KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08209 – PDF DOWNLOAD
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DESCRIPTION:
KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08209 – PDF DOWNLOAD
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 PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08209 – PDF DOWNLOAD
1 FOREWORD 3
1 1 BEFORE READING THIS MANUAL 4
1 2 SAFETY INFORMATION 5
1 3 DIRECTIONS OF THE MACHINE 6
1 4 SPECIFICATION AND SERIAL PLATE 7
1 4 1 PRODUCT IDENTIFICATION NUMBER 7
1 5 SERVICE METER LOCATION 8
1 6 DIVISION OF THE BINDER 9
1 7 DESIGNATED USE OF THE SHOVEL 10
1 8 DELIVERY OF THE SHOVEL 11
1 8 1 SPARE PARTS 11
1 8 2 SERVICE 11
1 9 EXPLANATION OF ABBREVIATIONS 12
1 10 CONTENTS 13
2 SAFETY 19
2 1 SAFETY INFORMATION 21
2 2 OVERVIEW 22
2 2 1 NORMAL OPERATIONS 22
2 2 2 REGULAR MAINTENANCE 22
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 22
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 22
2 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 23
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 24
2 4 1 UNDERSTANDING THE MACHINE 24
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 24
2 4 2 1 ENSURING SAFE OPERATION 24
2 4 3 PREPARATIONS FOR SAFE OPERATION 24
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 24
2 4 3 2 INSPECTING THE MACHINE 24
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 25
2 4 3 4 KEEP MACHINE CLEAN 25
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 25
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 26
2 4 3 7 IF A PROBLEM IS FOUND 26
2 4 4 FIRE PREVENTION 26
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 26
2 4 4 2 ACTION IF FIRE OCCURS 27
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 28
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 31
2 4 8 1 UNAUTHORIZED MODIFICATION 31
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 31
2 4 9 PRECAUTIONS AT JOBSITE 32
2 4 9 1 VISIBILITY FROM OPERATOR’S SEAT 33
2 4 9 2 CAMERA SYSTEM WITH MONITORS 33
2 4 9 3 ENSURE GOOD VISIBILITY 33
2 4 9 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 33
2 4 9 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 34
2 4 9 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 34
2 4 9 7 WORKING ON LOOSE GROUND 35
2 4 9 8 GAS, DUST, STEAM AND SMOKE 35
2 4 9 9 VENTILATION OF ENCLOSED AREAS 36
2 4 10 STARTING ENGINE 37
2 4 10 1 WARNING TAG 37
2 4 10 2 CHECKS BEFORE STARTING ENGINE 37
2 4 10 3 PRECAUTION WHEN STARTING ENGINE 37
2 4 10 4 PRECAUTION IN COLD AREAS 38
2 4 11 OPERATION 38
2 4 11 1 CHECKS BEFORE OPERATION 38
2 4 11 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 39
2 4 11 3 PRECAUTIONS WHEN travelling 40
2 4 11 4 TRAVELLING ON SLOPES 41
2 4 11 5 OPERATIONS ON SLOPES 42
2 4 11 6 PROHIBITED OPERATIONS 42
2 4 11 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 43
2 4 11 8 PARKING THE MACHINE 43
2 4 11 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 ENGINE FOR MAINTENANCE 46
2 5 1 3 WARNING TAG 46
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 47
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 48
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 48
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 48
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 49
2 5 1 9 NOISE 49
2 5 1 10 WHEN USING A HAMMER 49
2 5 1 11 PROPER TOOLS 50
2 5 1 12 ACCUMULATOR 50
2 5 1 13 PERSONNEL 50
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 51
2 5 2 1 PRECAUTION WHEN WELDING 51
2 5 2 2 BATTERY HANDLING 51
2 5 3 PRECAUTIONS WITH HIGH PRESSURE Fluid 52
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 53
