Komatsu HYDRAULIC MINING SHOVEL PC5500E-6 Operation & Maintenance Manual(15120-x-GB-0) PDF DOWNLOAD

Komatsu HYDRAULIC MINING SHOVEL PC5500E-6 Operation & Maintenance Manual(15120-x-GB-0) – PDF DOWNLOAD

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SERIAL NUMBER 15120

Komatsu HYDRAULIC MINING SHOVEL PC5500E-6 Operation & Maintenance Manual(15120-x-GB-0) – PDF DOWNLOAD

BEFORE READING THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used. Therefore,
the safety messages in this manual and on the machine may not include all possible safety precautions. If
you carry out any operation, inspection or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you
or others engage in prohibited uses or actions described in this manual. Improper operation and maintenance of
the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
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 machine may lead to additional
changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine 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 machines that comply with all applicable regulations
and standards of the country to which it has been shipped. If
the machine 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 regulations of
your country, consult Komatsu or your Komatsu distributor before
operating the machine.
Always keep the Operation and Maintenance Manual in the storage
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 SHOVEL PC5500E-6 Operation & Maintenance Manual(15120-x-GB-0) – PDF DOWNLOAD

1 FOREWORD…………………………………………………………………………………………………………………………………………. 3
1.1 BEFORE READING THIS MANUAL……………………………………………………………………………………………………………………. 4
1.2 DIRECTIONS OF THE MACHINE…………………………………………………………………………………………………………………….. 5
1.3 SPECIFICATION AND SERIAL PLATE………………………………………………………………………………………………………………… 6
1.3.1 PRODUCT IDENTIFICATION NUMBER……………………………………………………………………………………………………………. 6
1.4 DIVISION OF THE BINDER……………………………………………………………………………………………………………………….. 7
1.5 DESIGNATED USE OF THE SHOVEL………………………………………………………………………………………………………………….. 8
1.6 DELIVERY OF THE SHOVEL……………………………………………………………………………………………………………………….. 9
1.6.1 SPARE PARTS……………………………………………………………………………………………………………………………. 9
1.6.2 SERVICE……………………………………………………………………………………………………………………………….. 9
1.7 EXPLANATION OF ABBREVIATIONS………………………………………………………………………………………………………………….. 10
1.8 CONTENTS……………………………………………………………………………………………………………………………………. 11
2 SAFETY…………………………………………………………………………………………………………………………………………… 17
2.1 SAFETY INFORMATION…………………………………………………………………………………………………………………………… 18
2.2 OVERVIEW……………………………………………………………………………………………………………………………………. 19
2.2.1 NORMAL OPERATIONS………………………………………………………………………………………………………………………. 19
2.2.2 REGULAR MAINTENANCE…………………………………………………………………………………………………………………….. 19
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR…………………………………………………………………………………………………… 19
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR…………………………………………………. 19
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB……………………………………………………………………………………………………… 20
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR…………………………………………………………………………………………. 21
2.4.1 UNDERSTANDING THE MACHINE……………………………………………………………………………………………………………….. 21
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR……………………………………………………………………………………… 21
2.4.2.1 ENSURING SAFE OPERATION……………………………………………………………………………………………………………. 21
2.4.3 PREPARATIONS FOR SAFE OPERATION………………………………………………………………………………………………………….. 21
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT……………………………………………………………………………………….. 21
2.4.3.2 INSPECTING THE MACHINE…………………………………………………………………………………………………………….. 21
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT……………………………………………………………………………………. 22
2.4.3.4 KEEP MACHINE CLEAN………………………………………………………………………………………………………………… 22
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT……………………………………………………………………………………………. 22
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT………………………………………………………………………………………….. 23
2.4.3.7 IF A PROBLEM IS FOUND……………………………………………………………………………………………………………… 23
2.4.4 FIRE PREVENTION………………………………………………………………………………………………………………………… 23
2.4.4.1 PRECAUTIONS TO PREVENT FIRE………………………………………………………………………………………………………… 23
2.4.4.2 ACTION IF FIRE OCCURS……………………………………………………………………………………………………………… 24
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB………………………………………………………………………………………………….. 25
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…………………………………………………………………………………………….. 25
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…………………………………………………………………………….. 25
