KOMATSU PC4000-11 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08273 – PDF DOWNLOAD
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KOMATSU PC4000-11 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08273 – PDF DOWNLOAD
FOREWORD:
This is the original version of the Operation & Maintenance Manual, compiled in English, according to the serial number stated on the front cover.
BEFORE READING THIS MANUAL:
- This manual gives details of the operation and methods of inspection and maintenance for this excavator that must
be obeyed in order to use the excavator safely. Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of excavators. - Read, understand and follow all precautions and warnings in this manual and on the excavator before performing
operation and maintenance. Failure to do so may result in serious injury or death. - Komatsu cannot predict every circumstance that may involve a potential hazard when the excavator is used.
Therefore, the safety messages in this manual and on the excavator may not include all possible safety precautions. If you carry out any operation, inspection or maintenance under conditions that are not described in this
manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event
should you or others engage in prohibited uses or actions described in this manual. Improper operation and maintenance of the excavator can be hazardous and could result in serious injury or death.
TABLE OF CONTENTS:
KOMATSU PC4000-11 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08273 – PDF DOWNLOAD
1 FOREWORD 3
1 1 BEFORE READING THIS MANUAL 4
1 2 EC DECLARATION OF CONFORMITY 5
1 3 PRIVACY POLICY ON MACHINES EQUIPPED WITH MACHINE MONITORING SYSTEMS FOR THE EEA 6
1 4 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS 9
1 5 DIRECTIONS OF THE MACHINE 10
1 6 SPECIFICATION AND SERIAL PLATE 11
1 6 1 PRODUCT IDENTIFICATION NUMBER 11
1 7 DIVISION OF THE BINDER 12
1 8 DESIGNATED USE OF THE SHOVEL 13
1 9 DELIVERY OF THE SHOVEL 14
1 9 1 SPARE PARTS 14
1 9 2 SERVICE 14
1 10 EXPLANATION OF ABBREVIATIONS 15
2 SAFETY 25
2 1 SAFETY INFORMATION 26
2 2 OVERVIEW 27
2 2 1 NORMAL OPERATIONS 27
2 2 2 REGULAR MAINTENANCE 27
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 27
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 27
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 28
2 3 1 SOUND 28
2 3 2 VIBRATION 28
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 29
2 4 1 UNDERSTANDING THE MACHINE 29
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 29
2 4 2 1 ENSURING SAFE OPERATION 29
2 4 3 PREPARATIONS FOR SAFE OPERATION 29
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 29
2 4 3 2 INSPECTING THE MACHINE 29
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 30
2 4 3 4 KEEP MACHINE CLEAN 30
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 30
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 31
2 4 3 7 IF A PROBLEM IS FOUND 31
2 4 4 FIRE PREVENTION 31
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 31
2 4 4 2 ACTION IF FIRE OCCURS ON PC3000 32
2 4 4 3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000 33
2 4 4 4 EMERGENCY EXIT FROM OPERATOR’S CAB 33
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 34
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 34
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 34
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 34
2 4 5 4 WORKING IN HIGH PLACES 34
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 35
2 4 5 6 LEAVING THE MACHINE 35
2 4 6 BURN PREVENTION 35
2 4 6 1 Hot coolant 35
2 4 6 2 Hot oil 36
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 36
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 36
