of internal leakage.
AH06544
COMPONENT CODE:
H2
REF NO.
AH06545
DATE
November 22, 2006

Page 1 of 3
SUBJECT:
PURPOSE:
Installation hints
APPLICATION:
All types
FAILURE CODE:
H2Z6CA
DESCRIPTION:
Pay attention to the position of the lubricating holes and the

lubrication grooves when installing new bushes to ensure
good lubrication and maximum lifetime.
Install the bushes as shown at the next pages.
AH06545
Page 2 of 3
AH06545
Page 3 of 3
AH06545
COMPONENT CODE:
55
REF NO.
AH08504
DATE
August 7, 2008
Page 1 of 2
SUBJECT:
Windscreen
PURPOSE:
Mounting hints
APPLICATION:
PC4000; PC5500; PC8000
FAILURE CODE:
5532PB
DESCRIPTION:
Before carrying out any repairs, read all the safety instructions
of the Operation and Maintenance manual of your shovel.
The local safety rules must also be observed.
A different holes pattern is used since January 2007 for the frame of the windscreen.
We offer two types of windscreens for replacement of a damaged one:
1. Windscreen with mounting holes in the frame and
2. Windscreen without mounting holes.
We recommend using windscreen with new holes pattern in the frame, also for shovels,
delivered before 2007.
Advantages:
Only one fitting of new bore holes in the cab.
In case of a next windscreen exchange the same holes can be used.
AH08504
Page 2 of 2
Pos.
01
Pos.
Part No.
769 528 73 12 mm; green; drilled

12 mm; green;
797 251 73
undrilled
Part No.
793 739 73
797 253 73
01
Description
796 564 73
797 254 73
Description
12 mm; green;
drilled
12 mm; green;
undrilled
19 mm, with splinter
shield foil coating;
drilled
19 mm, with splinter
shield foil coating;
undrilled
AH08504
COMPONENT CODE:
71
REF NO.
AH08507
DATE
April 9, 2008
Page 1 of 9
SUBJECT:
Steel structure
PURPOSE:
Repair welding procedure
APPLICATION:
PC3000-6; PC4000-6; PC5500-6; PC8000-6
FAILURE CODE:
7100FE
DESCRIPTION:
W
Content
1.
2.
3.
4.
4.1
4.2
5.
6.
7.
8.
Introduction
General Protective Measures
Steps of the weld repair procedure
Selection of appropriate electrodes and welding rods
Selection of appropriate electrodes
Selection of appropriate welding rods
Preparation of the defective Part
Carrying out the Weld Repair
Post heating
Inspection of Repair
AH08507
Page 2 of 9
1. Introduction
Weld repairs can cause severe damage to an entire structure if performed incorrectly.
Therefore we recommend consulting your Komatsu Service Organization in order to
avoid improper welding procedures. If cracks are found in the steel construction of your
excavator, please inform our service department as soon as possible. Attach suitable
information material (photos, catalogue drawings etc.) showing the location and nature
of the crack.
2. General Protective Measures
Welding operations can cause damage to electronic components (Computers, Control
Units, Sensors etc.) in case the welding current goes through these units. Therefore
protective measures are necessary before any weld repair is started.
1. Observe the prevailing safety and fire prevention regulations. Get advice from
authorized Electricians for all medium and high voltage systems related
questions.
2. Before any weld repair is started, a survey should be made of the area and all
safety considerations satisfied such as fuel tanks, hydraulic oil reservoirs, oil
lines, electrical cables and synthetic materials.
3. Remove the battery main switch keys and switch off all circuit breakers, refer to
the Operation Manual of the Excavator for more information.
4. Attach the welding ground directly to the part that is being repaired. Do not allow
welding current to go through bearings. Welding current could arc the bearings,
resulting in severe damage to the bearing.
3. Steps of the weld repair procedure
1. Clean the damaged part or area to be repaired.
2. Inspect the worn or fractured area by visual inspection and/or non-destructive
testing.
3. Determine the type of material to be repaired.
4. Determine the welding electrode or the welding wire and process to be used.
5. Preheat before welding.
6. Weld by using appropriate welding techniques.
7. Post heat.
8. Make a survey of the repair welding.
AH08507
Page 3 of 9
4. Selection of appropriate welding electrodes and welding wires

Table 1: The components shown in illustrations 3 and 4 are made of six
different materials (a, b, c, d, e or f) as shown in the table below.
Material
designation
former
present
international
St52-3N
S355J2G3
1.0570 (17G1S)
GS24Mn6V
GS24Mn6V
1.1118
StE690
S690Q
1.8931
GS18NiMoCr36
GS18NiMoCr36
1.6759
TStE355
P355NL1
1.0566
Hardox 400
4.1 Selection of appropriate welding electrodes