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE……………………………………………………………………………………………………. 25
2.4.5.3 NO PEOPLE ON THE ATTACHMENT………………………………………………………………………………………………………… 25
2.4.5.4 WORKING IN HIGH PLACES…………………………………………………………………………………………………………….. 25
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK…………………………………………………………………………………………………… 26
2.4.5.6 LEAVING THE MACHINE……………………………………………………………………………………………………………….. 26
2.4.6 BURN PREVENTION………………………………………………………………………………………………………………………… 27
2.4.6.1 Hot coolant………………………………………………………………………………………………………………………. 27
2.4.6.2 Hot oil………………………………………………………………………………………………………………………….. 27
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS………………………………………………………………………………………………………. 27
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES………………………………………………………………………………………………. 28
2.4.8.1 UNAUTHORIZED MODIFICATION………………………………………………………………………………………………………….. 28
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS……………………………………………………………………………………….. 28
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)………………………………………………………………………………………………………. 29
2.4.10 PRECAUTIONS AT JOBSITE…………………………………………………………………………………………………………………. 30
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT……………………………………………………………………………………………………. 31
2.4.10.2 CAMERA SYSTEM WITH MONITORS……………………………………………………………………………………………………….. 31
2.4.10.3 ENSURE GOOD VISIBILITY……………………………………………………………………………………………………………. 31
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS……………………………………………………………………………………………… 31
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS………………………………………………………………………………………….. 32
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES……………………………………………………………………………………………… 32
2.4.10.7 WORKING ON LOOSE GROUND…………………………………………………………………………………………………………… 33
2.4.10.8 GAS, DUST, STEAM AND SMOKE………………………………………………………………………………………………………… 33
2.4.10.9 VENTILATION OF ENCLOSED AREAS……………………………………………………………………………………………………… 34
2.4.11 STARTING ENGINE……………………………………………………………………………………………………………………….. 35
2.4.11.1 WARNING TAG……………………………………………………………………………………………………………………… 35
2.4.11.2 CHECKS BEFORE STARTING ENGINE……………………………………………………………………………………………………… 35
2.4.11.3 PRECAUTION WHEN STARTING ENGINE……………………………………………………………………………………………………. 35
2.4.11.4 PRECAUTION IN COLD AREAS………………………………………………………………………………………………………….. 36
2.4.12 OPERATION…………………………………………………………………………………………………………………………….. 36
2.4.12.1 CHECKS BEFORE OPERATION…………………………………………………………………………………………………………… 36
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE……………………………………………………………………………………. 37
2.4.12.3 PRECAUTIONS WHEN travelling……………………………………………………………………………………………………….. 38
2.4.12.4 TRAVELLING ON SLOPES……………………………………………………………………………………………………………… 39
2.4.12.5 OPERATIONS ON SLOPES……………………………………………………………………………………………………………… 40
2.4.12.6 PROHIBITED OPERATIONS…………………………………………………………………………………………………………….. 40
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES……………………………………………………………………………………….. 41
2.4.12.8 PARKING THE MACHINE………………………………………………………………………………………………………………. 41
2.4.12.9 TRANSPORTATION…………………………………………………………………………………………………………………… 41
2.5 PRECAUTION FOR MAINTENANCE……………………………………………………………………………………………………………………. 42
2.5.1 GENERAL PRECAUTIONS…………………………………………………………………………………………………………………….. 42
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES………………………………………………………………………. 43
2.5.1.2 STOP ENGINE FOR MAINTENANCE………………………………………………………………………………………………………… 44
2.5.1.3 WARNING TAG………………………………………………………………………………………………………………………. 45
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY………………………………………………………………………………………………………. 46
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS……………………………………………………………………………………………… 46
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING……………………………………………………………………………….. 47
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS………………………………………………………………………………………….. 47
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT……………………………………………………………………………….. 48
2.5.1.9 NOISE……………………………………………………………………………………………………………………………. 48
2.5.1.10 WHEN USING A HAMMER………………………………………………………………………………………………………………. 48
2.5.1.11 PROPER TOOLS…………………………………………………………………………………………………………………….. 49
2.5.1.12 ACCUMULATOR……………………………………………………………………………………………………………………… 49
2.5.1.13 PERSONNEL……………………………………………………………………………………………………………………….. 49
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE………………………………………………………………………………………………… 50
2.5.2.1 PRECAUTION WHEN WELDING……………………………………………………………………………………………………………. 50
2.5.2.2 BATTERY HANDLING………………………………………………………………………………………………………………….. 50
