Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual – PDF DOWNLOAD

Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual – PDF DOWNLOAD

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Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 534
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Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual – PDF DOWNLOAD

SERIAL NUMBER 06372

The Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual is a comprehensive guide that provides detailed information on the operation and maintenance of the Komatsu PC3000-6 Hydraulic Mining Shovel. This manual is designed to be used by operators and maintenance personnel who are responsible for the safe and efficient operation of the machine.

• The manual is divided into several sections, each providing valuable information on specific aspects of the machine’s operation and maintenance. The first section provides an overview of the machine’s features and specifications, including its engine, hydraulic system, electrical system, and structural components. This section also includes information on the machine’s safety features and important safety guidelines for operating and maintaining the machine.
• The second section of the manual provides detailed information on the operation of the machine. This includes instructions for starting, operating, and shutting down the machine, as well as guidelines for operating the machine’s various components and systems. This section also includes information on how to use the machine’s monitoring and control systems to ensure proper operation and performance.
• The third section of the manual provides detailed information on the maintenance and servicing of the machine. This includes recommended maintenance schedules, procedures for routine maintenance, and troubleshooting procedures for identifying and fixing common problems. This section also includes information on how to service the machine’s engine, hydraulic system, and electrical system, as well as how to perform inspections and replace worn or damaged parts.
• The fourth section of the manual provides information on testing and adjusting the machine’s components and systems. This includes procedures for testing and adjusting the engine, hydraulic system, electrical system, and other components of the machine to ensure proper operation and performance.
• The manual also includes several appendices that provide additional information on topics such as specifications and dimensions, hydraulic system diagrams, and electrical system diagrams. These appendices can be especially useful for maintenance personnel who are responsible for maintaining and repairing the machine.
• Overall, the Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual is an essential resource for anyone involved in the operation and maintenance of this machine. Its detailed information and step-by-step procedures can help ensure the safe and efficient operation of the machine, and its troubleshooting procedures can help minimize downtime and increase productivity.

TABLE OF CONTENTS:

Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual – PDF DOWNLOAD

1 FOREWORD………………………………………………………………………………………………………………………………….. 3
1.1 BEFORE READING THIS MANUAL…………………………………………………………………………………………………………….. 4
1.2 EC DECLARATION OF CONFORMITY…………………………………………………………………………………………………………… 5
1.3 PRIVACY POLICY ON EXCAVATORS EQUIPPED WITH excavator MONITORING SYSTEMS FOR THE EEA………………………………………………………….. 6
1.4 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS………………………………………………………………………………………. 9
1.5 DIRECTIONS OF THE EXCAVATOR……………………………………………………………………………………………………………. 10
1.6 SPECIFICATION AND SERIAL PLATE…………………………………………………………………………………………………………. 11
1.6.1 PRODUCT IDENTIFICATION NUMBER…………………………………………………………………………………………………….. 11
1.7 DIVISION OF THE BINDER………………………………………………………………………………………………………………… 12
1.8 DESIGNATED USE OF THE EXCAVATOR………………………………………………………………………………………………………… 13
1.9 DELIVERY OF THE EXCAVATOR……………………………………………………………………………………………………………… 14
1.9.1 SPARE PARTS…………………………………………………………………………………………………………………….. 14
1.9.2 SERVICE………………………………………………………………………………………………………………………… 14
1.10 EXPLANATION OF ABBREVIATIONS………………………………………………………………………………………………………….. 15