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 53
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 55
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 (1), 63
2 7 5 5 INSTRUCTIONS FOR USE 65
3 OPERATION 67
3 1 FOREWORD 68
3 2 CONSTRUCTION OF THE SHOVEL 69
3 2 1 OVERALL VIEW 69
3 2 2 SUPERSTRUCTURE 70
3 2 2 1 Top view of Superstructure and side view of Machinery House 72
3 2 2 2 Main Hydraulic Oil Reservoir 74
3 2 2 3 Hydraulic Oil Cooler 75
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 76
3 2 3 1 Operating the hydraulic Access Ladder 77
3 2 4 EMERGENCY ESCAPE LADDER 80
3 2 5 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN AND OPERATOR WARNING SYSTEM 82
3 2 5 1 Emergency Motor Shutdown System actuated from Ground Man 83
3 2 5 2 Operator Warning System 83
3 2 6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 84
3 2 6 1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual 89
3 2 6 2 Operator’s Seat Adjustment 91
3 2 6 3 Co-driver’s Seat and Refrigerator Box 92
3 2 7 UNDERCARRIAGE 93
3 2 8 WORKING ATTACHMENT 94
3 2 8 1 Loader attachment with bottom dump bucket 94
3 2 8 2 Loader attachment with backhoe bucket 95
3 3 OPERATOR’S CAB – CONTROLS 96
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 96
3 3 1 1 HYDRAULIC CONTROL SYSTEM 97
3 3 2 SAFETY CIRCUIT FOR CONTROLS 97
3 3 2 1 EURO Control Pattern 99
3 3 3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 100
3 3 3 1 HYDRAULIC CONTROL SYSTEM 101
3 3 4 SAFETY CIRCUIT FOR CONTROLS 101
3 3 4 1 EURO Control Pattern 103
3 3 5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK 103
3 3 6 OPERATORS CONSOLE, OVERVIEW 105
3 3 6 1 Control Panel 107
3 3 6 2 Switch Board 109
3 3 7 INTERFACE PANEL FOR DIAGNOSTICS 111
3 4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 112
3 4 1 INTRODUCTION 113
3 4 1 1 Function of the keys (1 to 8) of Keyboard (B): 119
3 4 2 OPERATING THE ELECTRONIC MONITORING SYSTEM 121
3 4 3 AUTOMATIC DISPLAY OF MESSAGES 125
3 4 3 1 Emergency By-pass switch for the ECS- Shut-down Function 125
3 4 3 2 Message Classification 129
3 4 3 3 Emergency Indication of Operating Conditions 131
3 4 3 4 TEXT DISPLAY (A) 133
3 4 3 5 Display of message pages without present message 135
3 4 3 6 Display the Contents of Record (PROTOCOL) Memory, Fig 3-92 137
3 4 3 7 Display the Contents of Statistics Memory, 139
3 4 4 MENU CONTROL 149
3 4 4 1 Service Functions 149
3 4 4 2 Menu Control with Key Switch (C) and Key Group (D) 151
3 4 4 3 Menu Control with Key Switch (C) and Key Group (D) 153
3 4 4 4 Setting of Operational Data, menu item Service *SETTINGS* 155
3 4 4 5 Menu Control with Key Switch (C) and Key Group (D) 157
3 4 4 6 Menu Control with Key Switch (C) and Key Group (D) 159
3 4 4 7 Menu Control with Key Switch (C) and Key Group (D) 161
3 4 4 8 Menu Control with Key Switch (C) and Key Group (D) 163
3 4 4 9 Menu Control with Key Switch (C) and Key Group (D) 165
3 4 4 10 Menu Control with Key Switch (C) and Key Group (D) 167
3 4 4 11 Menu Control with Switch (C) and Key Group (D) 169
3 4 4 12 Menu Control with Switch (C) and Key Group (D) 171
3 4 4 13 Data Transfer from Protocol and Statistics Memory to various Downloading Equipment 173
3 4 4 14 Graphical Diagram 175
3 4 4 15 Overall View of Menu Control 175
3 4 4 16 Overall View of Fault Messages and Information Messages 175
3 4 5 MENU CONTROL LIST 175
3 4 6 FAULT AND INFORMATION MESSAGE LIST 190
3 4 6 1 Fault and Information Message List 190
3 5 CAMERA SYSTEM WITH MONITOR 216
3 5 1 LOCATION OF MONITOR AND CONTROL UNIT 217
3 5 1 1 Operating the Monitor 219
3 5 1 2 Ajustments of the Monitor 219
3 5 1 3 Arrangement of the Camera 223
