Komatsu Hydraulic Mining EXCAVATOR PC5500-6 Operation & Maintenance Manual – PDF DOWNLOAD

Komatsu Hydraulic Mining EXCAVATOR PC5500-6 Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu Hydraulic Mining EXCAVATOR PC5500-6 Operation & Maintenance Manual – PDF DOWNLOAD

BEFORE READING THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this excavator that must
be obeyed in order to use the excavator safely. Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of excavators.
Read, understand and follow all precautions and warnings in this manual and on the excavator before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that may involve a potential hazard when the excavator is used.
Therefore, the safety messages in this manual and on the excavator may not include all possible safety precau-
tions. 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 main-
tenance of the excavator can be hazardous and could result in serious injury or death.
If you sell the excavator, be sure to give this manual to the new owner together with the excavator.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of publication. Continuing improvements in the design of this excavator may lead to addi-
tional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your excavator or with questions regarding information contained in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: Komatsu delivers excavators that comply with all applicable regulations and standards of the country to which it has been shipped.
If the excavator has been purchased in another country, it may
lack certain safety devices and specifications that are necessary
for use in your country. If there is any question about whether
your product complies with the applicable standards and regula-
tions of your country, consult Komatsu or your Komatsu distributor
before operating the excavator.
Always keep the Operation and Maintenance Manual in the stor-
age space provided inside the operator’s cabin (see Fig.1-1) so that all relevant personnel can read it at any time. If this manual is
lost or damaged, contact your distributor immediately to arrange
for its replacement.

TABLE OF CONTENTS:

Komatsu Hydraulic Mining EXCAVATOR PC5500-6 Operation & Maintenance Manual – PDF DOWNLOAD

1.11CONTENTS
1 FOREWORD…………………………………………………………………………………. 1-1
1.1BEFORE READING THIS MANUAL……………………………………………………………………………………. 1-2
1.2EC DECLARATION OF CONFORMITY……………………………………………………………………………….. 1-3
1.3PRIVACY POLICY ON EXCAVATORS EQUIPPED WITH EXCAVATOR MONITORING SYSTEMS FOR THE EEA 1-4
1.4RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS………………………………… 1-7
1.5DIRECTIONS OF THE EXCAVATOR…………………………………………………………………………………… 1-8
1.6SPECIFICATION AND SERIAL PLATE……………………………………………………………………………….. 1-9
1.6.1 PRODUCT IDENTIFICATION NUMBER ……………………………………………………………………. 1-9
1.7DIVISION OF THE BINDER………………………………………………………………………………………………. 1-10
1.8DESIGNATED USE OF THE EXCAVATOR………………………………………………………………………… 1-11
1.9DELIVERY OF THE EXCAVATOR…………………………………………………………………………………….. 1-12
1.9.1 SPARE PARTS…………………………………………………………………………………………………….. 1-12
1.9.2 SERVICE …………………………………………………………………………………………………………….. 1-12
1.10EXPLANATION OF ABBREVIATIONS………………………………………………………………………………. 1-13
1.11CONTENTS…………………………………………………………………………………………………………………….. 1-15
2 SAFETY ……………………………………………………………………………………… 2-23
2.1SAFETY INFORMATION………………………………………………………………………………………………….. 2-24
2.2OVERVIEW…………………………………………………………………………………………………………………….. 2-25
2.2.1 NORMAL OPERATIONS ……………………………………………………………………………………….. 2-25
2.2.2 REGULAR MAINTENANCE …………………………………………………………………………………… 2-25
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR …………………………………………….. 2-25
