KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:PC4000-6-822) – PDF Download

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KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:PC4000-6-822)

KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:PC4000-6-822) – PDF DOWNLOAD:

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KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:PC4000-6-822)

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 PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:PC4000-6-822)

1 FOREWORD...............................................................................................................................................  3
	1.1 BEFORE READING THIS MANUAL.......................................................................................................................  4
	1.2 DIRECTIONS OF THE MACHINE........................................................................................................................  5
	1.3 SPECIFICATION AND SERIAL PLATE...................................................................................................................  6
		1.3.1 PRODUCT IDENTIFICATION NUMBER..............................................................................................................  6
	1.4 DIVISION OF THE BINDER...........................................................................................................................  7
	1.5 DESIGNATED USE OF THE SHOVEL.....................................................................................................................  8
	1.6 DELIVERY OF THE SHOVEL...........................................................................................................................  9
		1.6.1 SPARE PARTS................................................................................................................................  9
		1.6.2 SERVICE....................................................................................................................................  9
	1.7 EXPLANATION OF ABBREVIATIONS..................................................................................................................... 10
	1.8 CONTENTS......................................................................................................................................... 11
2 SAFETY................................................................................................................................................. 17
	2.1 SAFETY INFORMATION............................................................................................................................... 18
	2.2 OVERVIEW......................................................................................................................................... 19
		2.2.1 NORMAL OPERATIONS.......................................................................................................................... 19
		2.2.2 REGULAR MAINTENANCE........................................................................................................................ 19
		2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR.................................................................................................... 19
		2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR............................................ 19
	2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB....................................................................................................... 20
	2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR......................................................................................... 21
		2.4.1 UNDERSTANDING THE MACHINE.................................................................................................................. 21
		2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR..................................................................................... 21
			2.4.2.1 ENSURING SAFE OPERATION.............................................................................................................. 21
		2.4.3 PREPARATIONS FOR SAFE OPERATION............................................................................................................ 21
			2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT....................................................................................... 21
			2.4.3.2 INSPECTING THE MACHINE............................................................................................................... 21
			2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT................................................................................... 22
			2.4.3.4 KEEP MACHINE CLEAN................................................................................................................... 22
			2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT............................................................................................ 22
			2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT.......................................................................................... 23
			2.4.3.7 IF A PROBLEM IS FOUND................................................................................................................ 23
		2.4.4 FIRE PREVENTION............................................................................................................................ 23
			2.4.4.1 PRECAUTIONS TO PREVENT FIRE.......................................................................................................... 23
			2.4.4.2 ACTION IF FIRE OCCURS................................................................................................................ 24
			2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB................................................................................................... 25
		2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE............................................................................................. 25
			2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE........................................................................... 25
			2.4.5.2 NO JUMPING ON OR OFF THE MACHINE..................................................................................................... 25
			2.4.5.3 NO PEOPLE ON THE ATTACHMENT.......................................................................................................... 25
			2.4.5.4 WORKING IN HIGH PLACES............................................................................................................... 25
			2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK.................................................................................................... 26
			2.4.5.6 LEAVING THE MACHINE.................................................................................................................. 26
		2.4.6 BURN PREVENTION............................................................................................................................ 27
			2.4.6.1 Hot coolant.......................................................................................................................... 27
			2.4.6.2 Hot oil.............................................................................................................................. 27
		2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS........................................................................................................ 27
		2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................................................... 28
			2.4.8.1 UNAUTHORIZED MODIFICATION............................................................................................................ 28
			2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....................................................................................... 28
		2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)........................................................................................................ 29
		2.4.10 PRECAUTIONS AT JOBSITE.................................................................................................................... 30
			2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT..................................................................................................... 31
			2.4.10.2 CAMERA SYSTEM WITH MONITORS......................................................................................................... 31
			2.4.10.3 ENSURE GOOD VISIBILITY.............................................................................................................. 31
			2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS.............................................................................................. 31
			2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.......................................................................................... 32