Table 2: The following welding electrodes are required for the weld repairs:
Key number
Welding Electrode (AWS)
4
5*
7*
9*
E 7016
E 7018-G
E 8018-G
E 100 18-G
* Hydrogen content less than 5mg per 100ml
Table 3: Types of welding electrodes to be used for the different materials

(a to f)
Material
a
b
c
d
e
f
a
4
4
4
4
4
7
b
4
4
7
5
7
c
4
7
9
9
7
d
4
5
9
9
7
f
7
7
7
7
7
7
AH08507
Page 4 of 9
Example: Selection of the correct welding electrode for weld repair a crack in
the welded joint between material (a) and (c). The table 4 shows the
correct electrode with key number 4 in the red shaded field.
Table 4
Material
a
b
c
d
e
f
a
4
4
4
4
4
7
b
4
4
7
5
7
c
4
7
9
9
7
d
4
5
9
9
7
f
7
7
7
7
7
7
4.2. Selection of appropriate welding wires

Table 5: The following welding wires are required for the weld repairs
Key number
Welding wire (AWS)
21
25/25a
30
32
ER70 S6
ER100 S1
E70 T5
E90 T5-G
Table 6: Types of welding wires to be used for the different materials (a to f)

Welding wires
a
b
c
d
e
f
a
21; 30
21; 30
21; 30
21; 30
21; 30
25; 32
b
21; 30
21; 30
21; 30
21; 30
21; 30
---
c
21; 30
21; 30
25; 25a; 32
32
21; 30
25; 25a; 32
d
21; 30
21; 30
25; 25a; 32
32
21; 30
---
f
25; 25a; 32
--25; 25a; 32
--25; 25a; 32
25; 25a; 32
AH08507
Page 5 of 9
5. Preparation of the defective Part

Clean the fractured area or worn part of all oil, grease, paint, moisture, dirt, rust,
spalled material or any other materials, which may be detrimental to a weld.
Inspect the fractured areas carefully by non-destructive testing such as
magnetic particle or dye penetrant inspection.
When removing cracks, a V groove should be made with a 30 to 45 angle.
Remove defective material up to the bottom of the crack.
Illustration 1
Use electrodes out of a freshly opened can or from an electrode holding oven. Dry
the electrodes according to the instructions of the electrode manufacturer.
Preheating of the part before preparing it for weld repair is essential to reduce the
thermal shock. The preheat temperature depends on the composition of the
material, see table 7 for the required temperature. Measure the temperature
beside the joint at a distance equal to the sheet metal thickness using suitable
temperature indicating devices.
Table 7
Material
S355J2G3
P355NL1
S690Q
GS24Mn6V
GS18NiMoCr3
Hardox 400
Groove
depth
(mm)
<10
Preheat
temperature
(C)
20
Interpass
temperature
(C)
220
10 - 20
20 - 50
10
10 - 20
>20
<10
10 - 20
>20
50
100
50
100
150
50
100
150
220
220
150
180
220
150
180
180
>10
150
200
Post heat
temperature
(drop per hour)
50 degree. max.
AH08507
Page 6 of 9
6. Carrying out the Weld Repair
All weld repairs should be carried out by qualified and

experienced welders.
Provide the necessary equipment such as the correct clothing,
head gear, exhausts systems or respirators and if required
platforms for safe access to the repair area.
It is important to maintain the preheat temperature according to table 7
throughout the repair.
The interpass temperature should never exceed the maximum permissible
value shown in table 3. Measure the temperature beside the joint at a distance
equal to the sheet metal thickness using suitable temperature indicating
devices.
All cracks through the parent material will require a welding from both sides,
see illustration 1. The Service Bulletin No. 21-594 contains instructions for
making a Man Hole which is necessary for weld repairs from inside the boom
or stick.
When welding in a vertical position always weld using the vertical up technique.
Properly applied multiple pass welding is the required procedure, illustration 2.
Use a blunt-nosed chisel (C) to calk the weld beads (A and B) with the groove
wall before welding the space between the beads (A and B). Repeat the
calking of beads (A and B) at each weld layer.
Illustration 2
Once a repair has been started by preheating and welding, the part should be
worked on until completed.
A recommended technique for repair is to butter the groove with weld metal.
Buttering is the addition of one or more layers of weld metal to the face of the
joint or surfaces to be welded.
AH08507
Page 7 of 9
After the welding has been completed, check the repair for any undercuts,
overlaps or any other notch type discontinuity while the preheat is still up to
temperature. Make any repair necessary at this time.
After the repair cools, grind all butt-welded repairs smooth using 36 or finer grit
grinding material. All grinding marks should be parallel to the direction of
primary stress if possible. Make sure there is a smooth transition between the
weld metal and the parent plate.
7. Post heating
Maintain the preheat temperature according to table 7 for at least 15 minutes

