KOMATSU PC5500-11 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL 15185 – PDF DOWNLOAD
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KOMATSU PC5500-11 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL 15185 – 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 PC5500-11 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL 15185 – PDF DOWNLOAD
1 FOREWORD 3
1 1 BEFORE READING THIS MANUAL 4
1 2 EC DECLARATION OF CONFORMITY 5
1 3 PRIVACY POLICY ON EXCAVATORS EQUIPPED WITH excavator MONITORING SYSTEMS FOR THE EEA 6
1 4 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS 9
1 5 DIRECTIONS OF THE EXCAVATOR 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 EXCAVATOR 13
1 9 DELIVERY OF THE EXCAVATOR 14
1 9 1 SPARE PARTS 14
1 9 2 SERVICE 14
1 10 EXPLANATION OF ABBREVIATIONS 15
1 11 CONTENTS 17
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 excavator 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 excavator 29
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 30
2 4 3 4 KEEP excavator 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 EXCAVATOR 34
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator 34
2 4 5 2 NO JUMPING ON OR OFF THE excavator 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 excavator 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 excavator 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 53
2 5 1 4 Maintenance safety Switch 53
2 5 1 5 KEEP WORKPLACE CLEAN AND TIDY 54
2 5 1 6 APPOINT LEADER WHEN WORKING WITH OTHERS 55
2 5 1 7 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING 55
2 5 1 8 INSTALLING, REMOVING OR STORING ATTACHMENTS 55
2 5 1 9 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT 56
2 5 1 10 NOISE 56
2 5 1 11 WHEN USING A HAMMER 56
2 5 1 12 PROPER TOOLS 57
2 5 1 13 ACCUMULATOR 57
2 5 1 14 PERSONNEL 57
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 58
2 5 2 1 PRECAUTION WHEN WELDING 58
2 5 2 2 BATTERY HANDLING 58
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 59
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 60
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 61
2 5 3 3 REPLACEMENT OF HOSE LINES 61
2 5 3 4 INSPECTION OF HOSE LINES 61
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 62
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 62
2 5 3 7 AIR CONDITIONING MAINTENANCE 62
2 5 3 8 COMPRESSED AIR 63
2 5 3 9 WASTE MATERIALS 63
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 64
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 64
2 6 2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS 64
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 64
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 68
2 7 5 3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 69
2 7 5 4 INSTRUCTIONS FOR USE 69
2 8 SAFETY WARNING SIGNS 71
2 8 1 LOCATION AND DESCRIPTION OF THE SIGNS 72
2 8 2 LOCATION AND DESCRIPTION OF THE SIGNS FOR PC3400 74
3 OPERATION 101
3 1 FOREWORD 102
3 2 CONSTRUCTION OF THE EXCAVATOR 103
3 2 1 OVERALL VIEW 103
3 2 2 UNDERCARRIAGE AND SUPERSTRUCTURE 104
3 2 2 1 SUPERSTRUCTURE – TOP VIEW 106
3 2 2 2 MACHINERY HOUSE 108
3 2 3 HYDRAULICALLY OPERATED ACCESS/EGRESS STAIRWAY 110
3 2 3 1 Lowering the access/egress stairway in emergency situations 113
3 2 4 EMERGENCY ESCAPE LADDERS 114
3 2 4 1 Emergency escape from the operator’s cabin 115
3 2 4 2 FROM THE MACHINERY HOUSE 116
3 2 4 3 ESCAPE LADDER WINCH ASSEMBLY 119
3 2 5 BOOM ACCESS LADDER AND WALKWAY 120
3 2 6 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 122
3 2 6 1 Engine Shutdown System actuated from Ground Man (OPTIONAL Equipment) 123
3 2 6 2 Operator Warning System (Special Equipment) 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 ENGINE OIL MANAGEMENT SYSTEM 134
