KOMATSU PC4000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08257 – PDF DOWNLOAD
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KOMATSU PC4000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08257 – 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 PC4000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08257 – PDF DOWNLOAD
1 FOREWORD 3
1 1 BEFORE READING THIS MANUAL 4
1 2 EC DECLARATION OF CONFORMITY 5
1 3 DIRECTIONS OF THE MACHINE 6
1 4 SPECIFICATION AND SERIAL PLATE 7
1 4 1 PRODUCT IDENTIFICATION NUMBER 7
1 5 DIVISION OF THE BINDER 8
1 6 DESIGNATED USE OF THE SHOVEL 9
1 7 DELIVERY OF THE SHOVEL 10
1 7 1 SPARE PARTS 10
1 7 2 SERVICE 10
1 8 EXPLANATION OF ABBREVIATIONS 11
2 SAFETY 19
2 1 SAFETY INFORMATION 20
2 2 OVERVIEW 21
2 2 1 NORMAL OPERATIONS 21
2 2 2 REGULAR MAINTENANCE 21
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 21
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 21
2 3 SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATOR’S CAB 22
2 3 1 SOUND 22
2 3 2 VIBRATION 22
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 23
2 4 1 UNDERSTANDING THE MACHINE 23
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 23
2 4 2 1 ENSURING SAFE OPERATION 23
2 4 3 PREPARATIONS FOR SAFE OPERATION 23
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 23
2 4 3 2 INSPECTING THE MACHINE 23
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 24
2 4 3 4 KEEP MACHINE CLEAN 24
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 24
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 25
2 4 3 7 IF A PROBLEM IS FOUND 25
2 4 4 FIRE PREVENTION 25
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 25
2 4 4 2 ACTION IF FIRE OCCURS 27
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 27
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 28
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 28
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 28
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 28
2 4 5 4 WORKING IN HIGH PLACES 28
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 29
2 4 5 6 LEAVING THE MACHINE 29
2 4 6 BURN PREVENTION 29
2 4 6 1 Hot coolant 29
2 4 6 2 Hot oil 30
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 30
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 30
2 4 8 1 UNAUTHORIZED MODIFICATION 31
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 31
2 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 31
2 4 10 PRECAUTIONS AT JOBSITE 32
2 4 10 1 VISIBILITY FROM OPERATOR’S SEAT 33
2 4 10 2 CAMERA SYSTEM WITH MONITORS 33
2 4 10 3 ENSURE GOOD VISIBILITY 33
2 4 10 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 33
2 4 10 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 34
2 4 10 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 34
2 4 10 7 WORKING ON LOOSE GROUND 35
2 4 10 8 GAS, DUST, STEAM AND SMOKE 35
2 4 10 9 VENTILATION OF ENCLOSED AREAS 36
2 4 11 STARTING motor 37
2 4 11 1 WARNING TAG 37
2 4 11 2 CHECKS BEFORE STARTING motor 37
2 4 11 3 PRECAUTION WHEN STARTING motor 37
2 4 11 4 PRECAUTION IN COLD AREAS 38
2 4 12 OPERATION 38
2 4 12 1 CHECKS BEFORE OPERATION 38
2 4 12 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 39
2 4 12 3 PRECAUTIONS WHEN traveling 40
2 4 12 4 TRAVELLING ON SLOPES 41
2 4 12 5 OPERATIONS ON SLOPES 42
2 4 12 6 PROHIBITED OPERATIONS 42
2 4 12 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 43