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID……………………………………………………………………………………………………… 51
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE…………………………………………………………………………………………………. 51
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES………………………………………………………………………………………………. 52
2.5.3.3 REPLACEMENT OF HOSE LINES………………………………………………………………………………………………………….. 52
2.5.3.4 INSPECTION OF HOSE LINES…………………………………………………………………………………………………………… 52
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS………………………………………………………………………………………… 53
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE……………………………………………………………………………………………………….. 53
2.5.3.7 AIR CONDITIONING MAINTENANCE……………………………………………………………………………………………………….. 53
2.5.3.8 COMPRESSED AIR……………………………………………………………………………………………………………………. 54
2.5.3.9 WASTE MATERIALS…………………………………………………………………………………………………………………… 54
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS…………………………………………………………………………………. 55
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM……………………………………………………………………………………………………….. 55
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS……………………………………………………………………………… 55
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…………………………………………………………………………………………….. 55
2.7 SPECIAL SAFETY EQUIPMENT……………………………………………………………………………………………………………………… 56
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB…………………………………………………………………………………… 57
2.7.2 OBJECT HANDLING………………………………………………………………………………………………………………………… 57
2.7.3 LIGHTING………………………………………………………………………………………………………………………………. 57
2.7.4 WARNING BEACON…………………………………………………………………………………………………………………………. 57
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)………………………………………………………………………………… 57
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………………………………………………………… 57
2.7.5.2 INSTRUCTIONS FOR USE………………………………………………………………………………………………………………. 59
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL……………………………………………………………………………………… 61
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),………………………………………………. 61
2.7.5.5 INSTRUCTIONS FOR USE………………………………………………………………………………………………………………. 63
2.8 SAFETY WARNING SIGNS…………………………………………………………………………………………………………………………. 65
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS…………………………………………………………………………………………………….. 66
3 OPERATION………………………………………………………………………………………………………………………………………… 79
3.1 FOREWORD……………………………………………………………………………………………………………………………………. 80
3.2 CONSTRUCTION OF THE SHOVEL……………………………………………………………………………………………………………………. 81
3.2.1 OVERALL VIEW…………………………………………………………………………………………………………………………… 81
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…………………………………………………………………………………………………………. 82
3.2.2.1 SUPERSTRUCTURE – TOP VIEW………………………………………………………………………………………………………….. 84
3.2.2.2 MACHINERY HOUSE…………………………………………………………………………………………………………………… 88
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER……………………………………………………………………………………………………… 90
3.2.4 EMERGENCY ESCAPE LADDER…………………………………………………………………………………………………………………. 94
3.2.5 BOOM ACCESS LADDER AND WALKWAY…………………………………………………………………………………………………………… 96
3.2.6 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM………………………………………………………………………….. 98
3.2.6.1 Emergency Motor Shutdown System actuated from Ground Man (Special Equipment)…………………………………………………………….. 99
3.2.6.2 Operator Warning System (Special Equipment)………………………………………………………………………………………….. 99
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)……………………………………………………………………..100
3.2.7.1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual…………………………………………………………….105
3.2.7.2 Operator’s Seat Adjustment………………………………………………………………………………………………………….107
3.2.7.3 Co-driver’s Seat and Refrigerator Box………………………………………………………………………………………………..108
3.2.7.4 Sound Pressure Level in the Operator’s Cab……………………………………………………………………………………………109
3.3 OPERATOR’S CAB – CONTROLS……………………………………………………………………………………………………………………..110
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT………………………………………………………………………………………………………….110
3.3.1.1 Hydraulic Control System……………………………………………………………………………………………………………111
3.3.1.2 Safety Circuit for Controls…………………………………………………………………………………………………………111
3.3.1.3 EURO Control Pattern……………………………………………………………………………………………………………….113
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT………………………………………………………………………………………………..114
3.3.2.1 Hydraulic Control System……………………………………………………………………………………………………………115
3.3.2.2 Safety Circuit for Controls…………………………………………………………………………………………………………115
3.3.2.3 EURO Control Pattern……………………………………………………………………………………………………………….117
3.3.2.4 Automatic Float Position for Boom and Stick…………………………………………………………………………………………..117
