KOMATSU PC5500E-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15120 – PDF DOWNLOAD
DESCRIPTION:
KOMATSU PC5500E-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15120 – PDF DOWNLOAD
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 PC5500E-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15120 – PDF DOWNLOAD
1 FOREWORD 3
1 1 BEFORE READING THIS MANUAL 4
1 2 DIRECTIONS OF THE MACHINE 5
1 3 SPECIFICATION AND SERIAL PLATE 6
1 3 1 PRODUCT IDENTIFICATION NUMBER 6
1 4 DIVISION OF THE BINDER 7
1 5 DESIGNATED USE OF THE SHOVEL 8
1 6 DELIVERY OF THE SHOVEL 9
1 6 1 SPARE PARTS 9
1 6 2 SERVICE 9
1 7 EXPLANATION OF ABBREVIATIONS 10
1 8 CONTENTS 11
2 SAFETY 17
2 1 SAFETY INFORMATION 18
2 2 OVERVIEW 19
2 2 1 NORMAL OPERATIONS 19
2 2 2 REGULAR MAINTENANCE 19
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 19
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 19
2 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 20
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 21
2 4 1 UNDERSTANDING THE MACHINE 21
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 21
2 4 2 1 ENSURING SAFE OPERATION 21
2 4 3 PREPARATIONS FOR SAFE OPERATION 21
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 21
2 4 3 2 INSPECTING THE MACHINE 21
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 22
2 4 3 4 KEEP MACHINE CLEAN 22
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 22
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 23
2 4 3 7 IF A PROBLEM IS FOUND 23
2 4 4 FIRE PREVENTION 23
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 23
2 4 4 2 ACTION IF FIRE OCCURS 24
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 25
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 25
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 25
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 25
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 25
2 4 5 4 WORKING IN HIGH PLACES 25
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 26
2 4 5 6 LEAVING THE MACHINE 26
2 4 6 BURN PREVENTION 27
2 4 6 1 Hot coolant 27
2 4 6 2 Hot oil 27
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 27
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 28
2 4 8 1 UNAUTHORIZED MODIFICATION 28
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 28
2 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 29
2 4 10 PRECAUTIONS AT JOBSITE 30
2 4 10 1 VISIBILITY FROM OPERATOR’S SEAT 31
2 4 10 2 CAMERA SYSTEM WITH MONITORS 31
2 4 10 3 ENSURE GOOD VISIBILITY 31
2 4 10 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 31
2 4 10 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 32
2 4 10 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 32
2 4 10 7 WORKING ON LOOSE GROUND 33
2 4 10 8 GAS, DUST, STEAM AND SMOKE 33
2 4 10 9 VENTILATION OF ENCLOSED AREAS 34
2 4 11 STARTING ENGINE 35
2 4 11 1 WARNING TAG 35
2 4 11 2 CHECKS BEFORE STARTING ENGINE 35
2 4 11 3 PRECAUTION WHEN STARTING ENGINE 35
2 4 11 4 PRECAUTION IN COLD AREAS 36
2 4 12 OPERATION 36
2 4 12 1 CHECKS BEFORE OPERATION 36
2 4 12 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 37
2 4 12 3 PRECAUTIONS WHEN travelling 38
2 4 12 4 TRAVELLING ON SLOPES 39
2 4 12 5 OPERATIONS ON SLOPES 40
2 4 12 6 PROHIBITED OPERATIONS 40
2 4 12 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 41
2 4 12 8 PARKING THE MACHINE 41
2 4 12 9 TRANSPORTATION 41
2 5 PRECAUTION FOR MAINTENANCE 42
2 5 1 GENERAL PRECAUTIONS 42
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 43
2 5 1 2 STOP ENGINE FOR MAINTENANCE 44
2 5 1 3 WARNING TAG 45
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 46
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 46
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 47
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 47
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 48
