Komatsu Hydraulic Mining Excavator PC7000-11 Operation & Maintenance Manual – PDF DOWNLOAD

Komatsu Hydraulic Mining Excavator PC7000-11 Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu Hydraulic Mining Excavator PC7000-11 Operation & Maintenance Manual – PDF DOWNLOAD

SERIAL NUMBER 35014

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 PC7000-11 Operation & Maintenance Manual – PDF DOWNLOAD

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
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………………………………………… 2-56
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID……………………………………………………… 2-57
2.6ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……. 2-62
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM …………………………………………………………. 2-62
2.6.2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING
ADJUSTMENTS……………………………………………………………………………………………………. 2-62
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR……………………………….. 2-62
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 FOR PC3400…………………………………. 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/EGRESS STAIRWAY ………………………………. 3-114
3.2.4 EMERGENCY ESCAPE LADDERS ………………………………………………………………………. 3-118
3.2.5 BOOM ACCESS LADDER AND WALKWAY…………………………………………………………… 3-126
3.2.6 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…. 3-128
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE
STRUCTURE (FOPS)………………………………………………………………………………………….. 3-130
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
3.4MACHINE MONITOR……………………………………………………………………………………………………… 3-156
3.4.1 SEQUENCE OF DISPLAYS …………………………………………………………………………………. 3-157
3.4.2 OPENING SCREEN…………………………………………………………………………………………….. 3-157
3.4.3 FUNCTION CHECKING SCREEN…………………………………………………………………………. 3-158
3.4.4 MAIN GAUGE SCREENS 1 TO 3………………………………………………………………………….. 3-160
3.4.5 ECO GUIDANCE ………………………………………………………………………………………………… 3-166
3.4.6 AFTERTREATMENT DEVICE REGENERATION ……………………………………………………. 3-170
3.4.7 SCR INFORMATION …………………………………………………………………………………………… 3-172
3.4.8 MAINTENANCE ………………………………………………………………………………………………….. 3-173
3.4.9 MONITOR SETTING……………………………………………………………………………………………. 3-173
3.4.10 MESSAGE …………………………………………………………………………………………………………. 3-177
3.4.11 ACTION CODES…………………………………………………………………………………………………. 3-179
3.5OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING………………………………. 3-182
3.5.1 DIGITAL DISPLAY ………………………………………………………………………………………………. 3-182
3.5.2 LUMINOUS INDICATION. ……………………………………………………………………………………. 3-184
3.6CAMERA SYSTEM – KOMVISION……………………………………………………………………………………. 3-186
3.6.1 ABOUT THE SYSTEM…………………………………………………………………………………………. 3-187
3.6.2 KOMVISION SAFETY………………………………………………………………………………………….. 3-187
3.6.3 MAINTAINING THE SYSTEM ………………………………………………………………………………. 3-188
3.6.4 DAILY CHECK ……………………………………………………………………………………………………. 3-188
3.6.5 CAMERA OPERATION ……………………………………………………………………………………….. 3-188
3.6.6 CHECKS BEFORE OPERATION ………………………………………………………………………….. 3-189
3.6.7 MEANING OF ELEMENTS SHOWN ON THE DISPLAY ………………………………………….. 3-190
3.6.8 TOUCH SCREEN OPERATION ……………………………………………………………………………. 3-194
3.7MACHINERY HOUSE…………………………………………………………………………………………………….. 3-200
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES ………………………………………………….. 3-201
3.7.2 SAFETY SWITCH FOR MAINTENANCE ……………………………………………………………….. 3-203
3.7.3 BATTERY MAIN SWITCHES ……………………………………………………………………………….. 3-203
3.7.4 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT………………….. 3-205
3.8ELECTRICAL CONTROLLERS IN CAB BASE…………………………………………………………………. 3-206
3.8.1 CONTROLLERS IN CAB BASE ……………………………………………………………………………. 3-207
3.9CHECKS BEFORE STARTING THE ENGINES…………………………………………………………………. 3-208
3.10STARTING THE ENGINES……………………………………………………………………………………………… 3-214
3.10.1 STARTING PROCEDURE……………………………………………………………………………………. 3-217
3.10.2 ENGINE WARM-UP…………………………………………………………………………………………….. 3-225
3.10.3 HYDRAULIC OIL WARM-UP………………………………………………………………………………… 3-225
3.11MOVING THE EXCAVATOR…………………………………………………………………………………………… 3-227
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS ……………………………………………………………. 3-227
3.11.2 TRAVELING INSTRUCTIONS………………………………………………………………………………. 3-229
3.11.3 UNDERCARRIAGE TRACK SLIDERS…………………………………………………………………… 3-234
3.12SLEWING AND BRAKING THE SUPERSTRUCTURE……………………………………………………….. 3-236
3.12.1 SLEWING THE SUPERSTRUCTURE……………………………………………………………………. 3-236
3.13WORKING WITH THE ATTACHMENT……………………………………………………………………………… 3-239
3.13.1 COMBINED OPERATION CYCLES ………………………………………………………………………. 3-241
3.14WORKING INSTRUCTIONS……………………………………………………………………………………………. 3-243
3.14.1 STABILITY OF THE EXCAVATOR………………………………………………………………………… 3-243
3.14.2 FURTHER OPERATING PRACTICES …………………………………………………………………… 3-245
3.14.3 LOADING TRUCKS ……………………………………………………………………………………………. 3-249
3.15PARKING THE EXCAVATOR…………………………………………………………………………………………. 3-250
3.16STOPPING THE ENGINES……………………………………………………………………………………………… 3-252
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…………………………………………….. 3-255
3.17OPERATION OF THE LUBRICATION SYSTEM………………………………………………………………… 3-256
3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”…………………………………………………………….. 3-256
3.17.2 SLEW CIRCLE PINION LUBRICATION SYSTEM ”SLS” ………………………………………….. 3-257
3.18TRANSFER PUMP FOR HYDRAULIC OIL……………………………………………………………………….. 3-260
3.18.1 OPERATING THE TRANSFER PUMP…………………………………………………………………… 3-261
3.18.2 TRANSFUSION PROCEDURE …………………………………………………………………………….. 3-263
3.19SERVICE CENTER………………………………………………………………………………………………………… 3-266
3.19.1 SYSTEMS CONNECTED TO THE SERVICE CENTER …………………………………………… 3-267
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM …………………………………………………….. 3-269
3.19.3 RECEIVER PANEL WITH MONITOR BOX …………………………………………………………….. 3-271
3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS 3-279
3.20FIRE DETECTION AND SUPPRESSION SYSTEM……………………………………………………………. 3-280
3.20.1 DISPLAY MODULE …………………………………………………………………………………………….. 3-285
3.20.2 INTERFACE CONTROL MODULE………………………………………………………………………… 3-287
3.20.3 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT
GAS CARTRIDGES ON POWER HOUSE ROOF……………………………………………………. 3-289
3.21WORK ON THE LOADER ATTACHMENT………………………………………………………………………… 3-290
3.22TRANSPORTATION AND LIFTING OF THE EXCAVATOR………………………………………………… 3-291
3.22.1 DISASSEMBLING OF THE EXCAVATOR ……………………………………………………………… 3-291
3.22.2 TRANSPORTATION AND LIFTING……………………………………………………………………….. 3-291
3.23RETRIEVAL PROCEDURE……………………………………………………………………………………………… 3-292
3.23.1 GENERAL ………………………………………………………………………………………………………….. 3-292
3.24EXCAVATOR STORAGE………………………………………………………………………………………………… 3-293
3.24.1 GENERAL ………………………………………………………………………………………………………….. 3-293
3.24.2 PREPARING FOR STORAGE………………………………………………………………………………. 3-293
3.24.3 ONE MONTH REPETITIVE SERVICE PERIOD………………………………………………………. 3-293
3.24.4 SIX MONTH REPETITIVE SERVICE PERIOD………………………………………………………… 3-293
3.24.5 PREPARING FOR OPERATION …………………………………………………………………………… 3-294
3.25TROUBLE SHOOTING…………………………………………………………………………………………………… 3-295
3.25.1 GENERAL ………………………………………………………………………………………………………….. 3-295
3.25.2 ENGINE …………………………………………………………………………………………………………….. 3-295
3.25.3 HYDRAULIC SYSTEM…………………………………………………………………………………………. 3-296
3.25.4 FINAL DRIVES AND SLEW GEAR………………………………………………………………………… 3-297
3.25.5 CRAWLER TRACKS……………………………………………………………………………………………. 3-297
4 MAINTENANCE …………………………………………………………………………. 4-299
4.1FOREWORD………………………………………………………………………………………………………………….. 4-300
4.1.1 DEFINITIONS …………………………………………………………………………………………………….. 4-300
4.1.2 GENERAL RECOMMENDATIONS………………………………………………………………………… 4-300
4.2PRECAUTIONS FOR MAINTENANCE……………………………………………………………………………… 4-301
4.3FLUIDS AND LUBRICANTS……………………………………………………………………………………………. 4-302
4.3.1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES………………………. 4-302
4.3.2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES ………………………. 4-306
4.4FILLING CAPACITIES……………………………………………………………………………………………………. 4-307
4.5STANDARD TORQUE LIST…………………………………………………………………………………………….. 4-309
4.5.1 TORQUE FOR FLANGE JOINTS ………………………………………………………………………….. 4-310
4.5.2 TORQUES FOR SPECIAL COMPONENTS……………………………………………………………. 4-311
4.6LUBRICATION AND MAINTENANCE SCHEDULE……………………………………………………………. 4-313
4.6.1 INITIAL AND FIRST SERVICING ………………………………………………………………………….. 4-313
4.6.2 SERVICING THE CRITICAL BOLT CONNECTIONS……………………………………………….. 4-314
4.6.3 PERIODIC SERVICING INTERVALS …………………………………………………………………….. 4-314
4.6.4 PERIODIC SERVICING SCHEDULE …………………………………………………………………….. 4-314
4.6.5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS . 4-319
4.7SAFETY CRITICAL PARTS…………………………………………………………………………………………….. 4-320
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES ……………….. 4-321
4.7.2 INSPECTION OF HOSE LINES…………………………………………………………………………….. 4-321
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS …………………… 4-321
4.8EXTENDED SERVICE INTERVALS…………………………………………………………………………………. 4-323
4.8.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM ……………….. 4-323
4.8.2 MAINTENANCE OF THE ENGINE………………………………………………………………………… 4-327
4.8.3 ENGINE FUEL FILTER LOCATIONS…………………………………………………………………….. 4-329
4.8.4 VENTING THE AIR FROM THE FUEL FILTERS …………………………………………………….. 4-333
4.9INITIAL SERVICING………………………………………………………………………………………………………. 4-334
4.9.1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION…………… 4-334
4.9.2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS ……… 4-335
4.9.3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND
GREASE CONNECTIONS …………………………………………………………………………………… 4-336
4.9.4 SLEW CIRCLE PINION – CHECK GREASE INJECTORS AND GREASE
CONNECTIONS …………………………………………………………………………………………………. 4-337
4.9.5 SLEW CIRCLE TOOTHING LUBRICATION …………………………………………………………… 4-339
4.9.6 SLEW CIRCLE – CHECK TORQUE OF BOLT CONNECTIONS………………………………… 4-340
4.9.7 RE-TIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS … 4-341
4.10WHEN NECESSARY……………………………………………………………………………………………………… 4-344
4.10.1 HYDRAULIC OIL CHANGE ………………………………………………………………………………….. 4-345
4.10.2 FILLING THE HYDRAULIC SYSTEM…………………………………………………………………….. 4-347
4.10.3 BLEEDING THE HYDRAULIC SYSTEM ………………………………………………………………… 4-348
4.10.4 ENGINE AIR CLEANER MAINTENANCE ………………………………………………………………. 4-359
4.10.5 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS…………. 4-363
4.10.6 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…………………….. 4-365
4.10.7 GUIDE WHEELS – REPLACE FLOATING SEALS…………………………………………………… 4-367
4.11EVERY 10 OPERATING HOURS OR DAILY…………………………………………………………………….. 4-368
4.11.1 WALK – AROUND INSPECTION …………………………………………………………………………… 4-369
4.11.2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL CHECK…………………………… 4-373
4.11.3 RADIATORS – CHECK COOLANT LEVEL……………………………………………………………… 4-375
4.11.4 TRACK GROUPS – CLEAN ………………………………………………………………………………….. 4-375
4.11.5 CAMERA SYSTEM……………………………………………………………………………………………… 4-381
4.11.6 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB …………………………………… 4-383
4.12EVERY 50 OPERATING HOURS OR WEEKLY………………………………………………………………… 4-384
4.12.1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK
OIL LEVELS……………………………………………………………………………………………………….. 4-387
4.12.2 PTO (PUMP DISTRIBUTOR GEARS) – CHECK OIL LEVEL …………………………………….. 4-393
4.12.3 HYDRAULIC STAIRWAY – CHECK SAFETY SENSOR …………………………………………… 4-397
4.12.4 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY ……………………. 4-399
4.13EVERY 250 OPERATING HOURS OR MONTHLY…………………………………………………………….. 4-400
4.13.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION…………………… 4-401
4.13.2 SIGNAL HORN COMPRESSOR – LUBRICATE………………………………………………………. 4-403
4.13.3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN
BREATHER FILTER ……………………………………………………………………………………………. 4-403
4.13.4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER
FILTER………………………………………………………………………………………………………………. 4-403
4.13.5 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP
STATION …………………………………………………………………………………………………………… 4-405
4.13.6 CABIN AIR CLEANER – INSPECT ………………………………………………………………………… 4-407
4.13.7 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL ……… 4-409
4.13.8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL……………………………………… 4-411
4.13.9 CABIN HEATER FILTER – INSPECT …………………………………………………………………….. 4-413
4.13.10 CRITICAL BOLT CONNECTIONS – VISUAL CHECK ………………………………………………. 4-415
4.14EVERY 500 OPERATING HOURS OR QUARTERLY…………………………………………………………. 4-416
4.14.1 BATTERIES – CHECK FLUID LEVEL…………………………………………………………………….. 4-417
