Komatsu HYDRAULIC EXCAVATOR PC3400-11M0 Operation & Maintenance Manual – PDF DOWNLOAD

Description

Komatsu HYDRAULIC EXCAVATOR PC3400-11M0 Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

SERIAL NUMBERS 36301 and up

Komatsu HYDRAULIC EXCAVATOR PC3400-11M0 Operation & Maintenance Manual – PDF DOWNLOAD

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 HYDRAULIC EXCAVATOR PC3400-11M0 Operation & Maintenance Manual – PDF DOWNLOAD

1 FOREWORD…………………………………………………………………………………. 1-1
1.1 BEFORE READING THIS MANUAL ……………………………………………………………………………………. 1-2
1.2 EC DECLARATION OF CONFORMITY ……………………………………………………………………………….. 1-3
1.3 PRIVACY POLICY ON EXCAVATORS EQUIPPED WITH EXCAVATOR MONITORING SYSTEMS
FOR THE EEA…………………………………………………………………………………………………………………… 1-4
1.4 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS………………………………… 1-7
1.5 DIRECTIONS OF THE EXCAVATOR…………………………………………………………………………………… 1-8
1.6 SPECIFICATION AND SERIAL PLATE ……………………………………………………………………………….. 1-9
1.6.1 PRODUCT IDENTIFICATION NUMBER ……………………………………………………………………. 1-9
1.7 DIVISION OF THE BINDER ………………………………………………………………………………………………. 1-10
1.8 DESIGNATED USE OF THE EXCAVATOR ………………………………………………………………………… 1-11
1.9 DELIVERY OF THE EXCAVATOR …………………………………………………………………………………….. 1-12
1.9.1 SPARE PARTS…………………………………………………………………………………………………….. 1-12
1.9.2 SERVICE …………………………………………………………………………………………………………….. 1-12
1.10 EXPLANATION OF ABBREVIATIONS ………………………………………………………………………………. 1-13
1.11 CONTENTS …………………………………………………………………………………………………………………….. 1-15
2 SAFETY ……………………………………………………………………………………… 2-23
2.1 SAFETY INFORMATION ………………………………………………………………………………………………….. 2-24
2.2 OVERVIEW …………………………………………………………………………………………………………………….. 2-25
2.2.1 NORMAL OPERATIONS ……………………………………………………………………………………….. 2-25
2.2.2 REGULAR MAINTENANCE …………………………………………………………………………………… 2-25
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR …………………………………………….. 2-25
2.2.4 ADDITIONAL SAFETY PRECAUTIONS ………………………………………………………………….. 2-25
2.3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB. ………………………. 2-26
2.3.1 SOUND ……………………………………………………………………………………………………………….. 2-26
2.3.2 VIBRATION………………………………………………………………………………………………………….. 2-26
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………. 2-27
2.4.1 UNDERSTANDING THE EXCAVATOR …………………………………………………………………… 2-27
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ……………….. 2-27
2.4.3 PREPARATIONS FOR SAFE OPERATION……………………………………………………………… 2-27
2.4.4 FIRE PREVENTION ……………………………………………………………………………………………… 2-29
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR……………………………. 2-32
2.4.6 BURN PREVENTION ……………………………………………………………………………………………. 2-33
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS …………………………………………………….. 2-34
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES …………………………………… 2-34
2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS……………………….. 2-35
2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC) ……………………………………………………….. 2-35
2.4.11 PRECAUTIONS AT JOBSITE ………………………………………………………………………………… 2-36
2.4.12 STARTING MOTOR ……………………………………………………………………………………………… 2-41
2.4.13 OPERATION………………………………………………………………………………………………………… 2-42
2.5 PRECAUTION FOR MAINTENANCE…………………………………………………………………………………. 2-48
2.5.1 GENERAL PRECAUTIONS……………………………………………………………………………………. 2-48
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE………………………………………… 2-57
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID……………………………………………………… 2-58
