KOMATSU PC3000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 06320 – PDF DOWNLOAD

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KOMATSU PC3000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 06320 – PDF DOWNLOAD

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DESCRIPTION:

KOMATSU PC3000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 06320 – 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 PC3000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 06320 – PDF DOWNLOAD

1 FOREWORD 3
1 1 BEFORE READING THIS MANUAL 4
1 2 EC DECLARATION OF CONFORMITY 5
1 3 DIRECTIONS OF THE MACHINE 6
1 4 SPECIFICATION AND SERIAL PLATE 7
1 4 1 PRODUCT IDENTIFICATION NUMBER 7
1 5 DIVISION OF THE BINDER 8
1 6 DESIGNATED USE OF THE SHOVEL 9
1 7 DELIVERY OF THE SHOVEL 10
1 7 1 SPARE PARTS 10
1 7 2 SERVICE 10
1 8 EXPLANATION OF ABBREVIATIONS 11
1 9 CONTENTS 13
2 SAFETY 19
2 1 SAFETY INFORMATION 20
2 2 OVERVIEW 21
2 2 1 NORMAL OPERATIONS 21
2 2 2 REGULAR MAINTENANCE 21
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 21
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 21
2 3 SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATOR’S CAB 22
2 3 1 SOUND 22
2 3 2 VIBRATION 22
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 23
2 4 1 UNDERSTANDING THE MACHINE 23
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 23
2 4 2 1 ENSURING SAFE OPERATION 23
2 4 3 PREPARATIONS FOR SAFE OPERATION 23
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 23
2 4 3 2 INSPECTING THE MACHINE 23
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 24
2 4 3 4 KEEP MACHINE CLEAN 24
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 24
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 25
2 4 3 7 IF A PROBLEM IS FOUND 25
2 4 4 FIRE PREVENTION 25
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 25
2 4 4 2 ACTION IF FIRE OCCURS 27
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 27
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 28
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 28
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 28
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 28
2 4 5 4 WORKING IN HIGH PLACES 28
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 29
2 4 5 6 LEAVING THE MACHINE 29
2 4 6 BURN PREVENTION 29
2 4 6 1 Hot coolant 29
2 4 6 2 Hot oil 30
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 30
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 30
2 4 8 1 UNAUTHORIZED MODIFICATION 31
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 31
2 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 31
2 4 10 PRECAUTIONS AT JOBSITE 32
2 4 10 1 VISIBILITY FROM OPERATOR’S SEAT 33
2 4 10 2 CAMERA SYSTEM WITH MONITORS 33
2 4 10 3 ENSURE GOOD VISIBILITY 33
2 4 10 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 33
2 4 10 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 34
2 4 10 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 34
2 4 10 7 WORKING ON LOOSE GROUND 35
2 4 10 8 GAS, DUST, STEAM AND SMOKE 35
2 4 10 9 VENTILATION OF ENCLOSED AREAS 36
2 4 11 STARTING motor 37
2 4 11 1 WARNING TAG 37
2 4 11 2 CHECKS BEFORE STARTING motor 37
2 4 11 3 PRECAUTION WHEN STARTING motor 37
2 4 11 4 PRECAUTION IN COLD AREAS 38
2 4 12 OPERATION 38
