Komatsu PC8000-11 Hydraulic Mining Excavator Operation & Maintenance Manual OMM 12117-xD-GB-2 – PDF DOWNLOAD
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Komatsu PC8000-11 Hydraulic Mining Excavator Operation & Maintenance Manual OMM 12117-xD-GB-2 – 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.
1.1 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.
- If you sell the excavator, be sure to give this manual to the new owner together with the excavator. This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in
- The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of publication. Continuing improvements in the design of this excavator may lead to additional changes that are not reflected in this manual.
- Consult Komatsu or your Komatsu distributor for the latest available information concerning your excavator or with questions regarding information contained in this manual. The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:
- Komatsu delivers excavators that comply with all applicable regulations and standards of the country to which it has been shipped. If the excavator has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
- If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the excavator. Always keep the Operation and Maintenance Manual in the storage space provided inside the operator’s cabin (see Fig. 1-1) so that all relevant personnel can read it at any time. If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement.
TABLE OF CONTENTS:
Komatsu PC8000-11 Hydraulic Mining Excavator Operation & Maintenance Manual OMM 12117-xD-GB-2 – PDF DOWNLOAD
1 FOREWORD 3
11 BEFORE READING THIS MANUAL 4
12 EC DECLARATION OF CONFORMITY 5
13 PRIVACY POLICY ON EXCAVATORS EQUIPPED WITH excavator MONITORING SYSTEMS FOR THE EEA 6
14 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS 9
15 DIRECTIONS OF THE EXCAVATOR 10
16 SPECIFICATION AND SERIAL PLATE 11
161 PRODUCT IDENTIFICATION NUMBER 11
17 DIVISION OF THE BINDER 12
18 DESIGNATED USE OF THE EXCAVATOR 13
19 DELIVERY OF THE EXCAVATOR 14
191 SPARE PARTS 14
192 SERVICE 14
110 EXPLANATION OF ABBREVIATIONS 15
2 SAFETY 25
21 SAFETY INFORMATION 26
22 OVERVIEW 27
221 NORMAL OPERATIONS 27
222 REGULAR MAINTENANCE 27
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 27
224 ADDITIONAL SAFETY PRECAUTIONS 27
23 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 28
231 SOUND 28
232 VIBRATION 28
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 29
241 UNDERSTANDING THE excavator 29
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 29
2421 ENSURING SAFE OPERATION 29
243 PREPARATIONS FOR SAFE OPERATION 29
2431 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 29
2432 INSPECTING THE excavator 29
2433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 30
2434 KEEP excavator CLEAN 30
2435 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 30
2436 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 31
2437 IF A PROBLEM IS FOUND 31
244 FIRE PREVENTION 31
2441 PRECAUTIONS TO PREVENT FIRE 31
2442 ACTION IF FIRE OCCURS ON PC3000 32
2443 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000 33
2444 EMERGENCY EXIT FROM OPERATOR’S CAB 33
245 PRECAUTIONS WHEN GETTING ON OR OFF THE excavator 34
2451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator 34
2452 NO JUMPING ON OR OFF THE excavator 34
2453 NO PEOPLE ON THE ATTACHMENT 34
2454 WORKING IN HIGH PLACES 34
2455 LEAVING OPERATOR’S SEAT WITH LOCK 35
2456 LEAVING THE excavator 35
246 BURN PREVENTION 35
2461 Hot coolant 35
2462 Hot oil 36
247 PRECAUTIONS WHEN CLEANING CAB GLASS 36
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 36
249 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 37
