Komatsu PC4000-6 Hydraulic Mining Shovel Operation & Maintenance Manual – PDF DOWNLOAD

Komatsu PC4000-6 Hydraulic Mining Shovel Operation & Maintenance Manual – PDF DOWNLOAD

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Komatsu PC4000-6 Hydraulic Mining Shovel Operation & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 556
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Komatsu PC4000-6 Hydraulic Mining Shovel Operation & Maintenance Manual – PDF DOWNLOAD

SERIAL NUMBER 08257

The Komatsu PC4000-6 hydraulic mining shovel is a large and powerful machine designed for use in heavy mining operations. The Operation & Maintenance Manual provides comprehensive information for the operation, maintenance, and repair of this mining shovel. The manual is intended to be used by experienced operators and technicians who have the necessary knowledge and skills to perform the procedures described in the manual.

• The manual covers various topics such as safety information, operating instructions, routine maintenance procedures, and troubleshooting tips. It provides detailed information on the mining shovel’s systems and components, such as the engine, hydraulic system, electrical system, and undercarriage components. The manual also includes a list of recommended tools and spare parts, as well as detailed specifications for the machine.
• The manual provides step-by-step instructions for maintenance procedures, along with diagrams and illustrations to help operators and technicians understand the procedures. It also provides information on how to diagnose problems, as well as how to perform maintenance and repairs to correct those problems. By following the procedures in the manual, operators and technicians can ensure that the mining shovel is operating safely and efficiently.
• It is important to follow the instructions and procedures outlined in the manual to ensure the safe and proper operation of the mining shovel. The manual provides information on how to properly operate the machine, as well as how to perform routine maintenance and repairs to keep the machine in good working order.
• In summary, the Komatsu PC4000-6 Operation & Maintenance Manual provides valuable information for the operation, maintenance, and repair of this hydraulic mining shovel. The manual is essential for experienced operators and technicians who are responsible for the safe and efficient operation of the machine. By following the procedures in the manual, operators and technicians can ensure that the mining shovel is operating safely and efficiently.

TABLE OF CONTENTS:

Komatsu PC4000-6 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 DIRECTIONS OF THE MACHINE…………………………………………………………………………………. 6
1.4 SPECIFICATION AND SERIAL PLATE…………………………………………………………………………….. 7
1.4.1 PRODUCT IDENTIFICATION NUMBER………………………………………………………………………… 7
1.5 DIVISION OF THE BINDER……………………………………………………………………………………. 8
1.6 DESIGNATED USE OF THE SHOVEL………………………………………………………………………………. 9
1.7 DELIVERY OF THE SHOVEL……………………………………………………………………………………. 10
1.7.1 SPARE PARTS………………………………………………………………………………………… 10
1.7.2 SERVICE……………………………………………………………………………………………. 10
1.8 EXPLANATION OF ABBREVIATIONS………………………………………………………………………………. 11
2 SAFETY……………………………………………………………………………………………………….. 19
2.1 SAFETY INFORMATION……………………………………………………………………………………….. 20
2.2 OVERVIEW………………………………………………………………………………………………… 21
2.2.1 NORMAL OPERATIONS…………………………………………………………………………………… 21
2.2.2 REGULAR MAINTENANCE…………………………………………………………………………………. 21
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR……………………………………………………………….. 21
2.2.4 ADDITIONAL SAFETY PRECAUTIONS………………………………………………………………………… 21
2.3 SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATOR’S CAB…………………………………………………….. 22
2.3.1 SOUND……………………………………………………………………………………………… 22
2.3.2 VIBRATION………………………………………………………………………………………….. 22
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………………………………………… 23
2.4.1 UNDERSTANDING THE MACHINE……………………………………………………………………………. 23
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR………………………………………………….. 23
2.4.2.1 ENSURING SAFE OPERATION………………………………………………………………………… 23
2.4.3 PREPARATIONS FOR SAFE OPERATION………………………………………………………………………. 23