3 2 8 1 Oil Burning System “Centinel” combined with Oil Supply System “Reserve” 137
3 2 8 2 Eliminator Engine Oil Filtration System 138
3 3 OPERATOR’S CAB – CONTROLS 140
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 140
3 3 1 1 Hydraulic Control System 141
3 3 1 2 Safety Circuit for Controls 141
3 3 1 3 Control Pattern 143
3 3 2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 144
3 3 2 1 Hydraulic Control System 145
3 3 2 2 Safety Circuit for Controls 145
3 3 2 3 Control Pattern 147
3 3 3 OPERATOR’S CONSOLE 149
3 3 3 1 Control Panel 151
3 3 3 2 Switch Board 153
3 3 4 INTERFACE PANEL FOR DIAGNOSTICS 155
3 3 5 CONTROL MODULE FOR AUXILIARY CAB HEATER 157
3 4 MACHINE MONITOR 158
3 4 1 SEQUENCE OF DISPLAYS 159
3 4 2 OPENING SCREEN 159
3 4 3 MAIN gauge SCREENS 1 TO 4 160
3 4 3 1 Main gauge Screen 1 161
3 4 3 2 Main gauge Screen 2 163
3 4 3 3 Main gauge Screen 3 163
3 4 3 4 Main gauge Screen 4 165
3 4 3 5 Color Definition 165
3 4 4 FUEL CONSUMPTION SCREEN 167
3 4 5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR 167
3 4 6 MAIN SCREEN – CHANGE >TIME >SMR >DATE 168
3 4 7 MAINTENANCE MONITOR 168
3 4 7 1 Maintenance confirmation through Service Personnel 169
3 4 8 SETTINGS FOR OPERATOR 169
3 4 9 AUTOMATIC MESSAGES 174
3 4 9 1 Automatic Messages 174
3 4 9 2 Automatic Messages 176
Automatic Engine Messages 177
3 5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 178
3 5 1 Digital Display 178
3 5 1 1 Functions of the Buttons 182
3 6 CAMERA SYSTEM WITH MONITORS 186
3 6 1 LOCATION OF MONITORS AND CONTROL UNITS 187
3 6 1 1 Operating the Monitors 189
3 6 1 2 Arrangement of the Cameras 193
3 6 2 AUXILIARY HEATER FOR OPERATOR’S CAB 195
3 6 2 1 Special Equipment 195
3 6 2 2 Operation 195
3 7 MACHINERY HOUSE 196
3 7 1 EMERGENCY ENGINE SHUTDOWN SWITCHES 197
3 7 2 BATTERY MAIN SWITCH AND SAFETY SWITCH FOR MAINTENANCE 199
3 7 3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT 201
3 7 3 1 Operation Modes of Pump Regulation System 201
3 8 ELECTRICAL EQUIPMENT IN CAB BASE 202
3 8 1 STANDARD COMPONENTS IN CAB BASE 203
3 8 2 LOW VOLTAGE SWITCH BOARD IN CAB BASE 205
Checking diagnostic fault codes of the engine electronic controlled fuel system QUANTUM and of the engine monitoring system CENSE 207
3 8 3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS 209
3 8 4 BINARY FAULT CODE LIST 216
Combination Message 308 Trouble Can-Bus or Can Hardware 218
3 8 5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS 218
3 8 6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE (WHEN EQUIPPED) 221
3 9 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES (WHEN EQUIPPED) 224
3 9 1 Engine Coolant and Engine Oil Reserve Tank Heating 225
3 9 1 1 Engine Coolant and Engine Oil Heating 227
3 9 1 2 Hydraulic Oil and PTO Gear Oil Heating 229
3 10 CHECKS BEFORE STARTING THE ENGINES 230
3 10 1 COOLANT LEVEL 233
3 10 2 HYDRAULIC SYSTEM – CHECK OIL LEVEL 235
3 10 2 1 MACHINERY 235
3 10 2 2 OPERATOR’S SEAT ADJUSTMENT 235
3 10 2 3 OPERATOR’S SEAT ADJUSTMENT 235
3 11 STARTING THE ENGINES 236
3 11 1 STARTING PROCEDURE 239
3 11 1 1 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C 241
3 11 2 ENGINE WARM-UP 247
3 11 3 HYDRAULIC OIL WARM-UP 247
3 12 MOVING THE EXCAVATOR 249
3 12 1 TRAVEL CONTROL WITH FOOT PEDALS 249
3 12 1 1 TRAVEL ALARM / BACK-UP ALARM 251
3 12 2 traveling INSTRUCTIONS 251
3 12 2 1 TRAVELING 253
3 12 2 2 traveling LONG DISTANCES 255
3 12 3 UNDERCARRIAGE TRACK SLIDERS 256
3 13 SLEWING AND BRAKING THE SUPERSTRUCTURE 258
3 13 1 SLEWING THE SUPERSTRUCTURE 258
3 13 1 1 BRAKING THE SUPERSTRUCTURE 259
3 13 1 2 Hydraulic slew brake actuated by hydraulic access/egress stairway and Service Arm 260
3 13 1 3 Important Instructions for Slewing the Superstructure 260
3 14 WORKING WITH THE ATTACHMENT 261