3.3.3 OPERATOR’S CONSOLE………………………………………………………………………………………………………………………119
3.3.3.1 Control Panel……………………………………………………………………………………………………………………..121
3.3.4 Auxiliary Heaters for Operator’s Cab………………………………………………………………………………………………………125
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER……………………………………………………………………………………………………127
3.3.6 INTERFACE PANEL FOR DIAGNOSTICS…………………………………………………………………………………………………………..129
3.3.7 Auxiliary Heaters for Operator’s Cab………………………………………………………………………………………………………131
3.3.7.1 CONTROL MODULE FOR AUXILIARY CAB HEATER………………………………………………………………………………………………133
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR……………………………………………………………………………………………134
3.4.1 SEQUENCE OF DISPLAYS…………………………………………………………………………………………………………………….135
3.4.2 OPENING SCREEN………………………………………………………………………………………………………………………….135
3.4.3 MAIN GAUGE SCREENS 1 TO 3………………………………………………………………………………………………………………..136
3.4.3.1 Main Gauge Screen 1………………………………………………………………………………………………………………..137
3.4.3.2 Main Gauge Screen 2………………………………………………………………………………………………………………..139
3.4.3.3 Main Gauge Screen 3………………………………………………………………………………………………………………..139
3.4.3.4 Color Definition…………………………………………………………………………………………………………………..139
3.4.4 ENERGY CONSUMPTION SCREEN………………………………………………………………………………………………………………..141
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR………………………………………………………………………………………………..141
3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE……………………………………………………………………………………………………..142
3.4.7 MAINTENANCE MONITOR……………………………………………………………………………………………………………………..142
3.4.7.1 Maintenance confirmation through Service Personnel…………………………………………………………………………………….143
3.4.8 SETTINGS FOR OPERATOR……………………………………………………………………………………………………………………143
3.4.8.1 Settings Screens…………………………………………………………………………………………………………………..144
3.4.9 SERVICE MENU……………………………………………………………………………………………………………………………147
3.4.10 AUTOMATIC MESSAGES……………………………………………………………………………………………………………………..147
3.4.10.1 Automatic Messages………………………………………………………………………………………………………………..148
3.4.10.2 Automatic Motor Messages…………………………………………………………………………………………………………..151
3.4.11 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM…………………………………………………………………………………………..152
3.4.12 TABLE OF AVAILABLE INSTRUCTION MESSAGES…………………………………………………………………………………………………..164
3.5 CAMERA SYSTEM WITH MONITORS……………………………………………………………………………………………………………………168
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS…………………………………………………………………………………………………….169
3.5.1.1 Operating the Monitors……………………………………………………………………………………………………………..171
3.5.1.2 Ajustments of the Monitor…………………………………………………………………………………………………………..171
3.5.1.3 Typical Arrangement of the Cameras…………………………………………………………………………………………………..175
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING……………………………………………………………………………………………176
3.6.0.1 Digital Display……………………………………………………………………………………………………………………….176
3.6.0.2 Luminous Indication……………………………………………………………………………………………………………………178
3.6.1 AUXILIARY HEATER FOR OPERATOR’S CAB……………………………………………………………………………………………………….181
3.6.1.1 Special Equipment………………………………………………………………………………………………………………….181
3.6.1.2 Operation…………………………………………………………………………………………………………………………181
3.7 MACHINERY HOUSE………………………………………………………………………………………………………………………………182
3.7.1 EMERGENCY MOTOR 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
3.7.3.1 Operation Modes of Pump Regulation System…………………………………………………………………………………………….187
3.7.4 HEATERS FOR MACHINERY HOUSE………………………………………………………………………………………………………………189
3.8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE……………………………………………………………………………………………………….190
3.8.1 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET…………………………………………………………………………………………….191
3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE………………………………………………………………………………………………………193
3.8.3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS………………………………………………………………………………………………195
3.8.4 BINARY FAULT CODE LIST…………………………………………………………………………………………………………………..202
3.8.4.1 Combination Message 308 Trouble Can-Bus or Can Hardware………………………………………………………………………………..204
3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS…………………………………………………………………………………………204
3.8.6 MONITOR AND CONTROL PANEL IN CAB BASE……………………………………………………………………………………………………..207
3.8.7 SWITCH BOARD – MEDIUM VOLTAGE…………………………………………………………………………………………………………….209
3.9 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS…………………………………………………………………………………………………….210
3.9.1 WALK AROUND INSPECTION…………………………………………………………………………………………………………………..211
3.9.2 TURNING ON THE POWER SUPPLY………………………………………………………………………………………………………………211