2.2.4 ADDITIONAL SAFETY PRECAUTIONS ………………………………………………………………….. 2-25
2.3SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB……………………….. 2-26
2.3.1 SOUND ……………………………………………………………………………………………………………….. 2-26
2.3.2 VIBRATION………………………………………………………………………………………………………….. 2-26
2.4GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………. 2-27
2.4.1 UNDERSTANDING THE EXCAVATOR …………………………………………………………………… 2-27
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ……………….. 2-27
2.4.3 PREPARATIONS FOR SAFE OPERATION……………………………………………………………… 2-27
2.4.4 FIRE PREVENTION ……………………………………………………………………………………………… 2-29
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR……………………………. 2-32
2.4.6 BURN PREVENTION ……………………………………………………………………………………………. 2-33
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS …………………………………………………….. 2-34
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES …………………………………… 2-34
2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS……………………….. 2-35
2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC) ……………………………………………………….. 2-35
2.4.11 PRECAUTIONS AT JOBSITE ………………………………………………………………………………… 2-36
2.4.12 STARTING MOTOR ……………………………………………………………………………………………… 2-42
2.4.13 OPERATION………………………………………………………………………………………………………… 2-43
2.5PRECAUTION FOR MAINTENANCE…………………………………………………………………………………. 2-49
2.5.1 GENERAL PRECAUTIONS……………………………………………………………………………………. 2-49
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE………………………………………… 2-57
CONTENTS
– 16 PC5500-6
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID……………………………………………………… 2-58
2.6ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……. 2-63
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM …………………………………………………………. 2-63
2.6.2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS 2-
63
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR……………………………….. 2-63
2.7SPECIAL SAFETY EQUIPMENT……………………………………………………………………………………….. 2-64
2.7.1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB………….. 2-65
2.7.2 OBJECT HANDLING …………………………………………………………………………………………….. 2-65
2.7.3 LIGHTING ……………………………………………………………………………………………………………. 2-65
2.7.4 WARNING BEACON……………………………………………………………………………………………… 2-65
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ……….. 2-65
2.8SAFETY WARNING SIGNS………………………………………………………………………………………………. 2-73
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS …………………………………………………….. 2-74
2.8.2 LOCATION AND DESCRIPTION OF THE SIGNS …………………………………………………….. 2-76
3 OPERATION ……………………………………………………………………………… 3-103
3.1FOREWORD………………………………………………………………………………………………………………….. 3-104
3.2CONSTRUCTION OF THE EXCAVATOR…………………………………………………………………………. 3-105
3.2.1 OVERALL VIEW …………………………………………………………………………………………………. 3-105
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE ……………………………………………………… 3-106
3.2.3 HYDRAULICALLY OPERATED ACCESS/INGRESS STAIRWAY ……………………………… 3-112
3.2.4 EMERGENCY ESCAPE LADDER…………………………………………………………………………. 3-116
3.2.5 BOOM ACCESS LADDER AND WALKWAY…………………………………………………………… 3-120
3.2.6 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM …. 3-122
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE
(FOPS) 3-124
3.2.8 ENGINE OIL MANAGEMENT SYSTEM …………………………………………………………………. 3-134
3.3OPERATOR’S CAB – CONTROLS…………………………………………………………………………………… 3-140
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT……………………………………………………….. 3-140
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…………………………………. 3-144
3.3.3 OPERATOR’S CONSOLE ……………………………………………………………………………………. 3-149
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS……………………………………………………………… 3-155
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER…………………………………………….. 3-157