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT……………………………………………………. 23
2.4.3.2 INSPECTING THE MACHINE…………………………………………………………………………. 23
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT………………………………………………… 24
2.4.3.4 KEEP MACHINE CLEAN…………………………………………………………………………….. 24
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT………………………………………………………… 24
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT………………………………………………………. 25
2.4.3.7 IF A PROBLEM IS FOUND………………………………………………………………………….. 25
2.4.4 FIRE PREVENTION…………………………………………………………………………………….. 25
2.4.4.1 PRECAUTIONS TO PREVENT FIRE…………………………………………………………………….. 25
2.4.4.2 ACTION IF FIRE OCCURS………………………………………………………………………….. 27
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB………………………………………………………………. 27
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…………………………………………………………. 28
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…………………………………………. 28
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE………………………………………………………………… 28
2.4.5.3 NO PEOPLE ON THE ATTACHMENT…………………………………………………………………….. 28
2.4.5.4 WORKING IN HIGH PLACES…………………………………………………………………………. 28
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK……………………………………………………………….. 29
2.4.5.6 LEAVING THE MACHINE……………………………………………………………………………. 29
2.4.6 BURN PREVENTION…………………………………………………………………………………….. 29
2.4.6.1 Hot coolant…………………………………………………………………………………… 29
2.4.6.2 Hot oil………………………………………………………………………………………. 30
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…………………………………………………………………… 30
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………………………………………………………… 30
2.4.8.1 UNAUTHORIZED MODIFICATION………………………………………………………………………. 31
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS……………………………………………………. 31
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)…………………………………………………………………… 31
2.4.10 PRECAUTIONS AT JOBSITE……………………………………………………………………………… 32
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT………………………………………………………………… 33
2.4.10.2 CAMERA SYSTEM WITH MONITORS……………………………………………………………………. 33
2.4.10.3 ENSURE GOOD VISIBILITY………………………………………………………………………… 33
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS………………………………………………………….. 33
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS………………………………………………………. 34
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES………………………………………………………….. 34
2.4.10.7 WORKING ON LOOSE GROUND……………………………………………………………………….. 35
2.4.10.8 GAS, DUST, STEAM AND SMOKE…………………………………………………………………….. 35
2.4.10.9 VENTILATION OF ENCLOSED AREAS………………………………………………………………….. 36
2.4.11 STARTING motor…………………………………………………………………………………….. 37
2.4.11.1 WARNING TAG………………………………………………………………………………….. 37
2.4.11.2 CHECKS BEFORE STARTING motor…………………………………………………………………… 37
2.4.11.3 PRECAUTION WHEN STARTING motor…………………………………………………………………. 37
2.4.11.4 PRECAUTION IN COLD AREAS………………………………………………………………………. 38
2.4.12 OPERATION…………………………………………………………………………………………. 38
2.4.12.1 CHECKS BEFORE OPERATION……………………………………………………………………….. 38
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE………………………………………………… 39
2.4.12.3 PRECAUTIONS WHEN traveling…………………………………………………………………….. 40
2.4.12.4 TRAVELLING ON SLOPES………………………………………………………………………….. 41
2.4.12.5 OPERATIONS ON SLOPES………………………………………………………………………….. 42
2.4.12.6 PROHIBITED OPERATIONS…………………………………………………………………………. 42
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES……………………………………………………. 43
2.4.12.8 PARKING THE MACHINE…………………………………………………………………………… 43
2.4.12.9 TRANSPORTATION……………………………………………………………………………….. 43
2.5 PRECAUTION FOR MAINTENANCE………………………………………………………………………………… 44
2.5.1 GENERAL PRECAUTIONS…………………………………………………………………………………. 44
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…………………………………… 45
2.5.1.2 STOP motor FOR MAINTENANCE……………………………………………………………………… 46
2.5.1.3 WARNING TAG…………………………………………………………………………………… 47
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…………………………………………………………………… 48
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS………………………………………………………….. 48
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING……………………………………………. 49
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS………………………………………………………. 49
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT……………………………………………. 50