3.9.3 HYDRAULIC SYSTEM – CHECK OIL LEVEL………………………………………………………………………………………………………..213
3.9.4 Machinery House Doors……………………………………………………………………………………………………………………213
3.9.5 Operator’s Seat Adjustment……………………………………………………………………………………………………………….213
3.10 STARTING THE MAIN DRIVE MOTORS………………………………………………………………………………………………………………..214
3.10.1 Starting Procedure……………………………………………………………………………………………………………………..217
3.10.1.1 Hydraulic oil warm-up……………………………………………………………………………………………………………..219
3.11 MOVING THE SHOVEL……………………………………………………………………………………………………………………………221
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS………………………………………………………………………………………………………….221
3.11.1.1 TRAVEL ALARM / BACK-UP ALARM……………………………………………………………………………………………………….223
3.11.2 TRAVELLING INSTRUCTIONS…………………………………………………………………………………………………………………223
3.11.2.1 TRAVELLING LONG DISTANCES………………………………………………………………………………………………………….225
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE…………………………………………………………………………………………………………226
3.12.1 SLEWING THE SUPERSTRUCTURE………………………………………………………………………………………………………………226
3.12.1.1 MACHINES WITH “EURO” CONTROL……………………………………………………………………………………………………….226
3.12.1.2 MACHINES WITH “KMG” CONTROL………………………………………………………………………………………………………..227
3.12.1.3 BRAKING THE SUPERSTRUCTURE…………………………………………………………………………………………………………227
3.12.1.4 Hydraulic Swing Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System………………………………………228
3.12.1.5 Important Instructions for Slewing the Superstructure…………………………………………………………………………………228
3.13 WORKING WITH THE ATTACHMENT…………………………………………………………………………………………………………………..229
3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM………………………………………………………………………………………………229
3.13.1.1 BACKHOE………………………………………………………………………………………………………………………….229
3.13.1.2 FACE SHOVEL………………………………………………………………………………………………………………………229
3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM……………………………………………………………………………………………….230
3.13.2.1 BACKHOE………………………………………………………………………………………………………………………….230
3.13.2.2 FACE SHOVEL………………………………………………………………………………………………………………………230
3.13.2.3 BOTTOM DUMP BUCKET………………………………………………………………………………………………………………..231
3.13.2.4 OPERATING THE BUCKET CLAM………………………………………………………………………………………………………….231
3.13.3 COMBINED OPERATION CYCLES……………………………………………………………………………………………………………….232
3.14 WORKING INSTRUCTIONS…………………………………………………………………………………………………………………………234
3.14.1 STABILITY OF THE SHOVEL…………………………………………………………………………………………………………………234
3.14.2 SHOVEL OPERATION……………………………………………………………………………………………………………………….234
3.15 PARKING THE SHOVEL…………………………………………………………………………………………………………………………..237
3.15.0.1 CLEANING THE TRACK GROUPS……………………………………………………………………………………………………………..237
3.16 STOPPING THE MAIN DRIVE MOTORS………………………………………………………………………………………………………………..238
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM………………………………………………………………………………………………….241
3.17 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM…………………………………………………………………………………………………242
3.17.1 ISOLATING THE POWER SUPPLY………………………………………………………………………………………………………………245
3.17.2 PROCEDURE FOR ISOLTING THE POWER SUPPLY…………………………………………………………………………………………………..247
3.17.3 PERFORMING GROUNDING PROCEDURES………………………………………………………………………………………………………….249
3.18 OPERATION OF THE LUBRICATION SYSTEM……………………………………………………………………………………………………………254
3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT…………………………………………………………………………..254
3.18.1.1 Manual actuation of the central lubrication system……………………………………………………………………………………254
3.18.1.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM………………………………………………………………………………………..255
3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM -SLS-………………………………………………………………………………………………255
3.18.2.1 Manual actuation of the swing circle lubrication system……………………………………………………………………………….256
3.18.2.2 SWING CIRCLE LUBRICATION SYSTEM ”SLS”……………………………………………………………………………………………….256
3.18.2.3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM…………………………………………………………………………………….256
3.19 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM………………………………………………………………………………………………..258
3.19.1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS………………………………………………………………………259
3.19.1.1 Personnel Safety………………………………………………………………………………………………………………….259
3.19.2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB………………………………………………………………………………………….263
3.19.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM:……………………………………………………………………………………………263
3.19.4 IN The CASE OF A FIRE…………………………………………………………………………………………………………………..265
