KOMATSU PC8000-11 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL 12117 – PDF DOWNLOAD
DESCRIPTION:
KOMATSU PC8000-11 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL 12117 – 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 PC8000-11 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL 12117 – 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
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
3 OPERATION 95
3 1 FOREWORD 96
3 1 0 1 Connection of electrical installations by the Customer to the excavator 96
3 2 CONSTRUCTION OF THE EXCAVATOR 97
3 2 1 OVERALL VIEW 97
3 2 2 UNDERCARRIAGE AND SUPERSTRUCTURE 98
3 2 2 1 SUPERSTRUCTURE – TOP VIEW 103
3 2 3 UNDERCARRIAGE TRACK SLIDERS 104
3 2 3 1 MACHINERY HOUSE 107
3 2 3 2 Eliminator Engine Oil Filtration System 108
3 2 4 HYDRAULICALLY OPERATED ACCESS/INGRESS STAIRWAY 110
3 2 4 1 Lowering the Stairway in emergency situations 113
3 2 5 EMERGENCY ESCAPE Ladders 114
3 2 5 1 EMERGENCY ESCAPE FROM THE OPERATOR’S CABIN 115
3 2 5 2 Emergency escape from the Machinery house, engine area 117
3 2 5 3 Emergency escape from the Machinery house, Pump area 119
3 2 5 4 EMERGENCY ESCAPE FROM THE ROOF 120
3 2 5 5 ESCAPE LADDER WINCH ASSEMBLY 123
3 2 6 FOLDING LADDER INSIDE OF CARBODY 124
3 2 7 BOOM ACCESS LADDER AND WALKWAY 126
3 2 7 1 Engine Shutdown System actuated from MAN ON Ground (OPTIONAL) 129
3 2 7 2 Operator Warning System (OPTIONAL) 129
3 2 8 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 130
3 2 8 1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual 135
3 2 8 2 Operator’s Seat Adjustment 137
3 2 8 3 Co-driver’s Seat and Refrigerator Box 138
3 2 8 4 INSTRUCTIONS TO using and looking after THE SEAT BELTS 139
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 Switch Board 151
3 3 4 INTERFACE PANEL FOR DIAGNOSTICS 157
3 3 5 CONTROL MODULE FOR AUXILIARY CAB HEATER 159
3 4 KOMTRAX (MACHINE) MONITOR 160
3 4 1 SEQUENCE OF DISPLAYS 161
3 4 2 OPENING SCREEN 161
3 4 3 MAIN gage SCREENS 1-4 162
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 170
3 4 8 SETTINGS FOR OPERATOR 171
3 4 8 1 Settings Screens 172
3 4 9 SERVICE MENU 175
3 4 10 AUTOMATIC MESSAGES 175
3 4 10 1 Automatic Messages 176
3 4 10 2 Automatic ENGINE Messages 179
3 5 MODULE TO MONITOR DIESEL EXHAUST FLUID/ CATALYTIC REDUCTION (DEF/SCR) 180
3 5 1 LOCATION ON OPERATOR’S CONSOLE 180
3 5 2 DISPLAY ON OPERATOR’S CONSOLE 181
3 5 2 1 Engine After-treatment 181
3 6 CAMERA SYSTEM KOMVISION 182
3 6 0 1 The names, locations and views of the cameras 185
3 7 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 186
3 7 1 DIGITAL DISPLAY 186
3 7 2 LUMINOUS INDICATION 188
3 7 3 AUXILIARY HEATER FOR OPERATOR’S CAB 191
3 8 MACHINERY HOUSE 192
3 8 1 EMERGENCY ENGINE STOP SWITCHES 193
3 8 2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE 195
3 8 3 CENTRAL CONTROL AND FILTER PANEL 197
3 8 4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO 199
3 9 ELECTRICAL EQUIPMENT IN CAB BASE 200
3 9 1 STANDARD COMPONENTS IN CAB BASE 201
3 9 2 Preheating System (WHEN EQUIPPED) 203
3 10 CHECKS BEFORE STARTING THE ENGINES 206
3 10 1 HYDRAULIC SYSTEM – CHECK OIL LEVEL 211
3 10 1 1 Machinery House Doors 211
3 10 1 2 OPERATOR’S SEAT ADJUSTMENT 211
3 11 STARTING THE ENGINES 212