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS ……. 2-63
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM …………………………………………………………. 2-63
2.6.2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING
ADJUSTMENTS……………………………………………………………………………………………………. 2-63
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR……………………………….. 2-63
2.7 SPECIAL SAFETY EQUIPMENT……………………………………………………………………………………….. 2-64
2.7.1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB………….. 2-65
2.7.2 OBJECT HANDLING …………………………………………………………………………………………….. 2-65
2.7.3 LIGHTING ……………………………………………………………………………………………………………. 2-65
2.7.4 WARNING BEACON……………………………………………………………………………………………… 2-65
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ……….. 2-65
2.8 SAFETY WARNING SIGNS ………………………………………………………………………………………………. 2-73
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS …………………………………………………….. 2-74
2.8.2 LOCATION AND DESCRIPTION OF THE SIGNS FOR PC3400…………………………………. 2-76
3 OPERATION ……………………………………………………………………………… 3-103
3.1 FOREWORD………………………………………………………………………………………………………………….. 3-104
3.2 CONSTRUCTION OF THE EXCAVATOR …………………………………………………………………………. 3-105
3.2.1 OVERALL VIEW …………………………………………………………………………………………………. 3-105
3.2.2 SUPERSTRUCTURE…………………………………………………………………………………………… 3-106
3.2.3 HYDRAULICALLY OPERATED STAIRWAY …………………………………………………………… 3-116
3.2.4 EMERGENCY ESCAPE LADDERS ………………………………………………………………………. 3-122
3.2.5 BOOM ACCESS LADDER AND WALKWAY…………………………………………………………… 3-130
3.2.6 ENGINE SHUTDOWN SYSTEM ACTUATED FROM GROUND MAN ………………………. 3-132
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE
STRUCTURE (FOPS)………………………………………………………………………………………….. 3-134
3.2.8 UNDERCARRIAGE……………………………………………………………………………………………… 3-144
3.2.9 BACK HOE WORKING ATTACHMENT …………………………………………………………………. 3-145
3.3 OPERATOR’S CAB – CONTROLS …………………………………………………………………………………… 3-146
3.3.1 SAFETY CIRCUIT FOR CONTROLS …………………………………………………………………….. 3-147
3.3.2 OPERATOR’S CONSOLE ……………………………………………………………………………………. 3-151
3.4 MACHINE MONITOR …………………………………………………………………………………………………….. 3-152
3.4.1 SEQUENCE OF DISPLAYS …………………………………………………………………………………. 3-153
3.4.2 OPENING SCREEN…………………………………………………………………………………………….. 3-153
3.4.3 FUNCTION CHECKING SCREEN…………………………………………………………………………. 3-156
3.4.4 MAIN GAUGE SCREENS 1 TO 3………………………………………………………………………….. 3-157
3.4.5 ECO GUIDANCE ………………………………………………………………………………………………… 3-163
3.4.6 MAINTENANCE ………………………………………………………………………………………………….. 3-167
3.4.7 MONITOR SETTING……………………………………………………………………………………………. 3-167
3.4.8 MESSAGE …………………………………………………………………………………………………………. 3-170
3.4.9 ACTION CODES…………………………………………………………………………………………………. 3-172
3.5 CAMERA SYSTEM – KOMVISION……………………………………………………………………………………. 3-174
3.5.1 ABOUT THE SYSTEM…………………………………………………………………………………………. 3-175
3.5.2 KOMVISION SAFETY………………………………………………………………………………………….. 3-175
3.5.3 MAINTAINING THE SYSTEM……………………………………………………………………………….. 3-177
3.5.4 DAILY CHECK ……………………………………………………………………………………………………. 3-177
3.5.5 CAMERA OPERATION………………………………………………………………………………………… 3-177
3.5.6 CHECKS BEFORE OPERATION ………………………………………………………………………….. 3-179
3.5.7 EXPLANATION OF KOMVISION COMPONENTS…………………………………………………… 3-181
3.5.8 MEANING OF ELEMENTS SHOWN ON THE DISPLAY ………………………………………….. 3-182
3.5.9 TOUCH SCREEN OPERATION ……………………………………………………………………………. 3-186
3.6 OPERATING AIR CONDITIONING…………………………………………………………………………………… 3-191
3.6.1 VENTILATING WHILE COOLING …………………………………………………………………………. 3-191