			2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES.............................................................................................. 32
			2.4.10.7 WORKING ON LOOSE GROUND............................................................................................................. 33
			2.4.10.8 GAS, DUST, STEAM AND SMOKE.......................................................................................................... 33
			2.4.10.9 VENTILATION OF ENCLOSED AREAS....................................................................................................... 34
		2.4.11 STARTING ENGINE........................................................................................................................... 35
			2.4.11.1 WARNING TAG......................................................................................................................... 35
			2.4.11.2 CHECKS BEFORE STARTING ENGINE....................................................................................................... 35
			2.4.11.3 PRECAUTION WHEN STARTING ENGINE..................................................................................................... 35
			2.4.11.4 PRECAUTION IN COLD AREAS............................................................................................................ 36
		2.4.12 OPERATION................................................................................................................................. 36
			2.4.12.1 CHECKS BEFORE OPERATION............................................................................................................. 36
			2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE................................................................................... 37
			2.4.12.3 PRECAUTIONS WHEN travelling......................................................................................................... 38
			2.4.12.4 TRAVELLING ON SLOPES................................................................................................................ 39
			2.4.12.5 OPERATIONS ON SLOPES................................................................................................................ 40
			2.4.12.6 PROHIBITED OPERATIONS............................................................................................................... 40
			2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES....................................................................................... 41
			2.4.12.8 PARKING THE MACHINE................................................................................................................. 41
			2.4.12.9 TRANSPORTATION...................................................................................................................... 41
	2.5 PRECAUTION FOR MAINTENANCE....................................................................................................................... 42
		2.5.1 GENERAL PRECAUTIONS........................................................................................................................ 42
			2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES.................................................................... 43
			2.5.1.2 STOP ENGINE FOR MAINTENANCE.......................................................................................................... 44
			2.5.1.3 WARNING TAG.......................................................................................................................... 45
			2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY........................................................................................................ 46
			2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS.............................................................................................. 46
			2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING.............................................................................. 47
			2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS.......................................................................................... 47
			2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT.............................................................................. 48
			2.5.1.9 NOISE................................................................................................................................ 48
			2.5.1.10 WHEN USING A HAMMER................................................................................................................. 48
			2.5.1.11 PROPER TOOLS........................................................................................................................ 49
			2.5.1.12 ACCUMULATOR......................................................................................................................... 49
			2.5.1.13 PERSONNEL........................................................................................................................... 49
		2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................................................................. 50
			2.5.2.1 PRECAUTION WHEN WELDING.............................................................................................................. 50
			2.5.2.2 BATTERY HANDLING..................................................................................................................... 50
		2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID....................................................................................................... 51
			2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE.................................................................................................. 51
			2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES............................................................................................... 52
			2.5.3.3 REPLACEMENT OF HOSE LINES............................................................................................................ 52
			2.5.3.4 INSPECTION OF HOSE LINES............................................................................................................. 52
			2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................................................................................ 53
			2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE......................................................................................................... 53
			2.5.3.7 AIR CONDITIONING MAINTENANCE......................................................................................................... 53
			2.5.3.8 COMPRESSED AIR....................................................................................................................... 54
			2.5.3.9 WASTE MATERIALS...................................................................................................................... 54
	2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS................................................................................ 55
		2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM......................................................................................................... 55
		2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS............................................................................ 55
		2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR............................................................................................. 55
	2.7 SPECIAL SAFETY EQUIPMENT......................................................................................................................... 56
		2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB.................................................................................. 57
		2.7.2 OBJECT HANDLING............................................................................................................................ 57
		2.7.3 LIGHTING................................................................................................................................... 57
		2.7.4 WARNING BEACON............................................................................................................................. 57
		2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)............................................................................... 57
			2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)......................................................................... 57
			2.7.5.2 INSTRUCTIONS FOR USE................................................................................................................. 59
			2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL..................................................................................... 61
			2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),......................................... 61
			2.7.5.5 INSTRUCTIONS FOR USE................................................................................................................. 63
	2.8 SAFETY WARNING SIGNS............................................................................................................................. 65
		2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS...................................................................................................... 66
3 OPERATION.............................................................................................................................................. 79
	3.1 FOREWORD......................................................................................................................................... 80
	3.2 CONSTRUCTION OF THE SHOVEL....................................................................................................................... 81
		3.2.1 OVERALL VIEW............................................................................................................................... 81
		3.2.2 SUPERSTRUCTURE............................................................................................................................. 82
			3.2.2.1 Machinery House...................................................................................................................... 86
			3.2.2.2 Main Hydraulic Oil Reservoir......................................................................................................... 88
			3.2.2.3 Hydraulic Oil Cooler................................................................................................................. 89
			3.2.2.4 Fuel Tank............................................................................................................................ 90
			3.2.2.5 Counterweight........................................................................................................................ 91
		3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER....................................................................................................... 92
			3.2.3.1 Operating the hydraulic Access Ladder................................................................................................ 93
		3.2.4 EMERGENCY ESCAPE LADDER.................................................................................................................... 96
		3.2.5 BOOM ACCESS LADDER AND WALKWAY............................................................................................................. 98
		3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.......................................................................100
			3.2.6.1 Emergency Engine Shutdown System actuated from Ground Man (special equipment)........................................................101
			3.2.6.2 Operator Warning System (special equipment)..........................................................................................101
		3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)..................................................................102
			3.2.7.1 Operator’s Cab - Emergency Escape Hammer and Storage Box for Operation Manual........................................................107
			3.2.7.2 Operator’s Seat Adjustment...........................................................................................................109
			3.2.7.3 Co-driver’s Seat and Refrigerator Box................................................................................................110
		3.2.8 UNDERCARRIAGE..............................................................................................................................111
		3.2.9 WORKING ATTACHMENT.........................................................................................................................112
			3.2.9.1 Loader attachment with bottom dump bucket............................................................................................112
			3.2.9.2 Loader attachment with backhoe bucket................................................................................................113
		3.2.10 DIESEL ENGINE TYPE SDA 16V160E-2..........................................................................................................114
		3.2.11 ENGINE OIL MANAGEMENT SYSTEM..............................................................................................................116
			3.2.11.1 Oil Burning System "Centinel" combined with Oil Supply System "Reserve".............................................................118
			3.2.11.2 Eliminator Engine Oil Filtration System.............................................................................................119
	3.3 OPERATOR’S CAB - CONTROLS........................................................................................................................120
		3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...........................................................................................................120
			3.3.1.1 HYDRAULIC CONTROL SYSTEM.............................................................................................................121
		3.3.2 SAFETY CIRCUIT FOR CONTROLS................................................................................................................121
			3.3.2.1 EURO Control Pattern.................................................................................................................123
		3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT................................................................................................124
			3.3.3.1 HYDRAULIC CONTROL SYSTEM.............................................................................................................125
		3.3.4 SAFETY CIRCUIT FOR CONTROLS................................................................................................................125
			3.3.4.1 EURO Control Pattern.................................................................................................................127
		3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK................................................................................................127
		3.3.6 OPERATOR’S CONSOLE.........................................................................................................................129
			3.3.6.1 Switch Board.........................................................................................................................131
		3.3.7 INTERFACE PANEL FOR DIAGNOSTICS............................................................................................................137
		3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER....................................................................................................139
	3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR (KOMTRAX PLUS)............................................................................140
		3.4.1 SEQUENCE OF DISPLAYS.......................................................................................................................141
		3.4.2 OPENING SCREEN.............................................................................................................................141
		3.4.3 MAIN GAUGE SCREENS 1 TO 3..................................................................................................................142
			3.4.3.1 Main Gauge Screen 1..................................................................................................................143
			3.4.3.2 Main Gauge Screen 2..................................................................................................................145
			3.4.3.3 Main Gauge Screen 3..................................................................................................................145
			3.4.3.4 Color Definition.....................................................................................................................147
			3.4.3.5 Automatic Shutdown of the Machine....................................................................................................147
		3.4.4 FUEL CONSUMPTION SCREEN....................................................................................................................149
		3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR................................................................................................150
		3.4.6 MAIN SCREEN - CHANGE >TIME >SMR >DATE......................................................................................................150
		3.4.7 MAINTENANCE MONITOR........................................................................................................................151
			3.4.7.1 Maintenance confirmation through Service Personnel...................................................................................151
		3.4.8 SETTINGS FOR OPERATOR......................................................................................................................152
			3.4.8.1 Settings for Operator................................................................................................................153
			3.4.8.2 User ID Screen.......................................................................................................................153
			3.4.8.3 Reset Truck Counter 1................................................................................................................153
			3.4.8.4 Screen Adjustment....................................................................................................................154
			3.4.8.5 Date Adjustment Screen...............................................................................................................156
			3.4.8.6 Clock Adjustment Screen..............................................................................................................156
			3.4.8.7 Language Selection Screen............................................................................................................156
		3.4.9 AUTOMATIC MESSAGES.........................................................................................................................157
			3.4.9.1 Automatic Messages...................................................................................................................158
			3.4.9.2 Automatic Messages...................................................................................................................159
			3.4.9.3 Automatic Messages...................................................................................................................160
		3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM..........................................................................................161
		3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES...................................................................................................173
	3.5 CAMERA SYSTEM WITH MONITORS......................................................................................................................176
		3.5.1 LOCATION OF MONITORS AND CONTROL UNITS.....................................................................................................177
			3.5.1.1 Operating the Monitors...............................................................................................................179
			3.5.1.2 Ajustments of the Monitor............................................................................................................179
			3.5.1.3 Arrangement of the Cameras...........................................................................................................183
	3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...........................................................................................184
		3.6.1 Digital Display............................................................................................................................184
		3.6.2 AUXILIARY HEATER FOR OPERATOR’S CAB........................................................................................................189
	3.7 POWER HOUSE......................................................................................................................................190
		3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES.........................................................................................................191
		3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES........................................................................................193
		3.7.3 CENTRAL CONTROL AND FILTER PANEL...........................................................................................................195
	3.8 ELECTRICAL EQUIPMENT IN CAB BASE.................................................................................................................196
		3.8.1 STANDARD COMPONENTS IN CAB BASE............................................................................................................197
		3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE.......................................................................................................201
			3.8.2.1 Checking diagnostic fault codes of the engine electronic controlled fuel system QUANTUM and of the engine monitoring system CENSE....203
		3.8.3 MASTER TURBO CONTROLLER MTC - LED INDICATIONS..............................................................................................205
		3.8.4 BINARY FAULT CODE LIST.....................................................................................................................212
			3.8.4.1 Combination Message 308 Trouble Can-Bus or Can Hardware..............................................................................214
		3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS........................................................................................214
		3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE.....................................................................................217
	3.9 CHECKS BEFORE STARTING THE ENGINE................................................................................................................224
		3.9.0.1 Coolant Level............................................................................................................................227
		3.9.0.2 Machinery House Doors....................................................................................................................229
		3.9.0.3 Operator’s Seat Adjustment...............................................................................................................229
	3.10 STARTING THE ENGINE.............................................................................................................................230
		3.10.1 STARTING PROCEDURE........................................................................................................................233
		3.10.2 ENGINE WARM-UP............................................................................................................................241
		3.10.3 HYDRAULIC OIL WARM-UP.....................................................................................................................241
		3.10.4 JUMP START WITH BOOSTER BATTERIES.........................................................................................................241
	3.11 MOVING THE SHOVEL...............................................................................................................................243
		3.11.1 TRAVEL CONTROL WITH FOOT PEDALS...........................................................................................................243
			3.11.1.1 TRAVEL ALARM / BACK-UP ALARM........................................................................................................245
		3.11.2 TRAVELLING INSTRUCTIONS...................................................................................................................245
			3.11.2.1 TRAVELLING LONG DISTANCES...........................................................................................................247
	3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE..........................................................................................................248
		3.12.1 SLEWING THE SUPERSTRUCTURE................................................................................................................248
			3.12.1.1 MACHINES WITH "EURO" CONTROL........................................................................................................248
			3.12.1.2 MACHINES WITH "KMG" CONTROL.........................................................................................................249
		3.12.2 BRAKING THE SUPERSTRUCTURE................................................................................................................249
		3.12.3 SLEW PARKING BRAKE........................................................................................................................250
			3.12.3.1 Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System................................251
			3.12.3.2 IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE...............................................................................251
	3.13 WORKING WITH THE ATTACHMENT.....................................................................................................................252
		3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM..............................................................................................252
			3.13.1.1 Backhoe.............................................................................................................................252
			3.13.1.2 FACE SHOVEL.........................................................................................................................252
		3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM...............................................................................................253
			3.13.2.1 Backhoe.............................................................................................................................253
			3.13.2.2 FACE SHOVEL.........................................................................................................................253
		3.13.3 BOTTOM DUMP BUCKET........................................................................................................................254
			3.13.3.1 Operating the bucket clam...........................................................................................................254
			3.13.3.2 OPERATING THE BUCKET CLAM...........................................................................................................254
		3.13.4 DROP BALL OPERATION.......................................................................................................................255
			3.13.4.1 SAFETY INSTRUCTIONS.................................................................................................................255
			3.13.4.2 SAFETY DEVICES (SPECIAL EQUIPMENT)..................................................................................................257
			3.13.4.3 WORKING HINTS.......................................................................................................................257
		3.13.5 COMBINED OPERATION CYCLES.................................................................................................................258
	3.14 WORKING INSTRUCTIONS............................................................................................................................260
		3.14.1 STABILITY OF THE SHOVEL...................................................................................................................260
		3.14.2 SHOVEL OPERATION..........................................................................................................................260
	3.15 PARKING THE SHOVEL..............................................................................................................................263
		3.15.0.1 CLEANING THE TRACK GROUPS...............................................................................................................263
	3.16 STOPPING THE ENGINE.............................................................................................................................264
		3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM..................................................................................................267
	3.17 OPERATION OF THE LUBRICATION SYSTEM.............................................................................................................268
		3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”..........................................................................................................268
			3.17.1.1 Manual actuation of the central lubrication system..................................................................................268
			3.17.1.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM.......................................................................................269
		3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”..............................................................................................269
			3.17.2.1 Manual actuation of the swing circle lubrication system.............................................................................270
			3.17.2.2 SWING CIRCLE LUBRICATION SYSTEM ”SLS”...............................................................................................271
			3.17.2.3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM...................................................................................271
	3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS..........................................................................................................272
		3.18.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS..................................................................................................273
		3.18.1 HIGH LEVEL ALARM ”FIRE”...................................................................................................................277
		3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE.....................................................................................277
		3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS...........................................................................................277
			3.18.3.1 MANUAL ACTUATION....................................................................................................................277
			3.18.3.2 AUTOMATIC ACTUATION.................................................................................................................277
		3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS..............................279
		3.18.5 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF......................................................281
	3.19 TRANSFER PUMP FOR HYDRAULIC OIL.................................................................................................................282
		3.19.1 OPERATING THE TRANSFER PUMP...............................................................................................................283
		3.19.2 FUNCTIONS OF THE TRANSFER PUMP............................................................................................................285
	3.20 CENTRAL REFILLING SYSTEM........................................................................................................................288
		3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM.................................................................................................289
			3.20.1.1 Operation of the hydraulic Service Arm..............................................................................................289
		3.20.2 OPERATING THE HYDRAULIC SERVICE ARM.......................................................................................................291
		3.20.3 RECEIVER PANEL WITH MONITOR BOX...........................................................................................................293
			3.20.3.1 Refilling Procedure.................................................................................................................295
		3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM.................................297
			3.20.4.1 Refilling the Grease Containers of the Automatic Lubrication Systems................................................................299
	3.21 WORK ON THE LOADER ATTACHMENT...................................................................................................................300
		3.21.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS......................................................................................................300
	3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL........................................................................................................301
		3.22.1 DISASSEMBLING OF THE SHOVEL...............................................................................................................301
		3.22.2 TRANSPORTATION AND LIFTING................................................................................................................301
	3.23 RETRIEVAL PROCEDURE.............................................................................................................................302
	3.24 SHOVEL STORAGE..................................................................................................................................303
		3.24.0.1 GENERAL.................................................................................................................................303
		3.24.1 PREPARING FOR STORAGE.....................................................................................................................303
		3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD.......................................................................................................303
		3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD.......................................................................................................303
		3.24.4 PREPARING FOR OPERATION...................................................................................................................304
	3.25 TROUBLE SHOOTING................................................................................................................................305
		3.25.0.1 GENERAL.................................................................................................................................305
		3.25.1 ENGINE....................................................................................................................................305
		3.25.2 HYDRAULIC SYSTEM..........................................................................................................................306
