KOMATSU PC7000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 35005 – PDF DOWNLOAD
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KOMATSU PC7000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 35005 – 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 PC7000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 35005 – PDF DOWNLOAD
1 FOREWORD 9
1 1 BEFORE READING THIS MANUAL 10
1 2 EC DECLARATION OF CONFORMITY 11
1 3 DIRECTIONS OF THE MACHINE 12
1 4 SPECIFICATION AND SERIAL PLATE 13
1 4 1 PRODUCT IDENTIFICATION NUMBER 13
1 5 DIVISION OF THE BINDER 14
1 6 DESIGNATED USE OF THE SHOVEL 15
1 7 DELIVERY OF THE SHOVEL 16
1 7 1 SPARE PARTS 16
1 7 2 SERVICE 16
1 8 EXPLANATION OF ABBREVIATIONS 17
1 SAFETY 19
1 1 SAFETY INFORMATION 20
1 2 OVERVIEW 21
1 2 1 NORMAL OPERATIONS 21
1 2 2 REGULAR MAINTENANCE 21
1 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 21
1 2 4 ADDITIONAL SAFETY PRECAUTIONS 21
1 3 SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATOR’S CAB 22
1 3 1 SOUND 22
1 3 2 VIBRATION 22
1 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 23
1 4 1 UNDERSTANDING THE MACHINE 23
1 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 23
1 4 2 1 ENSURING SAFE OPERATION 23
1 4 3 PREPARATIONS FOR SAFE OPERATION 23
1 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 23
1 4 3 2 INSPECTING THE MACHINE 23
1 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 24
1 4 3 4 KEEP MACHINE CLEAN 24
1 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 24
1 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 25
1 4 3 7 IF A PROBLEM IS FOUND 25
1 4 4 FIRE PREVENTION 25
1 4 4 1 PRECAUTIONS TO PREVENT FIRE 25
1 4 4 2 ACTION IF FIRE OCCURS 27
1 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 27
1 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 28
1 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 28
1 4 5 2 NO JUMPING ON OR OFF THE MACHINE 28
1 4 5 3 NO PEOPLE ON THE ATTACHMENT 28
1 4 5 4 WORKING IN HIGH PLACES 28
1 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 29
1 4 5 6 LEAVING THE MACHINE 29
1 4 6 BURN PREVENTION 29
1 4 6 1 Hot coolant 29
1 4 6 2 Hot oil 30
1 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 30
1 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 30
1 4 8 1 UNAUTHORIZED MODIFICATION 31
1 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 31
1 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 31
1 4 10 PRECAUTIONS AT JOBSITE 32
1 4 10 1 VISIBILITY FROM OPERATOR’S SEAT 33
1 4 10 2 CAMERA SYSTEM WITH MONITORS 33
1 4 10 3 ENSURE GOOD VISIBILITY 33
1 4 10 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 33
1 4 10 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 34
1 4 10 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 34
1 4 10 7 WORKING ON LOOSE GROUND 35
1 4 10 8 GAS, DUST, STEAM AND SMOKE 35
1 4 10 9 VENTILATION OF ENCLOSED AREAS 36
1 4 11 STARTING motor 37
1 4 11 1 WARNING TAG 37
1 4 11 2 CHECKS BEFORE STARTING motor 37
1 4 11 3 PRECAUTION WHEN STARTING motor 37
1 4 11 4 PRECAUTION IN COLD AREAS 38
1 4 12 OPERATION 38
1 4 12 1 CHECKS BEFORE OPERATION 38
1 4 12 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 39
1 4 12 3 PRECAUTIONS WHEN travelling 40
1 4 12 4 TRAVELLING ON SLOPES 41
1 4 12 5 OPERATIONS ON SLOPES 42
1 4 12 6 PROHIBITED OPERATIONS 42
1 4 12 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 43
1 4 12 8 PARKING THE MACHINE 43
1 4 12 9 TRANSPORTATION 43
1 5 PRECAUTION FOR MAINTENANCE 44
1 5 1 GENERAL PRECAUTIONS 44
1 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 45