3.6.2 TEMPERATURE CONTROL ………………………………………………………………………………… 3-191
3.6.3 OFF SWITCH……………………………………………………………………………………………………… 3-192
3.6.4 FAN SWITCH……………………………………………………………………………………………………… 3-192
3.6.5 TEMPERATURE CONTROL SWITCH …………………………………………………………………… 3-193
3.7 OPERATING THE RADIO……………………………………………………………………………………………….. 3-206
3.7.1 POWER BUTTON……………………………………………………………………………………………….. 3-206
3.7.2 BAND/AUX SELECTOR BUTTON ………………………………………………………………………… 3-206
3.7.3 VOLUME CONTROL BUTTON …………………………………………………………………………….. 3-206
3.7.4 TUNING/TIME ADJUSTMENT BUTTON………………………………………………………………… 3-206
3.7.5 PRESET BUTTON………………………………………………………………………………………………. 3-207
3.7.6 DISPLAY SELECTOR BUTTON……………………………………………………………………………. 3-207
3.7.7 SOUND CONTROL BUTTON……………………………………………………………………………….. 3-207
3.7.8 DISPLAY……………………………………………………………………………………………………………. 3-207
3.7.9 AUX…………………………………………………………………………………………………………………… 3-208
3.7.10 METHOD FOR CONTROLLING RADIO (ADJUSTING THE FREQUENCY) ……………….. 3-209
3.7.11 METHOD FOR ADJUSTING THE FREQUENCY (AUTO-RESETTING)……………………… 3-209
3.7.12 METHOD FOR CALLING PRESET ……………………………………………………………………….. 3-209
3.7.13 METHOD FOR REGISTERING PRESET……………………………………………………………….. 3-210
3.7.14 METHOD FOR ADJUSTING BALANCE…………………………………………………………………. 3-210
3.7.15 METHOD FOR ADJUSTING TREBLE …………………………………………………………………… 3-210
3.7.16 METHOD FOR ADJUSTING BASS……………………………………………………………………….. 3-211
3.7.17 METHOD FOR ADJUSTING CLOCK …………………………………………………………………….. 3-211
3.7.18 STOW ANTENNA ……………………………………………………………………………………………….. 3-212
3.7.19 PRECAUTIONS DURING OPERATION…………………………………………………………………. 3-212
3.8 MACHINERY HOUSE …………………………………………………………………………………………………….. 3-214
3.8.1 EMERGENCY ENGINE STOP SWITCHES AND BATTERY DISCONNECT SWITCH …. 3-215
3.8.2 MAINTENANCE SAFETY SWITCH……………………………………………………………………….. 3-217
3.8.3 CENTRAL CONTROL AND FILTER PANEL…………………………………………………………… 3-219
3.9 ELECTRICAL EQUIPMENT IN CAB BASE ………………………………………………………………………. 3-220
3.9.1 STANDARD COMPONENTS IN CAB BASE…………………………………………………………… 3-221
3.10 CHECKS BEFORE STARTING THE ENGINE …………………………………………………………………… 3-222
3.10.1 COOLANT LEVEL ………………………………………………………………………………………………. 3-225
3.10.2 HYDRAULIC SYSTEM – CHECK OIL LEVEL………………………………………………………….. 3-227
3.10.3 MACHINERY HOUSE DOORS …………………………………………………………………………….. 3-227
3.10.4 OPERATOR’S SEAT ADJUSTMENT …………………………………………………………………….. 3-228
3.11 STARTING THE ENGINE ……………………………………………………………………………………………….. 3-230
3.11.1 STARTING PROCEDURE……………………………………………………………………………………. 3-233
3.11.2 ENGINE WARM-UP…………………………………………………………………………………………….. 3-237
3.11.3 HYDRAULIC OIL WARM-UP………………………………………………………………………………… 3-237
3.12 MOVING THE EXCAVATOR …………………………………………………………………………………………… 3-239
3.12.1 TRAVEL CONTROL WITH FOOT PEDALS ……………………………………………………………. 3-239
3.12.2 TRAVELING INSTRUCTIONS………………………………………………………………………………. 3-241
3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE……………………………………………………….. 3-244
3.13.1 SLEWING THE SUPERSTRUCTURE……………………………………………………………………. 3-244
3.13.2 BRAKING THE SUPERSTRUCTURE ……………………………………………………………………. 3-245
3.13.3 SLEW PARKING BRAKE……………………………………………………………………………………… 3-245
3.14 WORKING WITH THE ATTACHMENT……………………………………………………………………………… 3-247
3.14.1 COMBINED OPERATION CYCLES ………………………………………………………………………. 3-249
3.15 WORKING INSTRUCTIONS ……………………………………………………………………………………………. 3-251
3.15.1 STABILITY OF THE EXCAVATOR………………………………………………………………………… 3-251
3.15.2 FURTHER OPERATING PRACTICES …………………………………………………………………… 3-253