1.11 CONTENTS……………………………………………………………………………………………………………………………. 17
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 excavator………………………………………………………………………………………………………. 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 excavator……………………………………………………………………………………………………. 29
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT…………………………………………………………………………….. 30
2.4.3.4 KEEP excavator 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 ON PC3000……………………………………………………………………………………………… 32
2.4.4.3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000………………………………………………………………………… 33
2.4.4.4 EMERGENCY EXIT FROM OPERATOR’S CAB…………………………………………………………………………………………… 33
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR……………………………………………………………………………………. 34
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator……………………………………………………………………. 34
2.4.5.2 NO JUMPING ON OR OFF THE excavator…………………………………………………………………………………………… 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 excavator………………………………………………………………………………………………………. 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 TRAVELING IN FORWARD OR REVERSE……………………………………………………………………………… 46
2.4.13.3 PRECAUTIONS WHEN traveling…………………………………………………………………………………………………. 47
2.4.13.4 TRAVELING ON SLOPES……………………………………………………………………………………………………….. 48
2.4.13.5 OPERATIONS ON SLOPES………………………………………………………………………………………………………. 49
2.4.13.6 PROHIBITED OPERATIONS……………………………………………………………………………………………………… 49
2.4.13.7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES…………………………………………………………………………………. 50
2.4.13.8 PARKING THE excavator……………………………………………………………………………………………………… 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……………………………………………………………………………………………………………….. 53
2.5.1.4 Maintenance safety Switch…………………………………………………………………………………………………… 53
2.5.1.5 KEEP WORKPLACE CLEAN AND TIDY……………………………………………………………………………………………….. 54
2.5.1.6 APPOINT LEADER WHEN WORKING WITH OTHERS………………………………………………………………………………………. 55
2.5.1.7 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING………………………………………………………………………. 55
2.5.1.8 INSTALLING, REMOVING OR STORING ATTACHMENTS…………………………………………………………………………………… 55
2.5.1.9 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT………………………………………………………………………. 56
2.5.1.10 NOISE……………………………………………………………………………………………………………………. 56
2.5.1.11 WHEN USING A HAMMER……………………………………………………………………………………………………….. 56
2.5.1.12 PROPER TOOLS……………………………………………………………………………………………………………… 57
2.5.1.13 ACCUMULATOR………………………………………………………………………………………………………………. 57
2.5.1.14 PERSONNEL………………………………………………………………………………………………………………… 57
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………………………………………………………………………………………. 58
2.5.2.1 PRECAUTION WHEN WELDING…………………………………………………………………………………………………….. 58
2.5.2.2 BATTERY HANDLING…………………………………………………………………………………………………………… 58
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID………………………………………………………………………………………………. 59
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE………………………………………………………………………………………….. 60
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES……………………………………………………………………………………….. 61
2.5.3.3 REPLACEMENT OF HOSE LINES…………………………………………………………………………………………………… 61
2.5.3.4 INSPECTION OF HOSE LINES……………………………………………………………………………………………………. 61
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………………………………………………………………………………. 62
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE………………………………………………………………………………………………… 62
2.5.3.7 AIR CONDITIONING MAINTENANCE………………………………………………………………………………………………… 62
2.5.3.8 COMPRESSED AIR…………………………………………………………………………………………………………….. 63
2.5.3.9 WASTE MATERIALS……………………………………………………………………………………………………………. 63
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS………………………………………………………………………….. 64
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM………………………………………………………………………………………………… 64
2.6.2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS…………………………………………………………………….. 64
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR……………………………………………………………………………………… 64
2.7 SPECIAL SAFETY EQUIPMENT………………………………………………………………………………………………………………. 66
2.7.1 FRONT GUARD PROTECTIVE STRUCTURE ’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……………………………………………………………………………………………………….. 68