3.19.4.1 Indication of Alarm Condition at Control Module (5) when the electric Detection and Warning System -II- detects a Fire in the Machinery House:….265
3.20 TRANSFER PUMP FOR HYDRAULIC OIL……………………………………………………………………………………………………………….266
3.20.1 OPERATING THE TRANSFER PUMP……………………………………………………………………………………………………………..267
3.20.2 FUNCTIONS OF THE TRANSFER PUMP…………………………………………………………………………………………………………..269
3.21 CENTRAL REFILLING SYSTEM……………………………………………………………………………………………………………………..272
3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM…………………………………………………………………………………………………273
3.21.1.1 Operation of the service arm……………………………………………………………………………………………………….273
3.21.2 OPERATING THE HYDRAULIC SERVICE ARM………………………………………………………………………………………………………275
3.21.3 RECEIVER PANEL AND MONITOR BOX…………………………………………………………………………………………………………..277
3.21.3.1 Refilling Procedure:………………………………………………………………………………………………………………277
3.22 CABLE GUIDE (IF SO EQUIPPED)………………………………………………………………………………………………………………….279
3.22.1 LIFTING DEVICE FOR THE POWER CABLE……………………………………………………………………………………………………….279
3.23 SERVICE CRANE (SPECIAL EQUIPMENT)……………………………………………………………………………………………………………..280
3.23.1 OPERATING THE CRANE…………………………………………………………………………………………………………………….281
3.24 WORK ON THE LOADER ATTACHMENT…………………………………………………………………………………………………………………284
3.24.1 OBSERVE THE FOLLOWING INSTRUCTIONS……………………………………………………………………………………………………….284
3.25 TRANSPORTATION AND LIFTING OF THE SHOVEL……………………………………………………………………………………………………….285
3.25.1 DISASSEMBLING OF THE SHOVEL……………………………………………………………………………………………………………..285
3.25.2 TRANSPORTATION AND LIFTING………………………………………………………………………………………………………………285
3.26 RETRIEVAL PROCEDURE………………………………………………………………………………………………………………………….286
3.26.0.1 GENERAL……………………………………………………………………………………………………………………………..286
3.27 SHOVEL STORAGE………………………………………………………………………………………………………………………………287
3.27.1 PREPARING FOR STORAGE…………………………………………………………………………………………………………………..287
3.27.2 ONE MONTH REPETITIVE SERVICE PERIOD………………………………………………………………………………………………………287
3.27.3 SIX MONTH REPETITIVE SERVICE PERIOD………………………………………………………………………………………………………287
3.27.4 PREPARING FOR OPERATION…………………………………………………………………………………………………………………288
3.28 TROUBLE SHOOTING…………………………………………………………………………………………………………………………….289
3.28.1 MAIN DRIVE ELECTRIC MOTOR……………………………………………………………………………………………………………….289
3.28.2 HYDRAULIC SYSTEM……………………………………………………………………………………………………………………….290
3.28.3 FINAL DRIVES AND SWING GEAR……………………………………………………………………………………………………………..291
3.28.4 CRAWLER TRACKS…………………………………………………………………………………………………………………………291
4 MAINTENANCE……………………………………………………………………………………………………………………………………….293
4.1 FOREWORD…………………………………………………………………………………………………………………………………….294
4.1.1 DEFINITIONS…………………………………………………………………………………………………………………………….294
4.1.2 GENERAL RECOMMENDATIONS………………………………………………………………………………………………………………….294
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE……………………………………………………………………………………………………………..295
4.3 FLUIDS AND LUBRICANTS…………………………………………………………………………………………………………………………298
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES………………………………………………………………………………………..298
4.3.1.1 Grease for the bearings of the main drive Electric Motors………………………………………………………………………………298
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES…………………………………………………………………………………………299
4.3.3 MAIN DRIVE ELECTRIC MOTORS – BEARING LUBRICATION……………………………………………………………………………………………300
4.4 FILLING CAPACITIES……………………………………………………………………………………………………………………………301
4.5 STANDARD TORQUE LIST………………………………………………………………………………………………………………………….302
4.6 LUBRICATION AND MAINTENANCE SCHEDULE……………………………………………………………………………………………………………303
4.6.1 INITIAL SERVICING……………………………………………………………………………………………………………………….303
4.6.1.1 AFTER THE FIRST 250 OPERATING HOURS………………………………………………………………………………………………….303
4.6.1.2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS………………………………………………………………………………………….303
4.6.2 PERIODIC SERVICING INTERVALS……………………………………………………………………………………………………………..303
4.6.3 PERIODIC SERVICING SCHEDULE………………………………………………………………………………………………………………304
4.6.3.1 WHEN NECESSARY…………………………………………………………………………………………………………………….304
4.6.3.2 EVERY 10 OPERATING HOURS OR DAILY……………………………………………………………………………………………………304
4.6.3.3 EVERY 50 OPERATING HOURS OR WEEKLY…………………………………………………………………………………………………..304
4.6.3.4 EVERY 250 OPERATING HOURS OR MONTHLY…………………………………………………………………………………………………304
4.6.3.5 EVERY 500 OPERATING HOURS OR QUATERLY………………………………………………………………………………………………..305
4.6.3.6 EVERY 1000 OPERATING HOURS OR 6 MONTHLY………………………………………………………………………………………………305
4.6.3.7 EVERY 2000 OPEARTING HOURS OR YEARLY…………………………………………………………………………………………………306
