KOMATSU PC5500-6 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL 15178 – PDF DOWNLOAD
DESCRIPTION:
KOMATSU PC5500-6 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL 15178 – 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 machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
- Read, understand and follow all precautions and warnings in this manual and on the machine 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 machine is used.
- Therefore, the safety messages in this manual and on the machine 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 machine can be hazardous and could result in serious injury or death.
TABLE OF CONTENTS:
KOMATSU PC5500-6 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL 15178 – 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 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 excavator IS RUNNING 56
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 56
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE excavator 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 EXCAVATOR 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
2 8 2 LOCATION AND DESCRIPTION OF THE SIGNS 78
3 OPERATION 105
3 1 FOREWORD 106
3 2 CONSTRUCTION OF THE EXCAVATOR 107
3 2 1 OVERALL VIEW 107
3 2 2 UNDERCARRIAGE AND SUPERSTRUCTURE 108
3 2 2 1 SUPERSTRUCTURE – TOP VIEW 110
3 2 2 2 MACHINERY HOUSE 112
3 2 3 HYDRAULICALLY OPERATED access/ingress stairway 114
3 2 3 1 Lowering the STAIRWAY in emergency situations 117
3 2 4 EMERGENCY ESCAPE LADDER 118
3 2 4 1 FROM THE OPERATOR’S cab 118
3 2 4 2 FROM THE MACHINERY HOUSE 120
3 2 5 BOOM ACCESS LADDER AND WALKWAY 122
3 2 6 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 124
3 2 6 1 Engine Shutdown System actuated from Ground Man (OPTIONAL Equipment) 125
3 2 6 2 Operator Warning System (Special Equipment) 125
3 2 7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 126
3 2 7 1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual 131
3 2 7 2 Operator’s Seat Adjustment 133
3 2 7 3 Co-driver’s Seat and Refrigerator Box 134
3 2 7 4 INSTRUCTIONS TO using and looking after THE SEAT BELTS 135
3 2 8 ENGINE OIL MANAGEMENT SYSTEM 136
3 2 8 1 Oil Burning System “Centinel” combined with Oil Supply System “Reserve” 139
3 2 8 2 Eliminator Engine Oil Filtration System 140
3 3 OPERATOR’S CAB – CONTROLS 142
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 142
3 3 1 1 Hydraulic Control System 143
3 3 1 2 Safety Circuit for Controls 143
3 3 1 3 Control Pattern 145
3 3 2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 146
3 3 2 1 Hydraulic Control System 147
3 3 2 2 Safety Circuit for Controls 147
3 3 2 3 Control Pattern 149
3 3 3 OPERATOR’S CONSOLE 151
3 3 3 1 Control Panel 153
3 3 3 2 Switch Board 155
3 3 4 INTERFACE PANEL FOR DIAGNOSTICS 157
3 3 5 CONTROL MODULE FOR AUXILIARY CAB HEATER 159
3 4 MACHINE MONITOR 160
3 4 1 SEQUENCE OF DISPLAYS 161
3 4 2 OPENING SCREEN 161
3 4 3 MAIN gage SCREENS 1 TO 4 162
3 4 3 1 Main gage Screen 1 163
3 4 3 2 Main gage Screen 2 165
3 4 3 3 Main gage Screen 3 165
3 4 3 4 Main gage Screen 4 167
3 4 3 5 Color Definition 167
3 4 4 FUEL CONSUMPTION SCREEN 169
3 4 5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR 169
3 4 6 MAIN SCREEN – CHANGE >TIME >SMR >DATE 170
3 4 7 MAINTENANCE MONITOR 170
3 4 7 1 Maintenance confirmation through Service Personnel 171
3 4 8 SETTINGS FOR OPERATOR 171
3 4 9 AUTOMATIC MESSAGES 176