2.5.1.9 NOISE………………………………………………………………………………………… 50
2.5.1.10 WHEN USING A HAMMER…………………………………………………………………………… 50
2.5.1.11 PROPER TOOLS…………………………………………………………………………………. 51
2.5.1.12 ACCUMULATOR………………………………………………………………………………….. 51
2.5.1.13 PERSONNEL……………………………………………………………………………………. 51
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………………………………………………………….. 52
2.5.2.1 PRECAUTION WHEN WELDING………………………………………………………………………… 52
2.5.2.2 BATTERY HANDLING………………………………………………………………………………. 52
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID………………………………………………………………….. 53
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE……………………………………………………………… 53
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…………………………………………………………… 54
2.5.3.3 REPLACEMENT OF HOSE LINES………………………………………………………………………. 54
2.5.3.4 INSPECTION OF HOSE LINES……………………………………………………………………….. 54
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………………………………………………….. 55
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE……………………………………………………………………. 55
2.5.3.7 AIR CONDITIONING MAINTENANCE……………………………………………………………………. 55
2.5.3.8 COMPRESSED AIR………………………………………………………………………………… 56
2.5.3.9 WASTE MATERIALS……………………………………………………………………………….. 56
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……………………………………………… 57
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM……………………………………………………………………. 57
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS………………………………………….. 57
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…………………………………………………………. 57
2.7 SPECIAL SAFETY EQUIPMENT………………………………………………………………………………….. 58
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB……………………………………………….. 59
2.7.2 OBJECT HANDLING…………………………………………………………………………………….. 59
2.7.3 LIGHTING…………………………………………………………………………………………… 59
2.7.4 WARNING BEACON……………………………………………………………………………………… 59
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………………………….. 59
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)……………………………………….. 59
2.7.5.2 INSTRUCTIONS FOR USE…………………………………………………………………………… 61
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL………………………………………………….. 63
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS……………….. 63
2.7.5.5 INSTRUCTIONS FOR USE…………………………………………………………………………… 65
2.8 SAFETY WARNING SIGNS……………………………………………………………………………………… 67
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS…………………………………………………………………. 68
3 OPERATION…………………………………………………………………………………………………….. 85
3.1 FOREWORD………………………………………………………………………………………………… 86
3.2 CONSTRUCTION OF THE SHOVEL………………………………………………………………………………… 87
3.2.1 OVERALL VIEW……………………………………………………………………………………….. 87
3.2.2 SUPERSTRUCTURE……………………………………………………………………………………… 88
3.2.2.1 Machinery House……………………………………………………………………………….. 92
3.2.2.2 Main Hydraulic Oil Reservoir……………………………………………………………………. 94
3.2.2.3 Hydraulic Oil Cooler…………………………………………………………………………… 95
3.2.2.4 Fuel Tank…………………………………………………………………………………….. 96
3.2.2.5 Counterweight…………………………………………………………………………………. 97
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER………………………………………………………………….. 98
3.2.3.1 Operating the hydraulic Access Ladder……………………………………………………………. 99
3.2.3.2 LOWERING THE LADDER IN EMERGENCY SITUATIONS……………………………………………………….101
3.2.4 EMERGENCY ESCAPE LADDER………………………………………………………………………………102
3.2.5 BOOM ACCESS LADDER AND WALKWAY………………………………………………………………………..104
3.2.6 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE…………………………………………..106
3.2.7 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM………………………………………108
3.2.7.1 Emergency Engine Shutdown System actuated from Ground Man (OPTION)…………………………………..109
3.2.7.2 Operator Warning System (OPTION)…………………………………………………………………109
3.2.8 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)………………………………….110
3.2.8.1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual…………………………115
3.2.8.2 Operator’s Seat Adjustment………………………………………………………………………117
3.2.8.3 Co-driver’s Seat and Refrigerator Box…………………………………………………………….118
3.2.8.4 INSTRUCTIONS TO using and looking after THE SEAT BELTS……………………………………………..119
3.2.9 UNDERCARRIAGE……………………………………………………………………………………….120
3.2.10 WORKING ATTACHMENT………………………………………………………………………………….121
3.2.10.1 Loader attachment with bottom dump bucket………………………………………………………..121
3.2.10.2 Loader attachment with backhoe bucket……………………………………………………………122
3.2.11 DIESEL ENGINE TYPE SDA 16V160E-2……………………………………………………………………..123
3.2.12 ENGINE OIL MANAGEMENT SYSTEM…………………………………………………………………………126
3.2.12.1 Oil Burning System “Centinel” combined with Oil Supply System “Reserve”……………………………..128
3.2.12.2 Eliminator Engine Oil Filtration System………………………………………………………….129
3.3 OPERATOR’S CAB – CONTROLS………………………………………………………………………………….130
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT………………………………………………………………………130
3.3.1.1 HYDRAULIC CONTROL SYSTEM………………………………………………………………………..131
3.3.2 SAFETY CIRCUIT FOR CONTROLS…………………………………………………………………………..131
3.3.2.1 EURO Control Pattern……………………………………………………………………………133
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…………………………………………………………….134
3.3.3.1 HYDRAULIC CONTROL SYSTEM………………………………………………………………………..135
3.3.4 SAFETY CIRCUIT FOR CONTROLS…………………………………………………………………………..135
3.3.4.1 EURO Control Pattern……………………………………………………………………………137
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK…………………………………………………………….137
3.3.6 OPERATOR’S CONSOLE…………………………………………………………………………………..139
3.3.6.1 Switch Board…………………………………………………………………………………..141
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS……………………………………………………………………….145
3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER………………………………………………………………..147
3.4 VEHICLE HEALTH MONITORING SYSTEM Komtrax Plus – HEALTH MONITOR…………………………………………………148
3.4.1 SEQUENCE OF DISPLAYS…………………………………………………………………………………149
3.4.2 OPENING SCREEN………………………………………………………………………………………149
3.4.3 Function Checking Screen……………………………………………………………………………..150
3.4.4 MAIN GAUGE SCREENS 1 TO 3…………………………………………………………………………….151
3.4.4.1 Main Gauge Screen 1…………………………………………………………………………….152
3.4.4.2 Main Gauge Screen 2…………………………………………………………………………….154
3.4.4.3 Main Gauge Screen 3…………………………………………………………………………….154
3.4.4.4 Color Definition……………………………………………………………………………….154
3.4.5 ECO Guidance………………………………………………………………………………………..155
3.4.5.1 OPERATING RECORDS………………………………………………………………………………156
3.4.5.2 Average FUEL Consumption Logs……………………………………………………………………157
3.4.5.3 Machine Setting………………………………………………………………………………..158
3.4.5.4 Reset Truck Counter…………………………………………………………………………….158
3.4.6 Maintenance…………………………………………………………………………………………159
3.4.7 Monitor Setting……………………………………………………………………………………..159
3.4.7.1 Screen Adjustment………………………………………………………………………………160
3.4.7.2 Clock Adjustment……………………………………………………………………………….161
3.4.7.3 LANGUAGE………………………………………………………………………………………162
3.4.8 Automatic Messages…………………………………………………………………………………..163
3.4.8.1 Example OF Action Code L01………………………………………………………………………163
3.4.8.2 Example OF Action Code L03………………………………………………………………………164
3.4.8.3 EXAMPLE OF Action Code L04………………………………………………………………………164
3.5 CAMERA SYSTEM WITH MONITORS………………………………………………………………………………..166
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS…………………………………………………………………167
3.5.1.1 Operating the Monitors………………………………………………………………………….169
3.5.1.2 Arrangement of the Cameras………………………………………………………………………171
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING………………………………………………………..172
3.6.1 Digital Display……………………………………………………………………………………..172
3.6.2 AUXILIARY HEATER FOR OPERATOR’S CAB……………………………………………………………………177
3.7 MACHINERY HOUSE…………………………………………………………………………………………..178
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…………………………………………………………………….179
3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES……………………………………………………..181
3.7.3 CENTRAL CONTROL AND FILTER PANEL………………………………………………………………………183
3.8 ELECTRICAL EQUIPMENT IN CAB BASE……………………………………………………………………………184
3.8.1 STANDARD COMPONENTS IN CAB BASE……………………………………………………………………….185
3.8.1.1 Low voltage Switch Board………………………………………………………………………..187
3.8.2 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE (WHEN INSTALLED)……………………………………189
3.9 CHECKS BEFORE STARTING THE ENGINE…………………………………………………………………………..196
3.9.0.1 Coolant Level……………………………………………………………………………………..199
3.9.0.2 Machinery House Doors………………………………………………………………………………201
3.9.1 OPERATOR’S SEAT ADJUSTMENT……………………………………………………………………………201
3.10 STARTING THE ENGINE………………………………………………………………………………………202
3.10.1 STARTING PROCEDURE………………………………………………………………………………….205