3 11 1 STARTING PROCEDURE 215
3 11 2 COLD WEATHER STARTING AID 215
3 11 3 ENGINE WARMUP LOCK ON LOW IDLE 217
3 11 3 1 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C 217
3 11 4 HYDRAULIC OIL WARM-UP 223
3 11 4 1 Hydraulic Oil Viscosity and Temperature Chart 224
3 12 MOVING THE EXCAVATOR 225
3 12 1 TRAVEL CONTROL WITH FOOT PEDALS 225
3 12 1 1 TRAVEL ALARM / BACK-UP ALARM (Special equipment) 227
3 12 2 traveling INSTRUCTIONS 227
3 12 2 1 traveling LONG DISTANCES 229
3 12 3 UNDERCARRIAGE TRACK SLIDERS 230
3 13 SLEWING AND BRAKING THE SUPERSTRUCTURE 232
3 13 1 SLEWING THE SUPERSTRUCTURE 232
3 13 1 1 STANDARD CONTROL PATTERN 232
3 13 1 2 BRAKING THE SUPERSTRUCTURE 233
3 13 1 3 Hydraulic slew brake actuated by hydraulic access/INGRESS STAIRWAY and Service Arm of service center 233
3 13 1 4 Important Instructions for Slewing the Superstructure 234
3 14 WORKING WITH THE ATTACHMENT 235
3 14 0 1 FRONT shovel BUCKET 236
3 14 1 COMBINED OPERATION CYCLES 237
3 15 WORKING INSTRUCTIONS 239
3 15 1 STABILITY OF THE excavator 239
3 15 2 FURTHER OPERATING PRACTICES 241
3 15 3 Loading Trucks 245
3 16 PARKING THE EXCAVATOR 246
3 16 0 1 CLEANING THE TRACK GROUPS 246
3 17 STOPPING THE ENGINES 248
3 17 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 251
3 18 OPERATION OF THE LUBRICATION SYSTEM 252
3 18 1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE 252
3 18 1 1 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 253
3 18 2 slew CIRCLE PINION LUBRICATION SYSTEM ”SLS” 254
3 18 2 1 slew CIRCLE LUBRICATION SYSTEM ”SLS” 254
3 18 2 2 ADJUSTMENTS OF THE slew CIRCLELUBRICATION SYSTEM 255
3 18 2 3 Defining the Lubrication System Greasing Areas 255
3 19 TRANSFER PUMP FOR HYDRAULIC OIL 256
3 19 1 OPERATING THE TRANSFER PUMP 257
3 19 2 TRANSFUSION PROCEDURE 259
3 20 sERVICE CENTER 262
3 20 1 SYSTEMS CONNECTED TO THE SERVICE CENTER 263
3 20 1 1 Operation of the hydraulic Service Arm 263
3 20 2 OPERATING THE HYDRAULIC SERVICE ARM 265
3 20 3 SERVICE CENTER WITH MONITOR BOX 267
3 20 3 1 Refilling Procedure: 269
3 20 3 2 DRAINING PRODURE FOR DEF HOSES 271
3 20 4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOUSE ROOF 273
3 21 FIRE DETECTION AND SUPPRESSION SYSTEM 274
3 21 0 1 FIRE DETECTION AND SUPPRESSION SYSTEMS 275
3 21 1 DISPLAY MODULE 279
3 21 2 INTERFACE CONTROL MODULE 281
3 21 3 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF 283
3 22 WORK ON THE LOADER ATTACHMENT 284
3 22 1 OBSERVE THE FOLLOWING INSTRUCTIONS 284
3 23 TRANSPORTATION AND LIFTING OF THE EXCAVATOR 285
3 23 1 DISASSEMBLING OF THE EXCAVATOR 285
3 23 2 TRANSPORTATION AND LIFTING 285
3 24 RETRIEVAL PROCEDURE 286
3 24 1 GENERAL 286
3 25 EXCAVATOR STORAGE 287
3 25 1 GENERAL 287
3 25 2 PREPARING FOR STORAGE 287
3 25 3 ONE MONTH REPETITIVE SERVICE PERIOD 287
3 25 4 SIX MONTH REPETITIVE SERVICE PERIOD 287
3 25 5 PREPARING FOR OPERATION 288
3 26 TROUBLE SHOOTING 289
3 26 1 GENERAL 289
3 26 2 ENGINE 289
3 26 3 HYDRAULIC SYSTEM 290
3 26 4 FINAL DRIVES AND slew GEAR 291
3 26 5 CRAWLER TRACKS 291
4 MAINTENANCE 293
4 1 FOREWORD 294
4 1 1 GENERAL RECOMMENDATIONS 294
4 2 PRECAUTIONS FOR MAINTENANCE 295
4 3 FLUIDS AND LUBRICANTS 296
4 3 1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 296
4 3 2 Diesel Exhaust Fluid (DEF) 297