2 4 12 8 PARKING THE MACHINE 43
2 4 12 9 TRANSPORTATION 43
2 5 PRECAUTION FOR MAINTENANCE 44
2 5 1 GENERAL PRECAUTIONS 44
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 45
2 5 1 2 STOP motor FOR MAINTENANCE 46
2 5 1 3 WARNING TAG 47
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 48
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 48
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 49
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 49
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 50
2 5 1 9 NOISE 50
2 5 1 10 WHEN USING A HAMMER 50
2 5 1 11 PROPER TOOLS 51
2 5 1 12 ACCUMULATOR 51
2 5 1 13 PERSONNEL 51
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 52
2 5 2 1 PRECAUTION WHEN WELDING 52
2 5 2 2 BATTERY HANDLING 52
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 53
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 53
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 54
2 5 3 3 REPLACEMENT OF HOSE LINES 54
2 5 3 4 INSPECTION OF HOSE LINES 54
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 55
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 55
2 5 3 7 AIR CONDITIONING MAINTENANCE 55
2 5 3 8 COMPRESSED AIR 56
2 5 3 9 WASTE MATERIALS 56
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 57
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 57
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 57
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 57
2 7 SPECIAL SAFETY EQUIPMENT 58
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 59
2 7 2 OBJECT HANDLING 59
2 7 3 LIGHTING 59
2 7 4 WARNING BEACON 59
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 59
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 59
2 7 5 2 INSTRUCTIONS FOR USE 61
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 63
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 63
2 7 5 5 INSTRUCTIONS FOR USE 65
2 8 SAFETY WARNING SIGNS 67
2 8 1 LOCATION AND DESCRIPTION OF THE SIGNS 68
3 OPERATION 85
3 1 FOREWORD 86
3 2 CONSTRUCTION OF THE SHOVEL 87
3 2 1 OVERALL VIEW 87
3 2 2 SUPERSTRUCTURE 88
3 2 2 1 Machinery House 92
3 2 2 2 Main Hydraulic Oil Reservoir 94
3 2 2 3 Hydraulic Oil Cooler 95
3 2 2 4 Fuel Tank 96
3 2 2 5 Counterweight 97
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 98
3 2 3 1 Operating the hydraulic Access Ladder 99
3 2 3 2 LOWERING THE LADDER IN EMERGENCY SITUATIONS 101
3 2 4 EMERGENCY ESCAPE LADDER 102
3 2 5 BOOM ACCESS LADDER AND WALKWAY 104
3 2 6 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE 106
3 2 7 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 108
3 2 7 1 Emergency Engine Shutdown System actuated from Ground Man (OPTION) 109
3 2 7 2 Operator Warning System (OPTION) 109
3 2 8 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 110
3 2 8 1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual 115
3 2 8 2 Operator’s Seat Adjustment 117
3 2 8 3 Co-driver’s Seat and Refrigerator Box 118
3 2 8 4 INSTRUCTIONS TO using and looking after THE SEAT BELTS 119
3 2 9 UNDERCARRIAGE 120
3 2 10 WORKING ATTACHMENT 121
3 2 10 1 Loader attachment with bottom dump bucket 121
3 2 10 2 Loader attachment with backhoe bucket 122
3 2 11 DIESEL ENGINE TYPE SDA 16V160E-2 123
3 2 12 ENGINE OIL MANAGEMENT SYSTEM 126
3 2 12 1 Oil Burning System “Centinel” combined with Oil Supply System “Reserve” 128
