KOMATSU PC8000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 12086 – PDF DOWNLOAD

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KOMATSU PC8000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 12086 – PDF DOWNLOAD

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DESCRIPTION:

KOMATSU PC8000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 12086 – 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 PC8000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 12086 – PDF DOWNLOAD

1 FOREWORD 3
1 1 BEFORE READING THIS MANUAL 4
1 2 EC DECLARATION OF CONFORMITY 5
1 3 PRIVACY POLICY ON MACHINES EQUIPPED WITH MACHINE MONITORING SYSTEMS 6
1 4 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS 10
1 5 DIRECTIONS OF THE MACHINE 11
1 6 SPECIFICATION AND SERIAL PLATE 12
1 6 1 PRODUCT IDENTIFICATION NUMBER 12
1 7 DIVISION OF THE BINDER 13
1 8 DESIGNATED USE OF THE SHOVEL 14
1 9 DELIVERY OF THE SHOVEL 15
1 9 1 SPARE PARTS 15
1 9 2 SERVICE 15
1 10 EXPLANATION OF ABBREVIATIONS 16
2 SAFETY 25
2 1 SAFETY INFORMATION 26
2 2 OVERVIEW 27
2 2 1 NORMAL OPERATIONS 27
2 2 2 REGULAR MAINTENANCE 27
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 27
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 27
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 28
2 3 1 SOUND 28
2 3 2 VIBRATION 28
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 29
2 4 1 UNDERSTANDING THE MACHINE 29
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 29
2 4 2 1 ENSURING SAFE OPERATION 29
2 4 3 PREPARATIONS FOR SAFE OPERATION 29
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 29
2 4 3 2 INSPECTING THE MACHINE 29
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 30
2 4 3 4 KEEP MACHINE CLEAN 30
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 30
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 31
2 4 3 7 IF A PROBLEM IS FOUND 31
2 4 4 FIRE PREVENTION 31
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 31
2 4 4 2 ACTION IF FIRE OCCURS 33
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 33
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 34
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 34
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 34
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 34
2 4 5 4 WORKING IN HIGH PLACES 34
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 35
2 4 5 6 LEAVING THE MACHINE 35
2 4 6 BURN PREVENTION 35
2 4 6 1 Hot coolant 35
2 4 6 2 Hot oil 36
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 36
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 36
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 37
2 4 9 1 UNAUTHORIZED MODIFICATION 37
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 37
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 37
2 4 11 PRECAUTIONS AT JOBSITE 38
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 39
2 4 11 2 CAMERA SYSTEM WITH MONITORS 39
2 4 11 3 ENSURE GOOD VISIBILITY 39
2 4 11 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 39
2 4 11 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 40
2 4 11 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 40
2 4 11 7 Lightning Strikes 41
2 4 11 8 WORKING ON LOOSE GROUND 41
2 4 11 9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 42
2 4 11 10 VENTILATION OF ENCLOSED AREAS 43
2 4 12 STARTING motor 44
2 4 12 1 WARNING TAG 44
2 4 12 2 CHECKS BEFORE STARTING motor 44
2 4 12 3 PRECAUTION WHEN STARTING motor 44
2 4 12 4 PRECAUTION IN COLD AREAS 45
2 4 13 OPERATION 45
2 4 13 1 CHECKS BEFORE OPERATION 45
2 4 13 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 46
2 4 13 3 PRECAUTIONS WHEN traveling 47
2 4 13 4 TRAVELLING ON SLOPES 48
2 4 13 5 OPERATIONS ON SLOPES 49
2 4 13 6 PROHIBITED OPERATIONS 49
2 4 13 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 50
2 4 13 8 PARKING THE MACHINE 50
2 4 13 9 TRANSPORTATION 50
2 5 PRECAUTION FOR MAINTENANCE 51
2 5 1 GENERAL PRECAUTIONS 51
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 52
2 5 1 2 STOP motor FOR MAINTENANCE 53
2 5 1 3 WARNING TAG 54
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 55
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 55
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 56
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 56
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 57
2 5 1 9 NOISE 57
2 5 1 10 WHEN USING A HAMMER 57
2 5 1 11 PROPER TOOLS 58
2 5 1 12 ACCUMULATOR 58
2 5 1 13 PERSONNEL 58
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 59
2 5 2 1 PRECAUTION WHEN WELDING 59
2 5 2 2 BATTERY HANDLING 59
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 60
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 61
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 62
2 5 3 3 REPLACEMENT OF HOSE LINES 62
2 5 3 4 INSPECTION OF HOSE LINES 62
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 63
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 63
2 5 3 7 AIR CONDITIONING MAINTENANCE 63
2 5 3 8 COMPRESSED AIR 64
2 5 3 9 WASTE MATERIALS 64
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 65
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 65
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 65
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 65
2 7 SPECIAL SAFETY EQUIPMENT 66
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 67
2 7 2 OBJECT HANDLING 67
2 7 3 LIGHTING 67
2 7 4 WARNING BEACON 67
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 67
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 67
2 7 5 2 INSTRUCTIONS FOR USE 69
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 71
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 71
2 7 5 5 INSTRUCTIONS FOR USE 73
2 8 HIGH VOLTAGE SAFETY INSTRUCTIONS FOR MACHINES WITH ELECTRIC MOTOR 75
2 8 1 QUALIFICATION OF PERSONNEL 75
2 8 2 ELECTRICAL TOOLS 75
2 8 3 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT 76
2 8 4 CONNECTION OF PILOT LINE (GROUND CHECK WIRE) 76
2 8 5 PREPARATION BEFORE WORKING ON THE CABLE DRUM 76
2 8 6 PREPARATION BEFORE WORKING ON THE CABLE GUIDE 77
2 8 7 MODIFICATION OF THE ELECTRICAL SYSTEM 77
2 8 8 FIRE 77
2 8 9 GENERAL INSTRUCTIONS 78
2 8 10 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM 78
2 8 10 1 INTRODUCTION 78
2 8 10 2 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT 79
2 8 10 3 WORKING EQUIPMENT & PERSONAL PROTECTION 79
2 8 10 4 SPECIAL TOOLS REQUIRED 79
2 8 10 5 PERSONAL PROTECTION EQUIPMENT (PPE) 80
2 8 10 6 PREPARING THE MACHINE FOR HIGH VOLTAGE MAINTENANCE 80
2 8 10 7 POWER DISCONNECTION AND EARTHING 81
2 8 10 8 THE THREE STEPS To DEACTIVATE POWER 82
2 8 10 9 EARTHING PROCEDURES IN THE HV CABINET 84
2 8 10 10 THREE STEPS TO RECONNECTING THE POWER AFTER MAINTENANCE WORK 92
2 8 10 11 Step 1, inserting the key 92
2 8 10 12 Step 2, Switching earthing off 92
2 8 10 13 Step 3, Switching load on 93
2 9 SAFETY WARNING SIGNS 95
2 9 1 LOCATION AND DESCRIPTION OF THE SIGNS 96
3 OPERATION 113
3 1 FOREWORD 114
3 2 CONSTRUCTION OF THE SHOVEL 115
3 2 1 OVERALL VIEW WITH BACKHOE ATTACHMENT 115
3 2 2 OVERALL VIEW WITH BOTTOM DUMP BUCKET ATTACHMENT 116
3 2 3 SUPERSTRUCTURE 118
3 2 3 1 SUPERSTRUCTURE – TOP VIEW 122
3 2 3 2 MACHINERY HOUSE 124
3 2 4 UNDERCARRIAGE 126
3 2 5 HYDRAULICALLY OPERATED ACCESS LADDER 128
3 2 5 1 Lowering the ladder in emergency situations 131
3 2 6 EMERGENCY ESCAPE LADDER AT THE OPERATOR’S CAB PLATFORM 132
3 2 7 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR 134
3 2 8 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE 136
3 2 9 FOLDING LADDER INSIDE OF CARBODY 138
3 2 10 BOOM ACCESS LADDER AND WALKWAY 140
3 2 11 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 142
3 2 11 1 Emergency Motor Shutdown System actuated from Ground Man (Special Equipment) 143
3 2 11 2 Operator Warning System (Special Equipment) 143
3 2 12 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 144
3 2 12 1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual 149
3 2 12 2 Operator’s Seat Adjustment 151
3 2 12 3 Co-driver’s Seat and Refrigerator Box 152
3 2 12 4 INSTRUCTIONS TO using and looking after THE SEAT BELTS 153
3 3 OPERATOR’S CAB – CONTROLS 154
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 154
3 3 1 1 Hydraulic Control System 155
3 3 1 2 Safety Circuit for Controls 155
3 3 1 3 Control Pattern 157
3 3 2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 158
3 3 2 1 Hydraulic Control System 159
3 3 2 2 Safety Circuit for Controls 159
3 3 2 3 Control Pattern 161
3 3 3 OPERATOR’S CONSOLE 163
3 3 3 1 Control Panel 165
3 3 4 INTERFACE PANEL FOR DIAGNOSTICS 169
3 4 Komtrax Plus– VEHICLE HEALTH MONITOR 170
3 4 1 SEQUENCE OF DISPLAYS 171
3 4 2 OPENING SCREEN 171
3 4 3 MAIN GAUGE SCREENS 1 TO 3 172
3 4 3 1 Main Gauge Screen 1 173
3 4 3 2 Main Gauge Screen 2, Symbol explanation, 175
3 4 3 3 Main Gauge Screen 3, Symbol explanation 175
3 4 3 4 Color Definition 175
3 4 4 ENERGY CONSUMPTION SCREEN 177
3 4 5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR 177
3 4 6 MAIN SCREEN – CHANGE >TIME >SMR >DATE 178
3 4 7 MAINTENANCE MONITOR 178
3 4 7 1 Maintenance confirmation through Service Personnel 179
3 4 8 SETTINGS FOR OPERATOR 179
3 4 8 1 Settings Screens 180
3 4 9 SERVICE MENU 183
3 4 10 AUTOMATIC MESSAGES 183
3 4 10 1 Automatic Messages 184
3 4 10 2 Automatic Motor Messages 187
3 5 CAMERA SYSTEM WITH MONITORS (SPECIAL EQUIPMENT) 188
3 5 1 LOCATION OF MONITORS AND CONTROL UNITS 189
3 5 1 1 Operating the Monitors 191
3 5 1 2 Ajustments of the Monitor 191
3 5 1 3 Typical Arrangement of the Cameras 195
3 6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 196
3 6 0 1 Digital Display 196
3 6 0 2 Luminous Indication 198
3 7 MACHINERY HOUSE 200
3 7 1 MOTOR SHUTDOWN SWITCHES 201
3 7 2 MOTOR LOAD CUT-OFF SWITCH BOX (SPECIAL EQUIPMENT) 203
3 7 2 1 Cutting OFF THE POWER SUPPLY TO THE MOTORS 203
3 7 3 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE 205
3 7 4 CENTRAL CONTROL AND FILTER PANEL 207
3 7 5 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO 209
3 7 6 FLUID MONITORING MODULE (Special EQUIPMENT ONLY) 209
3 8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE 210
3 8 1 COMPONENTS IN THE MEDIUM VOLTAGE SWITCH CABINET 213
3 8 2 LOW VOLTAGE SWITCH BOARD IN CAB BASE 215
3 8 3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS 217
3 8 4 BINARY FAULT CODE LIST 224
3 8 4 1 Combination Message 308 Trouble Can-Bus or Can Hardware 226
3 8 5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS 226
3 8 6 MONITOR AND CONTROL PANEL 229
3 8 6 1 Medium Voltage Switch Board 231
3 9 PREHEATING SYSTEM 232
3 9 1 HYDRAULIC OIL AND PTO GEAR OIL HEATINGS 233
3 10 CHECKS BEFORE STARTING THE MOTORS 236
3 10 0 1 Machinery House Doors 238
3 10 0 2 OPERATOR’S SEAT ADJUSTMENT 238
3 11 STARTING THE MAIN DRIVE MOTORS 240
3 11 1 STARTING PROCEDURE 243
3 11 1 1 Hydraulic oil warm-up 245
3 12 MOVING THE SHOVEL 247
3 12 1 TRAVEL CONTROL WITH FOOT PEDALS 247
3 12 1 1 TRAVEL ALARM / BACK-UP ALARM (Special equipment) 249
3 12 2 TRAVELLING INSTRUCTIONS 249
3 12 2 1 TRAVELLING LONG DISTANCES 251
3 12 3 UNDERCARRIAGE TRACK SLIDERS 252
3 13 SLEWING AND BRAKING THE SUPERSTRUCTURE 254
3 13 1 SLEWING THE SUPERSTRUCTURE 254
3 13 1 1 BRAKING THE SUPERSTRUCTURE 255
3 13 1 2 Hydraulic slew brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System 255
3 13 1 3 Important Instructions for Slewing the Superstructure 255
3 14 WORKING WITH THE ATTACHMENT 256
3 14 0 1 FACE SHOVEL BUCKET 257
3 14 1 COMBINED OPERATION CYCLES 257
3 15 WORKING INSTRUCTIONS 260
3 15 1 STABILITY OF THE SHOVEL 260
3 15 2 FURTHER OPERATING PRACTICES 262
3 15 3 Loading Trucks 266
3 16 PARKING THE SHOVEL 267
3 17 PARKING THE SHOVEL 268
3 17 0 1 CLEANING THE TRACK GROUPS 268
3 18 STOPPING THE MAIN DRIVE MOTORS 270
3 18 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 273
3 19 OPERATION OF THE LUBRICATION SYSTEM 274
3 19 1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE 274
3 19 1 1 Manual actuation of the central lubrication system 274
3 19 1 2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 275
3 19 2 SWING CIRCLE PINION LUBRICATION SYSTEM -SLS- 276
3 19 2 1 Manual actuation of the swing circle lubrication system 276
3 19 2 2 SWING CIRCLE LUBRICATION SYSTEM ”SLS” 277
3 19 2 3 ADJUSTMENTS OF THE SWING CIRCLE LUBRICATION SYSTEM 277
3 19 2 4 Defining the Lubrication System Greasing Areas 277
3 20 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM 278
3 20 1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS 279
3 20 1 1 Personnel Safety 279
3 20 2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB 283
3 20 3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM 283
3 20 4 IN The CASE OF A FIRE 285
3 20 4 1 Indication of Alarm Condition at Control Module (5) when the electric Detection and Warning System -II- detects a Fire in the Machinery House: 285
3 20 5 DISPLAY MODULE 287
3 20 6 INTERFACE CONTROL MODULE 289
3 21 TRANSFER PUMP FOR HYDRAULIC OIL 290
3 21 1 OPERATING THE TRANSFER PUMP 291
3 21 2 TRANSFUSION PROCEDURE 293
3 22 CENTRAL REFILLING SYSTEM 296
3 22 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 297
3 22 1 1 Operation of the service arm 297
3 22 2 OPERATING THE HYDRAULIC SERVICE ARM 299
3 22 3 RECEIVER PANEL AND MONITOR BOX 301
3 22 3 1 Refilling Procedure: 301
3 22 4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOUSE ROOF 303
3 23 SERVICE CRANE (SPECIAL EQUIPMENT) 304
3 23 1 OPERATING THE CRANE 305
3 23 1 1 Preparing the crane for work 307
3 24 CABLE DRUM (SPECIAL EQUIPMENT) 308
3 24 1 DESCRIPTION OF MAIN COMPONENTS 309
3 24 2 OPERATION OF THE CABLE DRUM 311
3 24 2 1 Principle of Operation 313
3 24 2 2 Signal horn button override 313
3 24 2 3 Operation and Maintenance of the Cable Drum 313
3 24 2 4 Technical data – Rating plate 313
3 25 CABLE GUIDE (IF SO EQUIPPED) 315
3 25 1 LIFTING DEVICE FOR THE POWER CABLE 315
3 26 WORK ON THE LOADER ATTACHMENT 316
3 26 0 1 OBSERVE THE FOLLOWING INSTRUCTIONS 316
3 27 TRANSPORTATION AND LIFTING OF THE SHOVEL 317
3 27 1 DISASSEMBLING OF THE SHOVEL 317
3 27 2 TRANSPORTATION AND LIFTING 317
3 28 RETRIEVAL PROCEDURE 318
3 28 0 1 GENERAL 318
3 29 SHOVEL STORAGE 319
3 29 0 1 GENERAL 319
3 29 1 PREPARING FOR STORAGE 319
3 29 2 ONE MONTH REPETITIVE SERVICE PERIOD 319
3 29 3 SIX MONTH REPETITIVE SERVICE PERIOD 319
3 29 4 PREPARING FOR OPERATION 320
3 30 TROUBLE SHOOTING 321
3 30 1 GENERAL 321
3 30 2 MAIN DRIVE ELECTRIC MOTOR 321
3 30 3 HYDRAULIC SYSTEM 322
3 30 4 FINAL DRIVES AND SWING GEAR 323
3 30 5 CRAWLER TRACKS 323
4 MAINTENANCE 325
4 1 FOREWORD 326
4 1 0 1 DEFINITIONS 326
4 1 0 2 GENERAL RECOMMENDATIONS 326
4 2 PRECAUTIONS FOR MAINTENANCE 327
4 2 1 GROUNDING PROCEDURES FOR THE HIGH VOLTAGE SYSTEM 328
4 3 FLUIDS AND LUBRICANTS 329
4 3 1 LUBRICANTS FOR OPERATIONS IN COLD & ARCTIC CLIMATES 329
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 330
4 3 2 1 Recommended Hydraulic Oils 331
4 3 2 2 General Information to selecting hydraulic oils 332
4 3 3 MAIN DRIVE ELECTRIC MOTORS – BEARING LUBRICATION 333
4 4 FILLING CAPACITIES 334
4 5 STANDARD TORQUE LIST 335
4 5 1 Torque for Flange Joints 336
4 5 2 TORQUES FOR SPECIAL COMPONENTS 337
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 340
4 6 1 INITIAL SERVICING 340
4 6 1 1 INITIAL RUNNING-IN 340
4 6 1 2 AFTER THE FIRST 250 OPERATING HOURS 340
4 6 1 3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT 340
4 6 2 SERVICING THE CRITICAL BOLT CONNECTIONS 341
4 6 3 PERIODIC SERVICING INTERVALS 341
4 6 4 PERIODIC SERVICING SCHEDULE 342
4 6 4 1 WHEN NECESSARY 342
4 6 4 2 EVERY 10 OPERATING HOURS OR DAILY 342
4 6 4 3 EVERY 50 OPERATING HOURS OR WEEKLY 342
4 6 4 4 EVERY 250 OPERATING HOURS OR MONTHLY 343
4 6 4 5 EVERY 500 OPERATING HOURS OR QUATERLY 343
4 6 4 6 EVERY 1000 HOURS OR 6 MONTHLY 344
4 6 4 7 EVERY 2000 OPEARTING HOURS OR YEARLY 344
4 6 4 8 EVERY 3000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 345
4 6 5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM 346
4 6 6 MAINTENANCE OF THE MAIN DRIVE ELECTRIC MOTORS 347
4 7 SAFETY CRITICAL PARTS 348
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 348
4 7 2 INSPECTION OF HOSE LINES 349
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 349
4 8 FIRST SERVICING 350
4 8 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 350
4 8 2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 351
4 8 3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 352
4 8 4 SWING CIRCLE Pinion – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 353
4 8 5 SWING CIRCLE TOOTHING LUBRICATION 355
4 8 6 Swing circle – Check Torque OF BOLT CONNECTIONS 356
4 8 7 Re-tightening procedure of the crawler carrier mounting bolts 357
4 8 7 1 Procedure for ENSURING Proper Tightening OF the crawler carrier mounting bolts 358
4 8 7 2 Special hydraulic torque wrench 359
4 9 WHEN NECESSARY 360
4 9 1 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 361
4 9 2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 363
4 9 2 1 SERVICE THE GREASE FILTERS FOR REFILLABLE GREASE CONTAINERS OF THE CENTRAL lUBE SYSTEM AND SWING CIRCLE PINION LUBE SYSTEM 365
4 9 3 GUIDE WHEELS – REPLACE FLOATING SEALS 365
4 10 EVERY 10 OPERATING HOURS OR DAILY 366
4 10 1 WALK – AROUND INSPECTION 367
4 10 2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL Check 371
4 10 3 BOOM – CHECK LADDER AND WALKWAY 373
4 10 4 CLEANING THE TRACK GROUPS 373
4 10 5 Sliders (optional SPECIAL EQUIPMENT)- CHECK CONDITION 374
4 10 6 ELECTRICAL EQUIPMENT – CHECK CONDITION 374
4 10 7 CAMERA SYSTEM 377
4 10 8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 379
4 11 EVERY 50 OPERATING HOURS OR WEEKLY 380
4 11 1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL 381
4 11 1 1 Swing Gear, PART NUMBER 926 795 40 381
4 11 1 2 Swing gear, PART NUMBER 944 872 40 383
4 11 2 TRAVEL GEARS WITH NUMBER 927 842 40, CHECK OIL LEVEL IN GEAR BOXES, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS 385
4 11 3 TRAVEL GEARS WITH NUMBER 943 190 40, CHECK OIL LEVEL IN GEAR BOXES AND MOTOR ADAPTER HOUSINGS 387
4 11 4 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 389
4 11 5 PUMP DISTRIBUTOR GEARS – CHECK OIL LEVEL 391
4 11 6 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 393
4 11 7 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 395
4 11 7 1 ADDITIONAL HYDRAULIC OIL COOLER – INSPECT AND CLEAN IF NECESSARY 397
4 11 8 PTO GEAR OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 399
4 12 EVERY 250 OPERATING HOURS OR MONTHLY 400
4 12 1 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 401
4 12 2 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 401
4 12 3 SIGNAL HORN COMPRESSOR – LUBRICATE 401
4 12 4 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION 403
4 12 5 CABIN AIR CLEANER – INSPECT 405
4 12 6 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL 407
4 12 7 SLIP RING UNIT – Visual CHECK 408
4 12 8 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 411
4 12 9 ADDITIONAL AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 413
4 12 10 CABIN HEATER FILTER – INSPECT 415
4 13 EVERY 500 OPERATING HOURS OR MONTHLY 416
4 13 1 BATTERIES – CHECK FLUID LEVEL 417
4 13 2 GREASE INJECTORS – CHECK INDICATOR STEMS 418
4 13 2 1 CORRECTIVE ACTIONS 418
4 13 3 CHECKING THE SLEW RING 419
4 13 4 CHECKING THE SLIDERS (OPTIONAL EQUIPMENT) for wear 419
4 13 5 CYLINDER ROD PROTECTION (IF EQUIPPED), Inspect 421
4 13 6 DRIVE SHAFT HOUSINGS ON PTO GEARS – CHECK OIL LEVEL 423
4 13 7 CRAWLER TRACK – INSPECTION 425
4 13 7 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 425
4 13 7 2 Bleeding the System 429
4 13 8 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 431
4 13 9 EMERGENCY LOWERING OF ACCESS LADDER – TEST FUNCTIONALITY 433
4 14 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 434
4 14 1 Critical Bolt Connections 435
4 14 1 1 Check mounting of Operator’s cab 435
4 14 1 2 Check tightening torque of the counterweight mounting bolts, 437
4 14 1 3 Check condition and fastening of all three swing gears (01) and swing motors (02), 439
4 14 2 ELECTRICAL EQUIPMENT – MAINTENANCE 441
4 14 3 HYDRAULIC SYSTEM – FILTER SERVICE 443
4 14 4 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 455
4 14 4 1 Oil drain plugs 455
4 14 5 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 457
4 14 6 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 459
4 14 7 EMERGENCY MOTOR SHUTDOWN SWITCHES – TEST FUNCTIONALITY 461
4 14 8 TEST MAINTENANCE SAFETY SWITCH 463
4 14 9 MOTOR SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY 463
4 14 10 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 465
4 14 11 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 467
4 14 12 ALL OTHER HINGES AND AREAS TO LUBRICATE 469
4 14 13 CABIN AIR CLEANER – REPLACE FILTER 471
4 14 14 SLIP RING UNIT – LUBRICATE 473
4 15 EVERY 2000 OPERATING HOURS OR YEARLY 474
4 15 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 475
4 15 1 1 Hydraulic System – Change Oil 477
4 15 1 2 HYDRAULIC SYSTEM – REPLACE SUCTION STRAINER (6), FILLER SCREEN (11) AND PULSATION DAMPER (13) 479
4 15 1 3 HYDRAULIC SYSTEM – REPLACE SUCTION STRAINERS OF THE EIGHT MAIN HYDRAULIC PUMPS 481
4 15 1 4 HYDRAULIC SYSTEM – FILL THE OIL RESERVOIRS 483
4 15 1 5 BLEEDING THE MAIN HYDRAULIC PUMPS OF AIR 483
4 15 1 6 BLEEDING THE SECONDARY PUMPS OF AIR 485
4 15 1 7 Final checks: 485
4 15 2 EMERGENCY ESCAPE LADDERS – INSPECTION 487
4 15 2 1 Emergency Escape Ladder at the Operator’s Cab Platform 487
4 15 2 2 Emergency Escape Ladder at the upper Deck and Machinery House Escape Door 489
4 15 2 3 Emergency Escape Ladder and Escape Hatch in the Machinery House 491
4 15 3 HYDRAULIC HOSES – Check Condition 493
4 15 4 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 495
4 15 5 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 497
4 15 5 1 Functionality 497
4 15 6 SLIP RING UNIT – MAINTENANCE 497
4 16 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 502
4 16 1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 503
4 16 1 1 Swing Gears With PART NUMBER 926 795 40 503
4 16 1 2 SWING GEARS WITH PART NUMBER 944 872 40 507
4 16 1 3 Brake Housing – Change Oil (944 872 40) 509
4 16 1 4 Motor Adapter Housing – Change Oil 509
4 16 2 TRAVEL GEARS, CHANGE OIL IN GEAR BOXES, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS 511
4 16 2 1 Travel Gears, Change Oil: 511
4 16 2 2 BRAKE HOUSINGS – CHANGE OIL 513
4 16 2 3 MOTOR ADAPTER HOUSINGS – CHANGE OIL 513
4 16 3 TRAVEL GEARS WITH PART NUMBER 924 800 40, CHANGE OIL IN GEAR BOXES AND MOTOR ADAPTER HOUSINGS 515
4 16 3 1 Travel Gears, Change Oil: 515
4 16 3 2 Motor Adapter Housings – Change Oil 515
4 16 4 FINAL DRIVE HOUSINGS – CHANGE OIL 517
4 16 5 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 519
4 16 6 FLEXIBLE COUPLING – VISUAL CHECK 521
4 17 CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS 522
4 17 1 Critical BOLT CONNECTIONS – CHECK TORQUE LOAD 523
4 17 1 1 Retightening procedure of the crawler carrier mounting bolts 553
4 17 2 CHECKING THE STEEL STRUCTURES 561
4 18 EVERY 6000 OPERATING HOURS OR ONCE A YEAR 562
4 18 1 AUTOMATIC LUBRICATION SYSTEMS – replace pump outlet GREASE FILTERS 563
4 18 2 HIGH PRESSURE FILTERS – REPLACE 565
4 19 FIRE PREVENTION 566
4 19 1 PRECAUTIONS 567
4 20 WELD REPAIRS 568
4 20 0 1 GENERAL INFORMATION 568
4 20 1 GENERAL PROTECTIVE MEASURES 569
4 20 2 Weld repairs on major components of the excavator 569
4 20 2 1 COUNTERWEIGHT 569
4 20 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 571
4 20 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 573
4 20 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 575
4 20 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 579

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