2491 UNAUTHORIZED MODIFICATION 37
2492 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 37
2410 ELECTROMAGNETIC COMPATIBILITY (EMC) 37
2411 PRECAUTIONS AT JOBSITE 38
24111 VISIBILITY FROM OPERATOR’S SEAT 39
24112 CAMERA SYSTEM WITH MONITORS 39
24113 ENSURE GOOD VISIBILITY 39
24114 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 39
24115 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 40
24116 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 40
24117 Lightning Strikes 41
24118 WORKING ON LOOSE GROUND 41
24119 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 42
241110 VENTILATION OF ENCLOSED AREAS 43
2412 STARTING motor 44
24121 WARNING TAG 44
24122 CHECKS BEFORE STARTING motor 44
24123 PRECAUTION WHEN STARTING motor 44
24124 PRECAUTION IN COLD AREAS 45
2413 OPERATION 45
24131 CHECKS BEFORE OPERATION 45
24132 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 46
24133 PRECAUTIONS WHEN traveling 47
24134 TRAVELING ON SLOPES 48
24135 OPERATIONS ON SLOPES 49
24136 PROHIBITED OPERATIONS 49
24137 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 50
24138 PARKING THE excavator 50
24139 TRANSPORTATION 50
25 PRECAUTION FOR MAINTENANCE 51
251 GENERAL PRECAUTIONS 51
2511 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 52
2512 STOP motor FOR MAINTENANCE 53
2513 WARNING TAG 54
2514 KEEP WORKPLACE CLEAN AND TIDY 55
2515 APPOINT LEADER WHEN WORKING WITH OTHERS 55
2516 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING 56
2517 INSTALLING, REMOVING OR STORING ATTACHMENTS 56
2518 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT 57
2519 NOISE 57
25110 WHEN USING A HAMMER 57
25111 PROPER TOOLS 58
25112 ACCUMULATOR 58
25113 PERSONNEL 58
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 59
2521 PRECAUTION WHEN WELDING 59
2522 BATTERY HANDLING 59
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 60
2531 PRECAUTIONS WITH HIGH FUEL PRESSURE 61
2532 HANDLING HIGH PRESSURES HOSES OR PIPES 62
2533 REPLACEMENT OF HOSE LINES 62
2534 INSPECTION OF HOSE LINES 62
2535 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 63
2536 PRECAUTIONS FOR HIGH VOLTAGE 63
2537 AIR CONDITIONING MAINTENANCE 63
2538 COMPRESSED AIR 64
2539 WASTE MATERIALS 64
26 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 65
261 INSPECTION OF THE HYDRAULIC SYSTEM 65
262 TWO WORKERS ONLY WHEN THE excavator IS RUNNING DURING ADJUSTMENTS 65
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 65
27 SPECIAL SAFETY EQUIPMENT 66
271 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 67
272 OBJECT HANDLING 67
273 LIGHTING 67
274 WARNING BEACON 67
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 67
2751 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 67
2752 INSTRUCTIONS FOR USE 69
2753 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 71
2754 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 71
2755 INSTRUCTIONS FOR USE 73
28 SAFETY WARNING SIGNS 75
281 LOCATION AND DESCRIPTION OF THE SIGNS 76
3 OPERATION 95
31 FOREWORD 96
3101 Connection of electrical installations by the Customer to the excavator 96
32 CONSTRUCTION OF THE EXCAVATOR 97
321 OVERALL VIEW 97
322 UNDERCARRIAGE AND SUPERSTRUCTURE 98
3221 SUPERSTRUCTURE – TOP VIEW103
323 UNDERCARRIAGE TRACK SLIDERS104
3231 MACHINERY HOUSE107
3232 Eliminator Engine Oil Filtration System108
324 HYDRAULICALLY OPERATED ACCESS/INGRESS STAIRWAY110
3241 Lowering the Stairway in emergency situations113
325 EMERGENCY ESCAPE Ladders114
3251 EMERGENCY ESCAPE FROM THE OPERATOR’S CABIN115
3252 Emergency escape from the Machinery house, engine area117
3253 Emergency escape from the Machinery house, Pump area119
3254 EMERGENCY ESCAPE FROM THE ROOF120