1 5 1 2 STOP motor FOR MAINTENANCE 46
1 5 1 3 WARNING TAG 47
1 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 48
1 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 48
1 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 49
1 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 49
1 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 50
1 5 1 9 NOISE 50
1 5 1 10 WHEN USING A HAMMER 50
1 5 1 11 PROPER TOOLS 51
1 5 1 12 ACCUMULATOR 51
1 5 1 13 PERSONNEL 51
1 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 52
1 5 2 1 PRECAUTION WHEN WELDING 52
1 5 2 2 BATTERY HANDLING 52
1 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 53
1 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 53
1 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 54
1 5 3 3 REPLACEMENT OF HOSE LINES 54
1 5 3 4 INSPECTION OF HOSE LINES 54
1 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 55
1 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 55
1 5 3 7 AIR CONDITIONING MAINTENANCE 55
1 5 3 8 COMPRESSED AIR 56
1 5 3 9 WASTE MATERIALS 56
1 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 57
1 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 57
1 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 57
1 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 57
1 7 SPECIAL SAFETY EQUIPMENT 58
1 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 59
1 7 2 OBJECT HANDLING 59
1 7 3 LIGHTING 59
1 7 4 WARNING BEACON 59
1 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 59
1 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 59
1 7 5 2 INSTRUCTIONS FOR USE 61
1 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 63
1 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 63
1 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 UNDERCARRIAGE AND SUPERSTRUCTURE 88
3 2 2 1 SUPERSTRUCTURE 90
3 2 2 2 MACHINERY HOUSE 92
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 94
3 2 3 1 Lowering the ladder in emergency situations 97
3 2 4 EMERGENCY ESCAPE LADDERS 98
3 2 4 1 Emergency escape from the operator’s cabin 99
3 2 4 2 Emergency escape from the Machinery house 101
3 2 4 3 Emergency escape from the machinery house roof 103
3 2 4 4 ESCAPE LADDER WINCH ASSEMBLY 105
3 2 5 BOOM ACCESS LADDER AND WALKWAY 106
3 2 6 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 108
3 2 6 1 Engine Shutdown System actuated from Ground Man (Special Equipment) 109
3 2 6 2 Operator Warning System (Special Equipment) 109
3 2 7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 110
3 2 7 1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual 115
3 2 7 2 Operator’s Seat Adjustment 117
3 2 7 3 Co-driver’s Seat and Refrigerator Box 118
3 2 7 4 INSTRUCTIONS TO using and looking after THE SEAT BELTS 119
3 2 8 ENGINE OIL MANAGEMENT SYSTEM 120
3 2 8 1 Oil Burning System “Centinel” combined with Oil Supply System “Reserve” 123
3 2 8 2 Eliminator Engine Oil Filtration System 124
3 3 OPERATOR’S CAB – CONTROLS 126
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 126
3 3 1 1 Hydraulic Control System 127
3 3 1 2 Safety Circuit for Controls 127
3 3 1 3 Control Pattern 129
3 3 2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 130
3 3 2 1 Hydraulic Control System 131
3 3 2 2 Safety Circuit for Controls 131
3 3 2 3 Control Pattern 133
3 3 2 4 Automatic Float Position for Boom and Stick 133
3 3 3 OPERATOR’S CONSOLE 135
3 3 3 1 Control Panel 137
3 3 3 2 Switch Board 139
3 3 4 INTERFACE PANEL FOR DIAGNOSTICS 141
3 4 VEHICLE HEALTH MONITORING SYSTEM (Komtrax Plus)– HEALTH MONITOR 142