3 6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 224
3 6 1 Digital Display 224
3 6 2 Luminous Indication 226
3 6 3 Additional Air Conditioning/Heater Unit in Operator’s Cab 229
3 6 3 1 Functions of the Control Unit 229
3 7 MACHINERY HOUSE 230
3 7 1 EMERGENCY MOTOR SHUTDOWN SWITCHES 231
3 7 2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES 233
3 7 3 CENTRAL CONTROL AND FILTER PANEL 235
3 8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE 236
3 8 1 SWITCH BOARD (X2) IN CAB BASE 239
3 8 1 1 LEmergency Indication of Operating Conditions 241
3 8 1 2 High Pressure Filter “HPF” Identification Codes of LED H31 243
3 8 1 3 Emergency shutdown switches – Identification Codes of LED H116 245
3 8 2 COMPONENTS IN THE MEDIUM VOLTAGE SWITCH CABINET 247
3 8 3 MONITOR AND CONTROL PANEL 249
3 8 3 1 Medium Voltage Switch Board 251
3 8 4 PREHEATING SYSTEM 253
3 9 HIGH VOLTAGE SWITCH CABINET 256
3 10 CHECKS BEFORE STARTING THE MOTOR 258
3 10 1 Hydraulic System – Check Oil Level 261
3 10 2 Machinery House Doors 261
3 10 3 Operator’s Seat Adjustment 261
3 11 STARTING THE MAIN DRIVE MOTOR 262
3 11 1 STARTING PROCEDURE 265
3 12 MOVING THE SHOVEL 275
3 12 1 TRAVEL CONTROL WITH FOOT PEDALS 275
3 12 1 1 TRAVEL ALARM / BACK-UP ALARM (Special equipment) 277
3 12 2 TRAVELLING INSTRUCTIONS 277
3 13 SLEWING AND BRAKING THE SUPERSTRUCTURE 278
3 13 1 SLEWING THE SUPERSTRUCTURE 278
3 13 1 1 MACHINES WITH “EURO” CONTROL 278
3 13 1 2 MACHINES WITH “KMG” CONTROL 279
3 13 1 3 BRAKING THE SUPERSTRUCTURE 279
3 13 1 4 Hydraulic Swing Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System 280
3 13 1 5 Important Instructions for Slewing the Superstructure 280
3 14 WORKING WITH THE ATTACHMENT 281
3 14 1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM 281
3 14 1 1 BACKHOE 281
3 14 1 2 FACE SHOVEL 281
3 14 2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM 282
3 14 2 1 The illustrations show a typical construction of control stand and working attachment However, the shown operation – and working movements apply to this machine 282
3 14 2 2 BACKHOE 282
3 14 2 3 FACE SHOVEL 282
3 14 2 4 BOTTOM DUMP BUCKET 283
3 14 2 5 OPERATING THE BUCKET CLAM 283
3 14 3 DROP BALL OPERATION 284
3 14 3 1 SAFETY INSTRUCTIONS 284
3 14 3 2 SAFETY DEVICES (SPECIAL EQUIPMENT) 285
3 14 3 3 WORKING HINTS 286
3 14 4 COMBINED OPERATION CYCLES 287
3 15 WORKING INSTRUCTIONS 289
3 15 1 STABILITY OF THE SHOVEL 289
3 15 2 SHOVEL OPERATION 289
3 16 STOPPING THE MOTOR 292
3 16 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 295
3 17 OPERATION OF THE LUBRICATION SYSTEM 296
3 17 1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT 296
3 17 2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 297
3 17 3 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 298
3 17 3 1 Manual actuation of the swing circle lubrication system 298
3 17 3 2 SWING CIRCLE LUBRICATION SYSTEM ”SLS” 299
3 18 TRANSFER PUMP FOR HYDRAULIC OIL 300
3 18 1 OPERATING THE TRANSFER PUMP 301
3 18 2 FUNCTIONS OF THE TRANSFER PUMP 303
3 19 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM 306
3 19 1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS 307
3 19 1 1 Personnel Safety 307
3 19 2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB 311
3 19 3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM: 311
3 19 4 IN The CASE OF A FIRE 313
3 19 4 1 Indication of Alarm Condition at Control Module (5) when the electric Detection and Warning System -II- detects a Fire in the Machinery House: 313
3 20 CENTRAL REFILLING SYSTEM 314
3 20 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 315
3 20 2 RECEIVER PANEL AND MONITOR BOX 315
3 20 3 Refilling Procedure: 317
3 20 4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM 319
3 20 4 1 Refilling the Grease Containers of the Automatic Lubrication Systems 321
3 21 CABLE DRUM (IF SO EQUIPPED) 322
3 21 1 OPERATION OF THE CABLE DRUM 323
3 21 1 1 Principle of Operation 323
3 21 1 2 Operation and Maintenance of the Cable Drum 325
3 21 2 TRAVELLING INSTRUCTIONS 327
3 21 2 1 Travelling Instructions 329
3 22 CABLE GUIDE (IF SO EQUIPPED) 331
3 22 1 LIFTING DEVICE FOR THE POWER CABLE 331
3 23 WORK ON THE LOADER ATTACHMENT 332
3 23 1 OBSERVE THE FOLLOWING INSTRUCTIONS 332
3 24 TRANSPORTATION AND LIFTING OF THE SHOVEL 333
3 24 1 DISASSEMBLING OF THE SHOVEL 333
3 24 2 TRANSPORTATION AND LIFTING 333
3 25 RETRIEVAL PROCEDURE 334
3 25 0 1 GENERAL 334
3 26 SHOVEL STORAGE 335
3 26 0 1 GENERAL 335
3 26 1 PREPARING FOR STORAGE 335
3 26 2 ONE MONTH REPETITIVE SERVICE PERIOD 335
3 26 3 SIX MONTH REPETITIVE SERVICE PERIOD 335
3 26 4 PREPARING FOR OPERATION 336
3 27 TROUBLE SHOOTING 337
3 27 0 1 GENERAL 337
3 27 0 2 ENGINE 337
3 27 1 HYDRAULIC SYSTEM 338
3 27 2 FINAL DRIVES AND SWING GEAR 339
3 27 3 CRAWLER TRACKS 339
4 MAINTENANCE 341
4 1 FOREWORD 342
4 1 0 1 DEFINITIONS 342
4 1 0 2 GENERAL RECOMMENDATIONS 342
4 2 PRECAUTIONS FOR MAINTENANCE 343
4 3 FLUIDS AND LUBRICANTS 344
4 3 1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 344
4 3 1 1 Grease for the bearings of the main drive Electric Motors 344
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 345
4 3 3 MAIN DRIVE ELECTRIC MOTOR – BEARING LUBRICATION 346
4 4 FILLING CAPACITIES 347
4 5 STANDARD TORQUE LIST 348
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 349
4 6 1 INITIAL SERVICING 349
4 6 1 1 AFTER THE FIRST 250 OPERATING HOURS 349
4 6 1 2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS 349
4 6 2 PERIODIC SERVICING INTERVALS 349
4 6 3 PERIODIC SERVICING SCHEDULE 350
4 6 4 MAINTENANCE OF THE MAIN DRIVE ELECTRIC MOTOR 353
4 6 4 1 Lubrication Chart 355
4 6 5 REPLACEMENT OF HYDRAULIC HOSE LINES 356
4 6 5 1 INSPECTION OF HOSE LINES 356
4 6 6 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 356
4 7 WHEN NECESSARY 358
4 7 1 SWING CIRCLE TOOTHING LUBRICATION 359
4 7 2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS 361
4 7 2 1 CLEAN OR REPLACE FILTER ELEMENTS 363
4 7 3 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS 365
4 8 EVERY 10 OPERATING HOURS OR DAILY 366
4 8 1 WALK-AROUND INSPECTION 367
4 8 1 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 371
4 8 1 2 CHECK GREASE INJECTORS 373
4 8 1 3 CORRECTIVE ACTIONS 373
4 8 1 4 CHECK GREASE INJECTORS 375
4 8 2 CLEANING THE TRACK GROUPS 375
4 9 EVERY 50 OPERATING HOURS OR WEEKLY 376
4 9 1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 377
4 9 1 1 CHECK SWING MACHINERY OIL LEVEL 377
4 9 1 2 CHECK MOTOR ADAPTER HOUSING OIL LEVEL 377
4 9 1 3 CHECK SWING MACHINERY OIL LEVEL 379
4 9 2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S” – CHECK OIL LEVELS 381
4 9 2 1 CHECK TRAVEL GEAR OIL LEVEL 381
4 9 2 2 CHECK MOTOR ADAPTER HOUSING OIL LEVEL 381
4 9 2 3 CHECK BRAKE HOUSING OIL LEVEL 381
4 9 3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 383
4 9 3 1 CHECK BREATHER FILTERS 383
4 9 4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN” – CHECK OIL LEVELS 385
4 9 4 1 CHECK TRAVEL GEAR OIL LEVEL 385
4 9 4 2 CHECK MOTOR ADAPTER HOUSING OIL LEVEL 385
4 9 5 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 387
4 9 5 1 CHECK BREATHER FILTERS 387
4 9 6 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL 389
4 9 6 1 CHECK OIL LEVEL OF PTO GEAR 389
4 9 6 2 CHECK OIL LEVEL OF OIL COLLECTOR RESERVOIR (4) 389