2.7.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS……………………………………………. 69
2.7.5.4 INSTRUCTIONS FOR USE……………………………………………………………………………………………………….. 69
2.8 SAFETY WARNING SIGNS………………………………………………………………………………………………………………….. 71
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS……………………………………………………………………………………………… 72
2.8.2 LOCATION AND DESCRIPTION OF THE SIGNS FOR PC3400……………………………………………………………………………………. 74
3 OPERATION………………………………………………………………………………………………………………………………….101
3.1 FOREWORD……………………………………………………………………………………………………………………………..102
3.1.1 Connection of customer electrical installations to the excavator………………………………………………………………………102
3.2 CONSTRUCTION OF THE EXCAVATOR…………………………………………………………………………………………………………..103
3.2.1 OVERALL VIEW…………………………………………………………………………………………………………………….103
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE…………………………………………………………………………………………………..104
3.2.2.1 SUPERSTRUCTURE – TOP VIEW……………………………………………………………………………………………………106
3.2.2.2 MACHINERY HOUSE…………………………………………………………………………………………………………….108
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER……………………………………………………………………………………………….111
3.2.3.1 STANDARD OPERATION OF THE HYDRAULIC ACCESS LADDER………………………………………………………………………………113
3.2.3.2 EMERGENCY OPERATION OF THE HYDRAULIC ACCESS LADDER……………………………………………………………………………..115
3.2.4 EMERGENCY ESCAPE LADDER…………………………………………………………………………………………………………..116
3.2.5 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE……………………………………………………………………….118
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM…………………………………………………………………..120
3.2.6.1 Engine Shutdown System actuated from Ground Man………………………………………………………………………………..121
3.2.6.2 Operator Warning System……………………………………………………………………………………………………..121
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)………………………………………………………………122
3.2.7.1 Operator’s Seat Adjustment…………………………………………………………………………………………………..127
3.2.7.2 Co-driver’s Seat……………………………………………………………………………………………………………128
3.2.7.3 INSTRUCTIONS TO using and looking after THE SEAT BELTS………………………………………………………………………….129
3.3 OPERATOR’S CAB – CONTROLS………………………………………………………………………………………………………………130
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT…………………………………………………………………………………………………..130
3.3.1.1 Hydraulic Control System…………………………………………………………………………………………………….131
3.3.1.2 Safety Circuit for Controls………………………………………………………………………………………………….131
3.3.1.3 EURO Control Pattern………………………………………………………………………………………………………..133
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET…………………………………………………………………………………………………..134
3.3.2.1 Hydraulic Control System…………………………………………………………………………………………………….135
3.3.2.2 Safety Circuit for Controls………………………………………………………………………………………………….135
3.3.2.3 Automatic Float Position for Boom and Stick……………………………………………………………………………………135
3.3.2.4 EURO Control Pattern………………………………………………………………………………………………………..137
3.3.3 OPERATOR’S CONSOLE……………………………………………………………………………………………………………….139
3.3.3.1 Control Panel………………………………………………………………………………………………………………141
3.3.3.2 Rear Panel Controls…………………………………………………………………………………………………………145
3.4 MACHINE MONITOR KOMTRAX PLUS)…………………………………………………………………………………………………………..146
3.4.1 SEQUENCE OF DISPLAYS……………………………………………………………………………………………………………..147
3.4.2 OPENING SCREEN…………………………………………………………………………………………………………………..147
3.4.3 MAIN GAUGE SCREENS 1 TO 2…………………………………………………………………………………………………………148
3.4.4 Function of Keys F1 to F6…………………………………………………………………………………………………………150
3.4.5 FUEL CONSUMPTION SCREEN…………………………………………………………………………………………………………..153
3.4.6 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR…………………………………………………………………………………………154
3.4.7 MAIN SCREEN – CHANGE >TIME >SMR >DATE………………………………………………………………………………………………154
3.4.8 MAINTENANCE MONITOR………………………………………………………………………………………………………………155
3.4.8.1 Maintenance confirmation through Service Personnel……………………………………………………………………………..155
3.4.9 SETTINGS FOR OPERATOR…………………………………………………………………………………………………………….156
3.4.9.1 Settings for Operator……………………………………………………………………………………………………….157
3.4.9.2 User ID Screen……………………………………………………………………………………………………………..157
3.4.9.3 Reset Truck Counter 1……………………………………………………………………………………………………….157
3.4.9.4 Screen Adjustment…………………………………………………………………………………………………………..158
3.4.9.5 Date Adjustment Screen………………………………………………………………………………………………………160