3 4 1 SEQUENCE OF DISPLAYS 143
3 4 2 OPENING SCREEN 143
3 4 3 MAIN GAUGE SCREENS 1 TO 4 144
3 4 3 1 Main Gauge Screen 1 145
3 4 3 2 Main Gauge Screen 2 147
3 4 3 3 Main Gauge Screen 3 147
3 4 3 4 Main Gauge Screen 4 149
3 4 3 5 Color Definition 149
3 4 4 FUEL CONSUMPTION SCREEN 151
3 4 5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR 151
3 4 6 MAIN SCREEN – CHANGE >TIME >SMR >DATE 152
3 4 7 MAINTENANCE MONITOR 152
3 4 7 1 Maintenance confirmation through Service Personnel 153
3 4 8 SETTINGS FOR OPERATOR 153
3 4 9 AUTOMATIC MESSAGES 158
3 4 9 1 Automatic Messages 158
3 4 9 2 Automatic Messages 160
Automatic Engine Messages 161
3 5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 162
3 5 1 Digital Display 162
3 5 2 Luminous Indication 164
3 6 CAMERA SYSTEM WITH MONITORS 166
3 6 1 LOCATION OF MONITORS AND CONTROL UNITS 167
3 6 1 1 Operating the Monitors 169
3 6 1 2 Ajustments of the Monitor 169
3 6 1 3 Arrangement of the Cameras 173
3 7 MACHINERY HOUSE 174
3 7 1 EMERGENCY ENGINE SHUTDOWN SWITCHES 175
3 7 2 SAFETY SWITCH FOR MAINTENANCE 177
3 7 3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT 179
3 8 ELECTRICAL EQUIPMENT IN CAB BASE 180
3 8 1 COMPONENTS IN CAB BASE 181
3 8 2 MASTER TURBO CONTROLLER MTC – LED INDICATIONS 183
3 8 3 BINARY FAULT CODE LIST 190
Combination Message 308 Trouble Can-Bus or Can Hardware 192
3 8 4 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS 192
3 9 CHECKS BEFORE STARTING THE ENGINES 194
3 9 1 Coolant Level 197
3 9 1 1 HYDRAULIC SYSTEM – CHECK OIL LEVEL 199
3 9 1 2 Machinery House Doors 199
3 9 1 3 OPERATOR’S SEAT ADJUSTMENT 199
3 10 STARTING THE ENGINES 200
3 10 1 STARTING PROCEDURE 203
3 10 1 1 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C 205
3 10 2 ENGINE WARM-UP 211
3 10 3 HYDRAULIC OIL WARM-UP 211
3 11 MOVING THE SHOVEL 213
3 11 1 TRAVEL CONTROL WITH FOOT PEDALS 213
3 11 1 1 TRAVEL ALARM / BACK-UP ALARM 215
3 11 2 TRAVELLING INSTRUCTIONS 215
3 11 2 1 TRAVELLING LONG DISTANCES 217
3 12 SLEWING AND BRAKING THE SUPERSTRUCTURE 218
3 12 1 SLEWING THE SUPERSTRUCTURE 218
3 12 1 1 MACHINES WITH “EURO” CONTROL 218
3 12 1 2 MACHINES WITH “” CONTROL 219
3 12 1 3 BRAKING THE SUPERSTRUCTURE 219
3 12 1 4 Hydraulic slew brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System 220
3 12 1 5 Important Instructions for Slewing the Superstructure 220
3 13 WORKING WITH THE ATTACHMENT 221
3 13 0 1 FACE SHOVEL BUCKET 222
3 13 1 COMBINED OPERATION CYCLES 223
3 14 WORKING INSTRUCTIONS 225
3 14 1 STABILITY OF THE SHOVEL 225
3 14 2 FURTHER OPERATING PRACTICES 227
3 14 3 Loading Trucks 231
3 15 PARKING THE SHOVEL 232
3 15 0 1 CLEANING THE TRACK GROUPS 232
3 16 STOPPING THE ENGINES 233
3 16 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 236
3 17 OPERATION OF THE LUBRICATION SYSTEM 237
3 17 1 CENTRAL LUBRICATION SYSTEM ”CLS” 237
3 17 1 1 Manual actuation of the central lubrication system 237
3 17 1 2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 238
3 17 2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 238
3 17 2 1 Manual actuation of the swing circle lubrication system 239
3 17 2 2 SWING CIRCLE LUBRICATION SYSTEM ”SLS” 240
3 17 2 3 ADJUSTMENTS OF THE SWING CIRCLE LUBRICATION SYSTEM 240
3 17 2 4 Defining the Lubrication System Greasing Areas 240
3 18 TRANSFER PUMP FOR HYDRAULIC OIL 241
3 18 1 OPERATING THE TRANSFER PUMP 242
3 18 2 TRANSFUSION PROCEDURE 244
3 19 CENTRAL REFILLING SYSTEM 247
3 19 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 248
3 19 2 OPERATING THE HYDRAULIC SERVICE ARM 250