after the weld repair is finished and then cool the repair area slowly, refer to
table 3 for maximum allowable temperature drop per hour.
8. Inspection of Repair
Inspect the completed weld after it has cooled to the ambient temperature by
non-destructive procedures as dye penetrant, or magnetic particle inspection
and ultrasonic inspection, if possible.
A final inspection of the weld repair should be made after 24 hours in order to
detect hydrogen induced cracks.
If surface defects are found, remove all defects by grinding to a maximum
depth of 1.5 mm. Larger defects have to be removed according to the repair
procedures described on the preceding pages. Grind welds so they blend in
with the parent material. All spot welding also require preheating and post
heating.
It is not recommended to weld on reinforcement plates as the
main stress will remain ~float~ through the steel structure
regardless how many additional plates would be applied to the
structure.
AH08507
Page 8 of 9
Illustration 3
AH08507
Page 9 of 9
Illustration 4
AH08507
COMPONENT CODE:
71
REF NO.
AH08508
DATE
June 13, 2008

Page 1 of 3
SUBJECT:
PURPOSE:
Wear checking procedure
APPLICATION:
PC3000-1; PC3000-6; PC4000-6; PC5500-1; PC5500-6;

PC8000-1; PC8000-6
FAILURE CODE:
7100CA
DESCRIPTION:
For installation of bushes please refer also to Parts & Service

news AH06545.
1. Bushings of the attachment

2. Bushings between bolted track frame and undercarriage
(depends on the execution)
AH08508
Page 2 of 3
1. Bushings of the attachment
Illustration 1
Example for determining the clearance of the boom cylinder bushes
(The procedure for the other attachment bushes is analogues.)
1. Place the attachment on the ground as shown on illustration 1.
2. Raise the attachment a little bit from the ground.
3. Make a line with a felt pen from boom bearing to the boom cylinder barrel
(a = 30 cm).
4. Make a 2nd line with a felt pen from boom bearing to the boom cylinder piston rod
(b = 30 cm).
5. Press the attachment on the ground so far that the chains at c just remove from
the ground.
6. Measure the distances at a and b.
We recommend to renew the bushes if the clearance reaches a

value of about 3 mm.
AH08508
Page 3 of 3
2. Bushings between bolted track frame and undercarriage
1. Position the machine in a position
so that the track frame can be lifted of
the ground.
2. Install a dial gauge so that the

dial gauge magnetic portion is on
the side frame.
3. Set the pointer on to the car body
and set to zero.
4. Raise the track frame slowly off

the ground until the dial gouge
stops moving.
Record the measurement.
We recommend to renew the bushes if the clearance reaches a

value of about 3 mm.
AH08508
COMPONENT CODE:
REF NO.
DATE
6B
AH08516
September 17, 2008
Page 1 of 7
This PARTS & SERVICE NEWS supersedes the previous issue AH07519a which should
be discarded.
SUBJECT:
PURPOSE:
Hose standardization and routing improvement
APPLICATION:
H 485 (#12001 to 12019; 12021 to 12024)), H 685 (#12020);