3 2 12 2 Eliminator Engine Oil Filtration System 129
3 3 OPERATOR’S CAB – CONTROLS 130
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 130
3 3 1 1 HYDRAULIC CONTROL SYSTEM 131
3 3 2 SAFETY CIRCUIT FOR CONTROLS 131
3 3 2 1 EURO Control Pattern 133
3 3 3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 134
3 3 3 1 HYDRAULIC CONTROL SYSTEM 135
3 3 4 SAFETY CIRCUIT FOR CONTROLS 135
3 3 4 1 EURO Control Pattern 137
3 3 5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK 137
3 3 6 OPERATOR’S CONSOLE 139
3 3 6 1 Switch Board 141
3 3 7 INTERFACE PANEL FOR DIAGNOSTICS 145
3 3 8 CONTROL MODULE FOR AUXILIARY CAB HEATER 147
3 4 VEHICLE HEALTH MONITORING SYSTEM Komtrax Plus – HEALTH MONITOR 148
3 4 1 SEQUENCE OF DISPLAYS 149
3 4 2 OPENING SCREEN 149
3 4 3 Function Checking Screen 150
3 4 4 MAIN GAUGE SCREENS 1 TO 3 151
3 4 4 1 Main Gauge Screen 1 152
3 4 4 2 Main Gauge Screen 2 154
3 4 4 3 Main Gauge Screen 3 154
3 4 4 4 Color Definition 154
3 4 5 ECO Guidance 155
3 4 5 1 OPERATING RECORDS 156
3 4 5 2 Average FUEL Consumption Logs 157
3 4 5 3 Machine Setting 158
3 4 5 4 Reset Truck Counter 158
3 4 6 Maintenance 159
3 4 7 Monitor Setting 159
3 4 7 1 Screen Adjustment 160
3 4 7 2 Clock Adjustment 161
3 4 7 3 LANGUAGE 162
3 4 8 Automatic Messages 163
3 4 8 1 Example OF Action Code L01 163
3 4 8 2 Example OF Action Code L03 164
3 4 8 3 EXAMPLE OF Action Code L04 164
3 5 CAMERA SYSTEM WITH MONITORS 166
3 5 1 LOCATION OF MONITORS AND CONTROL UNITS 167
3 5 1 1 Operating the Monitors 169
3 5 1 2 Arrangement of the Cameras 171
3 6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 172
3 6 1 Digital Display 172
3 6 2 AUXILIARY HEATER FOR OPERATOR’S CAB 177
3 7 MACHINERY HOUSE 178
3 7 1 EMERGENCY ENGINE SHUTDOWN SWITCHES 179
3 7 2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES 181
3 7 3 CENTRAL CONTROL AND FILTER PANEL 183
3 8 ELECTRICAL EQUIPMENT IN CAB BASE 184
3 8 1 STANDARD COMPONENTS IN CAB BASE 185
3 8 1 1 Low voltage Switch Board 187
3 8 2 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE (WHEN INSTALLED) 189
3 9 CHECKS BEFORE STARTING THE ENGINE 196
3 9 0 1 Coolant Level 199
3 9 0 2 Machinery House Doors 201
3 9 1 OPERATOR’S SEAT ADJUSTMENT 201
3 10 STARTING THE ENGINE 202
3 10 1 STARTING PROCEDURE 205
3 10 1 1 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C 207
3 10 2 ENGINE WARM-UP 213
3 10 3 HYDRAULIC OIL WARM-UP 213
3 11 MOVING THE SHOVEL 215
3 11 1 TRAVEL CONTROL WITH FOOT PEDALS 215
3 11 1 1 TRAVEL ALARM / BACK-UP ALARM 217
3 11 2 TRAVELLING INSTRUCTIONS 217
3 11 2 1 TRAVELLING LONG DISTANCES 219
3 12 SLEWING AND BRAKING THE SUPERSTRUCTURE 220
3 12 1 SLEWING THE SUPERSTRUCTURE 220
3 12 1 1 MACHINES WITH “EURO” CONTROL 220
3 12 2 BRAKING THE SUPERSTRUCTURE 221
3 12 3 SLEW PARKING BRAKE 222
3 12 3 1 Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System 223
3 12 3 2 IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE 223
3 13 WORKING WITH THE ATTACHMENT 224
3 13 0 1 FACE SHOVEL BUCKET 225
3 13 1 COMBINED OPERATION CYCLES 226
3 14 WORKING INSTRUCTIONS 228
3 14 1 STABILITY OF THE SHOVEL 228
3 14 2 FURTHER OPERATING PRACTICES 230
3 14 3 Loading Trucks 234
3 15 PARKING THE SHOVEL 235
3 15 0 1 CLEANING THE TRACK GROUPS 236
3 16 STOPPING THE ENGINE 238
3 16 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 241
3 17 OPERATION OF THE LUBRICATION SYSTEM 242
3 17 1 CENTRAL LUBRICATION SYSTEM ”CLS” 242
3 17 1 1 Manual actuation of the central lubrication system 242
3 17 1 2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 243
3 17 2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 243
3 17 2 1 Manual actuation of the swing circle lubrication system 244
3 17 2 2 SWING CIRCLE LUBRICATION SYSTEM ”SLS” 246
3 17 2 3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM 246
3 18 FIRE DETECTION AND SUPPRESSION SYSTEMS 248
3 18 0 1 FIRE DETECTION AND SUPPRESSION SYSTEMS 249
3 18 1 HIGH LEVEL ALARM ”FIRE” 253
3 18 2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE 253
3 18 3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS 253
3 18 3 1 MANUAL ACTUATION 253
3 18 3 2 AUTOMATIC ACTUATION 253
3 18 4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS 255
3 18 5 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON machinery house ROOF 257
3 19 TRANSFER PUMP FOR HYDRAULIC OIL 258
3 19 1 OPERATING THE TRANSFER PUMP 259
3 19 2 FUNCTIONS OF THE TRANSFER PUMP 261
3 20 CENTRAL REFILLING SYSTEM 264
3 20 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 265
3 20 1 1 Operation of the hydraulic Service Arm 265
3 20 2 OPERATING THE HYDRAULIC SERVICE ARM 267
3 20 3 RECEIVER PANEL WITH MONITOR BOX 269
3 20 3 1 Refilling Procedure 271
3 20 4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM 273
3 20 4 1 Refilling the Grease Containers of the Automatic Lubrication Systems 275
3 21 WORK ON THE LOADER ATTACHMENT 276
3 21 0 1 OBSERVE THE FOLLOWING INSTRUCTIONS 276
3 22 TRANSPORTATION AND LIFTING OF THE SHOVEL 277
3 22 1 DISASSEMBLING OF THE SHOVEL 277
3 22 2 TRANSPORTATION AND LIFTING 277
3 23 RETRIEVAL PROCEDURE 278
3 24 SHOVEL STORAGE 279
3 24 0 1 GENERAL 279
3 24 1 PREPARING FOR STORAGE 279
3 24 2 ONE MONTH REPETITIVE SERVICE PERIOD 279
3 24 3 SIX MONTH REPETITIVE SERVICE PERIOD 279
3 24 4 PREPARING FOR OPERATION 280
3 25 TROUBLE SHOOTING 281
3 25 0 1 GENERAL 281
3 25 1 ENGINE 281
3 25 2 HYDRAULIC SYSTEM 282
3 25 3 FINAL DRIVES AND SWING MACHINERY 283
3 25 4 CRAWLER TRACKS 283
4 MAINTENANCE 285
4 1 FOREWORD 286
4 1 1 DEFINITIONS 286
4 1 2 GENERAL RECOMMENDATIONS 286
4 2 SAFETY PRECAUTIONS FOR MAINTENANCE 287
4 3 FLUIDS AND LUBRICANTS 288
4 3 1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 288
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 289
4 3 2 1 Recommended Hydraulic Oils 291
4 3 2 2 General Information to selecting hydraulic oils 292
4 4 FILLING CAPACITIES 294
4 5 STANDARD TORQUE LIST 295
4 5 1 Torque for Flange Joints 296
4 5 2 TORQUES FOR SPECIAL COMPONENTS 297
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 299
4 6 1 INITIAL SERVICING 299
4 6 1 1 INITIAL RUNNING-IN 299
4 6 1 2 AFTER THE FIRST 250 OPERATING HOURS 299
4 6 1 3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT 299
4 6 2 SERVICING THE CRITICAL BOLT CONNECTIONS 300
4 6 3 PERIODIC SERVICING INTERVALS 300
4 6 4 PERIODIC SERVICING SCHEDULE 301
4 6 4 1 When necessary 301
4 6 4 2 EVERY 10 OPERATING HOURS OR DAILY 301
4 6 4 3 EVERY 50 OPERATING HOURS OR WEEKLY 302
4 6 4 4 EVERY 250 OPERATING HOURS OR MONTHLY 302
4 6 4 5 EVERY 500 OPERATING HOURS OR QUATERLY 303
4 6 4 6 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS 303
4 6 4 7 EVERY 2000 OPERATING HOURS OR YEARLY 304
4 6 4 8 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 304
4 6 4 9 EVERY 6000 OPERATING HOURS OR EVERY TWO YEARS 305
4 6 5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM 306
4 6 5 1 Lubrication Chart 307
4 7 SAFETY CRITICAL PARTS 308
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 308
4 7 2 INSPECTION OF HOSE LINES 308
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 308
4 7 4 VENTING THE AIR FROM THE FUEL FILTERS 311
4 8 INITIAL SERVICING 312
4 8 1 INITIAL CHECKS FOR PROPER LUBRICATION 313
4 8 2 SWING CIRCLE – CHECK GREASE INJECTORS 315
4 8 3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GrEASE INJECTORS 317
4 8 4 SWING CIRCLE – CHECK TORQUE OF BOLT CONNECTIONS 319
4 8 5 Retightening procedure of the crawler carrier mounting bolts 321
4 9 EXTENDED SERVICE INTERVALS 327
4 9 1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM 327
4 9 1 1 Servicing Intervals 331
4 9 2 MAINTENANCE OF THE ENGINE 331
4 10 ENGINE FUEL FILTER LOCATION 332
4 10 1 fuel line connections on the engine 333
4 11 WHEN NECESSARY 334
4 11 1 ENGINE AIR CLEANER SERVICE 335
4 11 1 1 General Service Tips 337
4 11 2 SWING CIRCLE TOOTHING LUBRICATION 339
4 11 3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS 341
4 11 3 1 CLEAN OR REPLACE FILTER ELEMENTS 343
4 11 4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS 345
4 11 5 GUIDE WHEELS – REPLACE FLOATING SEALS 345
4 12 EVERY 10 OPERATING HOURS OR DAILY 346
4 12 1 WALK-AROUND INSPECTION 347
4 12 2 AIR CLEANER – CLEAN PRE-CLEANER 351
4 12 2 1 Clean dust cups of pre-cleaners 351
4 12 3 RADIATOR – CHECK COOLANT LEVEL 353
4 12 4 TRACK GROUPS – CLEAN 353
4 12 5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER 355
4 12 6 BOOM – CHECK LADDER AND WALKWAY 357
4 12 7 ELECTRICAL EQUIPMENT – CHECK VISUALLY 357
4 12 8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 359
4 13 EVERY 50 OPERATING HOURS OR WEEKLY 360
4 13 1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 361
4 13 1 1 Swing gears manufactured by “L&S” 361
4 13 1 2 Swing gears manufactured by SIEBENHAAR 363
4 13 1 3 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S” – CHECK OIL LEVELS 365
4 13 1 4 CHECK Motor Adapter HOUSING OIL LEVEL 365
4 13 1 5 CHECK BRAKE HOUSING OIL LEVEL 365
4 13 1 6 CHECK TRAVEL GEAR OIL LEVEL 365
4 13 2 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 367
4 13 2 1 CHECK BREATHER FILTERS 367
4 13 2 2 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN” – CHECK OIL LEVELS 369
4 13 3 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL 373
4 13 3 1 CHECK OIL LEVEL OF PTO GEAR 373
4 13 4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 375
4 13 5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 379
4 14 EVERY 250 OPERATING HOURS OR MONTHLY 380
4 14 1 AIR CONDITIONING 381
4 14 2 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 381
4 14 3 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 385
4 14 4 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 387
4 14 5 SIGNAL HORN COMPRESSOR – LUBRICATE 387
4 14 6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 387
4 14 7 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 387
4 14 8 AUTOMATIC LUBRICATION SYSTEMS – CLEAN BREATHER FILTER 389
4 14 9 CABIN AIR FILTERS – INSPECT 391
4 14 10 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 393
4 14 11 CABIN HEATER FILTER – INSPECT 395
4 15 EVERY 500 OPERATING HOURS OR MONTHLY 396
4 15 1 BATTERIES – CHECK FLUID LEVEL 397
4 15 1 1 STARTER BATTERIES 397
4 15 2 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL 399