3.10.1.1 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C………………………………207
3.10.2 ENGINE WARM-UP……………………………………………………………………………………..213
3.10.3 HYDRAULIC OIL WARM-UP……………………………………………………………………………….213
3.11 MOVING THE SHOVEL………………………………………………………………………………………..215
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS………………………………………………………………………215
3.11.1.1 TRAVEL ALARM / BACK-UP ALARM……………………………………………………………………217
3.11.2 TRAVELLING INSTRUCTIONS……………………………………………………………………………..217
3.11.2.1 TRAVELLING LONG DISTANCES………………………………………………………………………219
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE……………………………………………………………………..220
3.12.1 SLEWING THE SUPERSTRUCTURE…………………………………………………………………………..220
3.12.1.1 MACHINES WITH “EURO” CONTROL……………………………………………………………………220
3.12.2 BRAKING THE SUPERSTRUCTURE…………………………………………………………………………..221
3.12.3 SLEW PARKING BRAKE………………………………………………………………………………….222
3.12.3.1 Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System……223
3.12.3.2 IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE……………………………………………..223
3.13 WORKING WITH THE ATTACHMENT……………………………………………………………………………….224
3.13.0.1 FACE SHOVEL BUCKET………………………………………………………………………………..225
3.13.1 COMBINED OPERATION CYCLES……………………………………………………………………………226
3.14 WORKING INSTRUCTIONS……………………………………………………………………………………..228
3.14.1 STABILITY OF THE SHOVEL……………………………………………………………………………..228
3.14.2 FURTHER OPERATING PRACTICES………………………………………………………………………….230
3.14.3 Loading Trucks……………………………………………………………………………………..234
3.15 PARKING THE SHOVEL……………………………………………………………………………………….235
3.15.0.1 CLEANING THE TRACK GROUPS………………………………………………………………………….236
3.16 STOPPING THE ENGINE………………………………………………………………………………………238
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM………………………………………………………………241
3.17 OPERATION OF THE LUBRICATION SYSTEM………………………………………………………………………..242
3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”……………………………………………………………………..242
3.17.1.1 Manual actuation of the central lubrication system………………………………………………..242
3.17.1.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM…………………………………………………….243
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”…………………………………………………………..243
3.17.2.1 Manual actuation of the swing circle lubrication system……………………………………………244
3.17.2.2 SWING CIRCLE LUBRICATION SYSTEM ”SLS”……………………………………………………………246
3.17.2.3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM…………………………………………………246
3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS……………………………………………………………………..248
3.18.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS………………………………………………………………249
3.18.1 HIGH LEVEL ALARM ”FIRE”……………………………………………………………………………..253
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE…………………………………………………..253
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS………………………………………………………..253
3.18.3.1 MANUAL ACTUATION………………………………………………………………………………253
3.18.3.2 AUTOMATIC ACTUATION……………………………………………………………………………253
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS….255
3.18.5 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON machinery house ROOF……………………257
3.19 TRANSFER PUMP FOR HYDRAULIC OIL……………………………………………………………………………258
3.19.1 OPERATING THE TRANSFER PUMP………………………………………………………………………….259
3.19.2 FUNCTIONS OF THE TRANSFER PUMP……………………………………………………………………….261
3.20 CENTRAL REFILLING SYSTEM………………………………………………………………………………….264
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM……………………………………………………………..265
3.20.1.1 Operation of the hydraulic Service Arm…………………………………………………………..265
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM…………………………………………………………………..267
3.20.3 RECEIVER PANEL WITH MONITOR BOX………………………………………………………………………269
3.20.3.1 Refilling Procedure……………………………………………………………………………271
3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM…….273
3.20.4.1 Refilling the Grease Containers of the Automatic Lubrication Systems………………………………..275
3.21 WORK ON THE LOADER ATTACHMENT……………………………………………………………………………..276
3.21.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS………………………………………………………………….276
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL……………………………………………………………………277
3.22.1 DISASSEMBLING OF THE SHOVEL………………………………………………………………………….277
3.22.2 TRANSPORTATION AND LIFTING…………………………………………………………………………..277