H 655 (#12025 to 12027; 12030 to 12032);
PC8000-1 (#12033; 12035; 12036);
PC8000-6 (#12038 to 12053 without 12041; 12045 to 12047)
FAILURE CODE:
6B00FA
DESCRIPTION:
We recommend replacing the hydraulic lines on the stick and the boom according to the
description at the following pages and the hydraulic hoses between stick and boom.
Advantages:
All 6 new hydraulic hoses with the same Part no.
The hoses are shorter and therefore less lateral movement.
AH08516
Page 2 of 7
Description
1. Remove the 6 pipes on the boom (36; 37), all hydraulic hoses between stick and
boom (1), and all pipes on the stick (16 to 21) (Illustration 1).
2. Remove the lubrication line / hose (34; 35) (Illustration 5).
3. Cut off the old plates (32) (Illustration 1 + 6).
4. Weld on the two new plates (32) to the mounting rail (shift the
mounting rail 400 mm) (Illustration 6).
5. Install the six new pipes (36; 37) to the boom (Illustration 1).
6. Install the new blocks (3) (Illustration 2).
7. Install the new lubrication pipe (35) and the new lubrication hose (34) (Illustration 5).
8. Install additional and new clamps to the stick for the pipes according to
Illustrations 3 and 4.
9. Install the new pipes (16 to 21) to the stick (Illustration 1).
10. Install the 6 new hoses (1) and the distributer block (2).
11. Bleed the new lubrication line.
12. Bleed the new hydraulic hoses /lines refer to Parts & Service News AH06524.
AH08516
Page 3 of 7
Required parts PN 797 356 73 (Refer to drawings below)
(Required parts for cold weather design* PN 797 357 73)
Pos.
Part No.
Qty.
1*
2
3
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
23
24
25
26
27
28
29
30
31
32
33
34*
35
36
37
38
39
40
940 328 40
948 197 40
952 701 40
319 313 99
504 662 98
319 305 99
319 323 99
502 960 98
534 004 99
504 818 98
308 581 99
948 191 40
952 702 40
952 703 40
952 704 40
952 705 40
952 706 40
952 707 40
504 445 98
308 612 99
509 310 98
504 446 98
510 151 98
332 334 99
561 548 40
946 809 40
946 807 40
905 235 40
502 965 98
512 724 98
946 814 40
796 451 73
796 452 73
534 008 99
534 009 99
504 445 98
6
1
2
48
48
8
8
2
2
2
4
2
1
1
1
1
1
1
6
20
10
6
4
4
2
4
2
2
8
1
1
3
3
4
4
4
Description
Hose NW 50 x 3200
Clamp rail assy.
SAE-L-Block 2
Bolt M 20 x 120
Nut M 20
Bolt M 20 x 60
Bolt M 20 x 90
Plate
Plate
Clamp set
Bolt M 10 x 70
Pipe 38 x 240
Pipe assy. right
Pipe assy. left
Pipe assy. right
Pipe assy. left
Pipe assy. right
Pipe assy. left
Pair of clamps
Bolt M12 x 100
Locking plate
Pair of clamps
Bolt M12 x 120
Nut M12
Angel
Weld on plate (10x70x60)
Pipe bracket
weld on Plate
Plate
Hose for Lube system
Pipe for lube system
Pipe
Pipe
Cover Plate
Weld on plate
Pair of clamps
* Different Parts for cold weather design (- 50C) included in PN 797 357 73
1
940 765 40
6
Hose NW 50 x 3200
34
Hose for Lube system
907 078 40
1
AH08516
Page 4 of 7
Overview 1
Illustration 1
AH08516
Page 5 of 7
Overview 2
Illustration 2
AH08516
Page 6 of 7
New Pipe retaining clamps
Illustration 3
Illustration 4
AH08516
Page 7 of 7
New lubrication line
Illustration 5
Shifting of the mounting rail (400 mm)
Illustration 6
AH08516
COMPONENT CODE:
6B
REF NO.
DATE
AH08532
October 2, 2008
Page 1 of 4
SUBJECT:
PURPOSE:
Hose standardization and routing improvement
APPLICATION:
PC8000-6 (SN12028; 12029; 12046; 12054 to 12060)
FAILURE CODE:
6B00FA
DESCRIPTION:
We recommend replacing the hydraulic lines on the stick according to the description at
the following pages and the hydraulic hoses between stick and boom.
Advantages:
All 6 hydraulic hoses with the same length and straight hose connectors.
Only one clamp rail for the hoses necessary.
Routing improvement.
AH08532
Page 2 of 4
Description
1. Remove the both outer hydraulic hoses between stick and boom (1) and all pipes
on the stick (16 to 21) (Illustration 1).
2. Install the new blocks (3) (Illustration 2).
3. Install the new pipes (16 to 21) to the stick (Illustration 1).
4. Install the 2 new hoses (1) and the new clamp rail (2).
5. Bleed the new hydraulic hoses /lines refer to Parts & Service News AH06524.
Required parts PN 948 190 40 (Refer to drawings below)

Pos.
1*
2
3
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
Part No.
940 328 40
948 197 40
952 701 40
319 313 99
504 662 98
319 305 99
319 323 99
502 960 98
534 004 99
504 818 98
308 581 99
948 191 40
952 702 40
952 703 40
952 704 40
952 705 40
952 706 40
952 707 40
Qty.
2
1
2
48
48
8
8
2
2
2
4
2
1
1
1
1
1
1
Description
Hose NW 50 x 3200
Clamp rail assy.
SAE-L-Block 2
Bolt M 20 x 120
Nut M 20
Bolt M 20 x 60
Bolt M 20 x 90
Plate
Plate
Clamp set
Bolt M 10 x 70
Pipe 38 x 240
Pipe assy. right
Pipe assy. left
Pipe assy. right
Pipe assy. left
Pipe assy. right
Pipe assy. left
* Different Parts for cold weather design (- 50C)

1
940 765 40
2
Hose NW 50 x 3200
AH08532
Page 3 of 4
Overview 1
Illustration 1
AH08532
Page 4 of 4
Overview 2
Illustration 2
AH08532
Suppliers documentation
9 SUPPLIERS
DOCUMENTATION
Version 2010/1
PC8000-6
9 -1
Suppliers documentation
Contents of this chapter:

AVANTI HYTORQUE
9 -2
PC8000-6
Version 2010/1
XXI/Avanti/Stealth SERIES
Operational Manual
July 2004
Table of Contents
XXI/Avanti/Stealth SERIES Operational Manual
SECTION I
IMPORTANT SAFETY INSTRUCTIONS
SECTION II
BEFORE USE
2-1 Working Pressure

2-2 Hydraulic Connections
2-3 Electrical Connections
2-4 Air Connections
SECTION III
OPERATION
3-1 General
3-2 Connecting the System
3-3 Drive Direction Change
3-4 Reaction Arm XXI/Avanti
3-5 Setting Torque
3-6 Setting Pump Pressure
3-7 Tightening Procedures
3-8 Operating the XXI, Avanti & Stealth Systems
3-9 Loosening Procedures
SECTTION IV
4-1 Tool set up and operation
USE WITH LoaDISC
4-2 LoaDISC Tensioning
WASHER & CLAMP-NUT 4-3 LoaDISC De-tensioning
4-4 LoaDISC Lubrication
4-5 CLAMP-NUT Tensioning
4-6 Clamp-nut De-tensioning
4-7 Clamp Lubrication
SECTTION V
5-1 General Information
OPERATION
5-2 Hydraulic Connections
HYTORC POWER PACKS 5-3 Prior to Use
5-4 Operation Electric Pump-5-5 Operation Air Pump-5-6 Automatic Pump
5-7 Starting with Automatic System
SECTION VI
HELPFUL
INFORMATION
Tool Dimensions & Parts List

Field-proven Torquing Procedure
Pressure/Torque & Pressure/Load Conversion Chart
Recommended Torque For ASTM A193 Grade B7 Studs
INTRODUCING THE NEW GENERATION HYTORC
Thank you for buying the NEW HYTORC FREEDOM-LINE!

This manual is designed to provide you with the basic knowledge required to operate and maintain
your HYTORC bolting equipment. Please read this manual carefully and follow the instructions
provided. If you have any questions regarding HYTORC bolting equipment, please call us at
201-512-9500 or contact us at [email protected].
Your purchase of HYTORC bolting equipment entitles you to the following services at no extra
cost to you.
Free on-site training in the application and operation of your HYTORC bolting equipment
* Free semi-annual training
* Free annual tool inspection.
* Free loner tools in case of failure under warranty
* Free engineering assistance by calling 1-800-FOR-HYTORC or our international office.
Your local HYTORC bolting specialist is available around the clock for your convenience. Should
you require any assistance, please contact us to obtain our local specialists information.
World-wide Warranty
HYTORC bolting equipment is engineered to the latest technological standards and is accompanied
by our exclusive 12 word, 12-month warranty:
YOU BREAK IT UNDER NORMAL USE, WE FIX IT FREE OF CHARGE!
If your HYTORC equipment cannot be repaired on site, FREE loaner equipment will be made
available to you upon request, while under warranty.
INTRODUCTION
HYTORC tools are uniquely multi-purpose. They can be used as accurate bolting
equipment on conventional nuts in open or confined spaces. They also can be used as
reaction arm free tensioning equipments, when used with HYTORC LoaDISC washer or
HYTORC-Clamp, Hydraulically Actuated Mechanical Tensioner.
SECTION I
IMPORTANT SAFETY INSTRUCTIONS
HYTORC tools are designed for the safety of operators. However, they are powerful tools and certain
safety precautions should be observed to avoid accidents or personal injury. The following tips will
assist you.
READ ALL INSTRUCTIONS
KEEP WORK AREA CLEAN AND WELL LIT
CONSIDER WORK AREA
ENVIRONMENT
Electric pumps should never be used in any atmosphere

which can be considered potentially volatile. If there is any
doubt, use an air pump.
Also note: Metal to metal contact can cause sparks. Precautions must be taken.
AVOID PREMATURE TOOL
STARTING
The pump remote control should be operated by a

designated operator and ensure ALL CLEAR prior to
starting and to avoid premature tool starting.
STAY CLEAR DURING OPERATION
In most cases, the tool will allow hands free operation. If

the tool must be reset on bolt during operation, make sure the
remote control operator is aware of turning the pump off.
IMPORTANT NOTE: NEVER HOLD THE TOOL DURING OPERATION!