3.4.9.6 Clock Adjustment Screen……………………………………………………………………………………………………..160
3.4.9.7 Language Selection Screen……………………………………………………………………………………………………160
3.4.10 AUTOMATIC MESSAGES………………………………………………………………………………………………………………161
3.4.10.1 Automatic Messages…………………………………………………………………………………………………………162
3.4.10.2 Automatic Messages…………………………………………………………………………………………………………163
3.4.10.3 Automatic Messages…………………………………………………………………………………………………………164
3.4.11 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM……………………………………………………………………………………165
3.5 CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT)…………………………………………………………………………………………..178
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS……………………………………………………………………………………………..179
3.5.1.1 Operating the Monitors………………………………………………………………………………………………………181
3.5.1.2 ADjustments of the Monitor…………………………………………………………………………………………………..181
3.5.1.3 Typical Arrangement of the Cameras……………………………………………………………………………………………185
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…………………………………………………………………………………….186
3.6.1 Digital Display………………………………………………………………………………………………………………….186
3.6.2 CONTROL MODULE FOR AUXILIARY CAB HEATER (IF SO EQUIPPED)……………………………………………………………………………..191
3.6.3 AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED)………………………………………………………………………………….193
3.6.4 AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED)………………………………………………………………………………….195
3.6.5 FUEL PUMP ARRANGEMENT…………………………………………………………………………………………………………….197
3.7 MACHINERY HOUSE……………………………………………………………………………………………………………………….198
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…………………………………………………………………………………………………199
3.8 ELECTRICAL EQUIPMENT IN CAB BASE………………………………………………………………………………………………………..200
3.8.1 Access Cover for the Headlights mounted on Cab Base………………………………………………………………………………….203
3.8.2 SWITCH BOX (X2) IN CAB BASE……………………………………………………………………………………………………….205
3.9 PREHEATING SYTEM (OPTIONAL)…………………………………………………………………………………………………………….207
3.9.1 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE……………………………………………………………………………….207
3.9.2 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM ON THE COUNTERWEIGHT……………………………………………………………………….211
3.10 CHECKS BEFORE STARTING THE ENGINE………………………………………………………………………………………………………212
3.10.1 CHECK THE FOLLOWING ITEMS………………………………………………………………………………………………………..213
3.10.1.1 Coolant Level……………………………………………………………………………………………………………..215
3.10.1.2 HYDRAULIC SYSTEM – CHECK OIL LEVEL…………………………………………………………………………………………..217
3.10.1.3 OPERATOR’S SEAT ADJUSTMENT………………………………………………………………………………………………….217
3.11 STARTING THE ENGINE…………………………………………………………………………………………………………………..218
3.11.1 STARTING PROCEDURE………………………………………………………………………………………………………………219
3.11.2 STARTING PROCEDURE AT AMBIENT TEMPERATURE UP TO -25°………………………………………………………………………………..221
3.11.2.1 Cold Weather Starting at ambient Temperatures below 0°C to -25°C………………………………………………………………..221
3.11.2.2 Cold Weather Starting at ambient Temperatures below –25°C………………………………………………………………………223
3.11.2.3 Hydraulic Oil Viscosity and Temperature Chart…………………………………………………………………………………227
3.12 MOVING THE EXCAVATOR………………………………………………………………………………………………………………….228
3.12.1 TRAVEL CONTROL WITH FOOT PEDALS…………………………………………………………………………………………………..228
3.12.1.1 TRAVEL ALARM / BACK-UP ALARM………………………………………………………………………………………………..230
3.12.2 traveling INSTRUCTIONS…………………………………………………………………………………………………………..230
3.12.2.1 TRAVELING…………………………………………………………………………………………………………………233
3.12.2.2 TRAVELING LONG DISTANCES……………………………………………………………………………………………………235
3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE………………………………………………………………………………………………….236
3.13.1 SLEWING THE SUPERSTRUCTURE……………………………………………………………………………………………………….236
3.13.1.1 excavatorS WITH “EURO” CONTROL………………………………………………………………………………………………236
3.13.1.2 BRAKING THE SUPERSTRUCTURE………………………………………………………………………………………………….237
3.13.2 SLEW PARKING BRAKE………………………………………………………………………………………………………………237
3.13.2.1 Hydraulic slew brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System………………………………..238
3.13.2.2 Important Instructions for Slewing the Superstructure………………………………………………………………………….238
3.14 WORKING WITH THE ATTACHMENT……………………………………………………………………………………………………………239