3 4 9 1 Automatic Messages 176
3 4 9 2 Automatic Messages 178
Automatic Engine Messages 179
3 5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 180
3 5 1 Digital Display 180
3 5 2 Luminous Indication 182
3 6 CAMERA SYSTEM WITH MONITORS 184
3 6 1 LOCATION OF MONITORS AND CONTROL UNITS 185
3 6 1 1 Operating the Monitors 187
3 6 1 2 Ajustments of the Monitor 187
3 6 1 3 Arrangement of the Cameras 191
3 6 2 AUXILIARY HEATER FOR OPERATOR’S CAB 193
3 6 2 1 Special Equipment 193
3 6 2 2 Operation 193
3 7 MACHINERY HOUSE 194
3 7 1 EMERGENCY ENGINE SHUTDOWN SWITCHES 195
3 7 2 SAFETY SWITCH FOR MAINTENANCE 197
3 7 3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT 199
3 7 3 1 Operation Modes of Pump Regulation System 199
3 8 ELECTRICAL EQUIPMENT IN CAB BASE 200
3 8 1 STANDARD COMPONENTS IN CAB BASE 201
3 8 2 LOW VOLTAGE SWITCH BOARD IN CAB BASE 203
Checking diagnostic fault codes of the engine electronic controlled fuel system QUANTUM and of the engine monitoring system CENSE 205
3 8 3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS 207
3 8 4 BINARY FAULT CODE LIST 214
Combination Message 308 Trouble Can-Bus or Can Hardware 216
3 8 5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS 216
3 8 6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE (WHEN EQUIPPED) 219
3 9 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES (WHEN EQUIPPED) 222
3 9 1 Engine Coolant and Engine Oil Reserve Tank Heating 223
3 9 1 1 Engine Coolant and Engine Oil Heating 225
3 9 1 2 Hydraulic Oil and PTO Gear Oil Heating 227
3 10 CHECKS BEFORE STARTING THE ENGINES 228
3 10 1 Coolant Level 231
3 10 1 1 HYDRAULIC SYSTEM – CHECK OIL LEVEL 233
3 10 1 2 Machinery House Doors 233
3 10 1 3 OPERATOR’S SEAT ADJUSTMENT 233
3 10 1 4 OPERATOR’S SEAT ADJUSTMENT 233
3 11 STARTING THE ENGINES 234
3 11 1 STARTING PROCEDURE 237
3 11 1 1 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C 239
3 11 2 ENGINE WARM-UP 245
3 11 3 HYDRAULIC OIL WARM-UP 245
3 12 MOVING THE EXCAVATOR 247
3 12 1 TRAVEL CONTROL WITH FOOT PEDALS 247
3 12 1 1 TRAVEL ALARM / BACK-UP ALARM 249
3 12 2 traveling INSTRUCTIONS 249
3 12 2 1 traveling LONG DISTANCES 251
3 12 3 UNDERCARRIAGE TRACK SLIDERS 252
3 13 SLEWING AND BRAKING THE SUPERSTRUCTURE 254
3 13 1 SLEWING THE SUPERSTRUCTURE 254
3 13 1 1 BRAKING THE SUPERSTRUCTURE 255
3 13 1 2 Hydraulic slew brake actuated by hydraulic access/ingress stairway and Service Arm of service center 256
3 13 1 3 Important Instructions for Slewing the Superstructure 256
3 14 WORKING WITH THE ATTACHMENT 257
3 14 0 1 FRONT SHOVEL BUCKET 258
3 14 1 COMBINED OPERATION CYCLES 259
3 15 WORKING INSTRUCTIONS 262
3 15 1 STABILITY OF THE excavator 262
3 15 2 FURTHER OPERATING PRACTICES 264
3 15 3 Loading Trucks 268
3 16 PARKING THE Excavator 269
3 16 0 1 CLEANING THE TRACK GROUPS 269
3 17 STOPPING THE ENGINES 270
3 17 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 273
3 18 OPERATION OF THE LUBRICATION SYSTEM 274
3 18 1 CENTRAL LUBRICATION SYSTEM ”CLS” 274
3 18 1 1 Manual actuation of the central lubrication system 274
3 18 1 2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 275
3 18 2 SLEW CIRCLE PINION LUBRICATION SYSTEM ”SLS” 275
3 18 2 1 Manual actuation of the slew circle lubrication system 276
3 18 2 2 slew CIRCLE LUBRICATION SYSTEM ”SLS” 277
3 18 2 3 ADJUSTMENTS OF THE slew CIRCLELUBRICATION SYSTEM 277
3 18 2 4 Defining the Lubrication System Greasing Areas 277