2 5 1 9 NOISE 48
2 5 1 10 WHEN USING A HAMMER 48
2 5 1 11 PROPER TOOLS 49
2 5 1 12 ACCUMULATOR 49
2 5 1 13 PERSONNEL 49
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 50
2 5 2 1 PRECAUTION WHEN WELDING 50
2 5 2 2 BATTERY HANDLING 50
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 51
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 51
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 52
2 5 3 3 REPLACEMENT OF HOSE LINES 52
2 5 3 4 INSPECTION OF HOSE LINES 52
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 53
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 53
2 5 3 7 AIR CONDITIONING MAINTENANCE 53
2 5 3 8 COMPRESSED AIR 54
2 5 3 9 WASTE MATERIALS 54
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 55
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 55
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 55
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 55
2 7 SPECIAL SAFETY EQUIPMENT 56
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 57
2 7 2 OBJECT HANDLING 57
2 7 3 LIGHTING 57
2 7 4 WARNING BEACON 57
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 57
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 57
2 7 5 2 INSTRUCTIONS FOR USE 59
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 61
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1), 61
2 7 5 5 INSTRUCTIONS FOR USE 63
2 8 SAFETY WARNING SIGNS 65
2 8 1 LOCATION AND DESCRIPTION OF THE SIGNS 66
3 OPERATION 79
3 1 FOREWORD 80
3 2 CONSTRUCTION OF THE SHOVEL 81
3 2 1 OVERALL VIEW 81
3 2 2 UNDERCARRIAGE AND SUPERSTRUCTURE 82
3 2 2 1 SUPERSTRUCTURE – TOP VIEW 84
3 2 2 2 MACHINERY HOUSE 88
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 90
3 2 4 EMERGENCY ESCAPE LADDER 94
3 2 5 BOOM ACCESS LADDER AND WALKWAY 96
3 2 6 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 98
3 2 6 1 Emergency Motor Shutdown System actuated from Ground Man (Special Equipment) 99
3 2 6 2 Operator Warning System (Special Equipment) 99
3 2 7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 100
3 2 7 1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual 105
3 2 7 2 Operator’s Seat Adjustment 107
3 2 7 3 Co-driver’s Seat and Refrigerator Box 108
3 2 7 4 Sound Pressure Level in the Operator’s Cab 109
3 3 OPERATOR’S CAB – CONTROLS 110
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 110
3 3 1 1 Hydraulic Control System 111
3 3 1 2 Safety Circuit for Controls 111
3 3 1 3 EURO Control Pattern 113
3 3 2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 114
3 3 2 1 Hydraulic Control System 115
3 3 2 2 Safety Circuit for Controls 115
3 3 2 3 EURO Control Pattern 117
3 3 2 4 Automatic Float Position for Boom and Stick 117
3 3 3 OPERATOR’S CONSOLE 119
3 3 3 1 Control Panel 121
3 3 4 Auxiliary Heaters for Operator’s Cab 125
3 3 5 CONTROL MODULE FOR AUXILIARY CAB HEATER 127
3 3 6 INTERFACE PANEL FOR DIAGNOSTICS 129
3 3 7 Auxiliary Heaters for Operator’s Cab 131
3 3 7 1 CONTROL MODULE FOR AUXILIARY CAB HEATER 133
3 4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR 134
3 4 1 SEQUENCE OF DISPLAYS 135
3 4 2 OPENING SCREEN 135
3 4 3 MAIN GAUGE SCREENS 1 TO 3 136
3 4 3 1 Main Gauge Screen 1 137
3 4 3 2 Main Gauge Screen 2 139
3 4 3 3 Main Gauge Screen 3 139
3 4 3 4 Color Definition 139
3 4 4 ENERGY CONSUMPTION SCREEN 141
3 4 5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR 141
3 4 6 MAIN SCREEN – CHANGE >TIME >SMR >DATE 142
3 4 7 MAINTENANCE MONITOR 142
3 4 7 1 Maintenance confirmation through Service Personnel 143
3 4 8 SETTINGS FOR OPERATOR 143
3 4 8 1 Settings Screens 144
3 4 9 SERVICE MENU 147
3 4 10 AUTOMATIC MESSAGES 147
3 4 10 1 Automatic Messages 148
3 4 10 2 Automatic Motor Messages 151
3 4 11 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM 152
3 4 12 TABLE OF AVAILABLE INSTRUCTION MESSAGES 164