3.14.0.1 Front shovel BUCKET……………………………………………………………………………………………………………240
3.14.1 COMBINED OPERATION CYCLES………………………………………………………………………………………………………..241
3.15 WORKING INSTRUCTIONS………………………………………………………………………………………………………………….244
3.15.1 STABILITY OF THE excavator……………………………………………………………………………………………………….244
3.15.2 FURTHER OPERATING PRACTICES………………………………………………………………………………………………………246
3.15.3 Loading Trucks………………………………………………………………………………………………………………….250
3.16 PARKING THE excavator…………………………………………………………………………………………………………………251
3.16.1 CLEANING THE TRACK GROUPS………………………………………………………………………………………………………..251
3.17 STOPPING THE ENGINE…………………………………………………………………………………………………………………..252
3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM…………………………………………………………………………………………..255
3.18 AUTOMATIC LUBRICATION SYSTEMS………………………………………………………………………………………………………….256
3.18.1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS……………………………………………………………………………………..257
3.19 FIRE DETECTION AND SUPPRESSION SYSTEM…………………………………………………………………………………………………..260
3.19.1 FIRE DETECTION AND SUPPRESSION SYSTEMS…………………………………………………………………………………………….261
3.19.2 HIGH LEVEL ALARM -FIRE-………………………………………………………………………………………………………….265
3.19.3 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE……………………………………………………………………………….265
3.19.4 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM……………………………………………………………………………………..265
3.19.4.1 MANUAL ACTUATION…………………………………………………………………………………………………………..265
3.19.4.2 AUTOMATIC ACTUATION………………………………………………………………………………………………………..265
3.19.5 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM……………………………….267
3.19.6 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF……………………………………..269
3.20 CENTRAL REFILLING SYSTEM………………………………………………………………………………………………………………270
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM………………………………………………………………………………………….271
3.20.1.1 Operation of the hydraulic Service Arm……………………………………………………………………………………….271
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM……………………………………………………………………………………………….273
3.20.3 RECEIVER PANEL WITH MONITOR BOX…………………………………………………………………………………………………..275
3.20.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS…………………………………………………………………….279
3.21 TRANSFER PUMP FOR HYDRAULIC OIL………………………………………………………………………………………………………..280
3.21.1 OPERATING THE TRANSFER PUMP………………………………………………………………………………………………………281
3.21.2 FUNCTIONS OF THE TRANSFER PUMP……………………………………………………………………………………………………281
3.22 SERVICE CRANE (SPECIAL EQUIPMENT)………………………………………………………………………………………………………285
3.23 WORK ON THE LOADER ATTACHMENT………………………………………………………………………………………………………….286
3.23.1 OBSERVE THE FOLLOWING INSTRUCTIONS………………………………………………………………………………………………..286
3.24 TRANSPORTATION AND LIFTING OF THE excavator……………………………………………………………………………………………..287
3.24.1 DISASSEMBLING OF THE excavator……………………………………………………………………………………………………287
3.24.2 TRANSPORTATION AND LIFTING……………………………………………………………………………………………………….287
3.25 RETRIEVAL PROCEDURE…………………………………………………………………………………………………………………..288
3.25.1 GENERAL………………………………………………………………………………………………………………………..288
3.26 excavator STORAGE…………………………………………………………………………………………………………………….289
3.26.1 GENERAL………………………………………………………………………………………………………………………..289
3.26.2 PREPARING FOR STORAGE……………………………………………………………………………………………………………289
3.26.3 ONE MONTH REPETITIVE SERVICE PERIOD……………………………………………………………………………………………….289
3.26.4 SIX MONTH REPETITIVE SERVICE PERIOD……………………………………………………………………………………………….289
3.26.5 PREPARING FOR OPERATION………………………………………………………………………………………………………….290
3.27 TROUBLE SHOOTING……………………………………………………………………………………………………………………..291
3.27.1 GENERAL………………………………………………………………………………………………………………………..291
3.27.2 ENGINE…………………………………………………………………………………………………………………………291
3.27.3 HYDRAULIC SYSTEM………………………………………………………………………………………………………………..292
3.27.4 FINAL DRIVES AND SLEW GEAR……………………………………………………………………………………………………….293
3.27.5 CRAWLER TRACKS………………………………………………………………………………………………………………….293
4 MAINTENANCE………………………………………………………………………………………………………………………………..295
4.1 FOREWORD……………………………………………………………………………………………………………………………..296
4.1.1 DEFINITIONS……………………………………………………………………………………………………………………..296
4.1.2 GENERAL RECOMMENDATIONS…………………………………………………………………………………………………………..296
4.2 PRECAUTIONS FOR MAINTENANCE…………………………………………………………………………………………………………….297