4 3 2 1 Recommended Hydraulic Oils 297
4 3 2 2 General Information to selecting hydraulic oils 298
4 3 3 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 300
4 4 FILLING CAPACITIES 301
4 5 STANDARD TORQUE LIST 303
4 5 1 Torque for Flange Joints 304
4 5 2 TORQUES FOR SPECIAL COMPONENTS 305
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 308
4 6 1 INITIAL SERVICING 308
4 6 1 1 INITIAL RUNNING-IN 308
4 6 1 2 AFTER THE FIRST 250 OPERATING HOURS 308
4 6 1 3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT 308
4 6 2 SERVICING THE CRITICAL BOLT CONNECTIONS 309
4 6 3 PERIODIC SERVICING INTERVALS 309
4 6 4 PERIODIC SERVICING SCHEDULE 309
4 6 4 1 INITIAL SERVICING 309
4 6 4 2 WHEN NECESSARY (AND PREVENTATIVE MAINTENANCE) 310
4 6 4 3 EVERY 10 OPERATING HOURS OR DAILY 310
4 6 4 4 EVERY 50 OPERATING HOURS OR WEEKLY 310
4 6 4 5 EVERY 250 OPERATING HOURS OR MONTHLY 311
4 6 4 6 EVERY 500 OPERATING HOURS OR QUATERLY 311
4 6 4 7 EVERY 1000 OPERATING HOURS OR 6 MONTHLY 312
4 6 4 8 EVERY 2000 OPERATING HOURS OR YEARLY 312
4 6 4 9 EVERY 6000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 313
4 6 5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM 314
4 7 SAFETY CRITICAL PARTS 316
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 316
4 7 2 INSPECTION OF HOSE LINES 317
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 317
4 8 EXTENDED SERVICE INTERVALS 319
4 8 1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM 319
4 8 1 1 Servicing Intervals 323
4 8 2 MAINTENANCE OF THE ENGINE 323
4 8 3 ENGINE FUEL FILTER LOCATION 325
4 8 4 VENTING THE AIR FROM THE FUEL FILTERS 329
4 9 INITIAL SERVICING 330
4 9 1 WORKING ATTACHMENT (CLS 1)- INITIAL CHECKS FOR PROPER LUBRICATION 330
4 9 2 ATTACHMENT (CLS 1)- CHECK GREASE INJECTORS AND GREASE CONNECTIONS 331
4 9 3 CAR BODY AND RACEWAY OF SLEW RING (CLS 2)- CHECK GREASE INJECTORS AND GREASE CONNECTIONS 332
4 9 4 slew CIRCLE Pinion (SLS)- CHECK GREASE INJECTORS AND GREASE CONNECTIONS 333
4 9 5 slew CIRCLE TOOTHING LUBRICATION 335
4 9 6 slew circle – Check Torque OF BOLT CONNECTIONS 336
4 9 7 Re-tightening procedure of the crawler carrier mounting bolts 337
4 9 7 1 Procedure for ENSURING Proper Tightening OF the crawler carrier mounting bolts 338
4 9 7 2 Special hydraulic torque wrench 339
4 10 WHEN NECESSARY 340
4 10 1 ENGINE AIR CLEANER MAINTENANCE 341
4 10 1 1 General Service Tips 343
4 10 2 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 345
4 10 3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 347
4 10 4 SERVICE THE GREASE FILTERS FOR REFILLABLE GREASE CONTAINERS 349
4 10 5 GUIDE WHEELS – REPLACE FLOATING SEALS 349
4 11 EVERY 10 OPERATING HOURS OR DAILY 350
4 11 1 WALK – AROUND INSPECTION 351
4 11 2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL Check 355
4 11 2 1 BOOM – CHECK ACESS LADDER AND WALKWAY 357
4 11 3 AIR CLEANER – CLEAN 359
4 11 4 EXPANSION TANK OF RADIATORS- CHECK COOLANT LEVEL 361
4 11 5 TRACK GROUPS – Remove dirt 361
4 11 5 1 Sliders (optional SPECIAL EQUIPMENT)- CHECK CONDITION 362
4 11 5 2 ELECTRICAL EQUIPMENT (PREVENTATIVE MAINTENANCE) – CHECK CONDITION 362
4 11 6 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 365
4 12 EVERY 50 OPERATING HOURS OR WEEKLY 366
4 12 1 slew GEARS 367