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 37
2 4 9 1 UNAUTHORIZED MODIFICATION 37
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 37
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 37
2 4 11 PRECAUTIONS AT JOBSITE 38
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 39
2 4 11 2 CAMERA SYSTEM WITH MONITORS 39
2 4 11 3 ENSURE GOOD VISIBILITY 39
2 4 11 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 39
2 4 11 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 40
2 4 11 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 40
2 4 11 7 Lightning Strikes 41
2 4 11 8 WORKING ON LOOSE GROUND 41
2 4 11 9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 42
2 4 11 10 VENTILATION OF ENCLOSED AREAS 43
2 4 12 STARTING motor 44
2 4 12 1 WARNING TAG 44
2 4 12 2 CHECKS BEFORE STARTING motor 44
2 4 12 3 PRECAUTION WHEN STARTING motor 44
2 4 12 4 PRECAUTION IN COLD AREAS 45
2 4 13 OPERATION 45
2 4 13 1 CHECKS BEFORE OPERATION 45
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 46
2 4 13 3 PRECAUTIONS WHEN traveling 47
2 4 13 4 TRAVELING ON SLOPES 48
2 4 13 5 OPERATIONS ON SLOPES 49
2 4 13 6 PROHIBITED OPERATIONS 49
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 50
2 4 13 8 PARKING THE MACHINE 50
2 4 13 9 TRANSPORTATION 50
2 5 PRECAUTION FOR MAINTENANCE 51
2 5 1 GENERAL PRECAUTIONS 51
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 52
2 5 1 2 STOP motor FOR MAINTENANCE 53
2 5 1 3 WARNING TAG 54
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 55
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 55
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 56
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 56
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 57
2 5 1 9 NOISE 57
2 5 1 10 WHEN USING A HAMMER 57
2 5 1 11 PROPER TOOLS 58
2 5 1 12 ACCUMULATOR 58
2 5 1 13 PERSONNEL 58
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 59
2 5 2 1 PRECAUTION WHEN WELDING 59
2 5 2 2 BATTERY HANDLING 59
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 60
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 61
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 62
2 5 3 3 REPLACEMENT OF HOSE LINES 62
2 5 3 4 INSPECTION OF HOSE LINES 62
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 63
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 63
2 5 3 7 AIR CONDITIONING MAINTENANCE 63
2 5 3 8 COMPRESSED AIR 64
2 5 3 9 WASTE MATERIALS 64
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 65
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 65
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 65
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 65
2 7 SPECIAL SAFETY EQUIPMENT 66
2 7 1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 67
2 7 2 OBJECT HANDLING 67
2 7 3 LIGHTING 67
2 7 4 WARNING BEACON 67
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 67
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 67
2 7 5 2 INSTRUCTIONS FOR USE 69
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 71
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 71
2 7 5 5 INSTRUCTIONS FOR USE 73
2 8 SAFETY WARNING SIGNS 75
2 8 1 LOCATION AND DESCRIPTION OF THE SIGNS 76
3 OPERATION 95
3 1 FOREWORD 96
3 1 1 Connection of customer electrical installations to the excavator 96
3 2 CONSTRUCTION OF THE SHOVEL 97
3 2 1 OVERALL VIEW 97
3 2 2 SUPERSTRUCTURE 98
3 2 2 1 Machinery House 102
3 2 2 2 Main Hydraulic Oil Reservoir 104
3 2 2 3 Hydraulic Oil Cooler 105
3 2 2 4 Fuel Tank 106
3 2 2 5 Counterweight 107
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 108
3 2 3 1 LOWERING THE LADDER IN EMERGENCY SITUATIONS 111
3 2 4 EMERGENCY ESCAPE LADDERS 112