4.3 FLUIDS AND LUBRICANTS………………………………………………………………………………………………………………….298
4.3.1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES………………………………………………………………………………….298
4.3.2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…………………………………………………………………………………300
4.3.2.1 Recommended Hydraulic Oils…………………………………………………………………………………………………..301
4.3.2.2 General Information to selecting hydraulic oils………………………………………………………………………………..302
4.4 FILLING CAPACITIES…………………………………………………………………………………………………………………….304
4.5 STANDARD TORQUE LIST…………………………………………………………………………………………………………………..305
4.5.1 Torque for Flange Joints………………………………………………………………………………………………………….306
4.5.2 TORQUES FOR SPECIAL COMPONENTS…………………………………………………………………………………………………….307
4.6 LUBRICATION AND MAINTENANCE SCHEDULE…………………………………………………………………………………………………….309
4.6.1 INITIAL SERVICING………………………………………………………………………………………………………………..309
4.6.1.1 INITIAL RUNNING-IN………………………………………………………………………………………………………….309
4.6.1.2 AFTER THE FIRST 250 OPERATING HOURS…………………………………………………………………………………………..309
4.6.1.3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT………………………………………………………………309
4.6.2 SERVICING THE CRITICAL BOLT CONNECTIONS…………………………………………………………………………………………….310
4.6.3 PERIODIC SERVICING INTERVALS………………………………………………………………………………………………………310
4.6.4 PERIODIC SERVICING SCHEDULE……………………………………………………………………………………………………….310
4.6.4.1 WHEN NECESSARY……………………………………………………………………………………………………………..310
4.6.4.2 EVERY 10 OPERATING HOURS OR DAILY…………………………………………………………………………………………….311
4.6.4.3 EVERY 50 HOURS OR WEEKLY…………………………………………………………………………………………………….311
4.6.4.4 EVERY 250 HOURS OR MONTHLY…………………………………………………………………………………………………..312
4.6.4.5 EVERY 500 HOURS OR QUATERLY………………………………………………………………………………………………….312
4.6.4.6 EVERY 1000 HOURS OR 6 MONTHLY………………………………………………………………………………………………..313
4.6.4.7 EVERY 2000 HOURS OR YEARLY…………………………………………………………………………………………………..313
4.6.4.8 EVERY 3000 HOURS HOWEVER AT LEAST ONCE A YEAR………………………………………………………………………………….314
4.6.4.9 EVERY 6000 HOURS OPERATING HOURS OR AT LEAST ONCE A YEAR………………………………………………………………………..314
4.6.5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM……………………………………………………315
4.7 SAFETY CRITICAL PARTS………………………………………………………………………………………………………………….316
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES………………………………………………………………………………316
4.7.2 INSPECTION OF HOSE LINES………………………………………………………………………………………………………….316
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS………………………………………………………………………………..317
4.7.4 VENTING THE AIR FROM THE FUEL FILTERS………………………………………………………………………………………………321
4.8 INITIAL SERVICING……………………………………………………………………………………………………………………..322
4.8.1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION……………………………………………………………………………323
4.8.2 SLEW CIRCLE – CHECK GREASE INJECTORS……………………………………………………………………………………………….325
4.8.3 CAR BODY AND RACEWAY OF SLEW RING………………………………………………………………………………………………….327
4.8.4 SLEW circle – CHECK TORQUE OF BOLT CONNECTIONS………………………………………………………………………………………329
4.8.5 RETIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS………………………………………………………………………….331
4.9 WHEN NECESSARY………………………………………………………………………………………………………………………..336
4.9.1 ENGINE AIR CLEANER MAINTENANCE…………………………………………………………………………………………………….337
4.9.1.1 General Service Tips………………………………………………………………………………………………………..339
4.9.2 SLEW CIRCLE TOOTHING LUBRICATION…………………………………………………………………………………………………..341
4.9.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS…………………………………………………………………………………343
4.9.3.1 Service the Grease Filters for Refillable Grease Containers of the Central Lubrication System and SLEW circle pinion Lubrication System….345
4.9.4 GUIDE WHEELS – REPLACE FLOATING SEALS………………………………………………………………………………………………345
4.9.5 COLD STARTING AID, REPLACE FLUID CYLINDER…………………………………………………………………………………………..347
4.9.6 CLEANING THE EXCAVATOR……………………………………………………………………………………………………………349
4.9.6.1 Precautions for cleaning…………………………………………………………………………………………………….349
4.10 EVERY 10 OPERATING HOURS OR DAILY………………………………………………………………………………………………………352
4.10.1 WALK – AROUND INSPECTION…………………………………………………………………………………………………………353
4.10.1.1 GROUND CABLES – CHECK CONNECTION POINTS………………………………………………………………………………………357
4.10.2 AIR CLEANER – CLEAN PRECLEANER……………………………………………………………………………………………………359