3255 ESCAPE LADDER WINCH ASSEMBLY123
326 FOLDING LADDER INSIDE OF CARBODY124
327 BOOM ACCESS LADDER AND WALKWAY126
3271 Engine Shutdown System actuated from MAN ON Ground (OPTIONAL)129
3272 Operator Warning System (OPTIONAL)129
328 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)130
3281 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual135
3282 Operator’s Seat Adjustment137
3283 Co-driver’s Seat and Refrigerator Box138
3284 INSTRUCTIONS TO using and looking after THE SEAT BELTS139
33 OPERATOR’S CAB – CONTROLS140
331 CONTROLS WITH BACKHOE ATTACHMENT140
3311 Hydraulic Control System141
3312 Safety Circuit for Controls141
3313 Control Pattern143
332 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT144
3321 Hydraulic Control System145
3322 Safety Circuit for Controls145
3323 Control Pattern147
333 OPERATOR’S CONSOLE149
3331 Switch Board151
334 INTERFACE PANEL FOR DIAGNOSTICS157
335 CONTROL MODULE FOR AUXILIARY CAB HEATER159
34 KOMTRAX (MACHINE) MONITOR160
341 SEQUENCE OF DISPLAYS161
342 OPENING SCREEN161
343 MAIN gage SCREENS 1-4162
3431 Main gage Screen 1163
3432 Main gage Screen 2165
3433 Main gage Screen 3165
3434 Main gage Screen 4167
3435 Color Definition167
344 FUEL CONSUMPTION SCREEN169
345 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR169
346 MAIN SCREEN – CHANGE >TIME >SMR >DATE170
347 MAINTENANCE MONITOR170
3471 Maintenance confirmation through Service Personnel170
348 SETTINGS FOR OPERATOR171
3481 Settings Screens172
349 SERVICE MENU175
3410 AUTOMATIC MESSAGES175
34101 Automatic Messages176
34102 Automatic ENGINE Messages179
35 MODULE TO MONITOR DIESEL EXHAUST FLUID/ CATALYTIC REDUCTION (DEF/SCR)180
351 LOCATION ON OPERATOR’S CONSOLE180
352 DISPLAY ON OPERATOR’S CONSOLE181
3521 Engine After-treatment181
36 CAMERA SYSTEM KOMVISION182
3601 The names, locations and views of the cameras185
37 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING186
371 DIGITAL DISPLAY186
372 LUMINOUS INDICATION188
373 AUXILIARY HEATER FOR OPERATOR’S CAB191
38 MACHINERY HOUSE192
381 EMERGENCY ENGINE STOP SWITCHES193
382 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE195
383 CENTRAL CONTROL AND FILTER PANEL197
384 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO199
39 ELECTRICAL EQUIPMENT IN CAB BASE200
391 STANDARD COMPONENTS IN CAB BASE201
392 Preheating System (WHEN EQUIPPED)203
310 CHECKS BEFORE STARTING THE ENGINES206
3101 HYDRAULIC SYSTEM – CHECK OIL LEVEL211
31011 Machinery House Doors211
31012 OPERATOR’S SEAT ADJUSTMENT211
311 STARTING THE ENGINES212
3111 STARTING PROCEDURE215
3112 COLD WEATHER STARTING AID215
3113 ENGINE WARMUP LOCK ON LOW IDLE217
31131 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C217
3114 HYDRAULIC OIL WARM-UP223
31141 Hydraulic Oil Viscosity and Temperature Chart224
312 MOVING THE EXCAVATOR225
3121 TRAVEL CONTROL WITH FOOT PEDALS225
31211 TRAVEL ALARM / BACK-UP ALARM (Special equipment)227
3122 traveling INSTRUCTIONS227
31221 traveling LONG DISTANCES229
3123 UNDERCARRIAGE TRACK SLIDERS230
313 SLEWING AND BRAKING THE SUPERSTRUCTURE232
3131 SLEWING THE SUPERSTRUCTURE232
31311 STANDARD CONTROL PATTERN232
31312 BRAKING THE SUPERSTRUCTURE233
31313 Hydraulic slew brake actuated by hydraulic access/INGRESS STAIRWAY and Service Arm of service center233
31314 Important Instructions for Slewing the Superstructure234
314 WORKING WITH THE ATTACHMENT235
31401 FRONT shovel BUCKET236
3141 COMBINED OPERATION CYCLES237
315 WORKING INSTRUCTIONS239
3151 STABILITY OF THE excavator239
3152 FURTHER OPERATING PRACTICES241
3153 Loading Trucks245
316 PARKING THE EXCAVATOR246
31601 CLEANING THE TRACK GROUPS246
317 STOPPING THE ENGINES248
3171 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM251