GUARD AGAINST ELECTRIC
SHOCK
Ensure the pump is properly grounded and the proper

voltage is used.
STORE EQUIPMENT PROPERLY
When not in use, tools and accessories should be properly

stored to avoid deterioration.
USE THE RIGHT TOOL

Do use tools or attachments suitable for the applications.
*refer to our recommended torque/load chart
PROPER SAFETY ATTIRE
When handling/operating hydraulic equipment, wear

work gloves, hard hats, safety shoes, safety glasses and other
applicable clothing.
MOVING EQUIPMENT
Do not use hydraulic hoses, uniswivels, pump power or

remote cords as means of moving the equipment.
SECTION I
IMPORTANT SAFETY INSTRUCTIONS -continued from the previous pageHOSES
Do not kink hoses. Inspect and replace if damaged.
SHROUDS AND COVER PLATES
All tools are equipped with shrouds and/or cover plates

to prevent contact with the moving internal parts. Do not
use tools without these safety covers. If the covers are
missing or damaged, replace immediately.
MAINTAIN TOOLS
For the best results, inspect tools, power packs, hoses,

connectors, electric lines and accessories for visual
damage before each usage. Always follow instructions
for proper tool and pump maintenance.
SAFETY ALERT
Do not use power equipment under the influence of any

mood altering substance.
PRIOR TO OPERATION
Ensure that all hydraulic connectors are securely

connected. Verify that the hydraulic hoses are not
kinked. Insure the square drive and its retainer are
fully and securely engaged.
PRIOR TO USE (if use with reaction arm)
Before placing your tool on the application, cycle it to

ensure proper function. If using the torque mode,
locate a solid and secure reacting point. Be sure the
reaction arm is retained firmly and positioned to face
the same direction as the square drive. Be sure the
hydraulic hoses are free of the reacting point. Pressurize
the system momentarily; if the tool tends to ride up or
to creep, stop and adjust the reaction arm to a solid
and secure position.
NOTE: Remain clear of the reaction arm during operation and never put body parts between
reaction arm and reaction surface.
ALWAYS USE QUALITY
ACCESSORIES
Use genuine HYTORC accessories. Use correct size

accessories and engage them fully. Stay clear of all moving
accessories during operation.
DO NOT USE FORCE
Do not apply any impact by using hard objects on bolting

equipment or accessories. This may cause malfunction or
breakage.
ALWAYS CONSULT
Please contact HYTORC for any questions related to our

equipment or your bolting needs. Safety is always the
number one priority.
SECTION II
INSTRUCTIONS BEFORE USING YOUR NEW HYTORC
READ CAREFULLY: Most malfunctions, in new equipment, are the result of improper operation
and/or set-up.
PREPARATION: Remove HYTORC equipment from shipping container.
INSPECTION: Visually inspect all components for any damage during transportation. If damages
are found, notify HYTORC immediately.
2-1 Working Pressure
The tools maximum
working pressure is 10,000 PSI (700kg/cm2, 690 Bar)
Make sure that all hydraulic equipment used is rated
for 10,000 PSI operating pressure. To set pump
pressure for XXI models to 10,000 PSI for both
advance & retract, locate selector valve underneath
the couplers. Turn the pump off and loosen the lock
nut. Turn the center screw counter-clockwise until
it stops. Tighten the lock-nut. For Avanti & Stealth
models, turn the center screw clockwise until it stops.
Tighten the lock-nut to set the pump pressure to 1,500
PSI for retract.
2-2 Hydraulic Connections With older style pumps, (SST-10, SST-20),
the retract side of the system may remain pressurized after the pump
has been switched off. This trapped pressure makes it impossible to
loosen the retract-side fittings by hand. To release the pressure, find
the 5/16 manual override holes in the end of the black solenoids on the
pump. With a welding rod, Allen-key or similar device, push in on the
ends of both solenoids, each in turn, and the residual pressure will be
released. All fittings will, then, be hand tightened again. Hoses and
couplers must be free and unobstructed before and during the operation
of the tool. External impact on the couplers may break off the fittings.
Current pump models are equipped with an auto-pressure relief. Never disconnect or connect any
hydraulic hoses or fittings without first unloading wrench and the pump. Double check the gauge
reading to assure pressure has been released.
When making connections with quick disconnect couplings, make sure the couplings are fully engaged.
Threaded connections such as fittings and gauges must be clean and securely tightened and leak free.
CAUTION: Loose or improper threaded fittings can be potentially dangerous if pressurized. Severe
over tightening can cause premature thread failure. Never grab, touch or in any way come in contact
with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury.
SECTION II
INSTRUCTIONS BEFORE USING YOUR NEW HYTORC -continued from the previous
page2-3 ELECTRICAL CONNECTIONS
Ensure proper power availability to prevent motor failure or
dangerous electrical overloading. Compare the motor nameplate for required amperage. Do not use
electric pump, if three prong electrical plug is not whole. Minimize the length of extension cords and be
sure they are of adequate wire size, with ground connectors. Extension cord up to 50 feet should be #10
AWG gauge.
CAUTION: Electric motors may spark. Do not operate in an explosive atmosphere or in the presence
of conductive liquids. Use an air pump instead.
2-4 AIR CONNECTIONS Ensure that you have sufficient air flow of 80 psi ( 50 cfm) to operate your
pneumatic pump. If in doubt, compare the pump manufacturers recommended air flow rating prior
to pressurizing pump. Improper air flow may damage the pump motor. For best results, use air hose
larger than 3/4 diameter.
Use of a filter regulator lubricator (FRL) is highly recommended. (diagram below)
AIR ADJUSTMENT KNOB
AIR FLOW
ON/OFF LEVER
OIL LUBRICATOR
ADJUSTMENT KNOB
FILTER CAP
AIR PRESSURE GAUGE

CONDENSATION
BOWL
DRIER
1.
2.
Adjust flow to 1-2 drops per minute.