3.23 RETRIEVAL PROCEDURE………………………………………………………………………………………278
3.24 SHOVEL STORAGE…………………………………………………………………………………………..279
3.24.0.1 GENERAL………………………………………………………………………………………….279
3.24.1 PREPARING FOR STORAGE……………………………………………………………………………….279
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD…………………………………………………………………..279
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD…………………………………………………………………..279
3.24.4 PREPARING FOR OPERATION……………………………………………………………………………..280
3.25 TROUBLE SHOOTING…………………………………………………………………………………………281
3.25.0.1 GENERAL………………………………………………………………………………………….281
3.25.1 ENGINE…………………………………………………………………………………………….281
3.25.2 HYDRAULIC SYSTEM……………………………………………………………………………………282
3.25.3 FINAL DRIVES AND SWING MACHINERY……………………………………………………………………..283
3.25.4 CRAWLER TRACKS……………………………………………………………………………………..283
4 MAINTENANCE……………………………………………………………………………………………………285
4.1 FOREWORD…………………………………………………………………………………………………286
4.1.1 DEFINITIONS…………………………………………………………………………………………286
4.1.2 GENERAL RECOMMENDATIONS………………………………………………………………………………286
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE………………………………………………………………………….287
4.3 FLUIDS AND LUBRICANTS……………………………………………………………………………………..288
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…………………………………………………….288
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES……………………………………………………..289
4.3.2.1 Recommended Hydraulic Oils………………………………………………………………………291
4.3.2.2 General Information to selecting hydraulic oils……………………………………………………292
4.4 FILLING CAPACITIES………………………………………………………………………………………..294
4.5 STANDARD TORQUE LIST………………………………………………………………………………………295
4.5.1 Torque for Flange Joints……………………………………………………………………………..296
4.5.2 TORQUES FOR SPECIAL COMPONENTS………………………………………………………………………..297
4.6 LUBRICATION AND MAINTENANCE SCHEDULE………………………………………………………………………..299
4.6.1 INITIAL SERVICING……………………………………………………………………………………299
4.6.1.1 INITIAL RUNNING-IN……………………………………………………………………………..299
4.6.1.2 AFTER THE FIRST 250 OPERATING HOURS………………………………………………………………299
4.6.1.3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT………………………………….299
4.6.2 SERVICING THE CRITICAL BOLT CONNECTIONS………………………………………………………………..300
4.6.3 PERIODIC SERVICING INTERVALS………………………………………………………………………….300
4.6.4 PERIODIC SERVICING SCHEDULE…………………………………………………………………………..301
4.6.4.1 When necessary…………………………………………………………………………………301
4.6.4.2 EVERY 10 OPERATING HOURS OR DAILY………………………………………………………………..301
4.6.4.3 EVERY 50 OPERATING HOURS OR WEEKLY……………………………………………………………….302
4.6.4.4 EVERY 250 OPERATING HOURS OR MONTHLY……………………………………………………………..302
4.6.4.5 EVERY 500 OPERATING HOURS OR QUATERLY…………………………………………………………….303
4.6.4.6 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS………………………………………………………303
4.6.4.7 EVERY 2000 OPERATING HOURS OR YEARLY……………………………………………………………..304
4.6.4.8 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…………………………………………….304
4.6.4.9 EVERY 6000 OPERATING HOURS OR EVERY TWO YEARS……………………………………………………..305
4.6.5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM……………………….306
4.6.5.1 Lubrication Chart………………………………………………………………………………307
4.7 SAFETY CRITICAL PARTS……………………………………………………………………………………..308
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES………………………………………………….308
4.7.2 INSPECTION OF HOSE LINES……………………………………………………………………………..308
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS……………………………………………………308
4.7.4 VENTING THE AIR FROM THE FUEL FILTERS………………………………………………………………….311
4.8 INITIAL SERVICING…………………………………………………………………………………………312
4.8.1 INITIAL CHECKS FOR PROPER LUBRICATION………………………………………………………………….313
4.8.2 SWING CIRCLE – CHECK GREASE INJECTORS………………………………………………………………….315
4.8.3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GrEASE INJECTORS……………………………………………….317
4.8.4 SWING CIRCLE – CHECK TORQUE OF BOLT CONNECTIONS…………………………………………………………319
4.8.5 Retightening procedure of the crawler carrier mounting bolts……………………………………………..321
4.9 EXTENDED SERVICE INTERVALS…………………………………………………………………………………327
4.9.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM…………………………………………………..327
4.9.1.1 Servicing Intervals…………………………………………………………………………….331
4.9.2 MAINTENANCE OF THE ENGINE…………………………………………………………………………….331