3 5 CAMERA SYSTEM WITH MONITORS 168
3 5 1 LOCATION OF MONITORS AND CONTROL UNITS 169
3 5 1 1 Operating the Monitors 171
3 5 1 2 Ajustments of the Monitor 171
3 5 1 3 Typical Arrangement of the Cameras 175
3 6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 176
3 6 0 1 Digital Display 176
3 6 0 2 Luminous Indication 178
3 6 1 AUXILIARY HEATER FOR OPERATOR’S CAB 181
3 6 1 1 Special Equipment 181
3 6 1 2 Operation 181
3 7 MACHINERY HOUSE 182
3 7 1 EMERGENCY MOTOR SHUTDOWN SWITCHES 183
3 7 2 SAFETY SWITCH FOR MAINTENANCE 185
3 7 3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT 187
3 7 3 1 Operation Modes of Pump Regulation System 187
3 7 4 HEATERS FOR MACHINERY HOUSE 189
3 8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE 190
3 8 1 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET 191
3 8 2 LOW VOLTAGE SWITCH BOARD IN CAB BASE 193
3 8 3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS 195
3 8 4 BINARY FAULT CODE LIST 202
3 8 4 1 Combination Message 308 Trouble Can-Bus or Can Hardware 204
3 8 5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS 204
3 8 6 MONITOR AND CONTROL PANEL IN CAB BASE 207
3 8 7 SWITCH BOARD – MEDIUM VOLTAGE 209
3 9 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS 210
3 9 1 WALK AROUND INSPECTION 211
3 9 2 TURNING ON THE POWER SUPPLY 211
3 9 3 HYDRAULIC SYSTEM – CHECK OIL LEVEL 213
3 9 4 Machinery House Doors 213
3 9 5 Operator’s Seat Adjustment 213
3 10 STARTING THE MAIN DRIVE MOTORS 214
3 10 1 Starting Procedure 217
3 10 1 1 Hydraulic oil warm-up 219
3 11 MOVING THE SHOVEL 221
3 11 1 TRAVEL CONTROL WITH FOOT PEDALS 221
3 11 1 1 TRAVEL ALARM / BACK-UP ALARM 223
3 11 2 TRAVELLING INSTRUCTIONS 223
3 11 2 1 TRAVELLING LONG DISTANCES 225
3 12 SLEWING AND BRAKING THE SUPERSTRUCTURE 226
3 12 1 SLEWING THE SUPERSTRUCTURE 226
3 12 1 1 MACHINES WITH “EURO” CONTROL 226
3 12 1 2 MACHINES WITH “KMG” CONTROL 227
3 12 1 3 BRAKING THE SUPERSTRUCTURE 227
3 12 1 4 Hydraulic Swing Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System 228
3 12 1 5 Important Instructions for Slewing the Superstructure 228
3 13 WORKING WITH THE ATTACHMENT 229
3 13 1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM 229
3 13 1 1 BACKHOE 229
3 13 1 2 FACE SHOVEL 229
3 13 2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM 230
3 13 2 1 BACKHOE 230
3 13 2 2 FACE SHOVEL 230
3 13 2 3 BOTTOM DUMP BUCKET 231
3 13 2 4 OPERATING THE BUCKET CLAM 231
3 13 3 COMBINED OPERATION CYCLES 232
3 14 WORKING INSTRUCTIONS 234
3 14 1 STABILITY OF THE SHOVEL 234
3 14 2 SHOVEL OPERATION 234
3 15 PARKING THE SHOVEL 237
3 15 0 1 CLEANING THE TRACK GROUPS 237
3 16 STOPPING THE MAIN DRIVE MOTORS 238
3 16 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 241
3 17 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM 242
3 17 1 ISOLATING THE POWER SUPPLY 245
3 17 2 PROCEDURE FOR ISOLTING THE POWER SUPPLY 247
3 17 3 PERFORMING GROUNDING PROCEDURES 249
3 18 OPERATION OF THE LUBRICATION SYSTEM 254
3 18 1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT 254
3 18 1 1 Manual actuation of the central lubrication system 254
3 18 1 2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 255
3 18 2 SWING CIRCLE PINION LUBRICATION SYSTEM -SLS- 255
3 18 2 1 Manual actuation of the swing circle lubrication system 256
3 18 2 2 SWING CIRCLE LUBRICATION SYSTEM ”SLS” 256
3 18 2 3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM 256
3 19 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM 258
3 19 1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS 259
3 19 1 1 Personnel Safety 259
3 19 2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB 263
3 19 3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM: 263
3 19 4 IN The CASE OF A FIRE 265
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: 265
3 20 TRANSFER PUMP FOR HYDRAULIC OIL 266