4 9 7 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 391
4 9 8 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 393
4 10 EVERY 250 OPERATING HOURS OR MONTHLY 394
4 10 1 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 395
4 10 2 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 395
4 10 3 SIGNAL HORN COMPRESSOR – LUBRICATE 395
4 10 4 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER 397
4 10 5 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 401
4 10 5 1 Clean and inspect filter element (2) as follows: 401
4 10 6 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT (Heavy duty version, special equipment) 403
4 10 6 1 Clean pre-cleaner dust bowl 403
4 10 6 2 Clean and inspect main filter element 403
4 10 7 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL 405
4 10 8 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 407
4 10 9 AIR CONDITIONING FOR ELECTRICAL SWITCH CABINETS – CHECK REFRIGERANT LEVEL 409
4 10 10 Air Conditioner Unit for Medium Voltage and High Voltage Switch Cabinets 411
4 11 EVERY 500 OPERATING HOURS OR MONTHLY 412
4 11 1 BATTERIES – CHECK FLUID LEVEL 413
4 11 2 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL 415
4 11 2 1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS 415
4 11 3 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL 417
4 11 4 CRAWLER TRACK – INSPECTION 419
4 11 4 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 419
4 11 4 2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 421
4 11 4 3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 423
4 11 4 4 Bleeding the System 423
4 11 5 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 425
4 12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 426
4 12 1 HIGH STRENGTH BOLT CONNECTIONS 427
4 12 1 1 Retightening procedure of the crawler carrier mounting bolts 463
4 12 2 HYDRAULIC SYSTEM – FILTER SERVICE 475
4 12 3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 489
4 12 3 1 Oil drain plugs 489
4 12 3 2 PTO (PUMP DISTRIBUTOR GEAR) 489
4 12 3 3 SWING MACHINERY AND TRAVEL GEARS 489
4 12 4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 491
4 12 5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS 493
4 12 6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 495
4 12 7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 497
4 12 8 SLIP RING UNIT – LUBRICATE 499
4 13 EVERY 2000 OPERATING HOURS OR YEARLY 500
4 13 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 501
4 13 1 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 503
4 13 2 BLEEDING THE HYDRAULIC SYSTEM 513
4 13 3 GEAR PUMP FOR PTO GEAR LUBRICATION 515
4 13 4 EMERGENCY ESCAPE LADDER – INSPECTION 517
4 14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 518
4 14 1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 519
4 14 2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S”- CHANGE OIL 527
4 14 3 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN”- CHANGE OIL 533
4 14 3 1 TRAVEL GEARS – CHANGE OIL 533
4 14 4 FINAL DRIVE HOUSINGS – CHANGE OIL 537
4 14 5 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 539
4 15 FIRE PREVENTION 540
4 15 1 PRECAUTIONS 541
4 16 WELD REPAIRS 542
4 16 1 GENERAL INFORMATION 543
4 16 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL 543
4 16 2 1 COUNTERWEIGHT 543
4 16 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 545
4 16 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 547
4 16 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 549
4 16 5 1 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 549
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
I.G