		3.25.3 FINAL DRIVES AND SWING MACHINERY..........................................................................................................307
		3.25.4 CRAWLER TRACKS............................................................................................................................307
4 MAINTENANCE............................................................................................................................................309
	4.1 FOREWORD.........................................................................................................................................310
		4.1.0.1 DEFINITIONS..............................................................................................................................310
		4.1.0.2 GENERAL RECOMMENDATIONS..................................................................................................................310
	4.2 SAFETY PRECAUTIONS FOR MAINTENANCE...............................................................................................................311
	4.3 FLUIDS AND LUBRICANTS............................................................................................................................312
		4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES.......................................................................................312
		4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES........................................................................................313
	4.4 FILLING CAPACITIES...............................................................................................................................315
	4.5 STANDARD TORQUE LIST.............................................................................................................................316
	4.6 LUBRICATION AND MAINTENANCE SCHEDULE.............................................................................................................317
		4.6.1 INITIAL SERVICING..........................................................................................................................317
			4.6.1.1 AFTER THE FIRST 250 OPERATING HOURS..................................................................................................317
			4.6.1.2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS.........................................................................................317
		4.6.2 PERIODIC SERVICING INTERVALS...............................................................................................................317
		4.6.3 PERIODIC SERVICING SCHEDULE................................................................................................................318
			4.6.3.1 Lubrication Chart....................................................................................................................322
	4.7 SAFETY CRITICAL PARTS............................................................................................................................324
		4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES....................................................................................324
		4.7.2 INSPECTION OF HOSE LINES...................................................................................................................324
		4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS......................................................................................324
	4.8 EXTENDED SERVICE INTERVALS.......................................................................................................................327
		4.8.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM.....................................................................................327
			4.8.1.1 Servicing Intervals..................................................................................................................331
		4.8.2 MAINTENANCE OF THE ENGINE..................................................................................................................331
	4.9 ENGINE FUEL FILTER LOCATION......................................................................................................................332
		4.9.1 fuel line connections on the engine........................................................................................................333
	4.10 WHEN NECESSARY..................................................................................................................................334
		4.10.1 ENGINE AIR CLEANER SERVICE................................................................................................................335
			4.10.1.1 General Service Tips................................................................................................................337
		4.10.2 SWING CIRCLE TOOTHING LUBRICATION.........................................................................................................339
		4.10.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS.........................................................................................341
			4.10.3.1 CLEAN OR REPLACE FILTER ELEMENTS....................................................................................................343
		4.10.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...................................................................................345
	4.11 EVERY 10 OPERATING HOURS OR DAILY...............................................................................................................346
		4.11.1 WALK-AROUND INSPECTION....................................................................................................................347
			4.11.1.1 WORKING ATTACHMENT - INITIAL CHECKS FOR PROPER LUBRICATION..........................................................................351
			4.11.1.2 CHECK GREASE INJECTORS..............................................................................................................353
			4.11.1.3 CORRECTIVE ACTIONS..................................................................................................................353
			4.11.1.4 CHECK GREASE INJECTORS..............................................................................................................355
		4.11.2 AIR CLEANER - CLEAN PRE-CLEANER...........................................................................................................357
			4.11.2.1 Clean dust cups of pre-cleaners.....................................................................................................357
		4.11.3 RADIATOR - CHECK COOLANT LEVEL............................................................................................................359
		4.11.4 TRACK GROUPS - CLEAN......................................................................................................................359
		4.11.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER.................................................................................................361
		4.11.6 BOOM - CHECK LADDER AND WALKWAY...........................................................................................................363
	4.12 EVERY 50 OPERATING HOURS OR WEEKLY..............................................................................................................364
		4.12.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.................................................................................365
			4.12.1.1 Swing gears manufactured by "L&S"...................................................................................................365
			4.12.1.2 Swing gears manufactured by SIEBENHAAR..............................................................................................367
			4.12.1.3 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S" - CHECK OIL LEVELS....................................369
			4.12.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN" - CHECK OIL LEVELS................................................373
		4.12.2 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL...........................................................................377
			4.12.2.1 CHECK OIL LEVEL OF PTO GEAR.........................................................................................................377
			4.12.2.2 CHECK OIL LEVEL OF OIL COLLECTOR RESERVOIR (4)......................................................................................377
		4.12.3 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.............................................................................................379
		4.12.4 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY....................................................................................381
	4.13 EVERY 250 OPERATING HOURS OR MONTHLY............................................................................................................382
		4.13.1 AIR CONDITIONING..........................................................................................................................383