2 4 12 1 CHECKS BEFORE OPERATION 38
2 4 12 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 39
2 4 12 3 PRECAUTIONS WHEN travelling 40
2 4 12 4 TRAVELLING ON SLOPES 41
2 4 12 5 OPERATIONS ON SLOPES 42
2 4 12 6 PROHIBITED OPERATIONS 42
2 4 12 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 43
2 4 12 8 PARKING THE MACHINE 43
2 4 12 9 TRANSPORTATION 43
2 5 PRECAUTION FOR MAINTENANCE 44
2 5 1 GENERAL PRECAUTIONS 44
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 45
2 5 1 2 STOP motor FOR MAINTENANCE 46
2 5 1 3 WARNING TAG 47
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 48
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 48
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 49
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 49
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 50
2 5 1 9 NOISE 50
2 5 1 10 WHEN USING A HAMMER 50
2 5 1 11 PROPER TOOLS 51
2 5 1 12 ACCUMULATOR 51
2 5 1 13 PERSONNEL 51
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 52
2 5 2 1 PRECAUTION WHEN WELDING 52
2 5 2 2 BATTERY HANDLING 52
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 53
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 53
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 54
2 5 3 3 REPLACEMENT OF HOSE LINES 54
2 5 3 4 INSPECTION OF HOSE LINES 54
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 55
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 55
2 5 3 7 AIR CONDITIONING MAINTENANCE 55
2 5 3 8 COMPRESSED AIR 56
2 5 3 9 WASTE MATERIALS 56
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 57
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 57
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 57
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 57
2 7 SPECIAL SAFETY EQUIPMENT 58
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 59
2 7 2 OBJECT HANDLING 59
2 7 3 LIGHTING 59
2 7 4 WARNING BEACON 59
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 59
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 59
2 7 5 2 INSTRUCTIONS FOR USE 61
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 63
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 63
2 7 5 5 INSTRUCTIONS FOR USE 65
2 8 HIGH VOLTAGE SAFETY INSTRUCTIONS FOR MACHINES WITH ELECTRIC MOTOR 67
2 8 1 QUALIFICATION OF PERSONNEL 67
2 8 2 ELECTRICAL TOOLS 67
2 8 3 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT 68
2 8 4 CONNECTION OF PILOT LINE (GROUND CHECK WIRE) 68
2 8 5 PREPARATION BEFORE WORKING ON THE CABLE DRUM 68
2 8 6 PREPARATION BEFORE WORKING ON THE CABLE GUIDE 69
2 8 7 MODIFICATION OF THE ELECTRICAL SYSTEM 69
2 8 8 FIRE 69
2 8 9 GENERAL INSTRUCTIONS 70
2 9 SAFETY WARNING SIGNS 71
2 9 1 LOCATION AND DESCRIPTION OF THE SIGNS 72
3 OPERATION 87
3 1 FOREWORD 88
3 2 CONSTRUCTION OF THE SHOVEL 89
3 2 1 OVERALL VIEW 89
3 2 2 UNDERCARRIAGE AND SUPERSTRUCTURE 90
3 2 2 1 SUPERSTRUCTURE – TOP VIEW 92
3 2 2 2 Undercarriage 95
3 2 2 3 Attachment 97
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 98
3 2 3 1 Operating the hydraulic Access Ladder 99
3 2 4 EMERGENCY ESCAPE LADDER 102
3 2 5 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE (SPECIAL EQUIPMENT) 104
3 2 6 motor SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 106
3 2 6 1 motor Shutdown System actuated from Ground Man (Special Equipment) 107