3 19 3 RECEIVER PANEL WITH MONITOR BOX 252
3 19 3 1 Refilling Procedure: 256
3 19 4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS 258
3 20 WORK ON THE LOADER ATTACHMENT 259
3 20 0 1 OBSERVE THE FOLLOWING INSTRUCTIONS 259
3 21 TRANSPORTATION AND LIFTING OF THE SHOVEL 260
3 21 1 DISASSEMBLING OF THE SHOVEL 260
3 21 2 TRANSPORTATION AND LIFTING 260
3 22 RETRIEVAL PROCEDURE 261
3 22 1 GENERAL 261
3 23 SHOVEL STORAGE 262
3 23 1 GENERAL 262
3 23 2 PREPARING FOR STORAGE 262
3 23 3 ONE MONTH REPETITIVE SERVICE PERIOD 262
3 23 4 SIX MONTH REPETITIVE SERVICE PERIOD 262
3 23 5 PREPARING FOR OPERATION 263
3 24 TROUBLE SHOOTING 264
3 24 1 GENERAL 264
3 24 2 ENGINE 264
3 24 3 HYDRAULIC SYSTEM 265
3 24 4 FINAL DRIVES AND SWING GEAR 266
3 24 5 CRAWLER TRACKS 266
4 MAINTENANCE 267
4 1 FOREWORD 268
4 1 1 DEFINITIONS 268
4 1 2 GENERAL RECOMMENDATIONS 268
4 2 PRECAUTIONS FOR MAINTENANCE 269
4 3 FLUIDS AND LUBRICANTS 270
4 3 1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 270
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 271
4 3 2 1 Recommended Hydraulic Oils 272
4 3 2 2 General Information to selecting hydraulic oils 273
4 4 FILLING CAPACITIES 275
4 5 STANDARD TORQUE LIST 276
4 5 1 Torque for Flange Joints 277
4 5 2 TORQUES FOR SPECIAL COMPONENTS 278
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 280
4 6 1 INITIAL AND FIRST SERVICING 280
4 6 1 1 INITIAL RUNNING-IN 280
4 6 1 2 AFTER THE FIRST 250 OPERATING HOURS 280
4 6 1 3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT 280
4 6 2 SERVICING THE CRITICAL BOLT CONNECTIONS 281
4 6 3 PERIODIC SERVICING INTERVALS 281
4 6 3 1 WHEN NECESSARY 282
4 6 3 2 EVERY 10 OPERATING HOURS OR DAILY 282
4 6 3 3 EVERY 50 OPERATING HOURS OR WEEKLY 282
4 6 3 4 EVERY 250 OPERATING HOURS OR MONTHLY 283
4 6 3 5 EVERY 500 OPERATING HOURS OR QUATERLY 283
4 6 3 6 EVERY 1000 OPERATING HOURS OR 6 MONTHLY 284
4 6 3 7 EVERY 2000 OPERATING HOURS OR YEARLY 284
4 6 3 8 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 285
4 6 3 9 EVERY 6000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 285
4 6 4 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS 286
4 7 SAFETY CRITICAL PARTS 287
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 287
4 7 2 INSPECTION OF HOSE LINES 288
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 288
4 8 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM 291
4 8 0 1 Servicing Intervals 291
4 8 0 2 Extended Service Intervals for Engines with Engine Oil Management System 295
4 8 1 MAINTENANCE OF THE ENGINES 295
4 8 2 ENGINE FUEL FILTER LOCATIONS 297
4 8 2 1 Cleaning Practices Before Working on the Fuel System 299
4 8 3 VENTING THE AIR FROM THE FUEL FILTERS 301
4 9 FIRST SERVICING 302
4 9 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 302
4 9 2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 303
4 9 3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 304
4 9 4 SWING CIRCLE Pinion – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 305
4 9 5 Swing circle – Check Torque OF BOLT CONNECTIONS 306
4 9 6 Retightening procedure of the crawler carrier mounting bolts 307
4 9 6 1 Procedure for ENSURING Proper Tightening OF the crawler carrier mounting bolts 308
4 9 6 2 Special hydraulic torque wrench 309
4 10 WHEN NECESSARY 310
4 10 1 ENGINE AIR CLEANER MAINTENANCE 311
4 10 1 1 Check the Dust Cup 311
4 10 1 2 Servicing the filter elements 313
4 10 1 3 Replacing the safety filter element (4) if necessary: 313
4 10 1 4 General Service Tips 313
