Komatsu HYDRAULIC MINING SHOVEL PC8000E-6 Operation & Maintenance Manual(12086-xE-GB-0) – PDF

Komatsu HYDRAULIC MINING SHOVEL PC8000E-6 Operation & Maintenance Manual(12086-xE-GB-0) – PDF DOWNLOAD

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Komatsu HYDRAULIC MINING SHOVEL PC8000E-6 Operation & Maintenance Manual(12086-xE-GB-0) – PDF DOWNLOAD

SERIAL NUMBER 12086

1.1BEFORE 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 PC8000E-6 Operation & Maintenance Manual(12086-xE-GB-0) – 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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