Fill half way with grade 46 hydraulic oil supplied.
AUTO WATER DRAIN PORT
SECTION III
OPERATION Torquing Conventional Nuts
3-1 General All HYTORC tools are supplied completely assembled and are ready to use. A
HYTORC Hydraulic Power Pack, for use with your HYTORC tools, is recommended to provide
the speed, pressure and portability that makes your HYTORC SYSTEM more efficient and accurate.
The SYSTEM accuracy of your HYTORC tool is +-3% based upon manufacturers specifications.
This accuracy maybe certified through calibration by HYTORC or any other qualified calibration
facility whose program is traceable to the National Institute of Standards and Technology (N.I.S.T.)
Using a calibrated gauge enhances the accuracy of your HYTORC SYSTEM.
3-2 Connecting the SYSTEM
The wrench head and power pack are connected by a
10,000 PSI operating pressure (40,000 PSI burst) twin line hose assembly. Each end of the hose have
one male and one female connector to assure proper interconnection between pump and wrench
head.
IMPORTANT:
To avoid tool malfunction, do not reverse connectors.
Connect the twin line hose to the uniswivel as shown below. Make sure male couplers are connected to
female couplers. During the operation, check the connection to ensure the couplers are not loose.
Insure the connectors are fully engaged and screwed snugly and completely together.
Connect to tool
Connect to pump
*Connect male end of hose to female end of both tool and pump &
female end of hose to male end on both tool and pump
From hose
From hose
SECTION III
OPERATION Torquing Conventional Nuts -continued from the previous page3-3 Drive Direction Change
Avanti tools To remove the square drive, disengage the drive retainer assembly by
depressing the retaining round button and gently pulling on the square end of the square drive. The
square drive will slide out. To insert the drive in the tool, place the drive in the desired direction,
engage drive spline and ratchet spline, then twist bushing until engage to the housing spline. Push
drive through ratchet. Depress drive retainer button, engage retainer with drive and release button
to lock.
Button
Drive Retainer
Square Drive
The diagram on the right illustrates the direction that the square
drive should face for tightening and loosening of a standard
right hand fastener.
Loosening
Tightening
Stealth tools The Stealth tools use interchangeable ratcheting links. For tightening, simply engage
the nut with the right side of the link facing down. For loosening, the left side of the link faces down.
Ratcheting link can be detached from the Stealth power head by pulling the power head out while
pressing the button shown below.
STEALTH
MADE IN U.S.A.
STEALTH
MADEIN USA
Loosening
Link release button
3-4 Reaction Arm
Please read
operating
instructions
prior to use,
and use
common sense.
Tightening
KEEP HANDS
OFF DURING
OPERATION!
The Avanti can be used with a 360 degree adjustable universal reaction arm.
Make sure the reaction arm spline is fully

engaged on the square drive spline. Secure
the position by tightening the set screw on
the reaction arm.
*ALWAYS USE A SAFETY HANDLE
SECTION III
OPERATION Torquing Conventional Nuts -continued from the previous page3-5 Setting Torque
Once the SYSTEM is fully connected and the proper power supply is available, it is time to adjust the
pump pressure to the level needed on your job. When tightening, use the manufacturers specifications
to determine the torque value ultimately required. Appendix I which is presented as a guideline for
comparison only gives typical torque values specified for the most commonly encountered fasteners.
Torque sequence varies from plant to plant and even within the same plant may vary depending on the
gasket material and other factors. Always abide by on-site-procedures.
Always refer to the pressure-torque conversion table that came with the tool.
3-6 Setting the Pressure on the Pump
T Handle
To set the pressure on the pump, follow this procedure.