3 2 4 1 Emergency escape from the operator’s cabin 113
3 2 4 2 Emergency escape from the Machinery house 115
3 2 4 3 Emergency escape from the machinery house roof 117
3 2 4 4 ESCAPE LADDER WINCH ASSEMBLY 119
3 2 5 BOOM ACCESS LADDER AND WALKWAY 120
3 2 6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 122
3 2 6 1 Emergency Engine Shutdown System actuated from Ground Man (OPTION) 123
3 2 6 2 Operator Warning System (OPTION) 123
3 2 7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 124
3 2 7 1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual 129
3 2 7 2 Operator’s Seat Adjustment 131
3 2 7 3 Co-driver’s Seat and Refrigerator Box 132
3 2 7 4 INSTRUCTIONS TO using and looking after THE SEAT BELTS 133
3 2 8 UNDERCARRIAGE 134
3 2 9 WORKING ATTACHMENT 135
3 2 9 1 Loader attachment with bottom dump bucket 135
3 2 9 2 Loader attachment with backhoe bucket 136
3 2 10 DIESEL ENGINE TYPE SDA 16V160E-2 137
3 2 11 ENGINE OIL MANAGEMENT SYSTEM 140
3 2 11 1 Oil Burning System “Centinel” combined with Oil Supply System “Reserve” 142
3 2 11 2 Eliminator Engine Oil Filtration System 143
3 3 OPERATOR’S CAB – CONTROLS 144
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 144
3 3 1 1 HYDRAULIC CONTROL SYSTEM 145
3 3 2 SAFETY CIRCUIT FOR CONTROLS 145
3 3 2 1 EURO Control Pattern 147
3 3 3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 148
3 3 3 1 HYDRAULIC CONTROL SYSTEM 149
3 3 4 SAFETY CIRCUIT FOR CONTROLS 149
3 3 4 1 EURO Control Pattern 151
3 3 5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK 151
3 3 6 OPERATOR’S CONSOLE 153
3 3 6 1 Switch Board 155
3 3 7 INTERFACE PANEL FOR DIAGNOSTICS 159
3 3 8 CONTROL MODULE FOR AUXILIARY CAB HEATER 161
3 4 VEHICLE HEALTH MONITORING SYSTEM Komtrax Plus – HEALTH MONITOR 162
3 4 1 SEQUENCE OF DISPLAYS 163
3 4 2 OPENING SCREEN 163
3 4 3 Function Checking Screen 164
3 4 4 MAIN GAUGE SCREENS 1 TO 3 165
3 4 4 1 Main Gauge Screen 1 166
3 4 4 2 Main Gauge Screen 2 168
3 4 4 3 Main Gauge Screen 3 168
3 4 4 4 Color Definition 168
3 4 5 ECO Guidance 169
3 4 5 1 OPERATING RECORDS 170
3 4 5 2 Average FUEL Consumption Logs 171
3 4 5 3 Machine Setting 172
3 4 5 4 Reset Truck Counter 172
3 4 6 Maintenance 173
3 4 7 Monitor Setting 173
3 4 7 1 Screen Adjustment 174
3 4 7 2 Clock Adjustment 175
3 4 7 3 LANGUAGE 176
3 4 8 Automatic Messages 177
3 4 8 1 Example OF Action Code L01 177
3 4 8 2 Example OF Action Code L03 178
3 4 8 3 EXAMPLE OF Action Code L04 178
3 5 CAMERA SYSTEMS – SPECIAL EQUIPMENT 180
3 5 1 CAMERA SYSTEM – TYPE 1 180
3 5 1 1 Camera System with Monitors 180
3 5 1 2 LOCATION OF MONITORS AND CONTROL UNITS 181
3 5 1 3 Operating the Monitors 183
3 5 1 4 ARRANGEMENT OF THE CAMERAS 185
3 5 2 CAMERA SYSTEM – TYPE 2 (KomVision) 187
3 5 2 1 CAMERA SYSTEM WITH MONITOR 187
3 5 2 2 Operating the Monitor 189
3 5 2 3 Arrangement of the CAMERAS 191
3 6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 192
3 6 1 Digital Display 192
3 6 2 AUXILIARY HEATER FOR OPERATOR’S CAB 197
3 7 MACHINERY HOUSE 198
3 7 1 EMERGENCY ENGINE SHUTDOWN SWITCHES 199
3 7 2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES 201
3 7 3 CENTRAL CONTROL AND FILTER PANEL 203
3 8 ELECTRICAL EQUIPMENT IN CAB BASE 204
3 8 1 STANDARD COMPONENTS IN CAB BASE 205
3 8 1 1 Low voltage Switch Board 207
3 8 2 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE (WHEN INSTALLED) 209
3 9 CHECKS BEFORE STARTING THE ENGINE 216
3 9 0 1 Coolant Level 219
3 9 0 2 Machinery House Doors 221
3 9 1 OPERATOR’S SEAT ADJUSTMENT 221
3 10 STARTING THE ENGINE 222
3 10 1 STARTING PROCEDURE 225
3 10 1 1 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C 229
3 10 2 ENGINE WARM-UP 235
3 10 3 HYDRAULIC OIL WARM-UP 235