4.10.2.1 Clean dust cups of precleaners………………………………………………………………………………………………359
4.10.3 RADIATOR – CHECK COOLANT LEVEL……………………………………………………………………………………………………361
4.10.4 TRACK GROUPS – CLEAN…………………………………………………………………………………………………………….361
4.10.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER………………………………………………………………………………………….363
4.10.6 BOOM – CHECK LADDER AND WALKWAY…………………………………………………………………………………………………..365
4.10.7 ELECTRICAL EQUIPMENT – CHECK VISUALLY……………………………………………………………………………………………..365
4.10.8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB…………………………………………………………………………………………367
4.11 EVERY 50 OPERATING HOURS OR WEEKLY……………………………………………………………………………………………………..368
4.11.1 SLEW GEAR AND MOTOR ADAPTER HOUSING – CHECK OIL LEVEL……………………………………………………………………………….369
4.11.1.1 SLEW gear manufactured TYPE 2063…………………………………………………………………………………………….369
4.11.1.2 SLEW Gear TYPE 632770………………………………………………………………………………………………………371
4.11.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS…………………………………………………………….373
4.11.2.1 PLANETARY GEAR BOX – CHECK OIL LEVEL…………………………………………………………………………………………373
4.11.2.2 SPUR GEAR BOX – CHECK OIL LEVEL……………………………………………………………………………………………..375
4.11.2.3 BRAKE HOUSINGS – CHECK OIL LEVEL…………………………………………………………………………………………….375
4.11.2.4 MOTOR ADAPTER HOUSING – CHECK OIL LEVEL………………………………………………………………………………………375
4.11.2.5 MILEAGE INDICATOR (Special Equipment)………………………………………………………………………………………..375
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) – CHECK OIL LEVEL………………………………………………………………………………………377
4.11.3.1 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings………………………………………………………………….377
4.11.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR………………………………………………………………………………………379
4.11.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY………………………………………………………………………………381
4.12 EVERY 250 OPERATING HOURS OR MONTHLY……………………………………………………………………………………………………382
4.12.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION………………………………………………………………………………383
4.12.2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER – MAINTENANCE CHECK……………………………………………………………………385
4.12.3 GENERATOR – CHECK BELT TENSION……………………………………………………………………………………………………389
4.12.4 SIGNAL HORN COMPRESSOR – LUBRICATE………………………………………………………………………………………………..391
4.12.5 HYDRAULIC OIL COOLER FAN – CHECK CONDITION AND FASTENING…………………………………………………………………………….391
4.12.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN BREATHER FILTER……………………………………………………………………………….393
4.12.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT…………………………………………………………………………………..395
4.12.7.1 Clean and inspect filter element (3) as follows:………………………………………………………………………………395
4.12.8 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL…………………………………………………………………………………….397
4.12.9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL………………………………………………………………………..399
4.13 EVERY 500 OPERATING HOURS OR MONTHLY……………………………………………………………………………………………………400
4.13.1 BATTERIES – CHECK FLUID LEVEL…………………………………………………………………………………………………….401
4.13.2 FUEL TANK – DRAIN CONDENSATION……………………………………………………………………………………………………403
4.13.3 CRAWLER TRACK – INSPECTION……………………………………………………………………………………………………….405
4.13.3.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS………………………………………………………………………………………..405
4.13.3.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS……………………………………………………………………………………….407
4.13.3.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS……………………………………………………………………………………….409
4.13.3.4 Bleeding the System………………………………………………………………………………………………………..409
4.13.3.5 GREASE INJECTORS – CHECK INDICATOR STEMS……………………………………………………………………………………..410
4.13.3.6 CORRECTIVE ACTIONS…………………………………………………………………………………………………………410
4.13.4 EMERGENCY LOWERING OF ACCESS LADDER – Test FUNCTIONALITY…………………………………………………………………………….413
4.13.5 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS…………………………………………………………………………415
4.14 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH……………………………………………………………………………………………..416
4.14.1 CRITICAL BOLT CONNECTIONS………………………………………………………………………………………………………..417
4.14.2 HYDRAULIC SYSTEM – FILTER SERVICE…………………………………………………………………………………………………423
4.14.2.1 FILTER SERVICE…………………………………………………………………………………………………………….425