4.6.3.8 EVERY 3000 HOURS OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…………………………………………………………………………..306
4.6.4 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM…………………………………………………………..307
4.6.5 MAINTENANCE OF THE MAIN DRIVE MOTORS………………………………………………………………………………………………………307
4.6.5.1 Lubrication Chart………………………………………………………………………………………………………………….309
4.7 SAFETY CRITICAL PARTS…………………………………………………………………………………………………………………………310
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES……………………………………………………………………………………..310
4.7.2 INSPECTION OF HOSE LINES…………………………………………………………………………………………………………………310
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS……………………………………………………………………………………….310
4.8 WHEN NECESSARY……………………………………………………………………………………………………………………………….312
4.8.1 SWING CIRCLE TOOTHING LUBRICATION…………………………………………………………………………………………………………313
4.8.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS………………………………………………………………………………………..315
4.8.3 Service the Grease Filters for Refillable Grease Containers of the Central Lubrication System and Swing circle pinion Lubrication System,…………….317
4.8.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS……………………………………………………………………………………..319
4.9 EVERY 10 OPERATING HOURS OR DAILY………………………………………………………………………………………………………………320
4.9.1 WALK – AROUND INSPECTION…………………………………………………………………………………………………………………321
4.9.1.1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION……………………………………………………………………………..325
4.9.1.2 BOOM – CHECK LADDER AND WALKWAY……………………………………………………………………………………………………..327
4.9.1.3 CHECK GREASE INJECTORS……………………………………………………………………………………………………………..329
4.9.1.4 CORRECTIVE ACTIONS…………………………………………………………………………………………………………………329
4.9.1.5 SWING CIRCLE – CHECK GREASE INJECTORS………………………………………………………………………………………………..331
4.9.2 TRACK GROUPS – CLEAN…………………………………………………………………………………………………………………….333
4.10 EVERY 50 OPERATING HOURS OR WEEKLY…………………………………………………………………………………………………………….334
4.10.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…………………………………………………………………………………..335
4.10.1.1 Swing Gear manufactured by “L&S”……………………………………………………………………………………………………335
4.10.1.2 CHECK SWING GEAR OIL LEVEL…………………………………………………………………………………………………………335
4.10.1.3 CHECK MOTOR ADAPTER HOUSING OIL LEVEL……………………………………………………………………………………………….335
4.10.1.4 Swing gears manufactured by -SIEBENHAAR-…………………………………………………………………………………………….337
4.10.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS……………………………………………………………………….339
4.10.2.1 TRAVEL GEAR BOX – CHECK OIL LEVEL…………………………………………………………………………………………………..341
4.10.2.2 MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL…………………………………………………………………………………………….341
4.10.2.3 FINAL DRIVE HOUSING – CHECK OIL LEVEL……………………………………………………………………………………………….341
4.10.2.4 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES – CHECK BREATHER FILTERS…………………………………………………………..343
4.10.3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL…………………………………………………………………………..345
4.10.3.1 PUMP DISTRIBUTOR GEARS, CHECK OIL LEVEL:…………………………………………………………………………………………….345
4.10.3.2 OIL COLLECTOR RESERVOIR – CHECK OIL LEVEL……………………………………………………………………………………………347
4.10.3.3 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings…………………………………………………………………………347
4.10.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR……………………………………………………………………………………………..349
4.10.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY……………………………………………………………………………………..351
4.10.6 CLEANING THE DISTRIBUTOR GEAR COOLERS…………………………………………………………………………………………………….351
4.11 EVERY 250 OPERATING HOURS OR MONTHLY…………………………………………………………………………………………………………..352
4.11.1 SIGNAL HORN COMPRESSOR – LUBRICATE……………………………………………………………………………………………………….353
4.11.2 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER……………………………………………………………….353
4.11.3 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSION ONLY)………………………………………………………353
4.11.4 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER…………………………………………………………………………………355
4.11.5 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT………………………………………………………………………………………….357
4.11.5.1 Clean and inspect filter element (2) as follows:……………………………………………………………………………………..357
4.11.6 AIR CONDITIONING FOR OPERATOR’S CAB AND SWITCH CABINETS…………………………………………………………………………………….359
4.11.6.1 Air conditioning for Operator’s Cab…………………………………………………………………………………………………359
4.11.6.2 Air Conditioning for medium and high Voltage Switch Cabinets…………………………………………………………………………..361
4.11.7 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL………………………………………………………………………………………………363