318 OPERATION OF THE LUBRICATION SYSTEM252
3181 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE252
31811 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM253
3182 slew CIRCLE PINION LUBRICATION SYSTEM ”SLS”254
31821 slew CIRCLE LUBRICATION SYSTEM ”SLS”254
31822 ADJUSTMENTS OF THE slew CIRCLELUBRICATION SYSTEM255
31823 Defining the Lubrication System Greasing Areas255
319 TRANSFER PUMP FOR HYDRAULIC OIL256
3191 OPERATING THE TRANSFER PUMP257
3192 TRANSFUSION PROCEDURE259
320 sERVICE CENTER262
3201 SYSTEMS CONNECTED TO THE SERVICE CENTER263
32011 Operation of the hydraulic Service Arm263
3202 OPERATING THE HYDRAULIC SERVICE ARM265
3203 SERVICE CENTER WITH MONITOR BOX267
32031 Refilling Procedure:269
32032 DRAINING PRODURE FOR DEF HOSES271
3204 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOUSE ROOF273
321 FIRE DETECTION AND SUPPRESSION SYSTEM274
32101 FIRE DETECTION AND SUPPRESSION SYSTEMS275
3211 DISPLAY MODULE279
3212 INTERFACE CONTROL MODULE281
3213 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF283
322 WORK ON THE LOADER ATTACHMENT284
3221 OBSERVE THE FOLLOWING INSTRUCTIONS284
323 TRANSPORTATION AND LIFTING OF THE EXCAVATOR285
3231 DISASSEMBLING OF THE EXCAVATOR285
3232 TRANSPORTATION AND LIFTING285
324 RETRIEVAL PROCEDURE286
3241 GENERAL286
325 EXCAVATOR STORAGE287
3251 GENERAL287
3252 PREPARING FOR STORAGE287
3253 ONE MONTH REPETITIVE SERVICE PERIOD287
3254 SIX MONTH REPETITIVE SERVICE PERIOD287
3255 PREPARING FOR OPERATION288
326 TROUBLE SHOOTING289
3261 GENERAL289
3262 ENGINE289
3263 HYDRAULIC SYSTEM290
3264 FINAL DRIVES AND slew GEAR291
3265 CRAWLER TRACKS291
4 MAINTENANCE293
41 FOREWORD294
411 GENERAL RECOMMENDATIONS294
42 PRECAUTIONS FOR MAINTENANCE295
43 FLUIDS AND LUBRICANTS296
431 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES296
432 Diesel Exhaust Fluid (DEF)297
4321 Recommended Hydraulic Oils297
4322 General Information to selecting hydraulic oils298
433 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES300
44 FILLING CAPACITIES301
45 STANDARD TORQUE LIST303
451 Torque for Flange Joints304
452 TORQUES FOR SPECIAL COMPONENTS305
46 LUBRICATION AND MAINTENANCE SCHEDULE308
461 INITIAL SERVICING308
4611 INITIAL RUNNING-IN308
4612 AFTER THE FIRST 250 OPERATING HOURS308
4613 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT308
462 SERVICING THE CRITICAL BOLT CONNECTIONS309
463 PERIODIC SERVICING INTERVALS309
464 PERIODIC SERVICING SCHEDULE309
4641 INITIAL SERVICING309
4642 WHEN NECESSARY (AND PREVENTATIVE MAINTENANCE)310
4643 EVERY 10 OPERATING HOURS OR DAILY310
4644 EVERY 50 OPERATING HOURS OR WEEKLY310
4645 EVERY 250 OPERATING HOURS OR MONTHLY311
4646 EVERY 500 OPERATING HOURS OR QUATERLY311
4647 EVERY 1000 OPERATING HOURS OR 6 MONTHLY312
4648 EVERY 2000 OPERATING HOURS OR YEARLY312
4649 EVERY 6000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR313
465 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM314
47 SAFETY CRITICAL PARTS316
471 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES316
472 INSPECTION OF HOSE LINES317
473 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS317
48 EXTENDED SERVICE INTERVALS319
481 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM319
4811 Servicing Intervals323
482 MAINTENANCE OF THE ENGINE323
483 ENGINE FUEL FILTER LOCATION325
484 VENTING THE AIR FROM THE FUEL FILTERS329
49 INITIAL SERVICING330
491 WORKING ATTACHMENT (CLS 1)- INITIAL CHECKS FOR PROPER LUBRICATION330
492 ATTACHMENT (CLS 1)- CHECK GREASE INJECTORS AND GREASE CONNECTIONS331
493 CAR BODY AND RACEWAY OF SLEW RING (CLS 2)- CHECK GREASE INJECTORS AND GREASE CONNECTIONS332
494 slew CIRCLE Pinion (SLS)- CHECK GREASE INJECTORS AND GREASE CONNECTIONS333