3.4MACHINE MONITOR……………………………………………………………………………………………………… 3-158
3.4.1 SEQUENCE OF DISPLAYS …………………………………………………………………………………. 3-159
3.4.2 OPENING SCREEN…………………………………………………………………………………………….. 3-159
3.4.3 MAIN GAGE SCREENS 1 TO 4 ……………………………………………………………………………. 3-160
3.4.4 FUEL CONSUMPTION SCREEN ………………………………………………………………………….. 3-167
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR …………………………………… 3-167
3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE …………………………………………………… 3-168
3.4.7 MAINTENANCE MONITOR ………………………………………………………………………………….. 3-168
3.4.8 SETTINGS FOR OPERATOR ………………………………………………………………………………. 3-169
3.4.9 AUTOMATIC MESSAGES……………………………………………………………………………………. 3-174
3.5OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING………………………………. 3-178
3.5.1 DIGITAL DISPLAY ………………………………………………………………………………………………. 3-178
3.5.2 LUMINOUS INDICATION. ……………………………………………………………………………………. 3-180
3.6CAMERA SYSTEM WITH MONITORS……………………………………………………………………………… 3-182
3.6.1 LOCATION OF MONITORS AND CONTROL UNITS ………………………………………………. 3-183
3.6.2 AUXILIARY HEATER FOR OPERATOR’S CAB ……………………………………………………… 3-191
3.7MACHINERY HOUSE…………………………………………………………………………………………………….. 3-192
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES ………………………………………………….. 3-193
3.7.2 SAFETY SWITCH FOR MAINTENANCE ……………………………………………………………….. 3-195
3.7.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT………………….. 3-197
3.8ELECTRICAL EQUIPMENT IN CAB BASE………………………………………………………………………. 3-198
3.8.1 STANDARD COMPONENTS IN CAB BASE…………………………………………………………… 3-199
3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE …………………………………………………… 3-201
3.8.3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS…………………………………… 3-205
3.8.4 BINARY FAULT CODE LIST. ……………………………………………………………………………….. 3-212
3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS ………………….. 3-214
3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE (WHEN EQUIPPED)
3-217
3.9PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES (WHEN EQUIPPED)………. 3-220
3.9.1 ENGINE COOLANT AND ENGINE OIL RESERVE TANK HEATING…………………………. 3-221
3.10CHECKS BEFORE STARTING THE ENGINES…………………………………………………………………. 3-226
3.10.1 COOLANT LEVEL ………………………………………………………………………………………………. 3-229
3.11STARTING THE ENGINES……………………………………………………………………………………………… 3-232
3.11.1 STARTING PROCEDURE……………………………………………………………………………………. 3-235
3.11.2 ENGINE WARM-UP…………………………………………………………………………………………….. 3-243
3.11.3 HYDRAULIC OIL WARM-UP………………………………………………………………………………… 3-243
3.12MOVING THE EXCAVATOR…………………………………………………………………………………………… 3-245
3.12.1 TRAVEL CONTROL WITH FOOT PEDALS ……………………………………………………………. 3-245
3.12.2 TRAVELING INSTRUCTIONS………………………………………………………………………………. 3-247
3.12.3 UNDERCARRIAGE TRACK SLIDERS…………………………………………………………………… 3-250
3.13SLEWING AND BRAKING THE SUPERSTRUCTURE……………………………………………………….. 3-252
3.13.1 SLEWING THE SUPERSTRUCTURE……………………………………………………………………. 3-252
3.14WORKING WITH THE ATTACHMENT……………………………………………………………………………… 3-255
3.14.1 COMBINED OPERATION CYCLES ………………………………………………………………………. 3-257
3.15WORKING INSTRUCTIONS……………………………………………………………………………………………. 3-260
3.15.1 STABILITY OF THE EXCAVATOR………………………………………………………………………… 3-260
3.15.2 FURTHER OPERATING PRACTICES …………………………………………………………………… 3-262
3.15.3 LOADING TRUCKS ……………………………………………………………………………………………. 3-266
3.16PARKING THE EXCAVATOR…………………………………………………………………………………………. 3-267
3.17STOPPING THE ENGINES……………………………………………………………………………………………… 3-268
3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…………………………………………….. 3-271
3.18OPERATION OF THE LUBRICATION SYSTEM………………………………………………………………… 3-272
3.18.1 CENTRAL LUBRICATION SYSTEM ”CLS”…………………………………………………………….. 3-272
3.18.2 SLEW CIRCLE PINION LUBRICATION SYSTEM ”SLS” ………………………………………….. 3-273