4.14.3 BLEEDING RETURN OIL CHAMBER (IF EQUIPPED WITH OIL LEVEL GAUGE)……………………………………………………………………….437
4.14.4 PTO (PUMP DISTRIBUTOR GEAR), SLEW GEAR AND TRAVEL GEARS – OIL SAMPLE ANALYSIS………………………………………………………….441
4.14.4.1 Oil drain plugs……………………………………………………………………………………………………………441
4.14.5 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE……………………………………………………………………………………….443
4.14.6 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS………………………………………………………………………445
4.14.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES…………………………………………………………………………….447
4.14.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES……………………………………………………………………………447
4.14.9 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY……………………………………………………………………………..449
4.14.10 ENGINE SHUTDOWN PULL chains (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY…………………………………………………………………451
4.14.11 ELECTRICAL EQUIPMENT – MAINTENANCE……………………………………………………………………………………………….453
4.14.12 ENGINE AIR CLEANERS- INSPECT AND LUBRICATE HINGES………………………………………………………………………………….455
4.14.13 OIL SEPARATOR ELEMENT – REPLACE BREATHER FILTER……………………………………………………………………………………457
4.15 EVERY 2000 OPERATING HOURS OR YEARLY……………………………………………………………………………………………………458
4.15.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER………………………………………………………….459
4.15.1.1 Sequence of Servicing………………………………………………………………………………………………………459
4.15.1.2 Filling the Hydraulic System………………………………………………………………………………………………..467
4.15.1.3 Hydraulic oil viscosity and adjustment of temperature switch units………………………………………………………………469
4.15.1.4 Vent Suction Oil Reservoir and Hydraulic Pumps………………………………………………………………………………..471
4.15.2 EMERGENCY ESCAPE LADDERS – INSPECTION……………………………………………………………………………………………..473
4.15.3 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST…………………………………………………………………………………475
4.15.4 HYDRAULIC HOSES – CHECK CONDITION…………………………………………………………………………………………………477
4.15.5 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB…………………………………………………………………………………………479
4.15.5.1 Functionality……………………………………………………………………………………………………………..479
4.16 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…………………………………………………………………………………..480
4.16.1 SLEW GEAR AND MOTOR ADAPTER HOUSING – CHANGE OIL……………………………………………………………………………………481
4.16.1.1 SLEW gear TYPE 2063………………………………………………………………………………………………………..481
4.16.1.2 SLEW GEAR TYPE 632770………………………………………………………………………………………………………485
4.16.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL………………………………………………………………………….489
4.16.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL…………………………………………………………………………………………..493
4.16.4 PTO gear oil viscosity and adjustment of temperature switch units…………………………………………………………………….495
4.16.5 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD………………………………………………………………………………………497
4.16.6 OIL SEPARATOR ELEMENT – REPLACE…………………………………………………………………………………………………..515
4.17 EVERY 6000 HOURS OR AT LEAST ONCE A YEAR………………………………………………………………………………………………..516
4.17.1 AUTOMATIC LUBRICATION SYSTEMS – Replace GREASE FILTERS………………………………………………………………………………517
4.17.2 CHECK FAN DRIVE BEARING OF COOLANT RADIATOR………………………………………………………………………………………..519
4.18 FIRE PREVENTION………………………………………………………………………………………………………………………520
4.18.1 PRECAUTIONS…………………………………………………………………………………………………………………….521
4.19 WELD REPAIRS…………………………………………………………………………………………………………………………522
4.19.1 GENERAL PROTECTIVE MEASURES………………………………………………………………………………………………………523
4.19.2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR…………………………………………………………………………………..523
4.19.2.1 COUNTERWEIGHT……………………………………………………………………………………………………………..523
4.19.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…………………………………………………………………525
4.19.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT……………………………………………………………..527
4.19.5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE………………………………………………………………..529
4.19.5.1 Electrical Units in Cab Base………………………………………………………………………………………………..531
4.19.5.2 Engine Electronics…………………………………………………………………………………………………………531
4.19.6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE………………………………………………………………………………531
5 REVISION…………………………………………………………………………………………………………………………………..533
5.1 REVISION TABLE………………………………………………………………………………………………………………………..534