3 20 1 OPERATING THE TRANSFER PUMP 267
3 20 2 FUNCTIONS OF THE TRANSFER PUMP 269
3 21 CENTRAL REFILLING SYSTEM 272
3 21 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 273
3 21 1 1 Operation of the service arm 273
3 21 2 OPERATING THE HYDRAULIC SERVICE ARM 275
3 21 3 RECEIVER PANEL AND MONITOR BOX 277
3 21 3 1 Refilling Procedure: 277
3 22 CABLE GUIDE (IF SO EQUIPPED) 279
3 22 1 LIFTING DEVICE FOR THE POWER CABLE 279
3 23 SERVICE CRANE (SPECIAL EQUIPMENT) 280
3 23 1 OPERATING THE CRANE 281
3 24 WORK ON THE LOADER ATTACHMENT 284
3 24 1 OBSERVE THE FOLLOWING INSTRUCTIONS 284
3 25 TRANSPORTATION AND LIFTING OF THE SHOVEL 285
3 25 1 DISASSEMBLING OF THE SHOVEL 285
3 25 2 TRANSPORTATION AND LIFTING 285
3 26 RETRIEVAL PROCEDURE 286
3 26 0 1 GENERAL 286
3 27 SHOVEL STORAGE 287
3 27 1 PREPARING FOR STORAGE 287
3 27 2 ONE MONTH REPETITIVE SERVICE PERIOD 287
3 27 3 SIX MONTH REPETITIVE SERVICE PERIOD 287
3 27 4 PREPARING FOR OPERATION 288
3 28 TROUBLE SHOOTING 289
3 28 1 MAIN DRIVE ELECTRIC MOTOR 289
3 28 2 HYDRAULIC SYSTEM 290
3 28 3 FINAL DRIVES AND SWING GEAR 291
3 28 4 CRAWLER TRACKS 291
4 MAINTENANCE 293
4 1 FOREWORD 294
4 1 1 DEFINITIONS 294
4 1 2 GENERAL RECOMMENDATIONS 294
4 2 SAFETY PRECAUTIONS FOR MAINTENANCE 295
4 3 FLUIDS AND LUBRICANTS 298
4 3 1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 298
4 3 1 1 Grease for the bearings of the main drive Electric Motors 298
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 299
4 3 3 MAIN DRIVE ELECTRIC MOTORS – BEARING LUBRICATION 300
4 4 FILLING CAPACITIES 301
4 5 STANDARD TORQUE LIST 302
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 303
4 6 1 INITIAL SERVICING 303
4 6 1 1 AFTER THE FIRST 250 OPERATING HOURS 303
4 6 1 2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS 303
4 6 2 PERIODIC SERVICING INTERVALS 303
4 6 3 PERIODIC SERVICING SCHEDULE 304
4 6 3 1 WHEN NECESSARY 304
4 6 3 2 EVERY 10 OPERATING HOURS OR DAILY 304
4 6 3 3 EVERY 50 OPERATING HOURS OR WEEKLY 304
4 6 3 4 EVERY 250 OPERATING HOURS OR MONTHLY 304
4 6 3 5 EVERY 500 OPERATING HOURS OR QUATERLY 305
4 6 3 6 EVERY 1000 OPERATING HOURS OR 6 MONTHLY 305
4 6 3 7 EVERY 2000 OPEARTING HOURS OR YEARLY 306
4 6 3 8 EVERY 3000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 306
4 6 4 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM 307
4 6 5 MAINTENANCE OF THE MAIN DRIVE MOTORS 307
4 6 5 1 Lubrication Chart 309
4 7 SAFETY CRITICAL PARTS 310
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 310
4 7 2 INSPECTION OF HOSE LINES 310
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 310
4 8 WHEN NECESSARY 312
4 8 1 SWING CIRCLE TOOTHING LUBRICATION 313
4 8 2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 315
4 8 3 Service the Grease Filters for Refillable Grease Containers of the Central Lubrication System and Swing circle pinion Lubrication System, 317
4 8 4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS 319
4 9 EVERY 10 OPERATING HOURS OR DAILY 320
4 9 1 WALK – AROUND INSPECTION 321
4 9 1 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 325
4 9 1 2 BOOM – CHECK LADDER AND WALKWAY 327
4 9 1 3 CHECK GREASE INJECTORS 329
4 9 1 4 CORRECTIVE ACTIONS 329
4 9 1 5 SWING CIRCLE – CHECK GREASE INJECTORS 331
4 9 2 TRACK GROUPS – CLEAN 333
4 10 EVERY 50 OPERATING HOURS OR WEEKLY 334
4 10 1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 335
4 10 1 1 Swing Gear manufactured by “L&S” 335
4 10 1 2 CHECK SWING GEAR OIL LEVEL 335
4 10 1 3 CHECK MOTOR ADAPTER HOUSING OIL LEVEL 335
4 10 1 4 Swing gears manufactured by -SIEBENHAAR- 337
4 10 2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS 339
4 10 2 1 TRAVEL GEAR BOX – CHECK OIL LEVEL 341
4 10 2 2 MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL 341
4 10 2 3 FINAL DRIVE HOUSING – CHECK OIL LEVEL 341
4 10 2 4 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES – CHECK BREATHER FILTERS 343