4.10 ENGINE FUEL FILTER LOCATION……………………………………………………………………………….332
4.10.1 fuel line connections on the engine…………………………………………………………………..333
4.11 WHEN NECESSARY…………………………………………………………………………………………..334
4.11.1 ENGINE AIR CLEANER SERVICE…………………………………………………………………………..335
4.11.1.1 General Service Tips…………………………………………………………………………..337
4.11.2 SWING CIRCLE TOOTHING LUBRICATION…………………………………………………………………….339
4.11.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS………………………………………………………341
4.11.3.1 CLEAN OR REPLACE FILTER ELEMENTS………………………………………………………………..343
4.11.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS…………………………………………………345
4.11.5 GUIDE WHEELS – REPLACE FLOATING SEALS…………………………………………………………………345
4.12 EVERY 10 OPERATING HOURS OR DAILY………………………………………………………………………….346
4.12.1 WALK-AROUND INSPECTION………………………………………………………………………………347
4.12.2 AIR CLEANER – CLEAN PRE-CLEANER………………………………………………………………………351
4.12.2.1 Clean dust cups of pre-cleaners…………………………………………………………………351
4.12.3 RADIATOR – CHECK COOLANT LEVEL……………………………………………………………………….353
4.12.4 TRACK GROUPS – CLEAN………………………………………………………………………………..353
4.12.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER……………………………………………………………..355
4.12.6 BOOM – CHECK LADDER AND WALKWAY………………………………………………………………………357
4.12.7 ELECTRICAL EQUIPMENT – CHECK VISUALLY…………………………………………………………………357
4.12.8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB…………………………………………………………….359
4.13 EVERY 50 OPERATING HOURS OR WEEKLY…………………………………………………………………………360
4.13.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS……………………………………………….361
4.13.1.1 Swing gears manufactured by “L&S”……………………………………………………………….361
4.13.1.2 Swing gears manufactured by SIEBENHAAR…………………………………………………………..363
4.13.1.3 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S” – CHECK OIL LEVELS……….365
4.13.1.4 CHECK Motor Adapter HOUSING OIL LEVEL……………………………………………………………365
4.13.1.5 CHECK BRAKE HOUSING OIL LEVEL…………………………………………………………………..365
4.13.1.6 CHECK TRAVEL GEAR OIL LEVEL…………………………………………………………………….365
4.13.2 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL………………………………………………………………..367
4.13.2.1 CHECK BREATHER FILTERS…………………………………………………………………………367
4.13.2.2 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN” – CHECK OIL LEVELS………………….369
4.13.3 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL………………………………………….373
4.13.3.1 CHECK OIL LEVEL OF PTO GEAR…………………………………………………………………….373
4.13.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR………………………………………………………….375
4.13.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY………………………………………………….379
4.14 EVERY 250 OPERATING HOURS OR MONTHLY……………………………………………………………………….380
4.14.1 AIR CONDITIONING……………………………………………………………………………………381
4.14.2 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION………………………………………………….381
4.14.3 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL……………………………………………385
4.14.4 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE……………………………………………………………..387
4.14.5 SIGNAL HORN COMPRESSOR – LUBRICATE……………………………………………………………………387
4.14.6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER…………………….387
4.14.7 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER………………………………..387
4.14.8 AUTOMATIC LUBRICATION SYSTEMS – CLEAN BREATHER FILTER…………………………………………………..389
4.14.9 CABIN AIR FILTERS – INSPECT………………………………………………………………………….391
4.14.10 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL………………………………………………………….393
4.14.11 CABIN HEATER FILTER – INSPECT……………………………………………………………………….395
4.15 EVERY 500 OPERATING HOURS OR MONTHLY……………………………………………………………………….396
4.15.1 BATTERIES – CHECK FLUID LEVEL………………………………………………………………………..397
4.15.1.1 STARTER BATTERIES……………………………………………………………………………..397
4.15.2 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL………………………………399
4.15.2.1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS……………………………………………..399
4.15.3 FUEL TANK – DRAIN CONDENSATION……………………………………………………………………….401
4.15.3.1 DRAIN CONDENSATION AS FOLLOWS…………………………………………………………………..401
4.15.4 CRAWLER TRACK – INSPECTION…………………………………………………………………………..403
4.15.4.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS……………………………………………………………403
4.15.4.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS…………………………………………………………..405