3 19 FIRE DETECTION AND SUPPRESSION SYSTEM 278
3 19 0 1 FIRE DETECTION AND SUPPRESSION SYSTEMS 279
3 19 1 DISPLAY MODULE 283
3 19 2 INTERFACE CONTROL MODULE 285
3 19 3 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF 287
3 20 TRANSFER PUMP FOR HYDRAULIC OIL 288
3 20 1 OPERATING THE TRANSFER PUMP 289
3 20 2 FUNCTIONS OF THE TRANSFER PUMP 291
3 21 SERVICE CENTER 294
3 21 1 SYSTEMS CONNECTED TO THE SERVICE CENTER 295
3 21 1 1 Operation of the hydraulic Service Arm 295
3 21 2 OPERATING THE HYDRAULIC SERVICE ARM 297
3 21 3 RECEIVER PANEL WITH MONITOR BOX 299
3 21 3 1 Refilling Procedure: 303
3 21 4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOUSE ROOF 305
3 22 SERVICE CRANE (SPECIAL EQUIPMENT) 306
3 22 1 OPERATING THE CRANE 307
3 23 WORK ON THE LOADER ATTACHMENT 310
3 23 0 1 OBSERVE THE FOLLOWING INSTRUCTIONS 310
3 24 TRANSPORTATION AND LIFTING OF THE EXCAVATOR 311
3 24 1 DISASSEMBLING OF THE EXCAVATOR 311
3 24 2 TRANSPORTATION AND LIFTING 311
3 25 RETRIEVAL PROCEDURE 312
3 25 1 GENERAL 312
3 26 EXCAVATOR STORAGE 313
3 26 1 GENERAL 313
3 26 2 PREPARING FOR STORAGE 313
3 26 3 ONE MONTH REPETITIVE SERVICE PERIOD 313
3 26 4 SIX MONTH REPETITIVE SERVICE PERIOD 313
3 26 5 PREPARING FOR OPERATION 314
3 27 TROUBLE SHOOTING 315
3 27 1 GENERAL 315
3 27 2 ENGINE 315
3 27 3 HYDRAULIC SYSTEM 316
3 27 4 FINAL DRIVES AND SLEW GEAR 317
3 27 5 CRAWLER TRACKS 317
4 MAINTENANCE 319
4 1 FOREWORD 320
4 1 1 DEFINITIONS 320
4 1 2 GENERAL RECOMMENDATIONS 320
4 2 PRECAUTIONS FOR MAINTENANCE 321
4 2 1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 322
4 2 1 1 Recommended Hydraulic Oils 323
4 2 1 2 General Information to selecting hydraulic oils 324
4 2 2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 326
4 3 FILLING CAPACITIES 327
4 4 STANDARD TORQUE LIST 329
4 4 1 Torque for Flange Joints 330
4 4 2 TORQUES FOR SPECIAL COMPONENTS 331
4 5 LUBRICATION AND MAINTENANCE SCHEDULE 333
4 5 1 INITIAL SERVICING 333
4 5 1 1 INITIAL RUNNING-IN 333
4 5 1 2 AFTER THE FIRST 250 OPERATING HOURS 333
4 5 1 3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT 333
4 5 2 SERVICING THE CRITICAL BOLT CONNECTIONS 334
4 5 3 PERIODIC SERVICING INTERVALS 334
4 5 4 PERIODIC SERVICING SCHEDULE 334
4 5 4 1 INITIAL SERVICING 334
4 5 4 2 WHEN NECESSARY 335
4 5 4 3 EVERY 10 OPERATING HOURS OR DAILY 335
4 5 4 4 EVERY 50 OPERATING HOURS OR WEEKLY 335
4 5 4 5 EVERY 250 OPERATING HOURS OR MONTHLY 336
4 5 4 6 EVERY 500 OPERATING HOURS OR QUATERLY 336
4 5 4 7 EVERY 1000 OPERATING HOURS OR 6 MONTHLY 337
4 5 4 8 EVERY 2000 OPEARTING HOURS OR YEARLY 337
4 5 4 9 EVERY 3000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 338
4 5 4 10 EVERY 6000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 338
4 5 5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM 339
4 6 SAFETY CRITICAL PARTS 342
4 6 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 342
4 6 2 INSPECTION OF HOSE LINES 343
4 6 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 343
4 7 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM 345
4 7 0 1 Servicing Intervals 345
4 7 0 2 Extended Service Intervals for Engines with Engine Oil Management System 349
4 7 1 MAINTENANCE OF THE ENGINES 349
4 7 1 1 Cleaning Practices WHEN Working on the Fuel System 349
4 7 2 ENGINE FUEL FILTER LOCATIONS 351
4 7 3 VENTING THE AIR FROM THE FUEL FILTERS 355
4 8 INITIAL SERVICING 356