4 12 2 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 369
4 12 3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 371
4 12 4 PUMP DISTRIBUTOR GEARS 373
4 12 4 1 PTOs (PUMP DISTRIBUTOR GEARS), CHECK OIL LEVEL: 373
4 12 5 HYDRAULIC ACCESS/INGRESS STAIRWAY – CHECK SAFETY SENSOR 375
4 12 6 MAIN HYDRAULIC OIL & PTO COOLER- INSPECT AND CLEAN 377
4 13 EVERY 250 OPERATING HOURS OR MONTHLY 378
4 13 1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 379
4 13 2 SIGNAL HORN COMPRESSOR – LUBRICATE 381
4 13 3 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION 383
4 13 4 CABIN AIR CLEANER – INSPECT 385
4 13 5 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL 387
4 13 6 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 389
4 13 7 ADDITIONAL AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 391
4 13 8 CABIN HEATER FILTER – INSPECT 393
4 14 EVERY 500 OPERATING HOURS OR QUARTELY 394
4 14 1 BATTERIES – CHECK FLUID LEVEL 395
4 14 1 1 GREASE INJECTORS – CHECK INDICATOR STEMS 396
4 14 1 2 CORRECTIVE ACTIONS 396
4 14 1 3 CHECKING THE SLEW RING 396
4 14 1 4 CHECKING THE SLIDERS (OPTIONAL EQUIPMENT) for wear 397
4 14 2 CYLINDER ROD PROTECTION (IF EQUIPPED), Inspect 399
4 14 3 DRIVE SHAFT HOUSINGS ON PTO GEARS – CHECK OIL LEVEL 401
4 14 4 FUEL TANK – DRAIN CONDENSATION 403
4 14 5 CRAWLER TRACK – INSPECTION 405
4 14 5 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 405
4 14 5 2 Bleeding the System 409
4 14 6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION 411
4 14 7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 413
4 14 8 EMERGENCY LOWERING OF ACCESS/INGRESS STAIRWAY – TEST FUNCTIONALITY 415
4 15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 416
4 15 1 Critical Bolt Connections 417
4 15 1 1 Check mounting of Operator’s cab 417
4 15 1 2 Check tightening torque of the counterweight mounting bolts, 419
4 15 1 3 Check condition and fastening of all three slew gears (01) and slew motors (02), 421
4 15 2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 423
4 15 2 1 TEST MAINTENANCE SAFETY SWITCH (11) 425
4 15 3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY 425
4 15 4 ELECTRICAL EQUIPMENT – MAINTENANCE 427
4 15 5 HYDRAULIC SYSTEM – FILTER SERVICE 429
4 15 6 HIGH PRESSURE FILTERS 431
4 15 7 PTO’S (PUMP DISTRIBUTOR GEARS), slew GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 441
4 15 7 1 Oil plugs to take samples 441
4 15 8 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 443
4 15 9 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 445
4 15 10 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 447
4 15 11 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 449
4 15 12 ALL OTHER HINGES AND AREAS TO LUBRICATE 451
4 15 13 CABIN AIR CLEANER – REPLACE FILTER 453
4 15 14 Critical BOLT CONNECTIONS – VISUAL CHECK 455
4 16 EVERY 2000 OPERATING HOURS OR YEARLY 456
4 16 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 457
4 16 1 1 Hydraulic System – Change Oil 459
4 16 1 2 HYDRAULIC SYSTEM – REPLACE SUCTION STRAINER, FILLER SCREEN AND PULSATION DAMPER 461
4 16 1 3 HYDRAULIC SYSTEM – REPLACE SUCTION STRAINERS OF THE EIGHT MAIN HYDRAULIC PUMPS 463
4 16 1 4 HYDRAULIC SYSTEM – FILL THE OIL RESERVOIRS 465