3.16 PARKING THE EXCAVATOR………………………………………………………………………………………….. 3-257
3.17 STOPPING THE ENGINE ……………………………………………………………………………………………….. 3-260
3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…………………………………………….. 3-263
3.18 OPERATION OF THE LUBRICATION SYSTEM………………………………………………………………… 3-264
3.18.1 CENTRAL LUBRICATION SYSTEM ”CLS” ……………………………………………………………. 3-264
3.18.2 SLEW CIRCLE PINION LUBRICATION SYSTEM ”SLS” ………………………………………….. 3-265
3.19 TRANSFER PUMP FOR HYDRAULIC OIL ……………………………………………………………………….. 3-268
3.19.1 OPERATING THE TRANSFER PUMP …………………………………………………………………… 3-269
3.19.2 FUNCTIONS OF THE TRANSFER PUMP ……………………………………………………………… 3-271
3.20 CENTRAL REFILLING SYSTEM ……………………………………………………………………………………… 3-274
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…………………………………………. 3-275
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM …………………………………………………….. 3-277
3.20.3 RECEIVER PANEL WITH MONITOR BOX …………………………………………………………….. 3-279
3.20.4 REFILLABLE GREASE CONTAINERS ………………………………………………………………….. 3-285
3.21 WORK ON THE LOADER ATTACHMENT………………………………………………………………………… 3-288
3.22 TRANSPORTATION AND LIFTING OF THE EXCAVATOR………………………………………………… 3-289
3.22.1 DISASSEMBLING OF THE EXCAVATOR ……………………………………………………………… 3-289
3.22.2 TRANSPORTATION AND LIFTING……………………………………………………………………….. 3-289
3.23 RETRIEVAL PROCEDURE……………………………………………………………………………………………… 3-290
3.24 EXCAVATOR STORAGE………………………………………………………………………………………………… 3-291
3.24.1 PREPARING FOR STORAGE………………………………………………………………………………. 3-291
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD………………………………………………………. 3-291
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD………………………………………………………… 3-291
3.24.4 PREPARING FOR OPERATION …………………………………………………………………………… 3-292
3.25 PRECAUTIONS FOR TOWING ……………………………………………………………………………………….. 3-293
3.26 TROUBLE SHOOTING …………………………………………………………………………………………………… 3-294
3.26.1 GENERAL ………………………………………………………………………………………………………….. 3-294
3.26.2 ENGINE …………………………………………………………………………………………………………….. 3-294
3.26.3 HYDRAULIC SYSTEM…………………………………………………………………………………………. 3-295
3.26.4 FINAL DRIVES AND SWING GEAR………………………………………………………………………. 3-296
3.26.5 CRAWLER TRACKS……………………………………………………………………………………………. 3-296
4 MAINTENANCE …………………………………………………………………………. 4-297
4.1 FOREWORD………………………………………………………………………………………………………………….. 4-298
4.1.1 DEFINITIONS …………………………………………………………………………………………………….. 4-298
4.1.2 GENERAL RECOMMENDATIONS………………………………………………………………………… 4-298
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE ……………………………………………………………….. 4-299
4.3 FLUIDS AND LUBRICANTS……………………………………………………………………………………………. 4-300
4.3.1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES………………………. 4-300
4.3.2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES ………………………. 4-304
4.4 FILLING CAPACITIES ……………………………………………………………………………………………………. 4-305
4.5 STANDARD TORQUE LIST ……………………………………………………………………………………………. 4-306
4.5.1 TORQUE FOR FLANGE JOINTS………………………………………………………………………….. 4-307
4.6 LUBRICATION AND MAINTENANCE SCHEDULE……………………………………………………………. 4-308
4.6.1 INITIAL SERVICING ……………………………………………………………………………………………. 4-308
4.6.2 SERVICING THE CRITICAL BOLT CONNECTIONS……………………………………………….. 4-309
4.6.3 PERIODIC SERVICING INTERVALS…………………………………………………………………….. 4-309
4.6.4 PERIODIC SERVICING SCHEDULE …………………………………………………………………….. 4-310
4.6.5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS . 4-315
4.7 SAFETY CRITICAL PARTS…………………………………………………………………………………………….. 4-316
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES ……………….. 4-316
4.7.2 INSPECTION OF HOSE LINES ……………………………………………………………………………. 4-316
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS …………………… 4-316
4.8 EXTENDED SERVICE INTERVALS …………………………………………………………………………………. 4-319
4.8.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM ……………….. 4-319
4.8.2 MAINTENANCE OF THE ENGINE………………………………………………………………………… 4-323
4.9 INITIAL SERVICING ………………………………………………………………………………………………………. 4-324
4.9.1 WORKING ATTACHMENT – INITIAL CHECKS ………………………………………………………. 4-325
4.9.2 SLEW RING – CHECK TORQUE OF BOLT CONNECTIONS……………………………………. 4-337
4.9.3 RETIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS …. 4-339
4.10 WHEN NECESSARY ……………………………………………………………………………………………………… 4-344
4.10.1 HYDRAULIC OIL CHANGE ………………………………………………………………………………….. 4-345
4.10.2 FILLING THE HYDRAULIC SYSTEM…………………………………………………………………….. 4-348
4.10.3 ENGINE AIR CLEANER MAINTENANCE ………………………………………………………………. 4-355
4.10.4 SLEW CIRCLE TOOTHING LUBRICATION …………………………………………………………… 4-359
4.10.5 AUTOMATIC LUBRICATION SYSTEMS, FILL GREASE CONTAINERS……………………. 4-361
4.10.6 GUIDE WHEELS – BEARING INSPECTION …………………………………………………………… 4-363
4.10.7 REPLACING BUCKET TEETH AND SHROUDS …………………………………………………….. 4-364
4.10.8 LIP AND SIDE SHROUDS……………………………………………………………………………………. 4-368
4.10.9 J-BOLT SHROUD SEATING AND MAINTENANCE INSTRUCTIONS………………………… 4-371
4.10.10 AIR CONDITIONER…………………………………………………………………………………………….. 4-371
4.10.11 CHECK SEALS AROUND RADIATOR…………………………………………………………………… 4-374
4.11 EVERY 10 OPERATING HOURS OR DAILY …………………………………………………………………….. 4-376
4.11.1 WALK-AROUND INSPECTION …………………………………………………………………………….. 4-377
4.11.2 RADIATOR – CHECK COOLANT LEVEL ……………………………………………………………….. 4-381
4.11.3 TRACK GROUPS – CLEAN ………………………………………………………………………………….. 4-381
4.11.4 BOOM FOR BH – CHECK LADDER AND WALKWAY ……………………………………………… 4-383
4.11.5 ELECTRICAL EQUIPMENT – CHECK CONDITION ………………………………………………… 4-383
4.11.6 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB …………………………………… 4-387
4.11.7 CAMERA SYSTEM……………………………………………………………………………………………… 4-389
4.12 EVERY 50 OPERATING HOURS OR WEEKLY ………………………………………………………………… 4-390
4.12.1 PTO (PUMP DISTRIBUTOR GEARS) – CHECK OIL LEVEL …………………………………….. 4-395
4.12.2 HYDRAULICALLY OPERATED STAIRWAY…………………………………………………………… 4-398
4.12.3 HYDRAULIC OIL COOLERS AND RADIATORS- INSPECT AND CLEAN IF
NECESSARY……………………………………………………………………………………………………… 4-403
4.13 EVERY 250 OPERATING HOURS OR MONTHLY …………………………………………………………….. 4-404
4.13.1 AIR CONDITIONING……………………………………………………………………………………………. 4-405
4.13.2 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…………………… 4-405
4.13.3 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL ……… 4-409
4.13.4 SIGNAL HORN COMPRESSOR – CHECK……………………………………………………………… 4-411
4.13.5 HYDRAULIC OIL COOLER FAN MOTOR – CHECK FOR LEAKAGE…………………………. 4-411
4.13.6 RADIATOR FAN MOTOR – CHECK FOR LEAKAGE……………………………………………….. 4-411
4.13.7 TRACK FRAME CONNECTING BOLTS ………………………………………………………………… 4-413
4.13.8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL……………………………………… 4-415
4.13.9 CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTERS ………………………… 4-417
4.13.10 BATTERIES – CHECK FLUID LEVEL…………………………………………………………………….. 4-419
4.14 EVERY 500 OPERATING HOURS OR MONTHLY …………………………………………………………….. 4-422
4.14.1 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK
OIL LEVEL …………………………………………………………………………………………………………. 4-423
4.14.2 FUEL TANK – DRAIN CONDENSATION ………………………………………………………………… 4-427
4.14.3 CRAWLER TRACK – INSPECTION……………………………………………………………………….. 4-429
4.14.4 GROUND CABLES OF ENGINE, PRELUBRICATION PUMP AND ALTERNATOR – CHECK
FOR CORRECT CONNECTION……………………………………………………………………………. 4-435
4.14.5 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION … 4-437
4.14.6 EMERGENCY LOWERING OF STAIRWAY – TEST FUNCTIONALITY………………………. 4-441
4.14.7 EMERGENCY ESCAPE LADDERS ………………………………………………………………………. 4-443
4.14.8 CLEANING AIR CONDITIONER FILTERS……………………………………………………………… 4-445
4.14.9 REPLACING FUEL FILTERS ……………………………………………………………………………….. 4-449
4.15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS ………………………………………………. 4-451
4.15.1 CHANGING AIR CONDITION CONDENSER………………………………………………………….. 4-451
4.15.2 CRITICAL BOLT CONNECTIONS…………………………………………………………………………. 4-453
4.15.3 HYDRAULIC SYSTEM – FILTER SERVICE ……………………………………………………………. 4-459
4.15.4 PTO (PUMP DISTRIBUTOR GEAR), SLEW GEARS AND TRAVEL GEARS – OIL SAMPLE
ANALYSIS………………………………………………………………………………………………………….. 4-475
4.15.5 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE …………………………………… 4-477
4.15.6 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES ………….. 4-479
4.15.7 ALL OTHER HINGES AND AREAS TO LUBRICATE ………………………………………………. 4-481
4.15.8 EMERGENCY ENGINE STOP SWITCHES – TEST FUNCTIONALITY ………………………. 4-483
4.15.9 EMERGENCY ENGINE SHUTDOWN SYSTEM ACTUATED FROM GROUND MAN – TEST
FUNCTIONALITY………………………………………………………………………………………………… 4-485
4.15.10 ELECTRICAL EQUIPMENT – MAINTENANCE ……………………………………………………….. 4-487
4.15.11 RETIGHTENING LIP AND SIDE SHROUD J-BOLT…………………………………………………. 4-487
4.15.12 CHECKING AND RELEASING GAS IN THE ACCUMULATOR FOR CONTROL CIRCUIT 4-490
4.15.13 CHECK FUNCTION OF ACCUMULATOR FOR CONTROL CIRCUIT ……………………….. 4-491
4.16 EVERY 2000 OPERATING HOURS OR YEARLY ……………………………………………………………… 4-494
4.16.1 HYDRAULIC SYSTEM – CHANGE PULSATION DAMPER ………………………………………. 4-495
4.16.2 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST………………………….. 4-503
4.16.3 HYDRAULIC HOSES – CHECK CONDITION………………………………………………………….. 4-505
4.16.4 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB …………………………………… 4-507
4.17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR ………………………… 4-508
4.17.1 TRACK TENSIONING SYSTEM- CHECK ACCUMULATORS…………………………………… 4-509
4.17.2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL ……………………………………………….. 4-517
4.17.3 FLEXIBLE COUPLING – VISUAL CHECK ………………………………………………………………. 4-519
4.17.4 CRITICAL BOLT CONNECTIONS…………………………………………………………………………. 4-521
4.18 EVERY 4000 OPERATING HOURS HOWEVER AT LEAST EVERY TWO YEARS ……………….. 4-556
4.18.1 REPLACE ACCUMULATOR IN MAIN PUMP DRAIN CIRCUIT…………………………………. 4-557
4.19 FIRE PREVENTION ……………………………………………………………………………………………………….. 4-558
4.19.1 PRECAUTIONS ………………………………………………………………………………………………….. 4-559
4.20 WELD REPAIRS ……………………………………………………………………………………………………………. 4-560
4.20.1 GENERAL PROTECTIVE MEASURES………………………………………………………………….. 4-561
4.20.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
UNDERCARRIAGE …………………………………………………………………………………………….. 4-563
4.20.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
LOADER (BH) ATTACHMENT ……………………………………………………………………………… 4-565
4.20.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
SUPERSTRUCTURE ………………………………………………………………………………………….. 4-567
4.20.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…………………. 4-567

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