		4.13.2 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION....................................................................................383
		4.13.3 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL.............................................................................387
		4.13.4 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE.................................................................................................389
		4.13.5 SIGNAL HORN COMPRESSOR - LUBRICATE........................................................................................................389
		4.13.6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...................................................389
		4.13.7 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER................................................................389
		4.13.8 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER...............................................................................391
		4.13.9 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT.........................................................................................395
			4.13.9.1 Clean and inspect filter element (2) as follows:....................................................................................395
			4.13.9.2 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT (Heavy duty version, special equipment)...........................................397
			4.13.9.3 Clean pre-cleaner dust bowl.........................................................................................................397
			4.13.9.4 Clean and inspect main filter element...............................................................................................397
		4.13.10 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL.............................................................................................399
	4.14 EVERY 500 OPERATING HOURS OR MONTHLY............................................................................................................400
		4.14.1 BATTERIES - CHECK FLUID LEVEL.............................................................................................................401
		4.14.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL.................................................................................................403
		4.14.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL..............................................................405
			4.14.3.1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS...............................................................................405
		4.14.4 FUEL TANK - DRAIN CONDENSATION............................................................................................................407
			4.14.4.1 DRAIN CONDENSATION AS FOLLOWS.......................................................................................................407
		4.14.5 CRAWLER TRACK - INSPECTION................................................................................................................409
			4.14.5.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS...............................................................................................409
			4.14.5.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS..............................................................................................411
			4.14.5.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS..............................................................................................413
			4.14.5.4 Bleeding the System.................................................................................................................413
		4.14.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION.....................................................415
		4.14.7 GROUND CABLE OF OPERATOR’S CAB - CHECK FOR CORRECT CONNECTION.............................................................................417
	4.15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH.....................................................................................................418
		4.15.1 HIGH STRENGTH BOLT CONNECTIONS............................................................................................................419
		4.15.2 HYDRAULIC SYSTEM - FILTER SERVICE.........................................................................................................469
		4.15.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...........................................................483
			4.15.3.1 Oil drain plugs, illustration.......................................................................................................483
			4.15.3.2 PTO (PUMP DISTRIBUTOR GEAR).........................................................................................................483
			4.15.3.3 SWING GEARS AND TRAVEL GEARS........................................................................................................483
		4.15.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE..............................................................................................485
		4.15.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS....................................................................................487
		4.15.6 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES..................................................................................489
		4.15.7 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES.................................................................................491
	4.16 EVERY 2000 OPERATING HOURS OR YEARLY............................................................................................................492
		4.16.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER.............................................................493
		4.16.2 FILLING THE HYDRAULIC SYSTEM..............................................................................................................503
		4.16.3 BLEEDING THE HYDRAULIC SYSTEM.............................................................................................................505
		4.16.4 GEAR PUMP FOR PTO GEAR LUBRICATION........................................................................................................507
		4.16.5 EMERGENCY ESCAPE LADDER - INSPECTION......................................................................................................509
	4.17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR.........................................................................................510
		4.17.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL........................................................................................511
			4.17.1.1 Swing gears manufactured by "L&S"...................................................................................................511
			4.17.1.2 "SWING GEARS MANUFACTURED BY “SIEBENHAAR”...........................................................................................515
			4.17.1.3 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S"- CHANGE OIL....................................................519
			4.17.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN"- CHANGE OIL.......................................................525
		4.17.2 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL..................................................................................................531
	4.18 FIRE PREVENTION.................................................................................................................................532
		4.18.1 PRECAUTIONS...............................................................................................................................533
	4.19 WELD REPAIRS....................................................................................................................................534
		4.19.1 GENERAL PROTECTIVE MEASURES...............................................................................................................535
			4.19.1.1 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL......................................................................................535
			4.19.1.2 COUNTERWEIGHT.......................................................................................................................535
		4.19.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE.....................................................................537
		4.19.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT.................................................................539
		4.19.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE....................................................................541
		4.19.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE....................................................................................543

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