495 slew CIRCLE TOOTHING LUBRICATION335
496 slew circle – Check Torque OF BOLT CONNECTIONS336
497 Re-tightening procedure of the crawler carrier mounting bolts337
4971 Procedure for ENSURING Proper Tightening OF the crawler carrier mounting bolts338
4972 Special hydraulic torque wrench339
410 WHEN NECESSARY340
4101 ENGINE AIR CLEANER MAINTENANCE341
41011 General Service Tips343
4102 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS345
4103 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS347
4104 SERVICE THE GREASE FILTERS FOR REFILLABLE GREASE CONTAINERS349
4105 GUIDE WHEELS – REPLACE FLOATING SEALS349
411 EVERY 10 OPERATING HOURS OR DAILY350
4111 WALK – AROUND INSPECTION351
4112 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL Check355
41121 BOOM – CHECK ACESS LADDER AND WALKWAY357
4113 AIR CLEANER – CLEAN359
4114 EXPANSION TANK OF RADIATORS- CHECK COOLANT LEVEL361
4115 TRACK GROUPS – Remove dirt361
41151 Sliders (optional SPECIAL EQUIPMENT)- CHECK CONDITION362
41152 ELECTRICAL EQUIPMENT (PREVENTATIVE MAINTENANCE) – CHECK CONDITION362
4116 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB365
412 EVERY 50 OPERATING HOURS OR WEEKLY366
4121 slew GEARS367
4122 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS369
4123 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL371
4124 PUMP DISTRIBUTOR GEARS373
41241 PTOs (PUMP DISTRIBUTOR GEARS), CHECK OIL LEVEL:373
4125 HYDRAULIC ACCESS/INGRESS STAIRWAY – CHECK SAFETY SENSOR375
4126 MAIN HYDRAULIC OIL & PTO COOLER- INSPECT AND CLEAN377
413 EVERY 250 OPERATING HOURS OR MONTHLY378
4131 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION379
4132 SIGNAL HORN COMPRESSOR – LUBRICATE381
4133 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION383
4134 CABIN AIR CLEANER – INSPECT385
4135 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL387
4136 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL389
4137 ADDITIONAL AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL391
4138 CABIN HEATER FILTER – INSPECT393
414 EVERY 500 OPERATING HOURS OR QUARTELY394
4141 BATTERIES – CHECK FLUID LEVEL395
41411 GREASE INJECTORS – CHECK INDICATOR STEMS396
41412 CORRECTIVE ACTIONS396
41413 CHECKING THE SLEW RING396
41414 CHECKING THE SLIDERS (OPTIONAL EQUIPMENT) for wear397
4142 CYLINDER ROD PROTECTION (IF EQUIPPED), Inspect399
4143 DRIVE SHAFT HOUSINGS ON PTO GEARS – CHECK OIL LEVEL401
4144 FUEL TANK – DRAIN CONDENSATION403
4145 CRAWLER TRACK – INSPECTION405
41451 CHECK ADJUSTING RANGE OF GUIDE WHEELS405
41452 Bleeding the System409
4146 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION411
4147 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION413
4148 EMERGENCY LOWERING OF ACCESS/INGRESS STAIRWAY – TEST FUNCTIONALITY415
415 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH416
4151 Critical Bolt Connections417
41511 Check mounting of Operator’s cab417
41512 Check tightening torque of the counterweight mounting bolts,419
41513 Check condition and fastening of all three slew gears (01) and slew motors (02),421
4152 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY423
41521 TEST MAINTENANCE SAFETY SWITCH (11)425
4153 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY425
4154 ELECTRICAL EQUIPMENT – MAINTENANCE427
4155 HYDRAULIC SYSTEM – FILTER SERVICE429
4156 HIGH PRESSURE FILTERS431
4157 PTO’S (PUMP DISTRIBUTOR GEARS), slew GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS441
41571 Oil plugs to take samples441
4158 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE443
4159 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS445
41510 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES447