4 10 3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL 345
4 10 3 1 PUMP DISTRIBUTOR GEARS, CHECK OIL LEVEL: 345
4 10 3 2 OIL COLLECTOR RESERVOIR – CHECK OIL LEVEL 347
4 10 3 3 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings 347
4 10 4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 349
4 10 5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 351
4 10 6 CLEANING THE DISTRIBUTOR GEAR COOLERS 351
4 11 EVERY 250 OPERATING HOURS OR MONTHLY 352
4 11 1 SIGNAL HORN COMPRESSOR – LUBRICATE 353
4 11 2 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 353
4 11 3 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSION ONLY) 353
4 11 4 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER 355
4 11 5 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 357
4 11 5 1 Clean and inspect filter element (2) as follows: 357
4 11 6 AIR CONDITIONING FOR OPERATOR’S CAB AND SWITCH CABINETS 359
4 11 6 1 Air conditioning for Operator’s Cab 359
4 11 6 2 Air Conditioning for medium and high Voltage Switch Cabinets 361
4 11 7 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 363
4 12 EVERY 500 OPERATING HOURS OR QUARTERLY 364
4 12 1 BATTERIES – CHECK FLUID LEVEL 365
4 12 2 CRAWLER TRACK – INSPECTION 367
4 12 2 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 367
4 12 2 2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 369
4 12 2 3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 371
4 12 2 4 Bleeding the System 371
4 12 3 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 373
4 13 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 374
4 13 1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD 375
4 14 HYDRAULIC SYSTEM – FILTER SERVICE 431
4 14 0 1 FILTER SERVICE 433
4 14 1 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 445
4 14 1 1 Oil drain plugs 445
4 14 1 2 PTO (PUMP DISTRIBUTOR GEAR) 445
4 14 1 3 SWING GEARS AND TRAVEL GEARS 445
4 14 2 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 447
4 14 3 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 449
4 14 4 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 451
4 14 5 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 453
4 14 6 SLIP RING UNIT – LUBRICATE 455
4 15 EVERY 2000 OPERATING HOURS OR YEARLY 456
4 15 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 457
4 15 1 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 459
4 15 1 2 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 461
4 15 1 3 Replace Suction Strainers of Main Pumps 465
4 15 2 FILLING THE HYDRAULIC SYSTEM 467
4 15 3 BLEEDING THE HYDRAULIC SYSTEM 469
4 15 4 GEAR PUMPS FOR PTO GEAR LUBRICATION 471
4 15 5 EMERGENCY ESCAPE LADDER – INSPECTION 473
4 16 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 474
4 16 1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 475
4 16 1 1 Motor Adapter Housing, Change Oil: 477
4 16 1 2 SWING GEAR MANUFACTURED BY “SIEBENHAAR” 479
4 16 1 3 Brake Housing – Change Oil (Siebenhaar) 481
4 16 2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL 483
4 16 2 1 TRAVEL GEARS – CHANGE OIL 485
4 16 2 2 MOTOR ADAPTER HOUSINGS – CHANGE OIL 485
4 16 2 3 FINAL DRIVE HOUSINGS – CHANGE OIL 485
4 16 3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 487
4 16 3 1 Change the Oil 489
4 17 FIRE PREVENTION 490
4 17 1 PRECAUTIONS 491
4 18 WELD REPAIRS 492
4 18 1 GENERAL INFORMATION 492
4 18 1 1 GENERAL PROTECTIVE MEASURES 493
4 18 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 493
4 18 2 1 COUNTERWEIGHT 493
4 18 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 495
4 18 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 497
4 18 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 499
4 18 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 499
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