4 8 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 356
4 8 2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 357
4 8 3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 358
4 8 4 SWING CIRCLE Pinion – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 359
4 8 5 SWING CIRCLE TOOTHING LUBRICATION 361
4 8 6 Swing circle – Check Torque OF BOLT CONNECTIONS 362
4 8 7 Retightening procedure of the crawler carrier mounting bolts 363
4 8 7 1 Procedure for ENSURING Proper TIGHTening OF the crawler carrier mounting bolts 364
4 8 7 2 Special hydraulic torque wrench 365
4 9 WHEN NECESSARY 366
4 9 1 ENGINE AIR CLEANER MAINTENANCE 367
4 9 1 1 General Service Tips 369
4 9 2 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 371
4 9 3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 373
4 9 3 1 Service the Grease Filters for Refillable Grease Containers of the Central Lubrication System and Swing circle pinion Lubrication System 375
4 9 4 GUIDE WHEELS – REPLACE FLOATING SEALS 375
4 9 5 COLD STARTING AID, REPLACE FLUID CYLINDER 377
4 10 EVERY 10 OPERATING HOURS OR DAILY 378
4 10 1 WALK – AROUND INSPECTION 379
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 4 RADIATORS – CHECK COOLANT LEVEL 391
4 10 5 TRACK GROUPS – CLEAN 391
4 10 5 1 Sliders (optional SPECIAL EQUIPMENT)- CHECK CONDITION 391
4 10 6 ELECTRICAL EQUIPMENT – CHECK CONDITION 392
4 10 7 CAMERA SYSTEM 395
4 10 8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 397
4 11 EVERY 50 OPERATING HOURS OR WEEKLY 398
4 11 1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 399
4 11 1 1 Swing Gear, type 2063 399
4 11 1 2 Swing gear, type 632770 401
4 11 2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS 403
4 11 2 1 TRAVEL GEAR BOX – CHECK OIL LEVEL 405
4 11 2 2 MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL 405
4 11 2 3 FINAL DRIVE HOUSING – CHECK OIL LEVEL 405
4 11 2 4 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES – CHECK BREATHER FILTERS 407
4 11 3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL 409
4 11 3 1 PUMP DISTRIBUTOR GEARS, CHECK OIL LEVEL: 409
4 11 3 2 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings 411
4 11 3 3 fan Pumps – Check Oil Level in Drive Shaft Housings 411
4 11 4 HYDRAULIC access/ingress stairway – CHECK SAFETY SENSOR 413
4 11 5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 415
4 12 EVERY 250 OPERATING HOURS OR MONTHLY 416
4 12 1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 417
4 12 2 SIGNAL HORN COMPRESSOR – LUBRICATE 419
4 12 3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 419
4 12 4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 419
4 12 5 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION 421
4 12 6 CABIN AIR CLEANER – INSPECT 423
4 12 7 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 425
4 12 8 ADDITIONAL AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 427
4 12 9 CABIN HEATER FILTER – INSPECT 429
4 12 10 Critical BOLT CONNECTIONS – VISUAL CHECK 431
4 12 11 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 433
4 13 EVERY 500 OPERATING HOURS OR QUARTERLY 434
4 13 1 BATTERIES – CHECK FLUID LEVEL 435
4 13 2 GREASE INJECTORS – CHECK INDICATOR STEMS 436
4 13 2 1 CORRECTIVE ACTIONS 436
4 13 2 2 CHECKING THE SLEW RING 436
4 13 2 3 CHECKING THE SLIDERS (OPTIONAL EQUIPMENT) for wear 437
4 13 3 CYLINDER ROD PROTECTION (IF EQUIPPED), Inspect 439
4 13 4 FUEL TANK – DRAIN CONDENSATION 441