4 10 2 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 315
4 10 3 SWING CIRCLE TOOTHING LUBRICATION 317
4 10 4 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 319
4 10 4 1 Service the Grease Filters for Refillable Grease Containers 321
4 10 5 GUIDE WHEELS – REPLACE FLOATING SEALS 321
4 11 EVERY 10 OPERATING HOURS OR DAILY 322
4 11 1 WALK – AROUND INSPECTION 323
4 11 2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL Check 327
4 11 3 RADIATORS – CHECK COOLANT LEVEL 329
4 11 4 TRACK GROUPS – CLEAN 329
4 11 4 1 BOOM – CHECK LADDER AND WALKWAY 331
4 11 5 CAMERA SYSTEM 333
4 11 6 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 335
4 12 EVERY 50 OPERATING HOURS OR WEEKLY 336
4 12 0 1 Swing gears 337
4 12 1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS 339
4 12 1 1 TRAVEL GEAR BOX – CHECK OIL LEVEL 341
4 12 1 2 MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL 341
4 12 1 3 FINAL DRIVE HOUSING – CHECK OIL LEVEL 341
4 12 1 4 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES – CHECK BREATHER FILTERS 343
4 12 2 PTOs (PUMP DISTRIBUTOR GEARS) – CHECK OIL LEVEL 345
4 12 2 1 PTOs (PUMP DISTRIBUTOR GEARS), CHECK OIL LEVEL: 345
4 12 2 2 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings 347
4 12 2 3 Auxilliary drive- Check Oil Level in Drive Shaft Housings 347
4 12 3 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 349
4 12 4 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 351
4 13 EVERY 250 OPERATING HOURS OR MONTHLY 352
4 13 1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 353
4 13 2 SIGNAL HORN COMPRESSOR – LUBRICATE 355
4 13 3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 355
4 13 4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 355
4 13 5 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION 357
4 13 6 CABIN AIR CLEANER – INSPECT 359
4 13 7 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 361
4 13 8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 363
4 13 9 CABIN HEATER FILTER – INSPECT 365
4 14 EVERY 500 OPERATING HOURS OR QUARTERLY 366
4 14 1 BATTERIES – CHECK FLUID LEVEL 367
4 14 1 1 GREASE INJECTORS – CHECK INDICATOR STEMS 368
4 14 1 2 CORRECTIVE ACTIONS 368
4 14 2 CYLINDER ROD PROTECTION (IF EQUIPPED), Inspect 371
4 14 3 FUEL TANK 373
4 14 3 1 Drain Water and Sediments from Fuel Tank 373
4 14 3 2 Servicing the Fuel System 373
4 14 4 CRAWLER TRACK – INSPECTION 375
4 14 4 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 375
4 14 4 2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 377
4 14 4 3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 379
4 14 4 4 Bleeding the System 379
4 14 5 GROUND CABLES OF ENGINE AND ALTERNATOR – CHECK FOR CORRECT CONNECTION 381
4 14 6 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 383
4 14 7 EMERGENCY ESCAPE LADDERS 385
4 14 7 1 TEST FUNCTIONALITY 385
4 14 7 2 Lubricating 385
4 14 8 EMERGENCY LOWERING OF ACCESS LADDER – TEST FUNCTIONALITY 387
4 15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 388
4 15 1 Critical Bolt Connections 389
4 15 1 1 Check mounting of Operator’s cab 389
4 15 1 2 Check tightening torque of the counterweight mounting bolts, 391
4 15 1 3 Check condition and fastening of both swing gears (01) and swing motors (02) 393
4 15 2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 395
4 15 2 1 TEST MAINTENANCE SAFETY SWITCH (11) 397
4 15 3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY 397
4 15 4 ELECTRICAL EQUIPMENT – MAINTENANCE 399
4 15 5 CABIN AIR CLEANER – REPLACE PRIMARY FILTER 401
4 15 6 HYDRAULIC SYSTEM – FILTER SERVICE 403
4 15 6 1 FILTER SERVICE 405
4 15 7 BLEEDING AIR FROM THE RETURN OIL CHAMBERS 407
4 15 8 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 419
4 15 8 1 Oil drain plugs 419
4 15 9 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 421
4 15 10 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 423
4 15 11 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 425
4 15 12 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 427
4 16 EVERY 2000 OPERATING HOURS OR YEARLY 428
4 16 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 429
4 16 1 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 431
4 16 1 2 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 433
4 16 1 3 Replace Suction Strainers of Main Pumps 437
4 16 2 FILLING THE HYDRAULIC SYSTEM 439
4 16 3 BLEEDING THE HYDRAULIC SYSTEM 441
4 16 4 EMERGENCY ESCAPE LADDERS – INSPECTION 445
4 16 5 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 447
4 16 6 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 449
4 16 6 1 Functionality 449
4 17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 450
4 17 0 1 SWING GEAR 451
4 17 1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL 455
4 17 2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 459
4 17 3 FLEXIBLE COUPLING – VISUAL CHECK 461
4 18 CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS 462
4 18 1 Critical BOLT CONNECTIONS – CHECK TORQUE LOAD 463
4 18 1 1 Hydraulic Access Ladder 465
4 18 1 2 Check fastening and condition of railings (A, B, C, D and E) 467
4 18 1 3 Check fastening and condition of cab base 469
4 18 1 4 Check fastening and condition of fuel tank 471
4 18 1 5 Check fastening and condition of hydraulic oil cooler 473
4 18 1 6 Check fastening and condition of hydraulic oil tank 475
4 18 1 7 Check fastening of power house frame (01) to superstructure main frame 477
4 18 1 8 Check fastening and condition of the eight power house posts 479
4 18 1 9 Power House Louvers 481
4 18 1 10 Power house Roof 483
4 18 1 11 Check mounting and security of Diesel engines and pump distributor gears 485
4 18 1 12 Check mounting and security of each Diesel engine and pump distributor gear 487
4 18 1 13 Main Hydraulic pumps 489
4 18 1 14 Check fastening and condition of control valve carrier, main control valves (I, II and III) and swing control valve (5) 491
4 18 1 15 Check condition and fastening of swivel joint (A) 493
4 18 1 16 Crawler Carrier 495
4 18 1 17 Check condition and fastening of railings (01/02) and of steps (03, 04, 05 and 23) 499
4 18 1 18 Roof-mounted crane for grease barrel replacement (special equipment) Check condition and fastening of the crane 501
4 19 EVERY 6000 HOURS HOWEVER AT LEAST ONCE A YEAR 502
4 19 1 AUTOMATIC LUBRICATION SYSTEMS – replace pump outlet GREASE FILTERS 503
4 19 2 HYDRAULIC Oil TANK – CHECK LEAKAGE OIL SCREEN FILTER 505
4 19 3 CHANGING THE HIGH PRESSURE FILTERS 507
4 20 FIRE PREVENTION 508
4 20 1 PRECAUTIONS 509
4 21 WELD REPAIRS 510
4 21 1 GENERAL INFORMATION 510
4 21 1 1 GENERAL PROTECTIVE MEASURES 511
4 21 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 511
4 21 2 1 COUNTERWEIGHT 511
4 21 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 513
4 21 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 515
4 21 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 517
4 21 5 1 Electrical Units in Cab Base, 519
4 21 5 2 Engine Electronics 519
4 21 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 519
VIDEO PREVIEW OF THE MANUAL:
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