KOMATSU PC7000-11 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 35009 – PDF DOWNLOAD

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KOMATSU PC7000-11 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 35009 – PDF DOWNLOAD

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DESCRIPTION:

KOMATSU PC7000-11 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 35009 – 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 PC7000-11 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 35009 – PDF DOWNLOAD

1 FOREWORD 3
1 1 BEFORE READING THIS MANUAL 4
1 2 EC DECLARATION OF CONFORMITY 5
1 3 PRIVACY POLICY ON EXCAVATORS EQUIPPED WITH excavator MONITORING SYSTEMS FOR THE EEA 6
1 4 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS 9
1 5 DIRECTIONS OF THE EXCAVATOR 10
1 6 SPECIFICATION AND SERIAL PLATE 11
1 6 1 PRODUCT IDENTIFICATION NUMBER 11
1 7 DIVISION OF THE BINDER 12
1 8 DESIGNATED USE OF THE EXCAVATOR 13
1 9 DELIVERY OF THE EXCAVATOR 14
1 9 1 SPARE PARTS 14
1 9 2 SERVICE 14
1 10 EXPLANATION OF ABBREVIATIONS 15
2 SAFETY 23
2 1 SAFETY INFORMATION 24
2 2 OVERVIEW 25
2 2 1 NORMAL OPERATIONS 25
2 2 2 REGULAR MAINTENANCE 25
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 25
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 25
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 26
2 3 1 SOUND 26
2 3 2 VIBRATION 26
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 27
2 4 1 UNDERSTANDING THE MACHINE 27
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 27
2 4 2 1 ENSURING SAFE OPERATION 27
2 4 3 PREPARATIONS FOR SAFE OPERATION 27
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 27
2 4 3 2 INSPECTING THE MACHINE 27
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 28
2 4 3 4 KEEP MACHINE CLEAN 28
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 28
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 29
2 4 3 7 IF A PROBLEM IS FOUND 29
2 4 4 FIRE PREVENTION 29
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 29
2 4 4 2 ACTION IF FIRE OCCURS 31
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 31
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 32
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 32
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 32
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 32
2 4 5 4 WORKING IN HIGH PLACES 32
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 33
2 4 5 6 LEAVING THE MACHINE 33
2 4 6 BURN PREVENTION 33
2 4 6 1 Hot coolant 33
2 4 6 2 Hot oil 34
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 34
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 34
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 35
2 4 9 1 UNAUTHORIZED MODIFICATION 35
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 35
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 35
2 4 11 PRECAUTIONS AT JOBSITE 36
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 37
2 4 11 2 CAMERA SYSTEM WITH MONITORS 37
2 4 11 3 ENSURE GOOD VISIBILITY 37
2 4 11 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 37
2 4 11 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 38
2 4 11 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 38
2 4 11 7 Lightning Strikes 39
2 4 11 8 WORKING ON LOOSE GROUND 39
2 4 11 9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 40
2 4 11 10 VENTILATION OF ENCLOSED AREAS 41
2 4 12 STARTING motor 42
2 4 12 1 WARNING TAG 42
2 4 12 2 CHECKS BEFORE STARTING motor 42
2 4 12 3 PRECAUTION WHEN STARTING motor 42
2 4 12 4 PRECAUTION IN COLD AREAS 43
2 4 13 OPERATION 43
2 4 13 1 CHECKS BEFORE OPERATION 43
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 44
2 4 13 3 PRECAUTIONS WHEN traveling 45
2 4 13 4 TRAVELING ON SLOPES 46
2 4 13 5 OPERATIONS ON SLOPES 47
2 4 13 6 PROHIBITED OPERATIONS 47
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 48
2 4 13 8 PARKING THE MACHINE 48
2 4 13 9 TRANSPORTATION 48
2 5 PRECAUTION FOR MAINTENANCE 49
2 5 1 GENERAL PRECAUTIONS 49
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 50
2 5 1 2 STOP motor FOR MAINTENANCE 51
2 5 1 3 WARNING TAG 52
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 53
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 53
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 54
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 54
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 55
2 5 1 9 NOISE 55
2 5 1 10 WHEN USING A HAMMER 55
2 5 1 11 PROPER TOOLS 56
2 5 1 12 ACCUMULATOR 56
2 5 1 13 PERSONNEL 56
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 57
2 5 2 1 PRECAUTION WHEN WELDING 57
2 5 2 2 BATTERY HANDLING 57
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 58
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 59
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 60
2 5 3 3 REPLACEMENT OF HOSE LINES 60
2 5 3 4 INSPECTION OF HOSE LINES 60
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 61
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 61
2 5 3 7 AIR CONDITIONING MAINTENANCE 61
2 5 3 8 COMPRESSED AIR 62
2 5 3 9 WASTE MATERIALS 62
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 63
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 63
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 63
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 63
2 7 SPECIAL SAFETY EQUIPMENT 64
2 7 1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 65
2 7 2 OBJECT HANDLING 65
2 7 3 LIGHTING 65
2 7 4 WARNING BEACON 65
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 65
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 65
2 7 5 2 INSTRUCTIONS FOR USE 67
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 69
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 69
2 7 5 5 INSTRUCTIONS FOR USE 71
2 9 SAFETY WARNING SIGNS 73
2 9 1 LOCATION AND DESCRIPTION OF THE SIGNS 74
3 OPERATION 91
3 1 FOREWORD 92
3 2 CONSTRUCTION OF THE SHOVEL 93
3 2 1 OVERALL VIEW 93
3 2 2 UNDERCARRIAGE AND SUPERSTRUCTURE 94
3 2 2 1 SUPERSTRUCTURE 96
3 2 2 2 MACHINERY HOUSE 98
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 100
3 2 3 1 Lowering the ladder in emergency situations 103
3 2 4 EMERGENCY ESCAPE LADDERS 104
3 2 4 1 Emergency escape from the operator’s cabin 105
3 2 4 2 Emergency escape from the Machinery house 107
3 2 4 3 Emergency escape from the machinery house roof 109
3 2 4 4 ESCAPE LADDER WINCH ASSEMBLY 111
3 2 5 BOOM ACCESS LADDER AND WALKWAY 112
3 2 6 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 114
3 2 6 1 Engine Shutdown System actuated from Ground Man (Special Equipment) 115
3 2 6 2 Operator Warning System (Special Equipment) 115
3 2 7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 116
3 2 7 1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual 121
3 2 7 2 Operator’s Seat Adjustment 123
3 2 7 3 For more detailed information on the operator’s seat refer to the document filed in the volume 2 binder For more Information on the seat belt, refer to page 3-35 123
3 2 7 4 Co-driver’s Seat and Refrigerator Box 124
3 2 7 5 INSTRUCTIONS TO using and looking after THE SEAT BELTS 125
3 2 8 ENGINE OIL MANAGEMENT SYSTEM 126
3 2 8 1 Oil Burning System “Centinel” combined with Oil Supply System “Reserve” 129
3 2 8 2 Eliminator Engine Oil Filtration System 130
3 3 OPERATOR’S CAB – CONTROLS 132
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 132
3 3 1 1 Hydraulic Control System 133
3 3 1 2 Safety Circuit for Controls 133
3 3 1 3 Control Pattern 135
3 3 2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 136
3 3 2 1 Hydraulic Control System 137
3 3 2 2 Safety Circuit for Controls 137
3 3 2 3 Control Pattern 139
3 3 3 OPERATOR’S CONSOLE 141
3 3 3 1 Control Panel 143
3 3 3 2 Switch Board 145
3 3 4 INTERFACE PANEL FOR DIAGNOSTICS 147
3 4 Komtrax Plus– HEALTH MONITORING SYSTEM 148
3 4 1 SEQUENCE OF DISPLAYS 149
3 4 2 OPENING SCREEN 149
3 4 3 Function Checking Screen 150
3 4 4 MAIN GAUGE SCREENS 1 TO 3 151
3 4 4 1 Main Gauge Screen 1 152
3 4 4 2 Main Gauge Screen 2 154
3 4 4 3 Main Gauge Screen 3 154
3 4 4 4 Color Definition 154
3 4 5 ECO Guidance 155
3 4 5 1 OPERATING RECORDS 156
3 4 5 2 Average FUEL Consumption Logs 157
3 4 5 3 Machine Setting 158
3 4 5 4 Reset Truck Counter 158
3 4 6 Maintenance 159
3 4 7 Monitor Setting 159
3 4 7 1 Screen Adjustment 160
3 4 7 2 Clock Adjustment 161
3 4 7 3 LANGUAGE 162
3 4 8 Automatic Messages 163
3 4 8 1 Example OF Action Code L01 163
3 4 8 2 Example OF Action Code L03 164
3 4 8 3 EXAMPLE OF Action Code L04 164
3 5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 166
3 5 1 Digital Display 166
3 5 2 Luminous Indication 168
3 6 CAMERA SYSTEM – SPECIAL EQUIPMENT 170
3 6 1 Camera system, type 1 170
3 6 2 LOCATION OF MONITORS AND CONTROL UNITS 171
3 6 2 1 Operating the Monitors 173
3 6 2 2 Ajustments of the Monitor 173
3 6 2 3 Arrangement of the Cameras 177
3 6 3 CAMERA SYSTEM , TYPE 2 (KOMVISION) 178
3 6 3 1 The names, locations and views of the cameras 181
3 7 MACHINERY HOUSE 182
3 7 1 EMERGENCY ENGINE SHUTDOWN SWITCHES 183
3 7 2 SAFETY SWITCH FOR MAINTENANCE 185
3 7 3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT 187
3 8 ELECTRICAL CONTROLLERS IN CAB BASE 188
3 8 1 CONTROLLERS IN CAB BASE 189
3 9 CHECKS BEFORE STARTING THE ENGINES 190
3 9 1 Coolant Level 193
3 9 1 1 HYDRAULIC SYSTEM – CHECK OIL LEVEL 195
3 9 1 2 Machinery House Doors 195
3 9 1 3 OPERATOR’S SEAT ADJUSTMENT 195
3 10 STARTING THE ENGINES 196
3 10 1 STARTING PROCEDURE 199
3 10 1 1 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C 201
3 10 2 ENGINE WARM-UP 207
3 10 3 HYDRAULIC OIL WARM-UP 207
3 11 MOVING THE SHOVEL 209
3 11 1 TRAVEL CONTROL WITH FOOT PEDALS 209
3 11 1 1 TRAVEL ALARM / BACK-UP ALARM 211
3 11 2 TRAVELLING INSTRUCTIONS 211
3 11 2 1 TRAVELLING LONG DISTANCES 213
3 11 3 UNDERCARRIAGE TRACK SLIDERS 214
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 “” CONTROL 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 219
3 13 0 1 FACE SHOVEL BUCKET 220
3 13 1 COMBINED OPERATION CYCLES 221
3 14 WORKING INSTRUCTIONS 223
3 14 1 STABILITY OF THE SHOVEL 223
3 14 2 FURTHER OPERATING PRACTICES 225
3 14 3 Loading Trucks 229
3 15 PARKING THE SHOVEL 230
3 15 0 1 CLEANING THE TRACK GROUPS 230
3 16 STOPPING THE ENGINES 232
3 16 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 235
3 17 OPERATION OF THE LUBRICATION SYSTEM 236
3 17 1 CENTRAL LUBRICATION SYSTEM ”CLS” 236
3 17 1 1 Manual actuation of the central lubrication system 236
3 17 1 2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 237
3 17 2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 237
3 17 2 1 Manual actuation of the swing circle lubrication system 238
3 17 2 2 SWING CIRCLE LUBRICATION SYSTEM ”SLS” 239
3 17 2 3 ADJUSTMENTS OF THE SWING CIRCLE LUBRICATION SYSTEM 239
3 17 2 4 Defining the Lubrication System Greasing Areas 239
3 18 TRANSFER PUMP FOR HYDRAULIC OIL 240
3 18 1 OPERATING THE TRANSFER PUMP 241
3 18 2 TRANSFUSION PROCEDURE 243
3 19 CENTRAL REFILLING SYSTEM 246
3 19 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 247
3 19 2 OPERATING THE HYDRAULIC SERVICE ARM 249
3 19 3 RECEIVER PANEL WITH MONITOR BOX 251
3 19 3 1 Refilling Procedure: 255
3 19 4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS 257
3 20 FIRE DETECTION AND SUPPRESSION SYSTEM 258
3 20 0 1 FIRE DETECTION AND SUPPRESSION SYSTEMS 259
3 20 1 DISPLAY MODULE 263
3 20 2 INTERFACE CONTROL MODULE 265
3 20 3 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF 267
3 21 WORK ON THE LOADER ATTACHMENT 268
3 21 0 1 OBSERVE THE FOLLOWING INSTRUCTIONS 268
3 22 TRANSPORTATION AND LIFTING OF THE SHOVEL 269
3 22 1 DISASSEMBLING OF THE SHOVEL 269
3 22 2 TRANSPORTATION AND LIFTING 269
3 23 RETRIEVAL PROCEDURE 270
3 23 1 GENERAL 270
3 24 SHOVEL STORAGE 271
3 24 1 GENERAL 271
3 24 2 PREPARING FOR STORAGE 271
3 24 3 ONE MONTH REPETITIVE SERVICE PERIOD 271
3 24 4 SIX MONTH REPETITIVE SERVICE PERIOD 271
3 24 5 PREPARING FOR OPERATION 272
3 25 TROUBLE SHOOTING 273
3 25 1 GENERAL 273
3 25 2 ENGINE 273
3 25 3 HYDRAULIC SYSTEM 274
3 25 4 FINAL DRIVES AND SWING GEAR 275
3 25 5 CRAWLER TRACKS 275
4 MAINTENANCE 277
4 1 FOREWORD 278
4 1 1 DEFINITIONS 278
4 1 2 GENERAL RECOMMENDATIONS 278
4 2 PRECAUTIONS FOR MAINTENANCE 279
4 3 FLUIDS AND LUBRICANTS 280
4 3 1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 280
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 282
4 3 2 1 Recommended Hydraulic Oils 284
4 3 2 2 General Information to selecting hydraulic oils 285
4 4 FILLING CAPACITIES 287
4 5 STANDARD TORQUE LIST 288
4 5 1 Torque for Flange Joints 289
4 5 2 TORQUES FOR SPECIAL COMPONENTS 290
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 292
4 6 1 INITIAL AND FIRST SERVICING 292
4 6 1 1 INITIAL RUNNING-IN 292
4 6 1 2 AFTER THE FIRST 250 OPERATING HOURS 292
4 6 1 3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT 292
4 6 2 SERVICING THE CRITICAL BOLT CONNECTIONS 293
4 6 3 PERIODIC SERVICING INTERVALS 293
4 6 4 PERIODIC SERVICING SCHEDULE 293
4 6 4 1 WHEN NECESSARY 294
4 6 4 2 EVERY 10 OPERATING HOURS OR DAILY 294
4 6 4 3 EVERY 50 OPERATING HOURS OR WEEKLY 294
4 6 4 4 EVERY 250 OPERATING HOURS OR MONTHLY 295
4 6 4 5 EVERY 500 OPERATING HOURS OR QUATERLY 295
4 6 4 6 EVERY 1000 OPERATING HOURS OR 6 MONTHLY 296
4 6 4 7 EVERY 2000 OPERATING HOURS OR YEARLY 296
4 6 4 8 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 297
4 6 4 9 EVERY 6000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 297
4 6 5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS 298
4 7 SAFETY CRITICAL PARTS 299
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 299
4 7 2 INSPECTION OF HOSE LINES 300
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 300
4 8 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM 302
4 8 0 1 Servicing Intervals 302
4 8 0 2 Extended Service Intervals for Engines with Engine Oil Management System 306
4 8 1 MAINTENANCE OF THE ENGINES 306
4 8 2 ENGINE FUEL FILTER LOCATIONS 308
4 8 2 1 Cleaning Practices Before Working on the Fuel System 310
4 8 3 VENTING THE AIR FROM THE FUEL FILTERS 312
4 9 INITIAL SERVICING 313
4 9 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 313
4 9 2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 314
4 9 3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 315
4 9 4 SWING CIRCLE Pinion – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 316
4 9 5 SWING CIRCLE TOOTHING LUBRICATION 318
4 9 6 Swing circle – Check Torque OF BOLT CONNECTIONS 319
4 9 7 Retightening procedure of the crawler carrier mounting bolts 320
4 9 7 1 Procedure for ENSURING Proper Tightening OF the crawler carrier mounting bolts 321
4 9 7 2 Special hydraulic torque wrench 322
4 10 WHEN NECESSARY 323
4 10 1 ENGINE AIR CLEANER MAINTENANCE 324
4 10 1 1 Check the Dust Cup 324
4 10 1 2 Servicing the filter elements 326
4 10 1 3 Replacing the safety filter element (4) if necessary: 326
4 10 1 4 General Service Tips 326
4 10 2 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 328
4 10 3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 330
4 10 3 1 Service the Grease Filters for Refillable Grease Containers 332
4 10 4 GUIDE WHEELS – REPLACE FLOATING SEALS 332
4 11 EVERY 10 OPERATING HOURS OR DAILY 333
4 11 1 WALK – AROUND INSPECTION 334
4 11 2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL Check 338
4 11 3 RADIATORS – CHECK COOLANT LEVEL 340
4 11 4 TRACK GROUPS – CLEAN 340
4 11 4 1 Sliders (optional SPECIAL EQUIPMENT)- CHECK CONDITION 340
4 11 4 2 BOOM – CHECK LADDER AND WALKWAY 344
4 11 5 CAMERA SYSTEM 346
4 11 6 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 348
4 12 EVERY 50 OPERATING HOURS OR WEEKLY 349
4 12 0 1 Swing gears 350
4 12 1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL 352
4 12 1 1 TRAVEL GEAR BOX – CHECK OIL LEVEL 354
4 12 1 2 MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL 354
4 12 1 3 FINAL DRIVE HOUSING – CHECK OIL LEVEL 354
4 12 1 4 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES – CHECK BREATHER FILTERS 356
4 12 2 PTOs (PUMP DISTRIBUTOR GEARS) – CHECK OIL LEVEL 358
4 12 2 1 PTOs (PUMP DISTRIBUTOR GEARS), CHECK OIL LEVEL: 358
4 12 2 2 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings 360
4 12 2 3 Auxilliary drive- Check Oil Level in Drive Shaft Housings 360
4 12 3 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 362
4 12 4 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 364
4 13 EVERY 250 OPERATING HOURS OR MONTHLY 365
4 13 1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 366
4 13 2 SIGNAL HORN COMPRESSOR – LUBRICATE 368
4 13 3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 368
4 13 4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 368
4 13 5 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION 370
4 13 6 CABIN AIR CLEANER – INSPECT 372
4 13 7 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 374
4 13 8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 376
4 13 9 CABIN HEATER FILTER – INSPECT 378
4 14 EVERY 500 OPERATING HOURS OR QUARTERLY 379
4 14 1 BATTERIES – CHECK FLUID LEVEL 380
4 14 1 1 GREASE INJECTORS – CHECK INDICATOR STEMS 381
4 14 1 2 CORRECTIVE ACTIONS 381
4 14 1 3 CHECKING THE SLEW RING 381
4 14 1 4 CHECKING THE SLIDERS (OPTIONAL EQUIPMENT) for wear 382
4 14 2 CYLINDER ROD PROTECTION (IF EQUIPPED), Inspect 385
4 14 3 FUEL TANK 387
4 14 3 1 Drain Water and Sediments from Fuel Tank 387
4 14 3 2 Servicing the Fuel System 387
4 14 4 CRAWLER TRACK – INSPECTION 389
4 14 4 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 389
4 14 4 2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 391
4 14 4 3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 393
4 14 4 4 Bleeding the System 393
4 14 5 GROUND CABLES OF ENGINE AND ALTERNATOR – CHECK FOR CORRECT CONNECTION 395
4 14 6 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 397
4 14 7 EMERGENCY ESCAPE LADDERS 399
4 14 7 1 TEST FUNCTIONALITY 399
4 14 7 2 Lubricating 399
4 14 8 EMERGENCY LOWERING OF ACCESS LADDER – TEST FUNCTIONALITY 401
4 15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 402
4 15 1 Critical Bolt Connections 403
4 15 1 1 Check mounting of Operator’s cab 403
4 15 1 2 Check tightening torque of the counterweight mounting bolts, 405
4 15 1 3 Check condition and fastening of both swing gears (01) and swing motors (02) 407
4 15 2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 409
4 15 2 1 TEST MAINTENANCE SAFETY SWITCH (11) 411
4 15 3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY 411
4 15 4 ELECTRICAL EQUIPMENT – MAINTENANCE 413
4 15 5 CABIN AIR CLEANER – REPLACE PRIMARY FILTER 415
4 15 6 HYDRAULIC SYSTEM – FILTER SERVICE 417
4 15 6 1 FILTER SERVICE 419
4 15 7 BLEEDING AIR FROM THE RETURN OIL CHAMBERS 421
4 15 8 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 433
4 15 8 1 Oil drain plugs 433
4 15 9 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 435
4 15 10 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 437
4 15 11 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 439
4 15 12 ALL OTHER HINGES AND AREAS TO LUBRICATE 441
4 15 13 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 443
4 16 EVERY 2000 OPERATING HOURS OR YEARLY 444
4 16 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 445
4 16 1 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 447
4 16 1 2 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 449
4 16 1 3 Replace Suction Strainers of Main Pumps 453
4 16 2 FILLING THE HYDRAULIC SYSTEM 455
4 16 3 BLEEDING THE HYDRAULIC SYSTEM 456
4 16 4 BLEEDING THE SECONDARY PUMPS 464
4 16 5 EMERGENCY ESCAPE LADDERS – INSPECTION 467
4 16 6 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 469
4 16 7 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 471
4 16 7 1 Functionality 471
4 17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 472
4 17 0 1 SWING GEAR 473
4 17 1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL 477
4 17 2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 481
4 17 3 FLEXIBLE COUPLING – VISUAL CHECK 483
4 18 CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS 484
4 18 1 Critical BOLT CONNECTIONS – CHECK TORQUE LOAD 485
4 18 1 1 Hydraulic Access Ladder 487
4 18 1 2 Check fastening and condition of railings (A, B, C, D and E) 489
4 18 1 3 Check fastening and condition of cab base 491
4 18 1 4 Check fastening and condition of fuel tank 493
4 18 1 5 Check fastening and condition of hydraulic oil cooler 495
4 18 1 6 Check fastening and condition of hydraulic oil tank 497
4 18 1 7 Check fastening of power house frame (01) to superstructure main frame 499
4 18 1 8 Check fastening and condition of the eight power house posts 501
4 18 1 9 Power House Louvers 503
4 18 1 10 Power house Roof 505
4 18 1 11 Check mounting and security of Diesel engines and pump distributor gears 507
4 18 1 12 Check mounting and security of each Diesel engine and pump distributor gear 509
4 18 1 13 Main Hydraulic pumps 511
4 18 1 14 Check fastening and condition of control valve carrier, main control valves (I, II and III) and swing control valve (5) 513
4 18 1 15 Check condition and fastening of swivel joint (A) 515
4 18 1 16 Crawler Carrier (and sliders for cold regions if they are fitted as an option) 517
4 18 1 17 Check condition and fastening of railings (01/02) and of steps (03, 04, 05 and 23) 521
4 18 1 18 Roof-mounted crane for grease barrel replacement (special equipment) Check condition and fastening of the crane 523
4 19 EVERY 6000 HOURS HOWEVER AT LEAST ONCE A YEAR 524
4 19 1 AUTOMATIC LUBRICATION SYSTEMS – replace pump outlet GREASE FILTERS 525
4 19 2 HYDRAULIC Oil TANK – CHECK LEAKAGE OIL SCREEN FILTER 527
4 19 3 CHANGING THE HIGH PRESSURE FILTERS 529
4 20 FIRE PREVENTION 530
4 20 1 PRECAUTIONS 531
4 21 WELD REPAIRS 532
4 21 1 GENERAL INFORMATION 532
4 21 1 1 GENERAL PROTECTIVE MEASURES 533
4 21 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 533
4 21 2 1 COUNTERWEIGHT 533
4 21 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 535
4 21 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 537
4 21 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 539
4 21 5 1 Electrical Units in Cab Base, 541
4 21 5 2 Engine Electronics 541
4 21 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 541

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