3.19FIRE DETECTION AND SUPPRESSION SYSTEM……………………………………………………………. 3-276
3.19.1 DISPLAY MODULE …………………………………………………………………………………………….. 3-281
3.19.2 INTERFACE CONTROL MODULE………………………………………………………………………… 3-283
3.19.3 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS
CARTRIDGES ON POWER HOUSE ROOF 3-285
3.20TRANSFER PUMP FOR HYDRAULIC OIL……………………………………………………………………….. 3-286
3.20.1 OPERATING THE TRANSFER PUMP…………………………………………………………………… 3-287
3.20.2 FUNCTIONS OF THE TRANSFER PUMP ……………………………………………………………… 3-289
3.21SERVICE CENTER………………………………………………………………………………………………………… 3-292
3.21.1 SYSTEMS CONNECTED TO THE SERVICE CENTER …………………………………………… 3-293
3.21.2 OPERATING THE HYDRAULIC SERVICE ARM …………………………………………………….. 3-295
3.21.3 RECEIVER PANEL WITH MONITOR BOX …………………………………………………………….. 3-297
3.21.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS
MOUNTED ON THE POWER HOUSE ROOF 3-303
3.22SERVICE CRANE (SPECIAL EQUIPMENT)……………………………………………………………………… 3-304
3.22.1 OPERATING THE CRANE …………………………………………………………………………………… 3-305
3.23WORK ON THE LOADER ATTACHMENT………………………………………………………………………… 3-308
3.24TRANSPORTATION AND LIFTING OF THE EXCAVATOR………………………………………………… 3-309
3.24.1 DISASSEMBLING OF THE EXCAVATOR ……………………………………………………………… 3-309
3.24.2 TRANSPORTATION AND LIFTING……………………………………………………………………….. 3-309
3.25RETRIEVAL PROCEDURE……………………………………………………………………………………………… 3-310
3.25.1 GENERAL ………………………………………………………………………………………………………….. 3-310
3.26EXCAVATOR STORAGE………………………………………………………………………………………………… 3-311
3.26.1 GENERAL ………………………………………………………………………………………………………….. 3-311
3.26.2 PREPARING FOR STORAGE………………………………………………………………………………. 3-311
3.26.3 ONE MONTH REPETITIVE SERVICE PERIOD………………………………………………………. 3-311
3.26.4 SIX MONTH REPETITIVE SERVICE PERIOD………………………………………………………… 3-311
3.26.5 PREPARING FOR OPERATION …………………………………………………………………………… 3-312
3.27TROUBLE SHOOTING…………………………………………………………………………………………………… 3-313
3.27.1 GENERAL ………………………………………………………………………………………………………….. 3-313
3.27.2 ENGINE …………………………………………………………………………………………………………….. 3-313
3.27.3 HYDRAULIC SYSTEM…………………………………………………………………………………………. 3-314
3.27.4 FINAL DRIVES AND SLEW GEAR………………………………………………………………………… 3-315
3.27.5 CRAWLER TRACKS……………………………………………………………………………………………. 3-315
2 MAINTENANCE …………………………………………………………………………….. 2-3
2.1FOREWORD……………………………………………………………………………………………………………………… 2-4
2.1.1 DEFINITIONS ………………………………………………………………………………………………………… 2-4
2.1.2 GENERAL RECOMMENDATIONS……………………………………………………………………………. 2-4
2.2PRECAUTIONS FOR MAINTENANCE…………………………………………………………………………………. 2-5
2.2.1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES………………………….. 2-6
2.2.2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES ………………………… 2-10
2.3FILLING CAPACITIES……………………………………………………………………………………………………… 2-11
2.4STANDARD TORQUE LIST………………………………………………………………………………………………. 2-13
2.4.1 TORQUE FOR FLANGE JOINTS ……………………………………………………………………………. 2-14
2.4.2 TORQUES FOR SPECIAL COMPONENTS……………………………………………………………… 2-15
2.5LUBRICATION AND MAINTENANCE SCHEDULE……………………………………………………………… 2-17
2.5.1 INITIAL SERVICING ……………………………………………………………………………………………… 2-17
2.5.2 SERVICING THE CRITICAL BOLT CONNECTIONS…………………………………………………. 2-18
2.5.3 PERIODIC SERVICING INTERVALS ………………………………………………………………………. 2-18
2.5.4 PERIODIC SERVICING SCHEDULE ………………………………………………………………………. 2-18
2.5.5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE
HYDRAULIC SYSTEM 2-23
2.6SAFETY CRITICAL PARTS………………………………………………………………………………………………. 2-26
2.6.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES …………………. 2-26
2.6.2 INSPECTION OF HOSE LINES ……………………………………………………………………………… 2-27
2.6.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS …………………….. 2-27