3 14 0 1 FRONT SHOVEL BUCKET 262
3 14 1 COMBINED OPERATION CYCLES 263
3 15 WORKING INSTRUCTIONS 266
3 15 1 STABILITY OF THE excavator 266
3 15 2 FURTHER OPERATING PRACTICES 268
3 15 3 Loading Trucks 272
3 16 PARKING THE Excavator 273
3 16 0 1 CLEANING THE TRACK GROUPS 273
3 17 STOPPING THE ENGINES 274
3 17 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 277
3 18 OPERATION OF THE LUBRICATION SYSTEM 278
3 18 1 CENTRAL LUBRICATION SYSTEM ”CLS” 278
3 18 1 1 Manual actuation of the central lubrication system 278
3 18 1 2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 279
3 18 2 SLEW CIRCLE PINION LUBRICATION SYSTEM ”SLS” 279
3 18 2 1 Manual actuation of the slew circle lubrication system 280
3 18 2 2 slew CIRCLE LUBRICATION SYSTEM ”SLS” 281
3 18 2 3 ADJUSTMENTS OF THE slew CIRCLELUBRICATION SYSTEM 281
3 18 2 4 Defining the Lubrication System Greasing Areas 281
3 19 FIRE DETECTION AND SUPPRESSION SYSTEM 282
3 19 0 1 FIRE DETECTION AND SUPPRESSION SYSTEMS 283
3 19 1 DISPLAY MODULE 287
3 19 2 INTERFACE CONTROL MODULE 289
3 19 3 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF 291
3 20 TRANSFER PUMP FOR HYDRAULIC OIL 292
3 20 1 OPERATING THE TRANSFER PUMP 293
3 20 2 FUNCTIONS OF THE TRANSFER PUMP 295
3 21 CENTRAL REFILLING SYSTEM 298
3 21 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 299
3 21 1 1 Operation of the hydraulic Service Arm 299
3 21 2 OPERATING THE HYDRAULIC SERVICE ARM 301
3 21 3 RECEIVER PANEL WITH MONITOR BOX 303
3 21 3 1 Refilling Procedure: 307
3 21 4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOUSE ROOF 309
3 22 SERVICE CRANE (SPECIAL EQUIPMENT) 310
3 22 1 OPERATING THE CRANE 311
3 23 WORK ON THE LOADER ATTACHMENT 314
3 23 0 1 OBSERVE THE FOLLOWING INSTRUCTIONS 314
3 24 TRANSPORTATION AND LIFTING OF THE EXCAVATOR 315
3 24 1 DISASSEMBLING OF THE EXCAVATOR 315
3 24 2 TRANSPORTATION AND LIFTING 315
3 25 RETRIEVAL PROCEDURE 316
3 25 1 GENERAL 316
3 26 EXCAVATOR STORAGE 317
3 26 1 GENERAL 317
3 26 2 PREPARING FOR STORAGE 317
3 26 3 ONE MONTH REPETITIVE SERVICE PERIOD 317
3 26 4 SIX MONTH REPETITIVE SERVICE PERIOD 317
3 26 5 PREPARING FOR OPERATION 318
3 27 TROUBLE SHOOTING 319
3 27 1 GENERAL 319
3 27 2 ENGINE 319
3 27 3 HYDRAULIC SYSTEM 320
3 27 4 FINAL DRIVES AND SLEW GEAR 321
3 27 5 CRAWLER TRACKS 321
4 MAINTENANCE 323
4 1 FOREWORD 324
4 1 1 DEFINITIONS 324
4 1 2 GENERAL RECOMMENDATIONS 324
4 2 PRECAUTIONS FOR MAINTENANCE 325
4 2 1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 326
4 2 1 1 Recommended Hydraulic Oils 327
4 2 1 2 General Information to selecting hydraulic oils 328
4 2 1 3 General Information to using hydraulic oils 329
4 2 2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 330
4 3 FILLING CAPACITIES 331
4 4 STANDARD TORQUE LIST 333
4 4 1 Torque for Flange Joints 334
4 4 2 TORQUES FOR SPECIAL COMPONENTS 335
4 5 LUBRICATION AND MAINTENANCE SCHEDULE 337
4 5 1 INITIAL SERVICING 337
4 5 1 1 INITIAL RUNNING-IN 337
4 5 1 2 AFTER THE FIRST 250 OPERATING HOURS 337
4 5 1 3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT 337
4 5 2 SERVICING THE CRITICAL BOLT CONNECTIONS 338
4 5 3 PERIODIC SERVICING INTERVALS 338
4 5 4 PERIODIC SERVICING SCHEDULE 338
4 5 4 1 INITIAL SERVICING 338
4 5 4 2 WHEN NECESSARY 339
4 5 4 3 EVERY 10 OPERATING HOURS OR DAILY 339
4 5 4 4 EVERY 50 OPERATING HOURS OR WEEKLY 339
4 5 4 5 EVERY 250 OPERATING HOURS OR MONTHLY 340
4 5 4 6 EVERY 500 OPERATING HOURS OR QUATERLY 340
4 5 4 7 EVERY 1000 OPERATING HOURS OR 6 MONTHLY 341
4 5 4 8 EVERY 2000 OPEARTING HOURS OR YEARLY 341
4 5 4 9 EVERY 3000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 342
4 5 4 10 EVERY 6000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 342
4 5 5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM 343
4 6 SAFETY CRITICAL PARTS 344