4.12 EVERY 500 OPERATING HOURS OR QUARTERLY…………………………………………………………………………………………………………364
4.12.1 BATTERIES – CHECK FLUID LEVEL……………………………………………………………………………………………………………365
4.12.2 CRAWLER TRACK – INSPECTION………………………………………………………………………………………………………………367
4.12.2.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS……………………………………………………………………………………………….367
4.12.2.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS………………………………………………………………………………………………369
4.12.2.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS………………………………………………………………………………………………371
4.12.2.4 Bleeding the System……………………………………………………………………………………………………………….371
4.12.3 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION……………………………………………………………………………….373
4.13 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…………………………………………………………………………………………………….374
4.13.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD…………………………………………………………………………………………375
4.14 HYDRAULIC SYSTEM – FILTER SERVICE……………………………………………………………………………………………………………..431
4.14.0.1 FILTER SERVICE……………………………………………………………………………………………………………………….433
4.14.1 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…………………………………………………………….445
4.14.1.1 Oil drain plugs…………………………………………………………………………………………………………………..445
4.14.1.2 PTO (PUMP DISTRIBUTOR GEAR)………………………………………………………………………………………………………..445
4.14.1.3 SWING GEARS AND TRAVEL GEARS……………………………………………………………………………………………………….445
4.14.2 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE………………………………………………………………………………………………447
4.14.3 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS……………………………………………………………………………..449
4.14.4 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES……………………………………………………………………………………451
4.14.5 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES…………………………………………………………………………………..453
4.14.6 SLIP RING UNIT – LUBRICATE………………………………………………………………………………………………………………455
4.15 EVERY 2000 OPERATING HOURS OR YEARLY…………………………………………………………………………………………………………..456
4.15.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER…………………………………………………………………457
4.15.1.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER……………………………………………………………459
4.15.1.2 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER……………………………………………………………461
4.15.1.3 Replace Suction Strainers of Main Pumps……………………………………………………………………………………………..465
4.15.2 FILLING THE HYDRAULIC SYSTEM…………………………………………………………………………………………………………….467
4.15.3 BLEEDING THE HYDRAULIC SYSTEM……………………………………………………………………………………………………………469
4.15.4 GEAR PUMPS FOR PTO GEAR LUBRICATION………………………………………………………………………………………………………471
4.15.5 EMERGENCY ESCAPE LADDER – INSPECTION……………………………………………………………………………………………………..473
4.16 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR………………………………………………………………………………………….474
4.16.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL…………………………………………………………………………………………475
4.16.1.1 Motor Adapter Housing, Change Oil:………………………………………………………………………………………………….477
4.16.1.2 SWING GEAR MANUFACTURED BY “SIEBENHAAR”……………………………………………………………………………………………..479
4.16.1.3 Brake Housing – Change Oil (Siebenhaar)……………………………………………………………………………………………..481
4.16.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL…………………………………………………………………………….483
4.16.2.1 TRAVEL GEARS – CHANGE OIL………………………………………………………………………………………………………….485
4.16.2.2 MOTOR ADAPTER HOUSINGS – CHANGE OIL…………………………………………………………………………………………………485
4.16.2.3 FINAL DRIVE HOUSINGS – CHANGE OIL…………………………………………………………………………………………………..485
4.16.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL………………………………………………………………………………………………….487
4.16.3.1 Change the Oil……………………………………………………………………………………………………………………489
4.17 FIRE PREVENTION……………………………………………………………………………………………………………………………..490
4.17.1 PRECAUTIONS……………………………………………………………………………………………………………………………491
4.18 WELD REPAIRS………………………………………………………………………………………………………………………………..492
4.18.1 GENERAL INFORMATION…………………………………………………………………………………………………………………….492
4.18.1.1 GENERAL PROTECTIVE MEASURES………………………………………………………………………………………………………..493
4.18.2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR………………………………………………………………………………………….493
4.18.2.1 COUNTERWEIGHT…………………………………………………………………………………………………………………….493
4.18.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE………………………………………………………………………..495
4.18.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…………………………………………………………………….497
4.18.5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE……………………………………………………………………….499
4.18.6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE……………………………………………………………………………………..499

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