2.7EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM 2-29
2.7.1 MAINTENANCE OF THE ENGINES ……………………………………………………………………….. 2-33
2.7.2 ENGINE FUEL FILTER LOCATIONS………………………………………………………………………. 2-35
2.7.3 VENTING THE AIR FROM THE FUEL FILTERS ………………………………………………………. 2-39
2.8INITIAL SERVICING………………………………………………………………………………………………………… 2-40
2.8.1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION…………….. 2-40
2.8.2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS ……….. 2-41
2.8.3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND GREASE
CONNECTIONS 2-42
2.8.4 SWING CIRCLE PINION – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 2-
43
2.8.5 SWING CIRCLE TOOTHING LUBRICATION …………………………………………………………… 2-45
2.8.6 SWING CIRCLE – CHECK TORQUE OF BOLT CONNECTIONS………………………………… 2-46
2.8.7 RETIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS …… 2-47
2.9WHEN NECESSARY……………………………………………………………………………………………………….. 2-50
2.9.1 ENGINE AIR CLEANER MAINTENANCE ………………………………………………………………… 2-51
2.9.2 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS…………… 2-55
2.9.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS………………………. 2-57
2.9.4 GUIDE WHEELS – REPLACE FLOATING SEALS…………………………………………………….. 2-59
2.9.5 COLD STARTING AID, REPLACE FLUID CYLINDER ………………………………………………. 2-61
2.10EVERY 10 OPERATING HOURS OR DAILY………………………………………………………………………. 2-62
2.10.1 WALK – AROUND INSPECTION …………………………………………………………………………….. 2-63
2.10.2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL CHECK…………………………….. 2-69
2.10.3 AIR CLEANER – CLEAN PRE-CLEANER ………………………………………………………………… 2-73
2.10.4 RADIATORS – CHECK COOLANT LEVEL……………………………………………………………….. 2-75
2.10.5 TRACK GROUPS – CLEAN ……………………………………………………………………………………. 2-75
2.10.6 ELECTRICAL EQUIPMENT – CHECK CONDITION ………………………………………………….. 2-76
2.10.7 CAMERA SYSTEM……………………………………………………………………………………………….. 2-79
2.10.8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB …………………………………….. 2-81
2.11EVERY 50 OPERATING HOURS OR WEEKLY………………………………………………………………….. 2-82
2.11.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS …………….. 2-83
2.11.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS
2-87
2.11.3 PTO’S (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL ….. 2-93
2.11.4 HYDRAULIC ACCESS/INGRESS STAIRWAY – CHECK SAFETY SENSOR………………… 2-97
2.11.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY ……………………… 2-99
2.12EVERY 250 OPERATING HOURS OR MONTHLY…………………………………………………………….. 2-100
2.12.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…………………… 2-101
2.12.2 SIGNAL HORN COMPRESSOR – LUBRICATE………………………………………………………. 2-103
2.12.3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER
FILTER 2-103
2.12.4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER . 2-
103
2.12.5 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION 2-
105
2.12.6 CABIN AIR CLEANER – INSPECT ………………………………………………………………………… 2-107
2.12.7 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL ……… 2-109
2.12.8 ADDITIONAL AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL
2-111
2.12.9 CABIN HEATER FILTER – INSPECT …………………………………………………………………….. 2-113
2.12.10 CRITICAL BOLT CONNECTIONS – VISUAL CHECK ………………………………………………. 2-115
2.12.11 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL……………………………………… 2-117
2.13EVERY 500 OPERATING HOURS OR QUARTERLY…………………………………………………………. 2-118
2.13.1 BATTERIES – CHECK FLUID LEVEL…………………………………………………………………….. 2-119
2.13.2 GREASE INJECTORS – CHECK INDICATOR STEMS…………………………………………….. 2-120
2.13.3 CYLINDER ROD PROTECTION (IF EQUIPPED), INSPECT…………………………………….. 2-123
2.13.4 FUEL TANK – DRAIN CONDENSATION ………………………………………………………………… 2-125
2.13.5 CRAWLER TRACK – INSPECTION……………………………………………………………………….. 2-127