4.15.4.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS…………………………………………………………..407
4.15.4.4 Bleeding the System……………………………………………………………………………407
4.15.5 GROUND CABLES OF ENGINE, PRELUBRICATION PUMP AND ALTERNATOR – CHECK FOR CORRECT CONNECTION………………….409
4.15.6 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION……………………………………………411
4.15.6.1 GREASE INJECTORS – CHECK INDICATOR STEMS…………………………………………………………412
4.15.6.2 CORRECTIVE ACTIONS…………………………………………………………………………….412
4.15.7 EMERGENCY LOWERING OF ACCESS LADDER – Test FUNCTIONALITY………………………………………………..415
4.15.8 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS…………………………………………….417
4.16 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS………………………………………………………………..418
4.16.1 CRITICAL BOLT CONNECTIONS……………………………………………………………………………419
4.16.2 HYDRAULIC SYSTEM – FILTER SERVICE…………………………………………………………………….425
4.16.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS……………………………439
4.16.3.1 Oil drain plugs, illustration…………………………………………………………………..439
4.16.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…………………………………………………………..441
4.16.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS………………………………………………….443
4.16.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES………………………………………………..445
4.16.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES……………………………………………….447
4.16.8 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY…………………………………………………449
4.16.9 Engine SHUTDOWN PULL CHAINS – TEST FUNCTIONALITY……………………………………………………….451
4.16.10 ELECTRICAL EQUIPMENT – MAINTeNANCE…………………………………………………………………..453
4.16.11 CABIN AIR FILTER – REPLACE PRIMARY FILTER…………………………………………………………….455
4.17 EVERY 2000 OPERATING HOURS OR YEARLY……………………………………………………………………….456
4.17.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER……………………………..457
4.17.2 FILLING THE HYDRAULIC SYSTEM…………………………………………………………………………467
4.17.3 BLEEDING THE HYDRAULIC SYSTEM………………………………………………………………………..469
4.17.4 GEAR PUMP FOR PTO GEAR LUBRICATION……………………………………………………………………471
4.17.5 EMERGENCY ESCAPE LADDER – INSPECTION………………………………………………………………….473
4.17.6 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE………………………………………….475
4.17.7 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST…………………………………………………….477
4.17.8 HYDRAULIC HOSES – Check Condition…………………………………………………………………….479
4.17.9 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB…………………………………………………………….481
4.17.9.1 Functionality…………………………………………………………………………………481
4.18 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR………………………………………………………482
4.18.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL……………………………………………………..483
4.18.1.1 Swing gears manufactured by “L&S”……………………………………………………………….483
4.18.1.2 “SWING GEARS MANUFACTURED BY “SIEBENHAAR”………………………………………………………..487
4.18.1.3 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S”- CHANGE OIL……………………..491
4.18.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN”- CHANGE OIL………………………..497
4.18.2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL………………………………………………………………503
4.18.3 CRITICAL BOLT CONNECTIONS……………………………………………………………………………505
4.18.4 CABIN HEATER FILTER – REPLACE FILTER ELEMENT…………………………………………………………..541
4.19 EVERY 6000 OPERATING HOURS OR AT LEAST ONCE A YEAR…………………………………………………………..542
4.19.1 AUTOMATIC LUBRICATION SYSTEMS – Replace GREASE FILTERS………………………………………………….543
4.19.2 HYDRAULIC Oil TANK – CHECK LEAKAGE OIL SCREEN FILTER……………………………………………………545
4.20 FIRE PREVENTION………………………………………………………………………………………….546
4.20.1 PRECAUTIONS………………………………………………………………………………………..547
4.21 WELD REPAIRS…………………………………………………………………………………………….548
4.21.1 GENERAL PROTECTIVE MEASURES………………………………………………………………………….549
4.21.1.1 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL……………………………………………………549
4.21.1.2 COUNTERWEIGHT…………………………………………………………………………………549
4.21.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…………………………………….551
4.21.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…………………………………553
4.21.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE……………………………………555
4.21.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE………………………………………………….556

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