3 2 6 2 Operator Warning System (Special Equipment) 107
3 2 7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 108
3 2 7 1 Operator’s Seat Adjustment 113
3 2 7 2 Co-driver’s Seat 114
3 2 7 3 INSTRUCTIONS TO using and looking after THE SEAT BELTS 115
3 3 OPERATOR’S CAB – CONTROLS 116
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 116
3 3 1 1 Hydraulic Control System 117
3 3 1 2 Safety Circuit for Controls 117
3 3 1 3 EURO Control Pattern 119
3 3 2 CONTROLS WITH BOTTOM DUMP BUCKET 120
3 3 2 1 Hydraulic Control System 121
3 3 2 2 Safety Circuit for Controls 121
3 3 2 3 Automatic Float Position for Boom and Stick 121
3 3 2 4 EURO Control Pattern 123
3 3 3 OPERATOR’S CONSOLE 125
3 3 3 1 Control Panel 127
3 3 3 2 Rear Panel Controls 131
3 4 ELECTRONIC TEXT MONITORING SYSTEM ETM 132
3 4 1 INTRODUCTION 133
3 4 2 SYSTEM COMPONENTS 135
3 4 3 STRUCTURE AND FUNCTIONS OF THE CONTROL MENU 139
3 4 4 Fault and Information Message Classification 139
3 4 4 1 DISPLAYING THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY 141
3 4 4 2 Display the Contents of Statistics Memory 143
3 4 4 3 Transfering the data of the Statistics Memory and the Protocol Memory 145
3 4 4 4 Downloading the Data 145
3 4 4 5 Changing the Input Language 147
3 4 4 6 Settings of the Display Unit 147
3 4 4 7 TABLE OF MESSAGES 148
3 4 4 8 Explanation of statistics download information 163
3 4 4 9 Time Diagram of Statistics Print 163
3 5 CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT) 166
3 5 1 LOCATION OF MONITOR AND CONTROL UNIT 167
3 5 1 1 Operating the Monitors 169
3 5 1 2 Typical Arrangement of the Cameras 171
3 6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 172
3 6 1 Digital Display 172
3 7 MACHINERY HOUSE 176
3 7 1 EMERGENCY motor SHUTDOWN SWITCHES 177
3 8 ELECTRICAL EQUIPMENT IN CAB BASE 178
3 8 1 CAB BASE 181
3 8 1 1 Access Cover for the Headlights mounted on Cab Base 183
3 8 2 SWITCH BOX (X2) IN CAB BASE 185
3 8 3 Medium Voltage Switch Cabinet 187
3 8 3 1 Medium Voltage Switch Cabinet 189
3 8 4 PREHEATING SYSTEM 193
3 9 CHECKS BEFORE STARTING THE MOTOR 196
3 9 1 WALK AROUND INSPECTION 197
3 9 2 TURNING ON THE POWER SUPPLY 197
3 9 2 1 HYDRAULIC SYSTEM – CHECK OIL LEVEL 199
3 9 2 2 OPERATOR’S SEAT ADJUSTMENT 199
3 10 STARTING THE MOTOR 200
3 10 1 STARTING PROCEDURE AT AMBIENT TEMPERATURE UP TO -25°C 203
3 10 2 STARTING PROCEDURES AT AMBIENT TEMPERATURES FROM -25°C TO -40°C 205
3 10 2 1 Hydraulic Oil Viscosity and Temperature Chart 209
3 11 MOVING THE SHOVEL 210
3 11 1 TRAVEL CONTROL WITH FOOT PEDALS 210
3 11 1 1 PARKING BRAKE 212
3 11 1 2 TRAVEL ALARM / BACK-UP ALARM 212
3 11 2 TRAVELLING INSTRUCTIONS 212
3 11 2 1 TRAVELLING LONG DISTANCES 215
3 12 SLEWING AND BRAKING THE SUPERSTRUCTURE 216
3 12 1 SLEWING THE SUPERSTRUCTURE 216
3 12 1 1 MACHINES WITH “EURO” CONTROL 216
3 12 1 2 MACHINES WITH “KMG” CONTROLBraking the 217
3 12 1 3 BRAKING THE SUPERSTRUCTURE 217
3 12 1 4 Hydraulic slew brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System 218
3 12 1 5 Important Instructions for Slewing the Superstructure 218
3 13 WORKING WITH THE ATTACHMENT 220
3 13 1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM 220
3 13 1 1 BACKHOE 220
3 13 1 2 FACE SHOVEL 220
3 13 2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM 221
3 13 2 1 BACKHOE 221
3 13 2 2 FACE SHOVEL 221
3 13 2 3 BOTTOM DUMP BUCKET 222
3 13 2 4 OPERATING THE BUCKET CLAM 222
3 13 2 5 SAFETY DEVICES (SPECIAL EQUIPMENT) 224
3 13 2 6 WORKING HINTS 224
3 13 3 COMBINED OPERATION CYCLES 225
3 14 WORKING INSTRUCTIONS 227
3 14 1 STABILITY OF THE SHOVEL 227
3 14 2 SHOVEL OPERATION 227
3 15 PARKING THE SHOVEL 230
3 15 0 1 CLEANING THE TRACK GROUPS 230
3 16 STOPPING THE MOTOR 232
3 16 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 235
3 17 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM 236
3 17 1 ISOLATING THE POWER SUPPLY 239
3 17 2 PROCEDURE FOR ISOLATING THE POWER SUPPLY 241
3 17 3 PERFORMING GROUNDING PROCEDURES 243
3 18 AUTOMATIC LUBRICATION SYSTEMS 248
3 18 1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS 249
3 19 FIRE DETECTION AND SUPPRESSION SYSTEM 252
3 19 0 1 FIRE DETECTION AND SUPPRESSION SYSTEMS 253
3 19 0 2 FIRE DETECTION AND SUPPRESSION SYSTEM 255
3 19 1 HIGH LEVEL ALARM -FIRE- 257
3 19 2 Motor shut-down 257
3 19 3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM 257
3 19 3 1 MANUAL ACTUATION 257
3 19 3 2 AUTOMATIC ACTUATION 257
3 19 4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM 259
3 20 CENTRAL REFILLING SYSTEM 260
3 20 1 REFILLING SYSTEM FOR HYDRAULIC OIL RESERVOIR, GREASE BARRELS OF THE CENTRAL REFILLING SYSTEM AND SLEW RING GEAR LUBRICATION SYSTEM 261
3 20 2 REFILLING PROCEDURE 263
3 20 3 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS 265
3 21 TRANSFER PUMP FOR HYDRAULIC OIL 266
3 21 1 OPERATING THE TRANSFER PUMP 267
3 21 2 FUNCTIONS OF THE TRANSFER PUMP 267
3 22 CABLE GUIDE (IF SO EQUIPPED) 271
3 22 1 LIFTING DEVICE FOR THE POWER CABLE 271
3 23 WORK ON THE LOADER ATTACHMENT 272
3 23 0 1 OBSERVE THE FOLLOWING INSTRUCTIONS 272
3 24 TRANSPORTATION AND LIFTING OF THE SHOVEL 273
3 24 1 DISASSEMBLING OF THE SHOVEL 273
3 24 2 TRANSPORTATION AND LIFTING 273
3 25 RETRIEVAL PROCEDURE 274
3 25 1 GENERAL 274
3 26 SHOVEL STORAGE 275
3 26 1 GENERAL 275
3 26 2 PREPARING FOR STORAGE 275
3 26 3 ONE MONTH REPETITIVE SERVICE PERIOD 275
3 26 4 SIX MONTH REPETITIVE SERVICE PERIOD 275
3 26 5 PREPARING FOR OPERATION 276
3 27 TROUBLE SHOOTING 277
3 27 1 GENERAL 277
3 27 2 MAIN DRIVE ELECTRIC MOTOR 277
3 27 3 HYDRAULIC SYSTEM 278
3 27 4 FINAL DRIVES AND SWING GEAR 279
3 27 5 CRAWLER TRACKS 279
4 MAINTENANCE 281
4 1 FOREWORD 282
4 1 1 DEFINITIONS 282
4 1 2 GENERAL RECOMMENDATIONS 282
4 2 PRECAUTIONS FOR MAINTENANCE 283
4 3 FLUIDS AND LUBRICANTS 284
4 3 1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 284
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 285
4 3 3 MAIN DRIVE ELECTRIC MOTORS – BEARING LUBRICATION 286
4 3 3 1 Recommended Hydraulic Oils 287
4 3 3 2 General Information to selecting hydraulic oils 288
4 4 FILLING CAPACITIES 290
4 5 STANDARD TORQUE LIST 291
4 5 1 Torque for Flange Joints 292
4 5 2 TORQUES FOR SPECIAL COMPONENTS 293
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 295
4 6 1 INITIAL SERVICING 295
4 6 1 1 INITIAL RUNNING-IN 295
4 6 1 2 AFTER THE FIRST 250 OPERATING HOURS 295
4 6 1 3 AFTER THE FIRST 1000 OPERATING HOURS 295
4 6 2 SERVICING THE CRITICAL BOLT CONNECTIONS 296
4 6 3 PERIODIC SERVICING INTERVALS 296
4 6 4 PERIODIC SERVICING SCHEDULE 296
4 6 4 1 WHEN NECESSARY 296
4 6 4 2 EVERY 10 OPERATING HOURS OR DAILY 297
4 6 4 3 EVERY 50 OPERATING HOURS OR WEEKLY 297
4 6 4 4 EVERY 250 OPERATING HOURS OR MONTHLY 298
4 6 4 5 EVERY 500 OPERATING HOURS OR QUATERLY 298
4 6 4 6 EVERY 1000 OPERATING HOURS OR 6 MONTHLY 298
4 6 4 7 EVERY 2000 OPEARTING HOURS OR YEARLY 299
4 6 4 8 EVERY 3000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 300
4 6 4 9 EVERY 6000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 300
4 6 5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM 301
4 6 6 Lubrication Chart 302
4 7 SAFETY CRITICAL PARTS 303
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 303
4 7 2 INSPECTION OF HOSE LINES 303
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 303
4 8 INITIAL SERVICING 306
4 8 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 307
4 8 2 CAR BODY AND RACEWAY OF SLEW RING 309
4 8 3 SWING CIRCLE – CHECK GREASE INJECTORS 311
4 8 4 SWING CIRCLE – CHECK TORQUE OF BOLT CONNECTIONS 313
4 8 5 RETIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS 315
4 8 5 1 PROCEDURE FOR ENSURING PROPER TIGHTENING OF THE CRAWLER CARRIER MOUNTING BOLTS 317
4 9 WHEN NECESSARY 322
4 9 1 SWING CIRCLE TOOTHING LUBRICATION 323
4 9 2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 325
4 9 2 1 Service the Grease Filters for Refillable Grease Containers of the Central Lubrication System and Swing circle pinion Lubrication System 327
4 9 3 GUIDE WHEELS – REPLACE FLOATING SEALS 327
4 9 4 SLIP RING UNIT – VISUAL CHECK 328
4 10 EVERY 10 OPERATING HOURS OR DAILY 330
4 10 1 WALKAROUND INSPECTION 331
4 10 1 1 BOOM – CHECK LADDER AND WALKWAY 335
4 10 2 ELECTRICAL EQUIPMENT – CHECK CONDITION 335
4 11 EVERY 50 OPERATING HOURS OR WEEKLY 336
4 11 1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHECK OIL LEVEL 337
4 11 1 1 CHECK SWING GEAR OIL LEVEL 337
4 11 1 2 CHECK MOTOR ADAPTER HOUSING OIL LEVEL 337
4 11 1 3 Swing Gear manufactured by “Siebenhaar” or “Mitsui” 339
4 11 2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 341
4 11 2 1 PLANETARY GEAR BOX – CHECK OIL LEVEL 341
4 11 2 2 SPUR GEAR BOX – CHECK OIL LEVEL 343
4 11 2 3 BRAKE HOUSINGS – CHECK OIL LEVEL 343
4 11 2 4 MOTOR ADAPTER HOUSING – CHECK OIL LEVEL 343
4 11 2 5 MILEAGE INDICATOR (Special Equipment) 343
4 11 3 PTO (PUMP DISTRIBUTOR GEAR) – CHECK OIL LEVEL 345
4 11 3 1 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings 345
4 11 4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 347
4 11 5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 349
4 12 EVERY 250 OPERATING HOURS OR MONTHLY 350
4 12 1 SIGNAL HORN COMPRESSOR – LUBRICATE 351
4 12 2 HYDRAULIC OIL COOLER FAN – CHECK CONDITION AND FASTENING 351
4 12 3 AUTOMATIC LUBRICATION SYSTEMS – CLEAN BREATHER FILTER 353
4 12 4 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 355
4 12 4 1 Clean and inspect filter element (3) as follows: 355
4 12 5 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL 357
4 12 6 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 359
4 12 6 1 Checking the refrigerant level 359
4 12 7 AIR CONDITIONER UNIT FOR MEDIUM VOLTAGE AND HIGH VOLTAGE SWITCH CABINETS 361
4 12 8 CABLE GRIP – CHECK CONDITION 363
4 13 EVERY 500 OPERATING HOURS OR MONTHLY 364
4 13 1 BATTERIES – CHECK FLUID LEVEL 365
4 13 2 CRAWLER TRACK – INSPECTION 367
4 13 2 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 367
4 13 2 2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 369
4 13 2 3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 371
4 13 2 4 Bleeding the System 371
4 13 2 5 GREASE INJECTORS – CHECK INDICATOR STEMS 372
4 13 2 6 CORRECTIVE ACTIONS 372
4 13 3 EMERGENCY LOWERING OF ACCESS LADDER – Test FUNCTIONALITY 375
4 13 4 HIGH VOLTAGE SWITCH CABINET – VISUAL CHECK 377
4 13 5 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 379
4 14 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 380
4 14 1 CRITICAL BOLT CONNECTIONS 381
4 14 2 HYDRAULIC SYSTEM – FILTER SERVICE 387
4 14 2 1 FILTER SERVICE 389
4 14 3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 401
4 14 3 1 Oil drain plugs, 401
4 14 3 2 PTO (PUMP DISTRIBUTOR GEAR) 401
4 14 3 3 SWING GEAR AND TRAVEL GEARS 401
4 14 4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 403
4 14 5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 405
4 14 6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 407
4 14 7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 407
4 14 8 SLIP RING UNIT – LUBRICATE 409
4 14 8 1 Lubricate 409
4 14 9 EMERGENCY MOTOR SHUTDOWN SWITCHES – TEST FUNCTIONALITY 411
4 14 10 MOTOR SHUTDOWN PULL chains (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY 413
4 14 11 HIGH VOLTAGE SWITCH CABINET – CHECK SCREW CONNECTIONS 415
4 14 12 ELECTRICAL EQUIPMENT – MAINTENANCE 417
4 15 EVERY 2000 OPERATING HOURS OR YEARLY 418
4 15 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 419
4 15 1 1 Sequence of Servicing 419
4 15 1 2 Filling the Hydraulic System 427
4 15 1 3 Hydraulic oil viscosity and adjustment of temperature switch units 429
4 15 1 4 Vent Suction Oil Reservoir and Hydraulic Pumps 431
4 15 2 EMERGENCY ESCAPE LADDER – INSPECTION 433
4 15 3 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 435
4 15 4 SLIP RING UNIT – MAINTENANCE 437
4 16 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 442
4 16 1 SWING GEAR AND MOTOR ADAPTER HOUSING – CHANGE OIL 443
4 16 1 1 Swing gear manufactured by “L&S” 443
4 16 1 2 SWING GEAR MANUFACTURED BY “SIEBENHAAR” or “MITSUI” 447
4 16 2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL 451
4 16 2 1 TRAVEL GEARS – CHANGE OIL 453
4 16 2 2 BRAKE HOUSINGS – CHANGE OIL 453
4 16 2 3 MOTOR ADAPTER HOUSINGS – CHANGE OIL 453
4 16 3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 455
4 16 3 1 BLEEDING GEAR PUMP FOR PTO LUBRICATION 457
4 16 4 PTO GEAR OIL VISCOSITY AND ADJUSTMENT OF TEMPERATURE SWITCH UNITS 459
4 16 5 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD 461
4 17 EVERY 6000 HOURS OR AT LEAST ONCE A YEAR 480
4 17 1 AUTOMATIC LUBRICATION SYSTEMS – Replace GREASE FILTERS 481
4 17 2 HYDRAULIC Oil TANK – CHECK LEAKAGE OIL SCREEN FILTER 483
4 18 FIRE PREVENTION 484
4 18 1 PRECAUTIONS 485
4 19 WELD REPAIRS 486
4 19 1 GENERAL PROTECTIVE MEASURES 487
4 19 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 487
4 19 2 1 COUNTERWEIGHT 487
4 19 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 489
4 19 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 491
4 19 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 493
4 19 5 1 Electrical Units in Cab Base 495
4 19 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 495

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