41511 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES449
41512 ALL OTHER HINGES AND AREAS TO LUBRICATE451
41513 CABIN AIR CLEANER – REPLACE FILTER453
41514 Critical BOLT CONNECTIONS – VISUAL CHECK455
416 EVERY 2000 OPERATING HOURS OR YEARLY456
4161 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER457
41611 Hydraulic System – Change Oil459
41612 HYDRAULIC SYSTEM – REPLACE SUCTION STRAINER, FILLER SCREEN AND PULSATION DAMPER461
41613 HYDRAULIC SYSTEM – REPLACE SUCTION STRAINERS OF THE EIGHT MAIN HYDRAULIC PUMPS463
41614 HYDRAULIC SYSTEM – FILL THE OIL RESERVOIRS465
41615 BLEEDING THE MAIN HYDRAULIC PUMPS OF AIR465
4162 EMERGENCY ESCAPE LADDERS – INSPECTION467
41621 Emergency Escape Ladder ON the Operator’s Cab Platform467
41622 Emergency escape from the Machinery house, engine area469
41623 Emergency Escape Ladder ON the upper Deck and Machinery House Escape Door471
4163 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST473
4164 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB475
41641 Functionality475
417 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR476
4171 slew GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL477
41711 slew Gears, TYPE 2063477
41712 slew GEARS, TYPE 632770481
4172 TRAVEL GEARS, CHANGE OIL IN GEAR BOXES, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS485
41721 Travel Gears, Change Oil:485
41722 BRAKE HOUSINGS – CHANGE OIL487
41723 MOTOR ADAPTER HOUSINGS – CHANGE OIL487
4173 TRAVEL GEARS, type 631053, CHANGE OIL IN GEAR BOXES AND MOTOR ADAPTER HOUSINGS489
41731 Travel Gears, Change Oil:489
41732 Motor Adapter Housings – Change Oil489
4174 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL493
41741 CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS494
4175 Critical BOLT CONNECTIONS – CHECK TORQUE LOAD495
41751 Hydraulic Access/INGRESS STAIRWAY497
41752 Check condition and fastening of railings and ladders,499
41753 Check condition and fastening of all emergency escape ladders,501
41754 Check fastening and condition of main hydraulic oil cooler505
41755 Check fastening of power house frame to superstructure main frame507
41756 Check fastening and condition of the machinery house posts and roof carrier frame509
41757 Power house roof511
41758 Check mounting and security of Diesel engines513
41759 Check mounting and security of both Diesel engines515
417510 Pump distributor gear and hydraulic pumps517
417511 Control Valves519
417512 Check condition and fastening of rotary joint521
417513 main shut-off valve, compensator and suction oil reservoir523
417514 Check condition and fastening of travel gears, sprockets and travel motors525
417515 Crawler Carrier (and sliders for cold regions if they are fitted as an option)527
4176 CABIN HEATER FILTER – REPLACE FILTER ELEMENT529
4177 DEF (DIESEL EXHAUST FLUID) TANK – Drain531
4178 DEF (DIESEL EXHAUST FLUID) TANK – Replace SUCTION AND VENT FILTERS533
4179 OIL SEPARATOR ELEMENT – REPLACE (IF SO EQUIPPED)537
41710 CHECKING THE STEEL STRUCTURES539
418 EVERY 6000 HOURS HOWEVER AT LEAST ONCE A YEAR540
4181 AUTOMATIC LUBRICATION SYSTEMS – replace pump outlet GREASE FILTERS541
4182 HIGH PRESSURE FILTERS – REPLACE543
419 FIRE PREVENTION544
4191 PRECAUTIONS545
420 WELD REPAIRS546
4201 GENERAL PROTECTIVE MEASURES547
4202 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR547
42021 COUNTERWEIGHT547
4203 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE549
4204 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT551
4205 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE553
4206 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE557
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.M