4 16 1 5 BLEEDING THE MAIN HYDRAULIC PUMPS OF AIR 465
4 16 2 EMERGENCY ESCAPE LADDERS – INSPECTION 467
4 16 2 1 Emergency Escape Ladder ON the Operator’s Cab Platform 467
4 16 2 2 Emergency escape from the Machinery house, engine area 469
4 16 2 3 Emergency Escape Ladder ON the upper Deck and Machinery House Escape Door 471
4 16 3 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 473
4 16 4 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 475
4 16 4 1 Functionality 475
4 17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 476
4 17 1 slew GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 477
4 17 1 1 slew Gears, TYPE 2063 477
4 17 1 2 slew GEARS, TYPE 632770 481
4 17 2 TRAVEL GEARS, CHANGE OIL IN GEAR BOXES, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS 485
4 17 2 1 Travel Gears, Change Oil: 485
4 17 2 2 BRAKE HOUSINGS – CHANGE OIL 487
4 17 2 3 MOTOR ADAPTER HOUSINGS – CHANGE OIL 487
4 17 3 TRAVEL GEARS, type 631053, CHANGE OIL IN GEAR BOXES AND MOTOR ADAPTER HOUSINGS 489
4 17 3 1 Travel Gears, Change Oil: 489
4 17 3 2 Motor Adapter Housings – Change Oil 489
4 17 4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 493
4 17 4 1 CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS 494
4 17 5 Critical BOLT CONNECTIONS – CHECK TORQUE LOAD 495
4 17 5 1 Hydraulic Access/INGRESS STAIRWAY 497
4 17 5 2 Check condition and fastening of railings and ladders, 499
4 17 5 3 Check condition and fastening of all emergency escape ladders, 501
4 17 5 4 Check fastening and condition of main hydraulic oil cooler 505
4 17 5 5 Check fastening of power house frame to superstructure main frame 507
4 17 5 6 Check fastening and condition of the machinery house posts and roof carrier frame 509
4 17 5 7 Power house roof 511
4 17 5 8 Check mounting and security of Diesel engines 513
4 17 5 9 Check mounting and security of both Diesel engines 515
4 17 5 10 Pump distributor gear and hydraulic pumps 517
4 17 5 11 Control Valves 519
4 17 5 12 Check condition and fastening of rotary joint 521
4 17 5 13 main shut-off valve, compensator and suction oil reservoir 523
4 17 5 14 Check condition and fastening of travel gears, sprockets and travel motors 525
4 17 5 15 Crawler Carrier (and sliders for cold regions if they are fitted as an option) 527
4 17 6 CABIN HEATER FILTER – REPLACE FILTER ELEMENT 529
4 17 7 DEF (DIESEL EXHAUST FLUID) TANK – Drain 531
4 17 8 DEF (DIESEL EXHAUST FLUID) TANK – Replace SUCTION AND VENT FILTERS 533
4 17 9 OIL SEPARATOR ELEMENT – REPLACE (IF SO EQUIPPED) 537
4 17 10 CHECKING THE STEEL STRUCTURES 539
4 18 EVERY 6000 HOURS HOWEVER AT LEAST ONCE A YEAR 540
4 18 1 AUTOMATIC LUBRICATION SYSTEMS – replace pump outlet GREASE FILTERS 541
4 18 2 HIGH PRESSURE FILTERS – REPLACE 543
4 19 FIRE PREVENTION 544
4 19 1 PRECAUTIONS 545
4 20 WELD REPAIRS 546
4 20 1 GENERAL PROTECTIVE MEASURES 547
4 20 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 547
4 20 2 1 COUNTERWEIGHT 547
4 20 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 549
4 20 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 551
4 20 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 553
4 20 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 557
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