4 6 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 344
4 6 2 INSPECTION OF HOSE LINES 345
4 6 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 345
4 7 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM 347
4 7 0 1 Servicing Intervals 347
4 7 0 2 Extended Service Intervals for Engines with Engine Oil Management System 351
4 7 1 MAINTENANCE OF THE ENGINES 351
4 7 1 1 Cleaning Practices WHEN Working on the Fuel System 351
4 7 2 ENGINE FUEL FILTER LOCATIONS 353
4 7 3 VENTING THE AIR FROM THE FUEL FILTERS 357
4 8 INITIAL SERVICING 358
4 8 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 359
4 8 2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 359
4 8 3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 360
4 8 4 SWING CIRCLE Pinion – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 361
4 8 5 SWING CIRCLE TOOTHING LUBRICATION 363
4 8 6 Swing circle – Check Torque OF BOLT CONNECTIONS 364
4 8 7 Retightening procedure of the crawler carrier mounting bolts 365
4 8 7 1 Procedure for ENSURING Proper TIGHTening OF the crawler carrier mounting bolts 366
4 8 7 2 Special hydraulic torque wrench 367
4 9 WHEN NECESSARY 368
4 9 1 HYDRAULIC OIL CHANGE 369
4 9 2 FILLING THE HYDRAULIC SYSTEM 371
4 9 2 1 Bleeding the hydraulic oil tank 371
4 9 2 2 Bleeding the main and auxiliary pumps 372
4 9 3 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 375
4 9 4 AUTOMATIC LUBRICATION SYSTEMS, FILL GREASE CONTAINERS 377
4 9 4 1 Service the Grease Filters 379
4 9 5 GUIDE WHEELS – REPLACE FLOATING SEALS 379
4 9 6 COLD STARTING AID, REPLACE FLUID CYLINDER 381
4 10 EVERY 10 OPERATING HOURS OR DAILY 382
4 10 1 WALK – AROUND INSPECTION 383
4 10 2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL Check 385
4 10 2 1 BOOM – CHECK LADDER AND WALKWAY 387
4 10 3 AIR CLEANER – CLEAN PRE-CLEANER 389
4 10 3 1 Clean dust cups of pre-cleaners 389
4 10 3 2 General Service Tips 391
4 10 4 RADIATORS – CHECK COOLANT LEVEL 393
4 10 5 TRACK GROUPS – CLEAN 393
4 10 5 1 Sliders (optional SPECIAL EQUIPMENT) – CHECK CONDITION 393
4 10 6 ELECTRICAL EQUIPMENT – CHECK CONDITION 394
4 10 7 CAMERA SYSTEM 397
4 10 8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 399
4 11 EVERY 50 OPERATING HOURS OR WEEKLY 400
4 11 1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 401
4 11 1 1 Swing Gear, type 2063 401
4 11 1 2 Swing gear, type 632770 403
4 11 2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS 405
4 11 2 1 TRAVEL GEAR BOX – CHECK OIL LEVEL 407
4 11 2 2 MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL 407
4 11 2 3 FINAL DRIVE HOUSING – CHECK OIL LEVEL 407
4 11 2 4 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES – CHECK BREATHER FILTERS 409
4 11 3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL 411
4 11 3 1 PUMP DISTRIBUTOR GEARS, CHECK OIL LEVEL: 411
4 11 3 2 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings 413
4 11 3 3 fan Pumps – Check Oil Level in Drive Shaft Housings 413
4 11 4 HYDRAULIC ACCESS/INGRESS stairway – CHECK SAFETY SENSOR 415
4 11 5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 417
4 12 EVERY 250 OPERATING HOURS OR MONTHLY 418
4 12 1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 419
4 12 2 SIGNAL HORN COMPRESSOR – LUBRICATE 421
4 12 3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 421
4 12 4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 421
4 12 5 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION 423
4 12 6 CABIN AIR CLEANER – INSPECT 425
4 12 7 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 427
4 12 8 ADDITIONAL AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 429
4 12 9 CABIN HEATER FILTER – INSPECT 431
4 12 10 Critical BOLT CONNECTIONS – VISUAL CHECK 433
4 12 11 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 435