1. Loosen the knurled locking ring below the T handle on the pumps
external pressure regulator. Then turn the T handle counterclockwise until it turns freely and easily.
2. Turn the pump ON. Using the pumps remote control pendant,
push down the advance switch (or button on air pump) and hold it.
Locking Ring
3. While holding the pump in the advance mode, slowly turn the T handle
clockwise and observe the pump pressure gauge rise.
NOTE: Always adjust the regulator pressure up never down.
4. Once the desired pressure is reached. Turn off the pump and LOCK IN the pressure by tightening
the knurled lock nut. Turn on the pump once more and pressurize to verify the pressure is maintained.
3-7 Applying the Avanti the Tightening Process
1. Once your target pressure is set, cycle the tool three or four times to full pressure. Cycling the tool
ensures that the system is operating properly and removes trapped air, if any.
2. Place the proper size driving unit on the square drive and secure properly.
3. Place the tool on the bolt, making sure that everything is fully engaged. Further ensure that the drive
retainer is engaged.
4. Make sure the reaction arm is firmly abutted against a stationary object.
5. When positioning the wrench, make sure that the hose connections are well clear of any obstructions.
6. After all the above are confirmed, apply momentary pressure to the SYSTEM to ensure proper tool
placement.
SECTION III
OPERATION Torquing Conventional Nuts -continued from the previous page3-7 Applying the Stealth the Tightening Process
1. Once the target pressure is set (refer to 3-6) Cycle the tool several times to full pressure to assure
proper operation.
2. Place the right side of the ratchet link directly over the nut. Ensuring the hex is fully engaged
and the reaction pad portion of the link abuts solidly against an adjacent nut or other stationary
object. (see 3-3 for proper tool placement)
3. Ensure hose connections are clear of any obstacles.
4. After all the above are confirmed, apply momentary pressure to the SYSTEM to assure the
reaction point is stable.
3-8 Operating the Avanti and Stealth SYSTEMS
1. By pushing down on the remote control button in the advance position, the rear of the tool will
be pushed back until the reaction surface will contact its reaction point.
2. Continue to hold down the advance button as the socket turns until you hear a CLICK which
will signify the hydraulic cylinder inside the tool is fully extended and will not turn the socket
further.
3. Continuing to hold down the remote control button will result in a rapid buildup of pressure to
the point of where the gauge reads what was preset prior to applying the wrench.
IMPORTANT:
The reading of full preset pressure after the cylinder is extended DOES NOT
INDICATE that this pressure (torque) is applied to the bolt. It only indicates that the cylinder is
fully extended and cannot turn the nut further until the tool automatically resets itself.
Releasing the remote control button will retract the cylinder. The tool will automatically reset
itself and the operator will hear a CLICK indicating he can again push the remote control
button and the socket will turn. Each time the cylinder is extended and retracted, it is called a
cycle. Successive cycles are made until the tool STALLS at the preset Torque/PSI with an
accuracy of +-3%. Repeatability is +-1%.
IMPORTANT:
ALWAYS ATTEMPT ONE FINAL CYCLE
TO INSURE THE STALL POINT HAS BEEN REACHED.
NEVER HOLD THE TOOL DURING OPERATION.
Use safety handle to set and
remove tools.

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1.1 CONTENTS OF VOLUME 1 BINDER

CONTENTS OF VOLUME 1 BINDER

The volume 1 binder contains the Operation and Maintenance

This Operation and Maintenance Manual is the Original

SPECIFICATION AND SERIAL NUMBER PLATE

Product Identification Number

1.2 CONTENTS OF VOLUME 2 BINDER

CONTENTS OF VOLUME 2 BINDER

The volume 2 binder is being delivered with the Shovel. This

Read the Manuals before You Start the Engines.

your Personal SAFETY

Operating SAFETY, and

READY and EFFICIENT PERFORMANCE of your

Periodic preventive inspections and maintenance are the surest

1.3 DESIGNATED USE OF THE SHOVEL

DESIGNATED USE OF THE SHOVEL

This machine has been manufactured in accordance with

1.4 DELIVERY OF THE SHOVEL

DELIVERY OF THE SHOVEL

The Shovel is being delivered disassembled into its main components.

If there are any questions concerning the assembling procedure,

1.5 EXPLANATION OF ABBREVIATIONS

American Petroleum Institute

Engine Monitoring System

Central Lubrication System

German Institute for Standardization

Electronic Bucket Levelling System

Electronic Control Module (Engine)

Front Guard Protective Structure

Falling-Object Protective Structure

High Pressure Filter (Hydraulic Oil)

Light Emitting Diode

Electronic Control System (Engine)

Type of Engine Fuel System

Programmable Logic Controller

parts per million

Swing circle pinion Lubrication System

Vehicle Health Monitoring System

Revolutions Per Minute (RPM)

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS

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

SOUND PRESSURE LEVEL IN THE OPERATORS CAB. .............................................................. 2-5

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................... 2-6

2.4.10 STARTING ENGINE ............................................................................................................

PRECAUTION FOR MAINTENANCE..............................................................................................

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND

SPECIAL SAFETY EQUIPMENT.....................................................................................................

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

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

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

TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING,

SOUND PRESSURE LEVEL IN THE OPERATORS CAB.

SOUND PRESSURE LEVEL IN THE OPERATORS

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

GENERAL PRECAUTIONS COMMON TO OPERATION