3 11 MOVING THE SHOVEL 237
3 11 1 TRAVEL CONTROL WITH FOOT PEDALS 237
3 11 1 1 TRAVEL ALARM / BACK-UP ALARM 239
3 11 2 TRAVELING INSTRUCTIONS 239
3 11 2 1 TRAVELING LONG DISTANCES 241
3 12 SLEWING AND BRAKING THE SUPERSTRUCTURE 242
3 12 1 SLEWING THE SUPERSTRUCTURE 242
3 12 1 1 MACHINES WITH “EURO” CONTROL 242
3 12 2 BRAKING THE SUPERSTRUCTURE 243
3 12 3 SLEW PARKING BRAKE 243
3 12 3 1 Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System 244
3 12 3 2 IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE 244
3 13 WORKING WITH THE ATTACHMENT 245
3 13 0 1 FACE SHOVEL BUCKET 246
3 13 1 COMBINED OPERATION CYCLES 247
3 14 WORKING INSTRUCTIONS 249
3 14 1 STABILITY OF THE SHOVEL 249
3 14 2 FURTHER OPERATING PRACTICES 251
3 14 3 Loading Trucks 255
3 15 PARKING THE SHOVEL 256
3 15 0 1 CLEANING THE TRACK GROUPS 257
3 16 STOPPING THE ENGINE 258
3 16 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 261
3 17 OPERATION OF THE LUBRICATION SYSTEM 262
3 17 1 CENTRAL LUBRICATION SYSTEM ”CLS” 262
3 17 1 1 Manual actuation of the central lubrication system 262
3 17 1 2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 263
3 17 2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 263
3 17 2 1 Manual actuation of the swing circle lubrication system 264
3 17 2 2 SWING CIRCLE LUBRICATION SYSTEM ”SLS” 266
3 17 2 3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM 266
3 18 FIRE DETECTION AND SUPPRESSION SYSTEMS 268
3 18 0 1 FIRE DETECTION AND SUPPRESSION SYSTEMS 269
3 18 1 DISPLAY MODULE 273
3 18 2 INTERFACE CONTROL MODULE 275
3 18 3 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON machinery house ROOF 277
3 19 TRANSFER PUMP FOR HYDRAULIC OIL 278
3 19 1 OPERATING THE TRANSFER PUMP 279
3 19 2 FUNCTIONS OF THE TRANSFER PUMP 281
3 20 CENTRAL REFILLING SYSTEM 284
3 20 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 285
3 20 1 1 Operation of the hydraulic Service Arm 285
3 20 2 OPERATING THE HYDRAULIC SERVICE ARM 287
3 20 3 RECEIVER PANEL WITH MONITOR BOX 289
3 20 3 1 Refilling Procedure 291
3 20 4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM 293
3 20 4 1 Refilling the Grease Containers of the Automatic Lubrication Systems 295
3 21 WORK ON THE LOADER ATTACHMENT 296
3 21 0 1 OBSERVE THE FOLLOWING INSTRUCTIONS 296
3 22 TRANSPORTATION AND LIFTING OF THE SHOVEL 297
3 22 1 DISASSEMBLING OF THE SHOVEL 297
3 22 2 TRANSPORTATION AND LIFTING 297
3 23 RETRIEVAL PROCEDURE 298
3 24 SHOVEL STORAGE 299
3 24 0 1 GENERAL 299
3 24 1 PREPARING FOR STORAGE 299
3 24 2 ONE MONTH REPETITIVE SERVICE PERIOD 299
3 24 3 SIX MONTH REPETITIVE SERVICE PERIOD 299
3 24 4 PREPARING FOR OPERATION 300
3 25 TROUBLE SHOOTING 301
3 25 0 1 GENERAL 301
3 25 1 ENGINE 301
3 25 2 HYDRAULIC SYSTEM 302
3 25 3 FINAL DRIVES AND SWING MACHINERY 303
3 25 4 CRAWLER TRACKS 303
4 MAINTENANCE 305
4 1 FOREWORD 306
4 1 1 DEFINITIONS 306
4 1 2 GENERAL RECOMMENDATIONS 306
4 2 SAFETY PRECAUTIONS FOR MAINTENANCE 307
4 3 FLUIDS AND LUBRICANTS 308
4 3 1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 308
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 309
4 3 2 1 Recommended Hydraulic Oils 311
4 3 2 2 General Information to selecting hydraulic oils 312
4 4 FILLING CAPACITIES 314
4 5 STANDARD TORQUE LIST 315
4 5 1 Torque for Flange Joints 316
4 5 2 TORQUES FOR SPECIAL COMPONENTS 317
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 319
4 6 1 INITIAL SERVICING 319
4 6 1 1 INITIAL RUNNING-IN 319
4 6 1 2 AFTER THE FIRST 250 OPERATING HOURS 319
4 6 1 3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT 319
4 6 2 SERVICING THE CRITICAL BOLT CONNECTIONS 320
4 6 3 PERIODIC SERVICING INTERVALS 320
4 6 4 PERIODIC SERVICING SCHEDULE 321
4 6 4 1 When necessary 321
4 6 4 2 EVERY 10 OPERATING HOURS OR DAILY 321
4 6 4 3 EVERY 50 OPERATING HOURS OR WEEKLY 322
4 6 4 4 EVERY 250 OPERATING HOURS OR MONTHLY 322
4 6 4 5 EVERY 500 OPERATING HOURS OR QUATERLY 323
4 6 4 6 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS 323
4 6 4 7 EVERY 2000 OPERATING HOURS OR YEARLY 324
4 6 4 8 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 324
4 6 4 9 EVERY 6000 OPERATING HOURS OR EVERY TWO YEARS 325
4 6 5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM 326
4 6 5 1 Lubrication Chart 327
4 7 SAFETY CRITICAL PARTS 328
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 328
4 7 2 INSPECTION OF HOSE LINES 328
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 328
4 7 4 VENTING THE AIR FROM THE FUEL FILTERS 331
4 8 INITIAL SERVICING 332
4 8 1 INITIAL CHECKS FOR PROPER LUBRICATION 333
4 8 2 SWING CIRCLE – CHECK GREASE INJECTORS 335
4 8 3 SWING CIRCLE TOOTHING LUBRICATION 337
4 8 4 CAR BODY AND RACEWAY OF SLEW RING – CHECK GrEASE INJECTORS 339
4 8 5 SWING CIRCLE – CHECK TORQUE OF BOLT CONNECTIONS 341
4 8 6 Retightening procedure of the crawler carrier mounting bolts 343
4 9 EXTENDED SERVICE INTERVALS 349
4 9 1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM 349
4 9 1 1 Servicing Intervals 353
4 9 2 MAINTENANCE OF THE ENGINE 353
4 10 ENGINE FUEL FILTER LOCATION 354
4 10 1 fuel line connections on the engine 355
4 11 WHEN NECESSARY 356
4 11 1 ENGINE AIR CLEANER SERVICE 357
4 11 1 1 General Service Tips 359
4 11 2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS 361
4 11 2 1 CLEAN OR REPLACE FILTER ELEMENTS 363
4 11 3 TRACK ROLLERS – REPLACE FLOATING SEALS 365
4 11 4 GUIDE WHEELS – REPLACE FLOATING SEALS 365
4 12 EVERY 10 OPERATING HOURS OR DAILY 366
4 12 1 WALK-AROUND INSPECTION 367
4 12 2 AIR CLEANER – CLEAN PRE-CLEANER 371
4 12 2 1 Clean dust cups of pre-cleaners 371
4 12 3 RADIATOR – CHECK COOLANT LEVEL 373
4 12 4 TRACK GROUPS – CLEAN 373
4 12 5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER 375
4 12 6 BOOM – CHECK LADDER AND WALKWAY 377
4 12 7 ELECTRICAL EQUIPMENT – CHECK VISUALLY 377
4 12 8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 379
4 13 EVERY 50 OPERATING HOURS OR WEEKLY 380
4 13 1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 381
4 13 1 1 Swing gears type GFB 174 381
4 13 1 2 Swing gears TYPE 89 DS 03 383
4 13 1 3 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS TYPE GFA 280K – CHECK OIL LEVELS 385
4 13 1 4 CHECK Motor Adapter HOUSING OIL LEVEL 385
4 13 1 5 CHECK BRAKE HOUSING OIL LEVEL 385
4 13 1 6 CHECK TRAVEL GEAR OIL LEVEL 385
4 13 2 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 387
4 13 2 1 CHECK BREATHER FILTERS 387
4 13 2 2 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS TYPE ZHP 5 36 – CHECK OIL LEVELS 389
4 13 3 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL 393
4 13 3 1 CHECK OIL LEVEL OF PTO GEAR 393
4 13 4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 395
4 13 5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 399
4 14 EVERY 250 OPERATING HOURS OR MONTHLY 400
4 14 1 AIR CONDITIONING 401
4 14 2 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 401
4 14 3 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 405
4 14 4 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 407
4 14 5 SIGNAL HORN COMPRESSOR – LUBRICATE 407
4 14 6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE 407
4 14 7 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE 407
4 14 8 AUTOMATIC LUBRICATION SYSTEMS – CLEAN BREATHER FILTER 409
4 14 9 CABIN AIR FILTERS – INSPECT 411
4 14 10 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 413
4 14 11 CABIN HEATER FILTER – INSPECT 415