4 13 5 CRAWLER TRACK – INSPECTION 443
4 13 5 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 443
4 13 5 2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 445
4 13 5 3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 447
4 13 5 4 Bleeding the System 447
4 13 6 GROUND CABLES OF ENGINE AND ALTERNATOR – CHECK FOR CORRECT CONNECTION 449
4 13 7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 451
4 13 8 EMERGENCY LOWERING OF access/ingress stairway – TEST FUNCTIONALITY 453
4 14 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 454
4 14 1 CRITICAL BOLT CONNECTIONS 455
4 14 1 1 Check mounting of Operator’s cab 455
4 14 1 2 Check tightening torque of the counterweight mounting bolts, 457
4 14 2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 461
4 14 2 1 TEST MAINTENANCE SAFETY SWITCH (10) 463
4 14 3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY 463
4 14 4 ELECTRICAL EQUIPMENT – MAINTAINANCE 465
4 14 5 HYDRAULIC SYSTEM – FILTER SERVICE 467
4 14 5 1 FILTER SERVICE 469
4 14 6 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 481
4 14 6 1 Oil drain plugs 481
4 14 7 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 483
4 14 8 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 485
4 14 9 CABIN AIR CLEANER – REPLACE PRIMARY FILTER 487
4 14 10 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 489
4 14 11 ALL OTHER HINGES AND AREAS TO LUBRICATE 491
4 14 12 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 493
4 15 EVERY 2000 OPERATING HOURS OR YEARLY 494
4 15 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 495
4 15 1 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 497
4 15 1 2 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 499
4 15 1 3 Replace Suction Strainers of Main Pumps 503
4 15 2 FILLING THE HYDRAULIC SYSTEM 505
4 15 3 BLEEDING THE HYDRAULIC SYSTEM 507
4 15 4 GEAR PUMPS FOR PTO GEAR LUBRICATION 509
4 15 5 EMERGENCY ESCAPE LADDER – INSPECTION 511
4 15 6 access/ingress stairway EMERGENCY LOWERING CHAINS – INSPECTION 513
4 15 7 HYDRAULIC HOSES – Check Condition 515
4 15 8 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 517
4 15 9 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 519
4 15 9 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 534
4 16 4 FLEXIBLE COUPLING – VISUAL CHECK 537
4 17 CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS 538
4 17 1 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD 539
4 17 2 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 HYDRAULIC Oil TANK – CHECK LEAKAGE OIL SCREEN FILTER 585
4 18 3 CHANGING THE HIGH PRESSURE FILTERS 587
4 19 FIRE PREVENTION 588
4 19 1 PRECAUTIONS 589
4 20 WELD REPAIRS 590
4 20 1 GENERAL INFORMATION 590
4 20 1 1 GENERAL PROTECTIVE MEASURES 591
4 20 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 591
4 20 2 1 COUNTERWEIGHT 591
4 20 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 593
4 20 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 595
4 20 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 597
4 20 5 1 Electrical Units in Cab Base, 599
4 20 5 2 Engine Electronics 599
4 20 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 599
5 REVISION 601
5 1 Revised Edition from Previous model OR VERSION 602
5 1 1 Revision Version 1 from template 602
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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