4 13 EVERY 500 OPERATING HOURS OR QUARTERLY 436
4 13 1 BATTERIES – CHECK FLUID LEVEL 437
4 13 2 GREASE INJECTORS – CHECK INDICATOR STEMS 438
4 13 2 1 CORRECTIVE ACTIONS 438
4 13 2 2 CHECKING THE SLEW RING 438
4 13 2 3 CHECKING THE SLIDERS (OPTIONAL EQUIPMENT) for wear 439
4 13 3 CYLINDER ROD PROTECTION (IF EQUIPPED), Inspect 441
4 13 4 FUEL TANK – DRAIN CONDENSATION 443
4 13 5 CRAWLER TRACK – INSPECTION 445
4 13 5 1 CHECK ADJUSTING RANGE FOR IDLER 447
4 13 5 2 Bleeding the system 449
4 13 6 GROUND CABLES OF ENGINE AND ALTERNATOR – CHECK FOR CORRECT CONNECTION 451
4 13 7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 453
4 13 8 EMERGENCY ESCAPE LADDERS – CHECK FUNCTIONALITY 455
4 14 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 458
4 14 1 CRITICAL BOLT CONNECTIONS 459
4 14 1 1 Check mounting of Operator’s cab 459
4 14 1 2 Check tightening torque of the counterweight mounting bolts, 461
4 14 2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 465
4 14 2 1 TEST MAINTENANCE SAFETY SWITCH (10) 467
4 14 3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY 467
4 14 4 ELECTRICAL EQUIPMENT – MAINTAINANCE 469
4 14 5 HYDRAULIC SYSTEM – FILTER SERVICE 471
4 14 5 1 FILTER SERVICE 473
4 14 6 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 485
4 14 6 1 Oil drain plugs 485
4 14 7 TRACK TENSIONING SYSTEM- CHECK ACCUMULATORS 487
4 14 8 CABIN AIR CLEANER – REPLACE PRIMARY FILTER 489
4 14 9 ENGINE AIR CLEANERS- INSPECT AND LUBRICATE HINGES 491
4 14 10 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 493
4 14 11 ALL OTHER HINGES AND AREAS TO LUBRICATE 495
4 14 12 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 497
4 15 EVERY 2000 OPERATING HOURS OR YEARLY 498
4 15 1 HYDRAULIC SYSTEM – Change PULSATION DAMPER 499
4 15 1 1 HYDRAULIC SYSTEM – CHANGE PULSATION DAMPER (continued) 501
4 15 1 2 HYDRAULIC SYSTEM – CHANGE PULSATION DAMPER (continued) 503
4 15 1 3 Replace Suction Strainers of Main Pumps 507
4 15 2 GEAR PUMPS FOR PTO GEAR LUBRICATION 509
4 15 3 EMERGENCY ESCAPE LADDERS – INSPECTION 511
4 15 4 stairway EMERGENCY LOWERING CHAINS – INSPECTION 513
4 15 5 HYDRAULIC HOSES – Check Condition 515
4 15 6 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 517
4 15 7 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 519
4 15 7 1 Functionality 519
4 16 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 520
4 16 1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 521
4 16 1 1 Swing gear, type 2063 521
4 16 1 2 SWING GEAR, type 632770 525
4 16 2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL 529
4 16 3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 533
4 16 3 1 Change the Oil 533
4 16 4 FLEXIBLE COUPLING – VISUAL CHECK 535
4 17 CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS 536
4 17 1 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD 537
4 17 2 OIL SEPARATOR ELEMENT – REPLACE (IF SO EQUIPPED) 579
4 17 3 CHECKING THE STEEL STRUCTURES 581
4 18 EVERY 6000 OPERATING HOURS OR ONCE A YEAR 582
4 18 1 AUTOMATIC LUBRICATION SYSTEMS – replace pump outlet GREASE FILTERS 583
4 18 2 CHANGING THE HIGH PRESSURE FILTERS 585
4 19 FIRE PREVENTION 586
4 19 1 PRECAUTIONS 587
4 20 WELD REPAIRS 588
4 20 1 GENERAL INFORMATION 588
4 20 1 1 GENERAL PROTECTIVE MEASURES 589
4 20 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 589
4 20 2 1 COUNTERWEIGHT 589
4 20 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 591
4 20 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 593
4 20 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 595
4 20 5 1 Electrical Units in Cab Base, 597
4 20 5 2 Engine Electronics 597
4 20 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 597
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