4 15 EVERY 500 OPERATING HOURS OR MONTHLY 416
4 15 1 BATTERIES – CHECK FLUID LEVEL 417
4 15 1 1 STARTER BATTERIES 417
4 15 2 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL 419
4 15 2 1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS 419
4 15 3 FUEL TANK – DRAIN CONDENSATION 421
4 15 3 1 DRAIN CONDENSATION AS FOLLOWS 421
4 15 4 CRAWLER TRACK – INSPECTION 423
4 15 4 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 423
4 15 4 2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 425
4 15 4 3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 427
4 15 4 4 Bleeding the System 427
4 15 5 GROUND CABLES OF ENGINE, PRELUBRICATION PUMP AND ALTERNATOR – CHECK FOR CORRECT CONNECTION 429
4 15 6 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 431
4 15 6 1 GREASE INJECTORS – CHECK INDICATOR STEMS 432
4 15 6 2 CORRECTIVE ACTIONS 432
4 15 6 3 CHECKING THE SLEW RING 432
4 15 7 EMERGENCY LOWERING OF ACCESS LADDER – Test FUNCTIONALITY 435
4 15 8 EMERGENCY ESCAPE LADDERS 437
4 15 8 1 TEST FUNCTIONALITY 437
4 15 8 2 Lubricating 437
4 15 9 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 439
4 16 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS 440
4 16 1 CRITICAL BOLT CONNECTIONS 441
4 16 2 HYDRAULIC SYSTEM – FILTER SERVICE 447
4 16 3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 461
4 16 3 1 Oil drain plugs, illustration 461
4 16 4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 463
4 16 5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS 465
4 16 6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 467
4 16 7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 469
4 16 8 ALL OTHER HINGES AND AREAS TO LUBRICATE 471
4 16 9 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 473
4 16 10 Engine SHUTDOWN PULL CHAINS – TEST FUNCTIONALITY 475
4 16 11 ELECTRICAL EQUIPMENT – MAINTENANCE 477
4 16 12 CABIN AIR FILTER – REPLACE PRIMARY FILTER 479
4 17 EVERY 2000 OPERATING HOURS OR YEARLY 480
4 17 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 481
4 17 2 FILLING THE HYDRAULIC SYSTEM 491
4 17 3 BLEEDING THE HYDRAULIC SYSTEM 493
4 17 4 GEAR PUMP FOR PTO GEAR LUBRICATION 495
4 17 5 EMERGENCY ESCAPE LADDERS – INSPECTION 497
4 17 6 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 499
4 17 7 HYDRAULIC HOSES – Check Condition 501
4 17 8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 503
4 17 8 1 Functionality 503
4 18 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 504
4 18 1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 505
4 18 1 1 Swing gears TYPE GFB 174 505
4 18 1 2 SWING GEARS TYPE 89 DS 03 509
4 18 1 3 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS TYPE GFA 280K – CHANGE OIL 513
4 18 1 4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS TYPE ZHP 5 36 – CHANGE OIL 519
4 18 2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 525
4 18 3 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD 527
4 18 4 CABIN HEATER FILTER – REPLACE FILTER ELEMENT 561
4 18 5 OIL SEPARATOR ELEMENT – REPLACE (IF SO EQUIPPED) 563
4 19 EVERY 6000 OPERATING HOURS OR AT LEAST ONCE A YEAR 564
4 19 1 AUTOMATIC LUBRICATION SYSTEMS – Replace GREASE FILTERS 565
4 20 FIRE PREVENTION 566
4 20 1 PRECAUTIONS 567
4 21 WELD REPAIRS 568
4 21 1 GENERAL PROTECTIVE MEASURES 569
4 21 1 1 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL 569
4 21 1 2 COUNTERWEIGHT 569
4 21 2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 571
4 21 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 573
4 21 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 575
4 21 5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 576
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