4 15 2 1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS 399
4 15 3 FUEL TANK – DRAIN CONDENSATION 401
4 15 3 1 DRAIN CONDENSATION AS FOLLOWS 401
4 15 4 CRAWLER TRACK – INSPECTION 403
4 15 4 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 403
4 15 4 2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 405
4 15 4 3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 407
4 15 4 4 Bleeding the System 407
4 15 5 GROUND CABLES OF ENGINE, PRELUBRICATION PUMP AND ALTERNATOR – CHECK FOR CORRECT CONNECTION 409
4 15 6 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 411
4 15 6 1 GREASE INJECTORS – CHECK INDICATOR STEMS 412
4 15 6 2 CORRECTIVE ACTIONS 412
4 15 7 EMERGENCY LOWERING OF ACCESS LADDER – Test FUNCTIONALITY 415
4 15 8 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 417
4 16 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS 418
4 16 1 CRITICAL BOLT CONNECTIONS 419
4 16 2 HYDRAULIC SYSTEM – FILTER SERVICE 425
4 16 3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 439
4 16 3 1 Oil drain plugs, illustration 439
4 16 4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 441
4 16 5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS 443
4 16 6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 445
4 16 7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 447
4 16 8 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 449
4 16 9 Engine SHUTDOWN PULL CHAINS – TEST FUNCTIONALITY 451
4 16 10 ELECTRICAL EQUIPMENT – MAINTeNANCE 453
4 16 11 CABIN AIR FILTER – REPLACE PRIMARY FILTER 455
4 17 EVERY 2000 OPERATING HOURS OR YEARLY 456
4 17 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 457
4 17 2 FILLING THE HYDRAULIC SYSTEM 467
4 17 3 BLEEDING THE HYDRAULIC SYSTEM 469
4 17 4 GEAR PUMP FOR PTO GEAR LUBRICATION 471
4 17 5 EMERGENCY ESCAPE LADDER – INSPECTION 473
4 17 6 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE 475
4 17 7 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 477
4 17 8 HYDRAULIC HOSES – Check Condition 479
4 17 9 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 481
4 17 9 1 Functionality 481
4 18 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 482
4 18 1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 483
4 18 1 1 Swing gears manufactured by “L&S” 483
4 18 1 2 “SWING GEARS MANUFACTURED BY “SIEBENHAAR” 487
4 18 1 3 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S”- CHANGE OIL 491
4 18 1 4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN”- CHANGE OIL 497
4 18 2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 503
4 18 3 CRITICAL BOLT CONNECTIONS 505
4 18 4 CABIN HEATER FILTER – REPLACE FILTER ELEMENT 541
4 19 EVERY 6000 OPERATING HOURS OR AT LEAST ONCE A YEAR 542
4 19 1 AUTOMATIC LUBRICATION SYSTEMS – Replace GREASE FILTERS 543
4 19 2 HYDRAULIC Oil TANK – CHECK LEAKAGE OIL SCREEN FILTER 545
4 20 FIRE PREVENTION 546
4 20 1 PRECAUTIONS 547
4 21 WELD REPAIRS 548
4 21 1 GENERAL PROTECTIVE MEASURES 549
4 21 1 1 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL 549
4 21 1 2 COUNTERWEIGHT 549
4 21 2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 551
4 21 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 553
4 21 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 555
4 21 5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 556
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
I.G