4.14.2 CYLINDER ROD PROTECTION (IF EQUIPPED), INSPECT…………………………………….. 4-421
4.14.3 FUEL TANK ……………………………………………………………………………………………………….. 4-423
4.14.4 CRAWLER TRACK – INSPECTION……………………………………………………………………….. 4-425
4.14.5 GROUND CABLES OF ENGINE AND ALTERNATOR – CHECK FOR CORRECT
CONNECTION ……………………………………………………………………………………………………. 4-431
4.14.6 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION … 4-433
4.14.7 EMERGENCY ESCAPE LADDERS ………………………………………………………………………. 4-435
4.14.8 EMERGENCY LOWERING OF ACCESS/EGRESS STAIRWAY – TEST
FUNCTIONALITY………………………………………………………………………………………………… 4-437
4.15EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…………………………………………………. 4-438
4.15.1 CRITICAL BOLT CONNECTIONS…………………………………………………………………………. 4-439
4.15.2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY …………….. 4-445
4.15.3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST
FUNCTIONALITY………………………………………………………………………………………………… 4-447
4.15.4 ELECTRICAL EQUIPMENT – MAINTENANCE ……………………………………………………….. 4-449
4.15.5 CABIN AIR CLEANER – REPLACE PRIMARY FILTER ……………………………………………. 4-451
4.15.6 ENGINE AIR CLEANERS- INSPECT AND LUBRICATE HINGES……………………………… 4-453
4.15.7 HYDRAULIC SYSTEM – FILTER SERVICE ……………………………………………………………. 4-455
4.15.8 BLEEDING AIR FROM THE SUCTION OIL CHAMBERS…………………………………………. 4-459
4.15.9 HIGH PRESSURE FILTERS…………………………………………………………………………………. 4-463
4.15.10 PTO’S (PUMP DISTRIBUTOR GEARS), SLEW GEARS AND TRAVEL GEARS – OIL
SAMPLE ANALYSIS ……………………………………………………………………………………………. 4-471
4.15.11 HYDRAULIC OIL TANK – CHECK LEAKAGE OIL SCREEN……………………………………… 4-473
4.15.12 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE …………………………………… 4-475
4.15.13 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 4-477
4.15.14 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES ……………….. 4-479
4.15.15 ALL OTHER HINGES AND AREAS TO LUBRICATE ………………………………………………. 4-481
4.15.16 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES ………….. 4-483
4.16EVERY 2000 OPERATING HOURS OR YEARLY……………………………………………………………… 4-484
4.16.1 HYDRAULIC SYSTEM – EMPTYING……………………………………………………………………… 4-493
4.16.2 FILLING THE HYDRAULIC SYSTEM…………………………………………………………………….. 4-495
4.16.3 EMERGENCY ESCAPE LADDERS – INSPECTION ………………………………………………… 4-497
4.16.4 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST………………………….. 4-499
4.16.5 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB …………………………………… 4-501
4.16.6 HYDRAULIC HOSES – CHECK CONDITION………………………………………………………….. 4-503
4.17EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR………………………… 4-504
4.17.1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL. 4-509
4.17.2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL ……………………………………………….. 4-513
4.17.3 FLEXIBLE COUPLING – VISUAL CHECK ………………………………………………………………. 4-515
4.17.4 OIL SEPARATOR ELEMENT – REPLACE (IF SO EQUIPPED)…………………………………. 4-517
4.18CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS……………………………… 4-518
4.18.1 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD…………………………………… 4-519
4.18.2 CHECKING THE STEEL STRUCTURES ……………………………………………………………….. 4-557
4.19EVERY 6000 HOURS HOWEVER AT LEAST ONCE A YEAR…………………………………………….. 4-560
4.19.1 AUTOMATIC LUBRICATION SYSTEMS – REPLACE PUMP OUTLET GREASE
FILTERS ……………………………………………………………………………………………………………. 4-561
4.19.2 CHANGING THE HIGH PRESSURE FILTERS……………………………………………………….. 4-563
4.20FIRE PREVENTION……………………………………………………………………………………………………….. 4-564
4.20.1 PRECAUTIONS ………………………………………………………………………………………………….. 4-565
4.21WELD REPAIRS……………………………………………………………………………………………………………. 4-566
4.21.1 GENERAL INFORMATION…………………………………………………………………………………… 4-566
4.21.2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR………………………. 4-567
4.21.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
UNDERCARRIAGE …………………………………………………………………………………………….. 4-569
4.21.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
LOADER ATTACHMENT……………………………………………………………………………………… 4-571
4.21.5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
SUPERSTRUCTURE ………………………………………………………………………………………….. 4-573
4.21.6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE…………………. 4-575

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