2.13.6 GROUND CABLES OF ENGINE AND ALTERNATOR – CHECK FOR CORRECT CONNECTION
2-133
2.13.7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION … 2-135
2.13.8 EMERGENCY LOWERING OF ACCESS/INGRESS STAIRWAY – TEST FUNCTIONALITY. 2-
137
2.14EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…………………………………………………. 2-138
2.14.1 CRITICAL BOLT CONNECTIONS…………………………………………………………………………. 2-139
2.14.2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY …………….. 2-145
2.14.3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY.. 2-
147
2.14.4 ELECTRICAL EQUIPMENT – MAINTAINANCE ………………………………………………………. 2-149
2.14.5 HYDRAULIC SYSTEM – FILTER SERVICE ……………………………………………………………. 2-151
2.14.6 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE
ANALYSIS 2-165
2.14.7 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE …………………………………… 2-167
2.14.8 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 2-169
2.14.9 CABIN AIR CLEANER – REPLACE PRIMARY FILTER ……………………………………………. 2-171
2.14.10 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES ……………….. 2-173
2.14.11 ALL OTHER HINGES AND AREAS TO LUBRICATE ………………………………………………. 2-175
2.14.12 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES ………….. 2-177
2.15EVERY 2000 OPERATING HOURS OR YEARLY……………………………………………………………… 2-178
2.15.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION
DAMPER 2-179
2.15.2 FILLING THE HYDRAULIC SYSTEM…………………………………………………………………….. 2-189
2.15.3 BLEEDING THE HYDRAULIC SYSTEM ………………………………………………………………… 2-191
2.15.4 GEAR PUMPS FOR PTO GEAR LUBRICATION…………………………………………………….. 2-193
2.15.5 EMERGENCY ESCAPE LADDER – INSPECTION…………………………………………………… 2-195
2.15.6 ACCESS/INGRESS STAIRWAY EMERGENCY LOWERING CHAINS – INSPECTION… 2-197
2.15.7 HYDRAULIC HOSES – CHECK CONDITION………………………………………………………….. 2-199
2.15.8 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST………………………….. 2-201
2.15.9 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB …………………………………… 2-203
2.16EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR………………………… 2-204
2.16.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL ……………………….. 2-205
2.16.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL. 2-213
2.16.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL ……………………………………………….. 2-217
2.16.4 FLEXIBLE COUPLING – VISUAL CHECK ………………………………………………………………. 2-221
2.17CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS……………………………… 2-222
2.17.1 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD…………………………………… 2-223
2.17.2 CHECKING THE STEEL STRUCTURES……………………………………………………………….. 2-265
2.18EVERY 6000 OPERATING HOURS OR ONCE A YEAR…………………………………………………….. 2-266
2.18.1 AUTOMATIC LUBRICATION SYSTEMS – REPLACE PUMP OUTLET GREASE FILTERS .. 2-
267
2.18.2 HYDRAULIC OIL TANK – CHECK LEAKAGE OIL SCREEN FILTER …………………………. 2-269
2.18.3 CHANGING THE HIGH PRESSURE FILTERS……………………………………………………….. 2-271
2.19FIRE PREVENTION……………………………………………………………………………………………………….. 2-272
2.19.1 PRECAUTIONS ………………………………………………………………………………………………….. 2-273
2.20WELD REPAIRS……………………………………………………………………………………………………………. 2-274
2.20.1 GENERAL INFORMATION…………………………………………………………………………………… 2-274
2.20.2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR………………………. 2-275
2.20.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
2-277
2.20.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
2-279
2.20.5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
2-281
2.20.6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…………………. 2-283
3 REVISION …………………………………………………………………………………….. 3-1
3.1REVISED EDITION FROM PREVIOUS MODEL OR VERSION……………………………………………….. 3-2
3.1.1 REVISION……………………………………………………………………………………………………………… 3-2
IMAGES PREVIEW OF THE MANUAL: