KOMATSU PC3000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 06372 - PDF DOWNLO by www.heydownloads.com

OMM 06372-D-EN-6T2-P1-1.0

Operation & Maintenance Manual

PC3000-6

HYDRAULIC MINING SHOVEL

SERIAL NUMBER 06372

Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should be kept near the machine for reference and must be periodically reviewed by all personnel who will come into contact with it. Komatsu has Operation and Maintenance Manuals written in other languages. If a foreign language manual is required, contact your local distributor for availability.

PC3000-6

COPYRIGHT This material is property of Komatsu Germany GmbH and is not to be reproduced, used, or disclosed except in accordance with the written authorization of Komatsu Germany GmbH. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that the customer contact their distributor for information on the latest revision.

PC3000-6

1 FOREWORD This is the original version of the Operation & Maintenance Manual, compiled in English, according to the serial number stated on the front cover.

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BEFORE READING THIS MANUAL

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FOREWORD

BEFORE READING THIS MANUAL

This manual gives details of the operation and methods of inspection and maintenance for this excavator that must be obeyed in order to use the excavator safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of excavators.

Read, understand and follow all precautions and warnings in this manual and on the excavator before performing operation and maintenance. Failure to do so may result in serious injury or death.

Komatsu cannot predict every circumstance that may involve a potential hazard when the excavator is used. Therefore, the safety messages in this manual and on the excavator may not include all possible safety 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 excavator can be hazardous and could result in serious injury or death.

If you sell the excavator, be sure to give this manual to the new owner together with the excavator.

This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ).

The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of publication. Continuing improvements in the design of this excavator may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your excavator or with questions regarding information contained in this manual. The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1

(1))

Komatsu delivers excavators that comply with all applicable regulations and standards of the country to which it has been shipped. If the excavator has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the excavator. 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.

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EC DECLARATION OF CONFORMITY

Fig. 1-2 The Declaration of Conformity is a signed document that states that the excavator complies to European Community directives. The document is valid for diesel and electro driven excavators.This illustration is an example. .

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KOMATSU EXCAVATOR OPERATOR PRIVACY POLICY This Privacy Policy governs the processing of personal data which takes place when operators based in the European Economic Area or EEA (which consists of the EU, Norway, Liechtenstein or Iceland) operate Komatsu excavators equipped with excavator Monitoring Systems such as KOMTRAX, KOMTRAX Plus, K-plus 2, iMC or Smart Construction Cloud system (hereinafter together referred to as "excavator Monitoring Systems" or "MMS"), i.e. systems that allow the wireless monitoring of Komatsu excavators. The MMS are globally managed and maintained by Komatsu Limited, a Japanese corporation having its principal place of business at no. 3-6, Akasaka 2-Chome, Minato-Ku, Tokyo, Japan ("Komatsu"). MMS are made available in the EEA by Komatsu Europe International NV, a corporation organized and existing under the laws of Belgium, with registered office at 1800 Vilvoorde, Belgium, Mechelsesteenweg 586, registered in Brussels under number RPR/CER(0)404.968.268 ("Komatsu Europe", together with the other Komatsu subsidiaries in the EEA referred to as "we" or "us"). Komatsu Europe acts as Komatsu's representative in the EU with respect to MMS. 1. Who is responsible? Komatsu, Komatsu Europe, Komatsu distributors and dealers, as well as the owner of the excavator and your employer (when your employer is not the owner) are all responsible for the processing of your personal data through MMS. 2. How are responsibilities allocated? To arrange for the aforementioned shared responsibility, Komatsu, Komatsu Europe, the distributors, dealers, owners and your employer have put in place contractual arrangements between them which govern this shared responsibility. The essence of these arrangements is that you can always direct your questions and requests regarding the processing of your personal data (i.e. storage, collection, transfer etc. of all information that relates to you as operator) to the party with whom you have most direct relationship. In principle this means that you should first and foremost refer to your employer (if you are an employee) or your customer (if you are an independent contractor). Komatsu, Komatsu Europe, Komatsu distributors and dealers, as well as the owner of the excavator and your employer/customer (if he is not the owner) will liaise between each other to ensure that your questions, requests and rights regarding the processing of your personal data are given due regard. To be clear: –

For staff members of Komatsu Europe or of other Komatsu subsidiaries in the EEA, the request can be directed directly to Komatsu Europe by sending an e-mail to PrivacyOffice@komatsu.eu

–

For staff members or independent contractors of a distributor, a dealer or an owner, meaning you either work for or on behalf of a distributor, a dealer or an owner, you are to contact the distributor, the dealer or the owner with your questions or requests.

–

For staff members or independent contractors of another entity than the ones referred to above, you are to contact first and foremost your employer or customer.

If you are unsure who to contact, please send an e-mail to Komatsu Europe at PrivacyOffice@komatsu.eu stating your full name, function title and entity you work for, and we will refer your request to the appropriate responsible party. 3. What sort of personal data is processed? When you use a excavator equipped with MMS, the following types of personal data are collected and processed:

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personal identification data (e.g. names)

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current employment (e.g. function title and employer details)

–

details regarding: – your use and operation of the excavator – excavator location and position – usage times and statistics – error codes and frequency of those codes – pictures, videos and sound recordings

4. Why is your personal data processed? When you use Komatsu excavators equipped with MMS, your personal data is processed for the following reasons: (a) Safety and security (b) Warranty (c) Misuse and theft prevention (d) To provide training and develop training materials (e) To improve excavator and operational efficiency (f) To improve job site safety and efficiency (g) To provide faster and more tailored support service (h) To optimize job site layout, excavator resource allocation and driving routes (i) For real-time job site monitoring and management (j) Where applicable: to follow-up on rental agreements (k) To improve MMS and associated services (l) To evaluate, analyze and report on excavator usage (m) To comply with a legitimate request from law enforcement or other authorities We may also process your personal data to inform a third party in the context of a possible merger with, acquisition from/by or demerger by that third party, even if that third party is located outside of the EU. Please note that your employer can also use MMS to process data to evaluate your performance as employee as well as for other purposes, but this is entirely between you and your employer. 5. What makes the processing of your personal data legitimate? The data protection laws require us to precisely indicate to you which legal option we rely on to make the processing of your personal data legitimate. We need to clarify this for each of the purposes listed in section 4 above. For the purposes (a) to (l) as indicated in section 4 above as well as for the purpose of informing a third party in the context of a possible merger, acquisition or demerger, the processing of your personal data is necessary for our legitimate interests, which in this case concern: –

ensuring the safe and secure deployment of the excavators

–

preventing misuse and theft

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commercial interests which include handling warranties, the need to be able to improve MMS, our excavators and services and training materials and the need to be able to enter into corporate transactions.

For purpose (m) we need to process your personal data to comply with our legal obligations. Version 2019/4

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6. Recipients and transfers Your personal data may be sent to the following categories of recipients: –

yourself

–

your employer or business relations

–

companies within the Komatsu group of companies, including our affiliates, as well as our service providers who help us to provide MMS

–

governmental, judicial and other competent bodies in case of a justified yet legally binding request

Your personal data are transferred to Japan, for which model contract clauses on the basis of European Commission decision 2004/915/EC have been put in place between Komatsu and Komatsu Europe. For more information, please address your questions to PrivacyOffice@komatsu.eu 7.

How long will your personal data be stored?

Your personal data are only processed for as long as needed to achieve the purposes listed in section 4 above. We will deidentify your personal data when they are no longer necessary for the purposes outlined in the purpose for processing, unless there is: –

an overriding interest of Komatsu, Komatsu Europe or any third party in keeping your personal data identifiable

–

a legal or regulatory obligation or a judicial or administrative order that prevents us from de-identifying them

. Which rights do you have with regard to the processing of your personal data?

You have the right to request access to all personal data processed in MMS insofar it pertains to you. You can exercise this right first and foremost via most MMS directly. We reserve the right to refuse multiple requests for access that are clearly submitted for causing nuisance or harm to Komatsu, Komatsu Europe or other parties. You have the right to ask that any personal data pertaining to you which are inaccurate, are corrected free of charge. Some personal data you can correct yourself if you have access to the MMS web portal. If a request for correction is submitted, such request must be accompanied of proof of the flawed nature of the data for which correction is asked. You have the right to request that personal data pertaining to you will be deleted if they are no longer required in light of the purposes outlined above. However, you need to keep in mind that a request for deletion will be evaluated by us against: –

overriding interests of Komatsu, Komatsu Europe or any other third party

–

legal or regulatory obligations or administrative or judicial orders which may contradict such deletion

Instead of deletion you can also ask that we limit the processing of your personal data if and when (a) you contest the accuracy of that data, (b) the processing is illegitimate or (c) the data are no longer needed for the purposes which are outlined above, but you need them to defend yourself in judicial proceedings. You have the right to oppose the processing of personal data for the purposes (a) to (l) in section 4, but you are required to explain your particular circumstances on which your request for opposition is based. As explained earlier, if you wish to submit a request to exercise one or more of the rights listed in this section, you must first and foremost contact your employer. Each request addressed to us can be sent via e-mail to PrivacyOffice@komatsu.eu for all data subject right matters. An e-mail requesting to exercise a right will not be construed as consent with the processing of your personal data beyond what is required for handling your request. Such request should clearly state and specify which right you wish to exercise and the reasons for it, if such is required. It should also be dated and signed, and accompanied by a digitally scanned copy of your valid identity card proving your identity. Without prejudice to the allocation of responsibilities as outlined in section 1, we will promptly inform you of having received this request. If the request proves valid, we will notify you as soon as reasonably possible and at the latest thirty (30) days after having received the request. If you have any complaint regarding the processing of your personal data by Komatsu or Komatsu Europe via MMS, you may always contact us via the e-mail address mentioned in the first paragraph of this clause. If you remain unsatisfied with our response, you may file a complaint with the competent data protection authority.

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RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS

NOTICE Mining excavators produced by Komatsu Germany use only the Komtrax Plus system for wireless communication. The directives mentioned below are written for the Komtrax system but are also valid for the Orbcomm modems used in Komtrax Plus.

The Komtrax equipment is a wireless device using radio waves, so it is necessary to obtain authorization and conform to the laws of the country or territory where the excavator equipped with Komtrax is being used. Always contact your Komatsu distributor before exporting this excavator equipped with Komtrax or using it in a foreign country. Komtrax may already have been registered and used if the excavator is purchased as second-hand. For the registration and usage records of Komtrax, consult your Komatsu distributor. If the excavator has been lent out by the customer, the borrower or another third party may have been using Komtrax. Confirm with the owner about the using conditions of Komtrax. Komatsu may suspend Komtrax communication in the following cases: –

When Komatsu judges that Komtrax is used by an unregistered customer.

–

When Komatsu judges that Komtrax is used in a country or region where its use is not authorized.

–

In other cases that Komatsu or Komatsu distributors judges that it is necessary to suspend Komtrax communication.

If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages.

NOTICE For more information on Komtrax and therefore also Komtrax Plus and the Radio Equipment Directive (2014/53/EU), please refer to Komatsu Europe website. https://www.komatsu.eu/Komtrax-Radio-Equipment-Directive

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DIRECTIONS OF THE EXCAVATOR

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DIRECTIONS OF THE EXCAVATOR

Fig. 1-3 Legend for Fig. 1-3 (A)

Front

Right

(B)

Rear

Operator’s seat

(C)

Left

Sprocket

In this manual, the terms front, rear, left and right refer to the direction of travel as seen from the operator’s seat when the operator’s seat is facing the front and the sprocket is at the rear of the excavator. The main drive engines/motors on two engine/motor excavators are defined as rear and front whereby the rear engine is at the counterweight side of the excavator when viewed from the main hydraulic pump room.

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SPECIFICATION AND SERIAL PLATE

Fig. 1-4 The specification and serial plate is located on the outside of the driver’s cab near the door.

1.6.1

PRODUCT IDENTIFICATION NUMBER

The product Identification Number Code (PIN-Code) is printed in the space provided on the specification and serial plate. (Fig. 1-4)

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DIVISION OF THE BINDER

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DIVISION OF THE BINDER

Part 1: Foreword Part 2: Safety Instructions Part 3: Operation Manual Part 4: Lubrication- and Maintenance Manual Part 5: Depending on the volume of Part 3 a second binder "Volume 2" is being delivered with the excavator. This binder contains the Assembly Procedure Manual for the excavator specification booklet, service literature for the power unit (diesel motor or electric motor) and for special equipment. The electrical- and hydraulic diagrams are attached in the pocket of the front cover. Refer to the "TABLE OF CONTENTS VOLUME 2 BINDER" for details. Read the manuals before You Start the motors. Before operating the excavator, familiarize yourself with its instruments and controls. Observe the instructions in these manuals for: your personal SAFETY Operating SAFETY, and READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining excavator. Periodic preventive inspections and maintenance are the surest means of keeping the excavator in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses. Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If you have any questions concerning this literature please contact Komatsu Germany GmbH Service Information Department 8151.40 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY

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DESIGNATED USE OF THE EXCAVATOR

This excavator has been manufactured in accordance with advanced and up-to-date technology standards including recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the excavator and to other material property. The excavator must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual. Only trained safety-conscious operators who are fully aware of the risks involved should operate the excavator. Any functional disorders, especially those affecting the safety of the excavator, should, therefore, be rectified immediately. The hydraulic excavator is designed exclusively for excavating, i.e. excavation of bulk material and natural soil structure (e.g. earth, clay, sand and stones ashore and off-shore). Observe local and national safety regulations. Special conditions at the work site require additional safe working precautions, follow your company's safety instructions. Short traveling distances for changing the working site are considered as part of the designated use of the excavator. Using the excavator for purposes other than those mentioned above (such as object handling and use as a transport vehicle) is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user.

NOTICE Special use of the excavator beyond its designated use, e.g. object handling operations, require written agreement from the manufacturer and retrofitment of the excavator with respective safety related equipment before such special applications are permitted.

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DELIVERY OF THE EXCAVATOR

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DELIVERY OF THE EXCAVATOR

The excavator is delivered disassembled into its main components. For assembling the excavator refer to the separate manual ”Assembly Procedure” in Volume 2 Binder.

WARNING KNOW YOUR EXCAVATOR! Using the excavator without being aware of the hazards involved can lead to serious personal injury or death. Personnel entrusted with work on the excavator must have read the Assembly Manual, the Operation,Lubrication- and Maintenance Manual and in particular the section on safety before beginning work. Reading the instructions after work has begun is too late.

If there are any questions concerning the assembling procedure, contact your local Service Center. Prior to first operation, inspect the excavator thoroughly with the service worker responsible for the erection of the excavator. Check all fluid levels according to the lubrication and maintenance schedule. Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee. REMARKS: If the excavator is equipped with a fire suppression system, make sure that the system is ready for operation.

1.9.1

SPARE PARTS

For your spare part orders refer to the parts catalog. In order to keep your excavator in first-class operating condition use only genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU GERMANY GmbH from any guarantee.

1.9.2

SERVICE

For all questions related to your excavator please contact your local service center. In all your written or phoned inquiries please indicate the model and serial number of your excavator.

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EXPLANATION OF ABBREVIATIONS

Abbreviation

Definition

Ampere

AC/ DC

Alternating current / Direct current

API

American Petroleum Institute

cSt

Centistroke

°C

Degree Celsius

CENTRY

Motor Electronic Control System

CLS

Central Lubrication System

CW /CWW

Clockwise / Counter Clockwise (Anti Clockwise)

DEF

Diesel Exhaust Fluid

DIN

German Institute for Standardization

EBL

Electronic Bucket Leveling System

ECM

Electronic Control Module (motor) Electronic Control and Monitoring System

FGPS

Front Guard Protective Structure

FOPS

Falling-Object Protective Structure

Gear Lubricant

hours of operation

HPF

High Pressure Filter (Hydraulic Oil)

High Tension

International Protection marking for electronic equipment

LED

Light Emitting Diode

Low Tension

MPG

Multi-Purpose Grease

MTC

Master Turbo Controller

Newton

Newton meter

Planned Maintenance

ppm

parts per million

PTO

Power Take-Off (Pump Distributor Gear)

SLS

slew circle pinion Lubrication System

Volt

KOMTRAX plus

Machine monitor

1/min

Revolutions Per Minute (RPM)

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EXPLANATION OF ABBREVIATIONS

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CONTENTS

1.11 CONTENTS 1 FOREWORD.............................................................................................. 1-1 1.1

BEFORE READING THIS MANUAL ................................................................................................. 1-2

1.2

EC DECLARATION OF CONFORMITY ............................................................................................ 1-3

1.3

PRIVACY POLICY ON EXCAVATORS EQUIPPED WITH EXCAVATOR MONITORING SYSTEMS FOR THE EEA ................................................................................................................. 1-4

1.4

RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS ....................................... 1-7

1.5

DIRECTIONS OF THE EXCAVATOR................................................................................................ 1-8

1.6

SPECIFICATION AND SERIAL PLATE ............................................................................................ 1-9 1.6.1 PRODUCT IDENTIFICATION NUMBER ............................................................................... 1-9

1.7

DIVISION OF THE BINDER ............................................................................................................. 1-10

1.8

DESIGNATED USE OF THE EXCAVATOR .................................................................................... 1-11

1.9

DELIVERY OF THE EXCAVATOR .................................................................................................. 1-12 1.9.1 SPARE PARTS .................................................................................................................... 1-12 1.9.2 SERVICE ............................................................................................................................. 1-12

1.10 EXPLANATION OF ABBREVIATIONS ........................................................................................... 1-13 1.11 CONTENTS ...................................................................................................................................... 2-15

2 SAFETY ................................................................................................... 2-23 2.1

SAFETY INFORMATION ................................................................................................................. 2-24

2.2

OVERVIEW ...................................................................................................................................... 2.2.1 NORMAL OPERATIONS ..................................................................................................... 2.2.2 REGULAR MAINTENANCE ................................................................................................ 2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ..................................................... 2.2.4 ADDITIONAL SAFETY PRECAUTIONS .............................................................................

2.3

SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB. ............................ 2-26 2.3.1 SOUND ................................................................................................................................ 2-26 2.3.2 VIBRATION.......................................................................................................................... 2-26

2.4

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR......................... 2.4.1 UNDERSTANDING THE EXCAVATOR .............................................................................. 2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR .................... 2.4.3 PREPARATIONS FOR SAFE OPERATION........................................................................ 2.4.4 FIRE PREVENTION ............................................................................................................ 2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR.................................. 2.4.6 BURN PREVENTION .......................................................................................................... 2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .......................................... 2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS............................. 2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC) ................................................................. 2.4.11 PRECAUTIONS AT JOBSITE ............................................................................................. 2.4.12 STARTING MOTOR ............................................................................................................ 2.4.13 OPERATION........................................................................................................................

2.5

PRECAUTION FOR MAINTENANCE.............................................................................................. 2-49 2.5.1 GENERAL PRECAUTIONS ................................................................................................. 2-49

2-25 2-25 2-25 2-25 2-25

2-27 2-27 2-27 2-27 2-29 2-32 2-33 2-34 2-34 2-35 2-35 2-36 2-42 2-43

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2.5.2 2.5.3 2.6

PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 2-56 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 2-57

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS ....... 2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ................................................................... 2.6.2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS................................................................................................................... 2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR......................................

2-62 2-62

2.7

SPECIAL SAFETY EQUIPMENT..................................................................................................... 2.7.1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB .............. 2.7.2 OBJECT HANDLING ........................................................................................................... 2.7.3 LIGHTING ............................................................................................................................ 2.7.4 WARNING BEACON............................................................................................................ 2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ...........

2-64 2-65 2-65 2-65 2-65 2-65

2.8

SAFETY WARNING SIGNS ............................................................................................................. 2-69 2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS .............................................................. 2-70 2.8.2 LOCATION AND DESCRIPTION OF THE SIGNS FOR PC3400........................................ 2-72

2-62 2-62

3 OPERATION .............................................................................................. 3-1 3.1

FOREWORD....................................................................................................................................... 3-2 3.1.1 CONNECTION OF CUSTOMER ELECTRICAL INSTALLATIONS TO THE EXCAVATOR ......................................................................................................................... 3-2

3.2

CONSTRUCTION OF THE EXCAVATOR ......................................................................................... 3-3 3.2.1 OVERALL VIEW .................................................................................................................... 3-3 3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE ................................................................... 3-4 3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER ........................................................... 3-11 3.2.4 EMERGENCY ESCAPE LADDER....................................................................................... 3-16 3.2.5 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE ................................................................................................................................ 3-18 3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM ............................................................................................................ 3-20 3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS).......................................................................................................... 3-22

3.3

OPERATOR’S CAB - CONTROLS .................................................................................................. 3.3.1 CONTROLS WITH BACKHOE ATTACHMENT................................................................... 3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ................................................................... 3.3.3 OPERATOR’S CONSOLE ...................................................................................................

3-30 3-30 3-34 3-39

3.4

MACHINE MONITOR KOMTRAX PLUS) ........................................................................................ 3.4.1 SEQUENCE OF DISPLAYS ................................................................................................ 3.4.2 OPENING SCREEN............................................................................................................. 3.4.3 MAIN GAUGE SCREENS 1 TO 2........................................................................................ 3.4.4 FUNCTION OF KEYS F1 TO F6.......................................................................................... 3.4.5 FUEL CONSUMPTION SCREEN ........................................................................................ 3.4.6 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR ............................................ 3.4.7 MAIN SCREEN - CHANGE >TIME >SMR >DATE .............................................................. 3.4.8 MAINTENANCE MONITOR ................................................................................................. 3.4.9 SETTINGS FOR OPERATOR ............................................................................................. 3.4.10 AUTOMATIC MESSAGES................................................................................................... 3.4.11 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM .....................................

3-46 3-47 3-47 3-48 3-50 3-53 3-54 3-54 3-55 3-56 3-61 3-65

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CONTENTS

3.5

CAMERA SYSTEM WITH MONITORS (SPECIAL EQUIPMENT) .................................................. 3-78 3.5.1 LOCATION OF MONITORS AND CONTROL UNITS ......................................................... 3-79

3.6

OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING ....................................... 3.6.1 DIGITAL DISPLAY............................................................................................................... 3.6.2 CONTROL MODULE FOR AUXILIARY CAB HEATER (IF SO EQUIPPED) ...................... 3.6.3 AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED).................................. 3.6.4 AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED).................................. 3.6.5 FUEL PUMP ARRANGEMENT ...........................................................................................

3.7

MACHINERY HOUSE ...................................................................................................................... 3-98 3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES ............................................................. 3-99

3.8

ELECTRICAL EQUIPMENT IN CAB BASE .................................................................................. 3-100 3.8.1 ACCESS COVER FOR THE HEADLIGHTS MOUNTED ON CAB BASE ......................... 3-103 3.8.2 SWITCH BOX (X2) IN CAB BASE ..................................................................................... 3-105

3.9

PREHEATING SYTEM (OPTIONAL)............................................................................................. 3-107 3.9.1 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE .................... 3-107 3.9.2 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM ON THE COUNTERWEIGHT ........................................................................................................... 3-111

3-86 3-86 3-91 3-93 3-95 3-97

3.10 CHECKS BEFORE STARTING THE ENGINE .............................................................................. 3-112 3.10.1 CHECK THE FOLLOWING ITEMS.................................................................................... 3-113 3.11 STARTING THE ENGINE .............................................................................................................. 3-118 3.11.1 STARTING PROCEDURE ................................................................................................. 3-119 3.11.2 STARTING PROCEDURE AT AMBIENT TEMPERATURE UP TO -25° .......................... 3-121 3.12 MOVING THE EXCAVATOR ......................................................................................................... 3-128 3.12.1 TRAVEL CONTROL WITH FOOT PEDALS ...................................................................... 3-128 3.12.2 TRAVELING INSTRUCTIONS........................................................................................... 3-130 3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE................................................................. 3-136 3.13.1 SLEWING THE SUPERSTRUCTURE............................................................................... 3-136 3.13.2 SLEW PARKING BRAKE .................................................................................................. 3-137 3.14 WORKING WITH THE ATTACHMENT.......................................................................................... 3-139 3.14.1 COMBINED OPERATION CYCLES .................................................................................. 3-141 3.15 WORKING INSTRUCTIONS .......................................................................................................... 3.15.1 STABILITY OF THE EXCAVATOR.................................................................................... 3.15.2 FURTHER OPERATING PRACTICES .............................................................................. 3.15.3 LOADING TRUCKS ..........................................................................................................

3-144 3-144 3-146 3-150

3.16 PARKING THE EXCAVATOR ....................................................................................................... 3-151 3.16.1 CLEANING THE TRACK GROUPS................................................................................... 3-151 3.17 STOPPING THE ENGINE .............................................................................................................. 3-152 3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM..................................................... 3-155 3.18 AUTOMATIC LUBRICATION SYSTEMS ...................................................................................... 3-156 3.18.1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS ...................................... 3-157 3.19 FIRE DETECTION AND SUPPRESSION SYSTEM ...................................................................... 3.19.1 FIRE DETECTION AND SUPPRESSION SYSTEMS ....................................................... 3.19.2 HIGH LEVEL ALARM -FIRE- ............................................................................................. 3.19.3 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE ..................... 3.19.4 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM ...................................... 3.19.5 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM ..............................

3-160 3-161 3-165 3-165 3-165 3-167 5 -17

CONTENTS

3.19.6 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF ....................................... 3-169 3.20 CENTRAL REFILLING SYSTEM ................................................................................................... 3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM................................................. 3.20.2 OPERATING THE HYDRAULIC SERVICE ARM .............................................................. 3.20.3 RECEIVER PANEL WITH MONITOR BOX ....................................................................... 3.20.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS ..........................................................................................................................

3-170 3-171 3-173 3-175 3-179

3.21 TRANSFER PUMP FOR HYDRAULIC OIL ................................................................................... 3-180 3.21.1 OPERATING THE TRANSFER PUMP .............................................................................. 3-181 3.21.2 FUNCTIONS OF THE TRANSFER PUMP ........................................................................ 3-181 3.22 SERVICE CRANE (SPECIAL EQUIPMENT) ................................................................................. 3-185 3.23 WORK ON THE LOADER ATTACHMENT.................................................................................... 3-186 3.23.1 OBSERVE THE FOLLOWING INSTRUCTIONS ............................................................... 3-186 3.24 TRANSPORTATION AND LIFTING OF THE EXCAVATOR......................................................... 3-187 3.24.1 DISASSEMBLING OF THE EXCAVATOR ........................................................................ 3-187 3.24.2 TRANSPORTATION AND LIFTING................................................................................... 3-187 3.25 RETRIEVAL PROCEDURE............................................................................................................ 3-188 3.25.1 GENERAL .......................................................................................................................... 3-188 3.26 EXCAVATOR STORAGE............................................................................................................... 3.26.1 GENERAL .......................................................................................................................... 3.26.2 PREPARING FOR STORAGE........................................................................................... 3.26.3 ONE MONTH REPETITIVE SERVICE PERIOD................................................................ 3.26.4 SIX MONTH REPETITIVE SERVICE PERIOD.................................................................. 3.26.5 PREPARING FOR OPERATION .......................................................................................

3-189 3-189 3-189 3-189 3-189 3-190

3.27 TROUBLE SHOOTING .................................................................................................................. 3.27.1 GENERAL .......................................................................................................................... 3.27.2 ENGINE ............................................................................................................................. 3.27.3 HYDRAULIC SYSTEM....................................................................................................... 3.27.4 FINAL DRIVES AND SLEW GEAR.................................................................................... 3.27.5 CRAWLER TRACKS..........................................................................................................

3-191 3-191 3-191 3-192 3-193 3-193

4 MAINTENANCE ......................................................................................... 4-1 4.1

FOREWORD....................................................................................................................................... 4-2 4.1.1 DEFINITIONS ........................................................................................................................ 4-2 4.1.2 GENERAL RECOMMENDATIONS........................................................................................ 4-2

4.2

PRECAUTIONS FOR MAINTENANCE.............................................................................................. 4-3

4.3

FLUIDS AND LUBRICANTS.............................................................................................................. 4-4 4.3.1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES ................................ 4-4 4.3.2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES ................................ 4-6

4.4

FILLING CAPACITIES ..................................................................................................................... 4-10

4.5

STANDARD TORQUE LIST............................................................................................................. 4-11 4.5.1 TORQUE FOR FLANGE JOINTS ........................................................................................ 4-12 4.5.2 TORQUES FOR SPECIAL COMPONENTS........................................................................ 4-13

4.6

LUBRICATION AND MAINTENANCE SCHEDULE ........................................................................ 4-15 4.6.1 INITIAL SERVICING ............................................................................................................ 4-15 4.6.2 SERVICING THE CRITICAL BOLT CONNECTIONS.......................................................... 4-16

5 - 18

CONTENTS

4.6.3 4.6.4 4.6.5

PERIODIC SERVICING INTERVALS .................................................................................. 4-16 PERIODIC SERVICING SCHEDULE .................................................................................. 4-16 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM .......................................................................................... 4-21

4.7

SAFETY CRITICAL PARTS............................................................................................................. 4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES ...................... 4.7.2 INSPECTION OF HOSE LINES .......................................................................................... 4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS .......................... 4.7.4 VENTING THE AIR FROM THE FUEL FILTERS ................................................................

4-22 4-22 4-22 4-23 4-27

4.8

INITIAL SERVICING ........................................................................................................................ 4.8.1 WORKING ATTACHMENT - INITIAL CHECKS FOR PROPER LUBRICATION................. 4.8.2 SLEW CIRCLE - CHECK GREASE INJECTORS ............................................................... 4.8.3 CAR BODY AND RACEWAY OF SLEW RING ................................................................... 4.8.4 SLEW CIRCLE - CHECK TORQUE OF BOLT CONNECTIONS......................................... 4.8.5 RETIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS ......

4-28 4-29 4-31 4-33 4-35 4-37

4.9

WHEN NECESSARY ....................................................................................................................... 4.9.1 ENGINE AIR CLEANER MAINTENANCE ........................................................................... 4.9.2 SLEW CIRCLE TOOTHING LUBRICATION ....................................................................... 4.9.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS............................ 4.9.4 GUIDE WHEELS - REPLACE FLOATING SEALS .............................................................. 4.9.5 COLD STARTING AID, REPLACE FLUID CYLINDER ....................................................... 4.9.6 CLEANING THE EXCAVATOR ...........................................................................................

4-42 4-43 4-47 4-49 4-51 4-53 4-55

4.10 EVERY 10 OPERATING HOURS OR DAILY .................................................................................. 4.10.1 WALK - AROUND INSPECTION ......................................................................................... 4.10.2 AIR CLEANER - CLEAN PRECLEANER ............................................................................ 4.10.3 RADIATOR - CHECK COOLANT LEVEL ............................................................................ 4.10.4 TRACK GROUPS - CLEAN ................................................................................................. 4.10.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER................................................... 4.10.6 BOOM - CHECK LADDER AND WALKWAY....................................................................... 4.10.7 ELECTRICAL EQUIPMENT - CHECK VISUALLY .............................................................. 4.10.8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB ............................................

4-58 4-59 4-65 4-67 4-67 4-69 4-71 4-71 4-73

4.11 EVERY 50 OPERATING HOURS OR WEEKLY ............................................................................. 4.11.1 SLEW GEAR AND MOTOR ADAPTER HOUSING - CHECK OIL LEVEL .......................... 4.11.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS......................................................................................................................... 4.11.3 PTO (PUMP DISTRIBUTOR GEAR) - CHECK OIL LEVEL ................................................ 4.11.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR .......................................... 4.11.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY ...........................

4-74 4-75 4-79 4-83 4-85 4-87

4.12 EVERY 250 OPERATING HOURS OR MONTHLY ......................................................................... 4-88 4.12.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION.......................... 4-89 4.12.2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER - MAINTENANCE CHECK ................................................................................................................................ 4-91 4.12.3 GENERATOR - CHECK BELT TENSION ........................................................................... 4-95 4.12.4 SIGNAL HORN COMPRESSOR - LUBRICATE .................................................................. 4-97 4.12.5 HYDRAULIC OIL COOLER FAN - CHECK CONDITION AND FASTENING ...................... 4-97 4.12.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN BREATHER FILTER ........................... 4-99 4.12.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT .................................... 4-101 4.12.8 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL ...................................... 4-103

5 -19

CONTENTS

4.12.9 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL ......... 4-105 4.13 EVERY 500 OPERATING HOURS OR MONTHLY ....................................................................... 4.13.1 BATTERIES - CHECK FLUID LEVEL................................................................................ 4.13.2 FUEL TANK - DRAIN CONDENSATION ........................................................................... 4.13.3 CRAWLER TRACK - INSPECTION................................................................................... 4.13.4 EMERGENCY LOWERING OF ACCESS LADDER - TEST FUNCTIONALITY ................ 4.13.5 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS .............

4-106 4-107 4-109 4-111 4-119 4-121

4.14 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH.......................................................... 4-122 4.14.1 CRITICAL BOLT CONNECTIONS..................................................................................... 4-123 4.14.2 HYDRAULIC SYSTEM - FILTER SERVICE ...................................................................... 4-129 4.14.3 BLEEDING RETURN OIL CHAMBER (IF EQUIPPED WITH OIL LEVEL GAUGE) .......... 4-143 4.14.4 PTO (PUMP DISTRIBUTOR GEAR), SLEW GEAR AND TRAVEL GEARS - OIL SAMPLE ANALYSIS .......................................................................................................... 4-147 4.14.5 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE .......................................... 4-149 4.14.6 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS 4-151 4.14.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES .................... 4-153 4.14.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES .............. 4-153 4.14.9 EMERGENCY ENGINE SHUTDOWN SWITCHES - TEST FUNCTIONALITY ................. 4-155 4.14.10 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) - TEST FUNCTIONALITY............................................................................................................... 4-157 4.14.11 ELECTRICAL EQUIPMENT - MAINTENANCE ................................................................. 4-159 4.14.12 ENGINE AIR CLEANERS- INSPECT AND LUBRICATE HINGES.................................... 4-161 4.14.13 OIL SEPARATOR ELEMENT - REPLACE BREATHER FILTER ...................................... 4-163 4.15 EVERY 2000 OPERATING HOURS OR YEARLY ........................................................................ 4.15.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER ...................................................................................................... 4.15.2 EMERGENCY ESCAPE LADDERS - INSPECTION ......................................................... 4.15.3 PREVENTATIVE MAINTENANCE (PM) CLINIC - PERFORM TEST................................ 4.15.4 HYDRAULIC HOSES - CHECK CONDITION.................................................................... 4.15.5 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB ..........................................

4-164 4-165 4-179 4-181 4-183 4-185

4.16 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR .............................. 4-186 4.16.1 SLEW GEAR AND MOTOR ADAPTER HOUSING - CHANGE OIL.................................. 4-187 4.16.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL ........... 4-195 4.16.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL ........................................................ 4-199 4.16.4 PTO GEAR OIL VISCOSITY AND ADJUSTMENT OF TEMPERATURE SWITCH UNITS 4-201 4.16.5 CRITICAL BOLT CONNECTIONS - CHECK TORQUE LOAD .......................................... 4-203 4.16.6 OIL SEPARATOR ELEMENT - REPLACE ........................................................................ 4-221 4.17 EVERY 6000 HOURS OR AT LEAST ONCE A YEAR.................................................................. 4-222 4.17.1 AUTOMATIC LUBRICATION SYSTEMS - REPLACE GREASE FILTERS ....................... 4-223 4.17.2 CHECK FAN DRIVE BEARING OF COOLANT RADIATOR ............................................. 4-225 4.18 FIRE PREVENTION ....................................................................................................................... 4-226 4.18.1 PRECAUTIONS ................................................................................................................. 4-227 4.19 WELD REPAIRS ............................................................................................................................ 4.19.1 GENERAL PROTECTIVE MEASURES............................................................................. 4.19.2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR ............................ 4.19.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE............................................................................................................ 4.19.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER 5 - 20

4-228 4-229 4-229 4-231

CONTENTS

ATTACHMENT .................................................................................................................. 4-233 4.19.5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE ........................................................................................................ 4-235 4.19.6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...................... 4-237

5 REVISION .............................................................................................. 5-239 5.1

REVISION TABLE.......................................................................................................................... 5-240

5 -21

CONTENTS

5 - 22

SAFETY

2 SAFETY

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS INJURY OR DEATH. Please read and make sure that you fully understand the precautions described in this section and the safety labels on the excavator. When operating or servicing the excavator, always follow these precaution strictly.

General Safety Version 22

2 - 23

SAFETY INFORMATION

2.1

SAFETY

SAFETY INFORMATION

To enable you to use this excavator safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the excavator must always be followed. The safety information in this manual does not replace any safety rules or laws in your area. To identify important safety messages in the manual and on the excavator labels, the following signal words are used. The “Safety Alert Symbol” identifies important safety messages on excavators, in manuals, and elsewhere. When you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.

DANGER This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION This signal word indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE This signal word is used to alert you to information that must be followed to avoid damage to the excavator. This precaution is given where the excavator may be damaged or the service life reduced if the precaution is not followed.

NOTE!

This word is used in regard to non-specific safety relevant information.

REMARKS: This word is used for specific safety information that is useful to know.

2 - 24

General Safety Version 22

SAFETY

2.2

OVERVIEW

The appropriate safety information for specific working modes on the excavator can be found in the following:-

2.2.1

NORMAL OPERATIONS

–

For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.

–

For operational safety information, refer to section 2.4 on page 2-27.

–

For on site safety information, refer to section 2.4.3 on page 2-27.

2.2.2

REGULAR MAINTENANCE

–

For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section of the Operation and Maintenance Manual.

–

For maintenance safety information, refer to section 2.5 on page 2-49.

2.2.3

TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

–

For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 2-62.

–

For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through Komatsu Germany.

–

For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through Komatsu Germany.

2.2.4

ADDITIONAL SAFETY PRECAUTIONS

For Assembling, Disassembling and Transportation of the excavator –

Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional safety precautions given in the ASSEMBLY PROCEDURE MANUAL.

General Safety Version 22

2 - 25

SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB.

2.3

SAFETY

SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB.

Fig. 2-5

2.3.1

SOUND

The sound pressure level in the operator’s cab is measured according to ISO 6394 (Stationary test conditions), see Fig. 2-5. The associated uncertainty KpA is 2.5 dB(A).

2.3.2

VIBRATION

Information concerning hand - arm and whole body vibrations according to 2002/44/EC. – Hand-arm vibration emission is below the limit value of 2.5 m/s² – Whole body vibration emission is below the limit value of 0.5 m/s² Uncertainty of vibration measurement [K] in m/s²: Vibration emission

PC3000

PC4000

PC5500

PC7000

PC8000

Hand-arm

0,35

0,66

Whole body

0,10

0,20

0,21

2 - 26

General Safety Version 22

SAFETY

2.4

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

WARNING WHEN MISUSED, THESE EXCAVATORS ARE DANGEROUS. Mistakes in operation, inspection, or maintenance may result in personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the excavator carefully and obey the warnings.

2.4.1

UNDERSTANDING THE EXCAVATOR

Before operating the excavator, read this manual thoroughly. If there are any places in this manual that you do not understand, ask the person in charge of safety to give an explanation.

2.4.2

PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR

2.4.2.1

ENSURING SAFE OPERATION

–

Only trained and authorized personnel can operate and maintain the excavator.

–

During operations, personnel are not allowed outside of the operator’s cabin.

–

Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance on the excavator.

–

If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or repair your excavator may be severely impaired putting yourself and everyone else on your job site in danger.

–

When working with another operator or with a person on work site traffic duty, discuss the content of the operation beforehand and use predetermined signals when carrying out these operations.

–

Ensure that anybody working around the excavator outside the cabin is not within a designated dangerous area. The definition of a dangerous area is a 20m circle around the maximum extent of the working attachment.

2.4.3

PREPARATIONS FOR SAFE OPERATION

2.4.3.1

PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT

–

Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired immediately if they are damaged.

–

Understand the method of use of safety features and use them properly.

–

Never remove any safety features. Always keep them in good operating condition.

2.4.3.2

INSPECTING THE EXCAVATOR

Check the excavator before starting operations. If any abnormality is found, do not operate the excavator until repairs of the problem location have been completed.

General Safety Version 22

2 - 27

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.3.3

SAFETY

WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT

Refer to Fig. 2-6: –

Do not wear loose clothing and accessories. If these catch on the control levers or moving parts, there is a danger that it may cause the excavator to move unexpectedly.

–

Always wear a hard hat and safety shoes when working on the excavator outside of the cabin. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs and a safety belt when operating or maintaining the excavator.

–

If you have long hair and it hangs out from your hard hat, there is a hazard that it may get caught up in the excavator, so tie your hair up and be careful not to let it get caught.

–

Check that all protective equipment functions properly before using it.

2.4.3.4

Fig. 2-6

KEEP EXCAVATOR CLEAN

Refer to Fig. 2-7: –

When water gets into the electrical system, there is a hazard that it will cause malfunctions or a mis-operation. If there is any mis-operation, there is a danger that the excavator may move unexpectedly and cause serious personal injury or death. When washing the excavator with high pressure water or steam, do not come into direct contact with electrical components.

–

If you get on or off the excavator or carry out inspection or maintenance when the excavator is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the excavator. Always keep the excavators clean.

–

Only use compatible cleaning agents and observe the supplier specifications in order to prevent damage to parts and seals.

2.4.3.5

Fig. 2-7

PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT

–

When entering the operator’s compartment, always remove all mud and oil from your shoes. If you operate the pedal with mud or oil affixed to your shoes, you may slip and this may cause a serious accident.

–

Do not leave tools or excavator parts lying around inside the operator’s compartment. If tools or parts get into the control devices, they may obstruct operation and cause the excavator to move unexpectedly, resulting in serious personal injury or death.

–

Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.

–

Do not use a cell phone when driving or operating the excavator. This may lead to mistakes in operation, which could cause serious personal injury or death.

–

Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.

–

Do not block the front of the intake or output of the heating system or heated air.

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General Safety Version 22

SAFETY

2.4.3.6

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur, refer to Fig. 2-8. –

Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies.

–

Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used.

–

Provide a first aid kit. Carry out periodic checks and add to the contents if necessary.

Fig. 2-8

2.4.3.7

IF A PROBLEM IS FOUND

If you find any problems in the excavator during operation and maintenance (noise, vibration, smell, incorrect gauges, smoke, oil, leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge and have the necessary action taken. Do not operate the excavator until the problem has been corrected.

2.4.4

FIRE PREVENTION

2.4.4.1

PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, antifreeze, or window washer fluid. Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer fluid. There is a danger they may catch fire. To prevent fire, always observe the following: Refer to Fig. 2-9: – Do not smoke or use any flame near fuel or other flammable substances. – Stop the motors before adding fuel. – Do not leave the excavator while adding fuel or oil. – Tighten all fuel and oil caps securely. – Be careful not to spill fuel on overheated surfaces or on parts of the electrical system. – After adding fuel or oil, wipe up any spillage. – Put greasy rags and other flammable materials into a safe container to maintain safety in the workplace.

Fig. 2-9

– When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline. There is a danger that they may catch fire. – Do not weld or use a cutting torch to cut any pipe or tubes that contain flammable liquids. –

Determine well ventilated areas for storing oil and fuel. Keep the oil and fuel in the determined place and do not allow unauthorized persons to enter.

General Safety Version 22

2 - 29

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

SAFETY

NOTICE WELDING! Welding work on the excavator is hazardous. Before carrying out grinding or welding work on the excavator, remove any flammable materials.

–

Fire caused by accumulation of flammable material. Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or affixed around the motors, exhaust manifold, muffler or battery, or inside the under covers.

–

Fire coming from electrical wiring Short circuits in the electrical system can cause fire. To prevent fire, always observe the following: – Keep all electrical connections clean and securely tightened. – Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring.

–

Fire coming from piping Check that all hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or death.

–

Explosion caused by lighting equipment – When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications. – When taking the electrical power for the lighting from the excavator itself, follow the instructions of this manual.

–

Fire from blocked heating – Do not block the front of the intake or output of the heating system or heated air.

2.4.4.2

ACTION IF FIRE OCCURS ON PC3000

–

Activate the STOP switch to stop the motor.

–

Use the stairway and steps to get off the excavator.

–

When escaping from the cab, use the ladder provided for emergency escape or the mechanically operated ladder to descend down the side of the cab, refer to Fig. 2-10.

Fig. 2-10

2 - 30

General Safety Version 22

SAFETY

2.4.4.3

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000

–

Activate the STOP switch to stop the motor.

–

Use the stairway and steps to get off the excavator.

–

When escaping from the cab, use the ladder provided for emergency escape or the mechanically operated ladder to descend down the side of the cab, refer to Fig. 2-11.

Fig. 2-11

–

After escaping with the emergency escape ladder, activate the motor stop chains ( Fig. 2-12 Pos. 1) to shut down the motor if they are equipped on your excavator.

Fig. 2-12

2.4.4.4

EMERGENCY EXIT FROM OPERATOR’S CAB

–

If the cab door does not open, or is unable to be used correctly, use the window for an emergency escape from the operator’s cab (1).

–

Break the glass using the emergency hammer (2)

–

Remove the glass to get safe access to the locks.

–

Turn the four levers (4) mounted on the sun visor 180° in any direction to remove the sun visor.

–

Push out the visor and let it drop down.

–

Exit the cabin very carefully through the window.

Fig. 2-13

General Safety Version 22

2 - 31

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

SAFETY

2.4.5

PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR

2.4.5.1

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE EXCAVATOR

To prevent personal injury caused by slipping or falling off the excavator, always do as follows. –

Always use the handrails and steps when getting on or off the excavator.

–

To ensure safety, always face the excavator and maintain three-point contact (both feet and one hand, or both hands and one foot - see Fig. 2-14). with the handrails and steps to ensure that you support yourself.

–

When walking on the excavator, move only in areas that have non-slip padded walkways and non-slip gratings. Extra care is to be taken when moving outside of these areas.

–

Before getting on or off the excavator, check the handrails and steps. If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.

2.4.5.2

Fig. 2-14

NO JUMPING ON OR OFF THE EXCAVATOR

–

Never jump on or off the excavator. Never get on or off a moving excavator.

–

If the excavator starts to move when there is no operator on the excavator, do not jump onto the excavator and try to stop it.

2.4.5.3

NO PEOPLE ON THE ATTACHMENT

Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment. There is danger of falling and suffering serious personal injury. Refer to further information refer to section 2.7 on page 2-64.

2.4.5.4

WORKING IN HIGH PLACES

When working in high places, use safety harness and fall absorber to ensure that the work can be carried out safely. For further information refer to section 2.7 on page 2-64.

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General Safety Version 22

SAFETY

2.4.5.5

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

LEAVING OPERATOR’S SEAT WITH LOCK

Refer to Fig. 2-15: –

Before standing up from the operator's seat in order to adjust the seat, always lower the work equipment to the ground, turn off the motor, relieve the pressure in the hydraulic system and set lock lever to LOCK position (Position L). If the lock is not applied, there is danger of serious personal injury if the work equipment control levers are touched by mistake and the excavator moves suddenly. For information on relieving the pressure in the hydraulic system, refer to chapter ’RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the ’OPERATION’ part of this manual. Fig. 2-15

2.4.5.6 –

LEAVING THE EXCAVATOR

When leaving the excavator, always lower the work equipment completely to the ground, turn off the motor, relieve the pressure in the hydraulic system and set lock lever (1) securely to the LOCK position (L), then stop the motor. Always lock the cabin and take the cabin key with you, and keep it in a specified place. For information on relieving the pressure in the hydraulic system, refer to chapter ’RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the ’OPERATION’ part of this manual.

Fig. 2-16

2.4.6

BURN PREVENTION

2.4.6.1

HOT COOLANT

Refer to Fig. 2-17: –

To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap (Fig. 2-18) by hand before starting the operation. Even when the coolant has cooled down, loosen the cap slowly to relieve the pressure inside the radiator before removing the cap.

Fig. 2-17

General Safety Version 22

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GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.6.2

SAFETY

HOT OIL

Refer to Fig. 2-18: –

To prevent burns from hot oil spurting out when checking or draining the oil, wait for the oil to cool to a temperature where it is possible to touch the cap or plug by hand before starting the operation. Even when the oil has cooled down, loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.

Fig. 2-18

2.4.7

PRECAUTIONS WHEN CLEANING CAB GLASS

Always keep the cab glass clean to ensure good visibility when operating. Use an ethyl alcohol based washer liquid. Methyl alcohol based liquid may irritate your eyes, so do not use it. If the cab glass on the work equipment side is broken, there is a hazard that the intruding objects may contact the operator's body directly. Stop operation immediately and replace the glass.

2.4.8

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

On job sites where there is a hazard that falling objects (Fig. 2-19), flying objects (Fig. 2-20), or intruding objects may hit or enter the operator's cab, consider the operating conditions and install the necessary guards to protect the operator. –

When carrying out operations in mines or quarries where there is danger of falling or flying rocks, order/use the optionally available front guard.

–

When carrying out the above operations, always ensure that bystanders are a safe distance away and are not in hazard from falling or flying objects.

–

These recommendations assume that the conditions are for standard operations, but it may be necessary to add additional guards according to the operating conditions on the job site. Always contact your Komatsu distributor for advice.

2 - 34

Fig. 2-19

General Safety Version 22

SAFETY

2.4.9

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS

–

Ensure that all personnel not relevant to work on the excavator are out of the working area.

–

Workers or spotters around the excavator should be protected using a physical barrier that also ensures positive communications

–

They must always wear appropriate Personal Protection Equipment (PPE). For further information, refer to section 2.4.3.3 on page 2-28

–

Review work practices that may ensure that the likelihood of ejected material (especially from the undercarriage) is reduced.

2.4.9.1

Fig. 2-20

UNAUTHORIZED MODIFICATION

–

Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting in modifications made without authorization from Komatsu.

–

Any modifications made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor.

2.4.9.2 –

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.

2.4.10

ELECTROMAGNETIC COMPATIBILITY (EMC)

The use of retrofitted electrical and electronic equipment such as radars, computers, radio units and other appliances, working with high frequency electromagnetic waves, can interfere with the electronic control system of the excavator which can lead to damage to the excavator and to personnel. Only use equipment which meets the requirements of the standard ISO 13766 - Electromagnetic Compatibility for Earth-Moving Machinery. Obtain advice from authorized electricians regarding the electromagnetic compatibility of the equipment, prior to installation. REMARKS: If appliances which interfere with the electronic control system of the excavator are installed, control of the excavator will be impaired. If a malfunction is experienced, release the operating levers and the pedals and strike the emergency shut-down button. Komatsu can not be made liable for any injuries, accidents, product failures or other property damage resulting from installation of non-EMC certified equipment.

General Safety Version 22

2 - 35

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.11

PRECAUTIONS AT JOBSITE

Fig. 2-21

2 - 36

General Safety Version 22

SAFETY

2.4.11.1

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

VISIBILITY FROM OPERATOR’S SEAT

WARNING THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGEROUS! Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of person and equipment is always ensured.

Fig. 2-21 shows an example of general blind areas of large Komatsu hydraulic mining excavators. The shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operator’s seat, and the excavator is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from outside surface of the excavator. Please be fully aware that there are places that can not seen when operating the excavator. The blind areas (A) differ depending on the excavator type, attachment and position of attachment.

2.4.11.2

CAMERA SYSTEM WITH MONITORS

Komatsu Germany offers camera systems and monitors to improve the overall visibility. See the latest version of the OMM part 3, for typical arrangement of cameras and monitors. The camera system can be installed ex works and can also be retrofitted in the field. If you need more information, please contact your local Komatsu distributor.

2.4.11.3

ENSURE GOOD VISIBILITY

When operating or traveling in places with poor visibility, if it is impossible to confirm the condition of the job side or obstacle is in the area around the excavator, there is danger that the excavator may suffer damage or the operator may suffer serious personal injury. When operating or traveling in places with poor visibility, always observe the following items strictly. –

The operator must survey the area to minimize all potential hazards.

–

If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful attention to the signs and follow the instructions of the flagman.

–

The signals should be given only by one flagman.

–

When working in dark places, turn on the working lamps and front lamps of the excavator, and if necessary, set up additional lighting in the area.

–

Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.

–

Check the mirrors or all visual aids on the excavator before starting operations every day. Clean off any dirt and adjust the view to ensure good visibility.

–

In areas where it is impossible to confirm the area around the excavator and observation cameras have been set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of the excavator.

–

Any modifications to the excavator that results in restrictions to the visibility of the operator require a new risk assessment. Also refer to section 2.4.9.1 on page 2-35.

2.4.11.4

CHECKING SIGNS AND SIGNALMAN’S SIGNALS

–

Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.

–

Only one signalman should give signals.

General Safety Version 22

2 - 37

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

–

SAFETY

Make sure that all workers understand the meaning of all signals and signs before starting work.

2.4.11.5

INVESTIGATE AND CONFIRM JOBSITE CONDITIONS

On the job site, there are various hidden dangers that may lead to personal injury or death. Before starting operations, always check the following to confirm there are no dangers on the job site. –

When carrying out operations near combustible materials, there is a hazard of fire, so be careful when operating.

–

Check the terrain and condition of the ground at the work site, and determine the safest method of operation. Do not operate where there is a hazard of landslides or falling rocks.

–

If water lines, gas lines, or high-voltage electrical lines may be buried under the work site, contact each utility and identify their locations. Be careful not to sever or damage any of these lines (Fig. 2-22).

–

Take necessary measures to prevent any unauthorized person from entering the operating area.

–

If there is a fire near the excavator, there is danger of sparks being sucked in and causing a fire on the excavator.

–

When traveling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations.

–

Maintain the travel path on the job site so that there is no obstruction to travel operations.

2.4.11.6

Fig. 2-22

DO NOT GO CLOSE TO HIGH VOLTAGE CABLES

DANGER HIGH VOLTAGE! There is a hazard of electric shock, which may cause serious injury, death or property damage. Even going close to highvoltage cables can cause an electric shock, which may cause serious burns or death. Do not travel or operate the excavator near electric cables (Fig. 2-23).

Fig. 2-23

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General Safety Version 22

SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

On job sites where the excavator may go close to electric cables, always do as follows. –

Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.

–

Always maintain a safe distance (see the table on the right) between the excavator and the electric cable. Check with the local power company about safe operating procedure before starting operations.

–

To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body.

–

Use a signalman to give warning if the excavator approaches too close to the electric cables.

–

When carrying out operations near high voltage cables, do not let anyone near the excavator.

–

If the excavator should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone near the excavator.

2.4.11.7

Voltage of Cables 100 V - 200 V 6,600 V 22,000 V 66,000 V 154,000 V 187,000 V 275,000 V 500,000 V

Safety Distance Over 2 m (7 ft) Over 2 m (7 ft) Over 3 m (10 ft) Over 4 m (14 ft) Over 5 m (17 ft) Over 6 m (20 ft) Over 7 m (23 ft) Over 11 m (36 ft)

LIGHTNING STRIKES

The excavator is vulnerable to strikes by lightning, A maximum of two people are allowed in the cabin and they must be sitting in appropriate seats. Stop working when the storm is close, lower the attachment to the ground and wait for the storm to pass.Stop working when the storm is close, lower the attachment to the ground and wait for the storm to pass. A possible lightning strike may damage the mechanical bearings and the electrical systems. Check the excavator after a lightning strike for possible damages and repair if necessary.

2.4.11.8

WORKING ON LOOSE GROUND

–

Avoid traveling or operating your excavator too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the excavator, there is a hazard that the excavator may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas.

–

When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the excavator will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the excavator from rolling over or falling.

General Safety Version 22

2 - 39

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.11.9

SAFETY

GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES

WARNING DIESEL FUMES! Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. - Always start and operate the engine in a well-ventilated area. - If in an enclosed area, vent the exhaust to the outside. - Do not modify or tamper with the exhaust system. - Do not idle the engine except as necessary.

WARNING RISK OF EXPOLSION AND FIRE! Welding, flame-cutting and grinding work on the excavator increases the risk of explosion and fire which may result in serious injury or death. All relevant safety measures must be followed and only under expressly obtained authorization. Special care must be taken before welding, flame-cutting and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting and grinding operations are carried out on the counterweight.

REMARKS: More information to expelling the gas from the counterweight chambers can be obtained from Komatsu service.

WARNING RISK OF EXPLOSION! Substances and objects igniting can lead to fire or explosion resulting in serious injury or death. Before carrying out welding, flame-cutting and grinding operations, clean the excavator and its surroundings from dust and other flammable substances and make sure that the premises are adequately ventilated as there is a risk of explosion.

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General Safety Version 22

SAFETY

2.4.11.10

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

VENTILATION OF ENCLOSED AREAS

WARNING POISONOUS FUMES! Unventilated areas where poisonous fumes can accumulate can kill. Always ensure adequate ventilation.

Refer to Fig. 2-24: –

Operate internal combustion motors and fuel operated heating systems only on adequately ventilated premises. Before starting the excavator on enclosed premises, make sure that there is sufficient ventilation. Observe the regulations in force at the respective site.

–

If it is necessary to start the motor within an enclosed area, or when handling fuel, flushing oil, or paint, open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning.

Fig. 2-24

General Safety Version 22

2 - 41

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.12

STARTING MOTOR

2.4.12.1

WARNING TAG

–

SAFETY

If there is a "DANGER DO NOT OPERATE!" warning tag displayed, it means that someone is carrying out inspection and maintenance on the excavator (Fig. 2-25). If the warning sign is ignored and the excavator is operated, there is a danger that the person carrying out the inspection or maintenance may be caught in the rotating parts or moving parts and suffer personal injury or death. Do not start the motor or touch the levers.

Fig. 2-25

2.4.12.2

CHECKS BEFORE STARTING MOTOR

Carry out the following checks before starting the motor at the beginning of the day's work to ensure that there is no problem with the operation of the excavator. If this inspection is not carried out properly, problems may occur with the operation of the excavator, and there is the danger that this could lead to serious personal injury or death. –

Remove all dirt from the surface of the window glass to ensure a good view.

–

Completely remove all flammable materials accumulated around the motor and battery, and remove any dirt from the windows, mirrors, handrails, stairway and steps.

–

Check the coolant levels, fuel levels, and oil levels, and check for damage to the electric wiring.

–

Adjust the operator's seat to a position where it is easy to carry out operations, check the camera system functions and check that there is no damage or wear to the seat belt or mounting clamps.

–

Check the operation of the instruments and gauges, check the angle of the mirror, and check that the control levers are all at the Neutral position.

–

Before starting the motor, check that lock lever (Fig. 2-26) is in LOCK position (L).

–

Adjust the mirrors so that the rear of the excavator can be seen clearly from the operator's seat.

–

Check that there are no persons or obstacles above, below, or in the area around the excavator.

2.4.12.3

Fig. 2-26

PRECAUTION WHEN STARTING MOTOR

–

Start and operate the excavator only while seated.

–

Do not short circuit the starting motor circuit to start the motor. Short circuiting can cause fire.

–

When starting the motor, sound the horn as a warning.

–

Do not let any person on the excavator other than the operator and the operator's assistant (1 person). For demonstration purposes or during training, more than two people can be present in the operator’s cabin at the same time. All personnel within the cabin at such times must secure good hand-holds and be aware of sudden movements. All appropriate relevant safety measures are to be observed.

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General Safety Version 22

SAFETY

2.4.12.4

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

PRECAUTION IN COLD AREAS

–

Carry out the warming-up operation thoroughly. If the excavator is not thoroughly warmed up before the control levers or control pedals are operated, the reaction of the excavator will be slow or the excavator may move in a way not expected by the operator. Particularly in cold weather, be sure to carry out the warming-up operation thoroughly.

–

If the battery electrolyte is frozen, do not charge the battery or start the motor with a different power source. There is a hazard that this will ignite the battery and cause the battery to explode.

–

Before charging or starting the motor with a different power source, melt the battery electrolyte and check that there is no leakage of electrolyte before starting.

2.4.13

OPERATION

2.4.13.1

CHECKS BEFORE OPERATION

If the checks before starting are not carried out properly, the excavator will be unable to display its full performance, and there is also danger that it may lead to serious personal injury or death. When carrying out the checks, move the excavator to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the excavator. –

Always fasten your seat belt.

–

Check that the movement of the excavator matches the display on the control pattern label in the cabin. If it does not match, replace it immediately with the correct control pattern label.

–

Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel system and swing system.

–

Check for any problem in the sound of the excavator, vibration, heat, smell, or gauges; check also that there is no leakage of oil or fuel.

–

If any problem is found, carry out repairs immediately.

General Safety Version 22

2 - 43

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.13.2 –

SAFETY

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

Before traveling, set the excavator so that sprocket (1) is behind the operator's seat (Fig. 2-27).

REMARKS: An exception to this is when the excavator is traveling on a slope. The drive system and the sprocket should then always face downhill. –

If sprocket (1) is in front of the operator's cab, the excavator moves in the opposite direction from the operation of the pedals (front and rear travel is reversed, left and right steering is reversed). Be extremely careful when operating the excavator in this situation.

Fig. 2-27 –

Before traveling, check again that there is no one in the surrounding area, and that there are no obstacles (Fig. 2-28).

–

Before traveling, sound the horn to warn people in the area.

–

Always operate the excavator only when seated.

–

Do not allow anyone apart from the operator to ride on the excavator.

–

Check that the travel alarm works properly.

–

Secure the cab door when it is both open and closed.

–

Always keep the cab door closed when operating the excavator. Fig. 2-28

–

If there is an area to the rear of the excavator which cannot be seen, position a signal person. Take special care not to hit other excavators, objects or people when turning or swinging the excavator (Fig. 2-29)

Fig. 2-29 NOTE!

2 - 44

Always be sure to carry out the above precautions even when the excavator is equipped with mirrors or camera systems.

General Safety Version 22

SAFETY

2.4.13.3

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

PRECAUTIONS WHEN TRAVELING

–

When traveling on flat ground, keep the work equipment 100 to 150 cm (39 to 59 in) high above the ground (Fig. 2-30).

–

If the view to the right side is poor, raise the boom to ensure better visibility.

–

When traveling on rough ground, travel at low speed and do not operate the steering suddenly. There is danger that the excavator may turn over. The work equipment may hit the ground surface and cause the excavator to lose its balance, or may damage the excavator or structures in the area.

–

Fig. 2-30 –

Avoid traveling over obstacles when possible. If the excavator has to travel over an obstacle, keep the work equipment close to the ground and travel at low speed. Never travel over obstacles which make the excavator tilt strongly to one side (Fig. 2-31).

–

When traveling or carrying out operations, always keep a safe distance from people, structures or other excavators to avoid coming into contact with them.

Fig. 2-31

General Safety Version 22

2 - 45

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.13.4

TRAVELING ON SLOPES

Incorrect traveling on slopes may cause the excavator to tip over, slip to the side or lose a track. Always do as follows. –

Keep the work equipment 100 - 150 cm (39 - 59 in) above the ground surface so that the work equipment can be lowered to the ground immediately to stop the excavator in emergencies (Fig. 2-32).

–

When travel up slopes, set the operator's cab facing uphill, when travel down slopes, set the operator's cab facing downhill. Always be aware and informed about the firmness and bearing capacity of the ground under the excavator when traveling. Cavities and underground mines may cause the ground beneath the excavator to collapse.

REMARKS: Always ensure the drive system and the sprocket face downhill no matter if traveling up slope or down. –

Fig. 2-32

When traveling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 100 to 150 cm (39 to 59 in) above the ground, and travel at low speed (Fig. 2-33).

Fig. 2-33 –

When traveling downhill, keep the travel pedals close to the neutral position, and travel at low speed.

–

Always travel straight up or down a slope. traveling at an angle or across the slope is extremely dangerous.

–

Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the excavator, then travel on to the slope again (Fig. 2-34).

–

Travel on slippery ground with low speed. Even with slight slopes there is a hazard that the excavator may slip

Fig. 2-34

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General Safety Version 22

SAFETY

2.4.13.5

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

OPERATIONS ON SLOPES

–

When working on slopes, there is a hazard that the excavator may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully.

–

Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded. This operation is dangerous, and may cause the excavator to tip over.

–

If the excavator has to be used on a slope, pile the soil to make a platform (A on Fig. 2-35) that will keep the excavator as horizontal as possible. Fig. 2-35

2.4.13.6 –

PROHIBITED OPERATIONS

Never dig the work face under an overhang. There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the excavator (Fig. 2-36).

Fig. 2-36 –

Do not excavate too deeply under the front of the excavator. The ground under the excavator may collapse and cause the excavator to fall (Fig. 2-37).

Fig. 2-37

General Safety Version 22

2 - 47

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

–

To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations (Fig. 2-38).

–

Generally speaking, the excavator is more liable to overturn when the work equipment is at the side than when it is at the front or rear.

SAFETY

– Do not suddenly lower, swing, or stop the work equipment. – Do not suddenly extend or retract the boom cylinder. There is a hazard that impact will cause the excavator to tip over. –

Do not pass the bucket over the head of other workers or over the operator's seat of dump trucks or other hauling equipment. The load may spill or the bucket may hit the dump truck and cause serious injury or property damage.

2.4.13.7

Fig. 2-38

TRAVELING ON FROZEN OR SNOW COVERED SURFACES

–

Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the excavator, and do not operate the pedals suddenly. Even a slight slope may cause the excavator to slip, so be particularly careful when working on slopes.

–

With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the excavator to tip over.

–

If the excavator enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful not to leave the road shoulder or to get trapped in a snow drift.

–

When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen. There is a hazard of the excavator tipping over or hitting covered objects, so always carry out operations carefully.

2.4.13.8

PARKING THE EXCAVATOR

–

Park the excavator on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low.

–

Lower the work equipment completely to the ground.

–

When leaving the excavator, set lock lever (Fig. 2-39, Pos 1) to the LOCK position (L), then stop the motor.

–

Always close the operator's cab door, and use the key to lock all the equipment in order to prevent any unauthorized person from moving the excavator. Always remove the key, take it with you, and leave it in the specified place.

–

If it is necessary to park the excavator on a slope, always set the bucket on the downhill side, then dig it into the ground.

2.4.13.9

Fig. 2-39

TRANSPORTATION

This excavator must be disassembled for transportation. When transporting the excavator, please consult your Komatsu distributor. Use only appropriate means of transport and lifting gear of adequate capacity. The recommissioning procedure must be strictly in accordance with the General Assembly Procedure Manual.

2 - 48

General Safety Version 22

SAFETY

PRECAUTION FOR MAINTENANCE

2.5

PRECAUTION FOR MAINTENANCE

2.5.1

GENERAL PRECAUTIONS

–

Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation,- Lubrication and Maintenance Manual, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

–

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

–

In any work concerning the operation, conversion or adjustment of the excavator and its safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the Operation,- Lubrication and Maintenance Manual and the information on maintenance work.

–

Ensure that the maintenance area is adequately secured.

–

If the excavator is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: – locking the principal control elements and removing the ignition key and/or – attaching a warning tag to the main switch or control levers. – setting the maintenance safety switch to the 0 position and securing it with a padlock

–

Carry out maintenance and repair work only if the excavator is positioned on stable and level ground and has been secured against inadvertent movement and buckling.

–

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

–

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

–

For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Never use excavator parts as a climbing aid. Wear a safety harness when carrying out maintenance work at greater heights. Keep all handles, steps, handrails, platforms, landings, stairways and ladders free from dirt, snow and ice.

–

Always tighten any screwed connections that have been loosened during maintenance and repair.

–

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work.

–

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

–

Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 2-23.

–

Park the excavator at a safe place on level ground. Proceed according to the instructions ”Parking the excavator”. Lower the attachment flat onto the ground. Move all control levers to neutral position.

–

Stop the motors and move all control levers through their shift positions to relieve the pressure in the hydraulic system. Refer to ”Stopping the motors” for detailed description of the stopping procedure. Also see the chapter ’Relieving The Pressure In The Hydraulic System’ in the ’Operation’ part of this manual.

–

Before any maintenance work is started, set the maintenance safety switch to 0 position. Find to the location of the maintenance safety switch refer to section 2.5.1.3 on page 2-51. In the 0 position the motors can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten padlocks can be attached to the holes provided.

–

A warning plate ”Caution excavator Maintenance” must be fixed in the Operator’s cab before any lubrication or maintenance work is started.

–

Block the excavator to prevent excavator movement

General Safety Version 22

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PRECAUTION FOR MAINTENANCE

SAFETY

–

Always use safety devices to block hydraulic cylinders. Never rely on the excavator hydraulic system to hold when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidentally strike the control levers causing the loader to fall.

–

Oily cloth and flammable material must be removed from the excavator Clean the excavator before starting maintenance work.

–

Switch-off battery main switch and remove key, before working on the electrical system.

–

Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this necessary. Observe the local safety rules.

–

Never allow unauthorized persons access to the excavator during lubrication and maintenance work.

–

Clean the excavator with a steam jet, especially after servicing the hydraulic system and fuel system.

WARNING BEWARE OF STEAM! Hot steam can cause serious personal injury. When using a steam cleaner, wear safety glasses and protective clothing.

–

For cleaning the excavator and its components use only fresh water with a salt content of less than 0.05%.

–

DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid valves, sensors, cable connections and bearings.

–

Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the excavator.

2.5.1.1

SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES

–

Any work on and with the excavator must be executed by reliable personnel only. Statutory minimum age limits must be observed.

–

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

–

All personnel must be aware of the appropriate safety measures when working on or around the excavator.

–

Make sure that only authorized personnel works on or with the excavator.

–

Define the excavator operator’s responsibilities - also with regard to observing traffic regulations - giving the operator the authority to refuse instruction by third parties that are contrary to safety.

–

Do not allow persons to be trained or instructed or persons taking part in a general training course on or with the excavator without being permanently supervised by an experienced person.

–

Work on the electrical system and equipment of the excavator must be carried out only by skilled electricians or by persons instructed under the supervision and guidance of a skilled electrician and in accordance with electrical rules and regulations.

–

Work on the chassis, brake and steering systems must be performed only by skilled personnel who have been specifically trained for such work.

–

Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

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General Safety Version 22

SAFETY

2.5.1.2

PRECAUTION FOR MAINTENANCE

STOP MOTOR FOR MAINTENANCE

Refer to Fig. 2-40: –

Stop the excavator on firm, level ground.

–

Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low.

–

Lower the work equipment completely to the ground and stop the motor.

Fig. 2-40 –

Turn the main key switch to the ON position. Operate the work equipment control lever back and forth, left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit, and then push up lock lever (Fig. 2-41, Pos 1) to the LOCK position (L).

–

Check that the battery main switch is off and main power is not conducted. (Wait for approx. one minute after activating the motor STOP switch and press the horn switch. If the horn does not sound, it is not activated.)

Fig. 2-41

2.5.1.3

WARNING TAG

–

Always attach the “DO NOT OPERATE“ warning tag (Fig. 2-42) to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the excavator. Attach additional warning tags around the excavator if necessary.

–

Keep this warning tag in the tool box while it is not used. If there is not the tool box, keep the tag in the operation manual pocket.

–

If any other person starts the motor, or touches or operates the control levers or control pedals while you are performing service or maintenance, you may suffer serious injury. Fig. 2-42

2.5.1.4

MAINTENANCE SAFETY SWITCH

–

Before entering the machinery house, switch off maintenance safety switch (Fig. 2-43). The maintenance safety switch is in different positions in the machine house, depending on the type of excavator. (Fig. 2-43).

–

The maintenance safety switch is usually located in the machinery house, next to the entrance door

Before beginning maintenance operations, set the safety switch to "0" to prevent a starting of the motors. Secure this position by inserting a padlock into the holes of the safety switch. Up to ten padlocks can be attached.

General Safety Version 22

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PRECAUTION FOR MAINTENANCE

SAFETY

Fig. 2-43

2.5.1.5

KEEP WORKPLACE CLEAN AND TIDY

CAUTION HAZARD OF ACCIDENTS! If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure yourself. Keep clean.

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General Safety Version 22

SAFETY

PRECAUTION FOR MAINTENANCE

Observe the following points. –

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out operations safely.

–

Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying

–

Never block walkways, doors, stairways, ladders or emergency escape routes with foreign objects.

2.5.1.6

APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the excavator or when removing and installing the work equipment, appoint a leader and follow his instructions during the operation.

2.5.1.7 –

TWO WORKERS FOR MAINTENANCE WHEN THE EXCAVATOR IS RUNNING

To prevent injury, do not perform maintenance or adjustments while the motor runs. If work must be carried out with the motor running, carry out the operation with at least two workers and do as follows: – One worker must always sit in the operator's seat and be ready to stop the motor at any time. All workers must maintain contact with each other and be fully aware of all relevant safety measures.

–

For safety information when working with high pressure oil in the hydraulic system, refer to section 2.6 on page 2-62.

–

When carrying out operations near rotating parts, there is a hazard of being caught in the parts, so be careful not to come close (Fig. 2-44).

–

Fig. 2-44

Do not touch any control levers or pedals. If they must be operated, always give a signal to other workers to warn them to move to a safe place.

2.5.1.8

INSTALLING, REMOVING OR STORING ATTACHMENTS

–

Appoint a leader before starting removal or installation operations for attachments.

–

Place attachments that have been removed from the excavator in a stable condition so that they do not fall (Fig. 2-45). And take steps to prevent unauthorized persons from entering the storage area.

Fig. 2-45

General Safety Version 22

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PRECAUTION FOR MAINTENANCE

2.5.1.9

SAFETY

PRECAUTIONS WHEN WORKING UNDER THE EXCAVATOR OR EQUIPMENT

–

If it is necessary to go under the work equipment or the excavator to carry out service and maintenance (Fig. 2-46), support the work equipment and excavator securely with blocks and stands strong enough to support the weight of the work equipment and excavator.

–

It is extremely dangerous to work under the excavator if the track shoes are lifted off the ground and the excavator is supported only with the work equipment. If any of the control levers are touched by accident, or there is damage to the hydraulic piping, the work equipment or the excavator will suddenly drop. This is extremely dangerous. Never work under the work equipment or the excavator. Fig. 2-46

2.5.1.10

NOISE

When carrying out maintenance of the motor and you are exposed to noise for long periods of time, wear ear covers or ear plugs while working. If the noise from the excavator is too loud, it may cause temporary or permanent hearing problems.

2.5.1.11

WHEN USING A HAMMER

When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. –

If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, there is a hazard that pieces might be scattered and cause injury. Always wear safety glasses and gloves (Fig. 2-47).

–

When hitting pins or bucket teeth, there is a hazard that broken pieces might be sent flying and injure people in the surrounding area. Always check that there is no one in the surrounding area.

–

There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.

Fig. 2-47

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General Safety Version 22

SAFETY

2.5.1.12

PRECAUTION FOR MAINTENANCE

PROPER TOOLS

Refer to Fig. 2-48: –

Use only tools suited to the task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury.

Fig. 2-48

2.5.1.13

ACCUMULATOR

Refer to Fig. 2-49: The accumulator is charged with high-pressure nitrogen gas. When handling the accumulator, careless procedure may cause an explosion which could lead to serious injury or property damage. For this reason, always observe the following precautions. –

Do not disassemble the accumulator.

–

Do not bring it near flame or dispose of it in fire.

–

Do not make holes in it, weld it, or use a cutting torch.

–

Do not hit or roll the accumulator, or subject it to any impact.

–

When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed.

2.5.1.14

Fig. 2-49

PERSONNEL

Only authorized personnel can service and repair the excavator. Do not allow unauthorized personnel into the area. If necessary, employ an observer.

General Safety Version 22

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PRECAUTION FOR MAINTENANCE

SAFETY

2.5.2

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2.5.2.1

PRECAUTION WHEN WELDING

WARNING EXPOLSION AND FIRE! Welding, flame-cutting and grinding work on the excavator increases the risk of explosion and fire which may result in serious injury or death. All relevant safety measures must be followed and only under expressly obtained authorization.

WARNING RESIDUAL ENERGY RELEASED! Serious injuries can occur when uncontrolled energy is released during welding or any cutting work. All relevant safety measures must be followed to prevent the uncontrolled release of energy.

Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out cutting work or welding, so never allow any unqualified personnel to carry out welding. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.

2.5.2.2

BATTERY HANDLING

WARNING EXPLOSION AND FIRE! Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Wrong handling can lead to serious injury or fire. For this reason, always observe the following precautions.

–

Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line.

–

When working with batteries, always wear safety glasses and rubber gloves.

–

Never smoke or use any flame near the battery (Fig. 2-50).

Fig. 2-50

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General Safety Version 22

SAFETY

PRECAUTION FOR MAINTENANCE

–

If you spill acid on your clothes or skin, immediately flush the area with large amount of water.

–

If acid gets into your eyes (Fig. 2-51), flush them immediately with large amount of water and seek medical attention.

–

Before working with batteries, activate the STOP switch and remove battery main switch key.

Fig. 2-51 As there is a hazard that sparks will be generated, always do as follows. –

Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other metal objects lying around near the battery.

–

When disconnecting the battery terminals, wait for approx. one minute after activating the motor STOP switch and be sure to disconnect the grounding terminal (negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then the grounding (-) terminal. Make sure that all the terminals are connected securely.

–

Attach the battery terminal securely.

–

Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take it to a well-ventilated place, and remove the battery caps before charging it.

–

Tighten the battery caps securely.

–

Install the battery securely to the determined place.

2.5.3

PRECAUTIONS WITH HIGH PRESSURE FLUID

WARNING FLUID UNDER HIGH PRESSURE! The hydraulic system is always under internal pressure and can lead to serious injury when leaking. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released.

General Safety Version 22

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PRECAUTION FOR MAINTENANCE

2.5.3.1

SAFETY

PRECAUTIONS WITH HIGH FUEL PRESSURE

–

For details of the method of releasing the pressure, see the latest version of the Operation and Maintenance Manual. If the circuit is still under pressure, do not carry out any inspection or replacement operation.

–

If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses.

–

When carrying out inspections, wear full-face protection and penetration resistant clothing and gloves (leather).

–

There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly (Fig. 2-52). If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.

Fig. 2-52

High pressure is generated inside the motor fuel piping when the motor is running. When carrying out inspection or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the motor to let the internal pressure go down before starting inspection or maintenance.

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General Safety Version 22

SAFETY

2.5.3.2 –

PRECAUTION FOR MAINTENANCE

HANDLING HIGH PRESSURES HOSES OR PIPES

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious injury or death. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor.

Replace the hose if any of the following problems are found. –

Damaged or leaking hydraulic fitting.

–

Frayed or cut covering or exposed reinforcement wire layer.

–

Covering swollen in places.

–

Twisted or crushed movable portion.

–

Foreign material embedded in covering.

2.5.3.3

REPLACEMENT OF HOSE LINES

Hydraulic hoses are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years.

NOTICE HYDRAULIC HOSE STORAGE! The hydraulic hose lifetime can become porous. The maximum permissible storage time of hydraulic hoses must be observed.

–

This storage period is part of the usable lifetime and must be considered when installing a new hose line. If, for example, a hose line with a one year storage time is to be installed, the remaining service life of the hose line must be considered. All hose lines are marked with the date of production.

–

Hose lines considered as Safety Critical Parts have to be replaced earlier. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for further information.

All hydraulic hoses of the excavator have to be replaced when their service life has expired, even if there is no visible damage. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for further information.

NOTICE GENUINE PARTS! Genuine parts are guaranteed. Repairs on hydraulic hoses are not allowed. Use ONLY GENUINE Komatsu Germany replacement hose lines.

2.5.3.4

INSPECTION OF HOSE LINES

Inspect all hoses, hose lines and fittings carefully during the course of the daily walk-around inspection. Check for leaks and damages. Beware of pinhole leakages. Replace damaged parts without delay. General Safety Version 22

2 - 59

PRECAUTION FOR MAINTENANCE

SAFETY

Some examples of faults on hydraulic hoses requiring replacement of the concerned part: –

Damage to the outer layer (e.g. chafed spots, cuts or scratches).

–

Brittle top layers. Flaws on the hose material

–

Distortion of the hose line (strong deviation from the original shape) under pressurized and pressureless conditions or when kinked or crushed, e.g. disintegration of hose layers or blistering.

–

Leaks.

–

Detachment of hose and fitting. Damaged hose fitting.

2.5.3.5

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating the excavator, the user of the excavator must always carry out periodic maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts given in the table. These parts are particularly closely connected to safety and fire prevention. With these parts, the material changes as time passes, or they easily wear or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function completely. However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately. If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. –

Ask your Komatsu distributor to replace safety critical parts.

2.5.3.6

PRECAUTIONS FOR HIGH VOLTAGE

DANGER HIGH VOLTAGE! High voltage appliances cause serious injury or death. Authorized staff only.

–

When the motor is running and immediately after it is stopped, high voltage is generated inside the motor controller and the motor injector.

–

The headlights also operates using high voltage. Never perform maintenance on the headlights.

–

If it is necessary to touch the inside of the controller or the motor injector portion, or the headlight electrics please contact your Komatsu distributor.

–

The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff only.

2.5.3.7

AIR CONDITIONING MAINTENANCE

WARNING AIR CONDITIONING REFRIGERANT IS HARMFUL! If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite. Never touch refrigerant.

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SAFETY

2.5.3.8

PRECAUTION FOR MAINTENANCE

COMPRESSED AIR

WARNING COMPRESSED AIR IS HAZARDOUS! When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. Wear protective clothing.

–

When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment.

–

Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.

2.5.3.9

WASTE MATERIALS

Operation –

Avoid motor idling over long periods. Long periods of idling (more than 10 minutes), will not only waste fuel, but is also harmful to the motor.

–

Avoid operation against the main relief valves of the hydraulic system. Move control lever to neutral position before the loader attachment stalls due to overload.

–

Position trucks in such a way, that loading operation can be carried out in a safe and economic manner. Avoid swing angles over 90°.

Maintenance

Fig. 2-53

–

Preserve our environment. To prevent environmental pollution, pay careful attention to the method of disposing waste materials.

–

Always drain fluids from your excavator into containers. Never drain fluids onto the ground or dump it into the sewage system, rivers, the sea or lakes. (Fig. 2-53).

–

Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in accordance with local environmental regulations and laws.

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ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS

SAFETY

2.6

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS

2.6.1

INSPECTION OF THE HYDRAULIC SYSTEM

A hands-on approach to inspecting the hoses and pipes of the hydraulic system can only be made when the excavator is shut down and there is no oil pressure in the hydraulic system. –

Do not use your hands during inspection or move in the vicinity of the hydraulic system’s piping or tubing when the motor is running before checking for leaks, as hydraulic fluid escaping under pressure can cause serious injuries.

–

Additional to the general personal protective clothing as described on page 2-28, full face protection and penetration resistant clothing and gloves must be worn.

–

Troubleshooting and adjustments may only be performed by personnel trained by Komatsu Germany in safe and correct hydraulic handling procedures.

–

Before troubleshooting or adjustments, the inspection of areas of potential dangers for damages, leaks or loose connections on the pressure lines and hydraulic components must be carried out visually only when the motor is shutdown and when there is no hydraulic pressure in the system.

–

When the excavator is running, the areas of potential danger can only be entered when no leakages or other irregularities have been noticed when the high pressure oil circulation has been brought up to maximum pressure from a safe distance (operator’s cab, machinery house roof, stairway platform).

2.6.2

TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS

To prevent injury, do not carry out adjustments with the motor running. If work must be carried out with the motor running, perform the task with, at maximum, two maintenance workers and an operator and do as follows. –

An operator that has been trained on the excavator he is operating, must always sit in the operator's seat and be ready to stop the motor at any time. All workers must maintain contact with the other workers and be fully aware of all relevant safety measures.

–

When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in the parts, so be careful not to come close (Fig. 2-54).

–

Do not touch any control levers or control pedals. If any control levers or control pedals must be operated, always give a signal to the other workers to warn them to move to a safe place. Fig. 2-54

2.6.3

AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR

General safety rules for working on the excavator –

Only trained personnel who are aware of all dangers are allowed to work on the hydraulic system

–

Visually inspect all potential danger areas for leakages before pressure build up.

–

Do not remain on or around the excavator for longer than is absolutely necessary in order to perform your tasks.

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General Safety Version 22

SAFETY

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS

Please continue reading on the next page.

General Safety Version 22

2 - 63

SPECIAL SAFETY EQUIPMENT

2.7

SAFETY

SPECIAL SAFETY EQUIPMENT

Fig. 2-55

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General Safety Version 22

SAFETY

2.7.1

SPECIAL SAFETY EQUIPMENT

FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB

The excavator must be equipped with a front guard protective structure "OPG Front Guard” if it is used for applications where there is a risk of hitting objects from the front.

2.7.2

OBJECT HANDLING

Object handling operations are not allowed.

2.7.3

LIGHTING

The excavator must only be operated when the operator has sufficient visibility in relation to the work area. Disturbing shady areas or dazzling effects must be avoided. If necessary, the excavator must be retrofitted with additional lighting equipment (working lights) in order to ensure sufficient visibility conditions.

2.7.4

WARNING BEACON

The excavator can be retrofitted with a warning beacon which is fitted on the cab roof by means of a magnetic bracket. REMARKS: The above-mentioned special safety devices can be ordered as accessories together with the excavator. They are also available as a field package for installation through our service organization.

2.7.5

SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

The safety harness should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. See the following pages for further information.

2.7.5.1

SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

WARNING RISK OF FALLING! Falling from the boom can cause serious injury or death. Always use a Safety Harness (1) in conjunction with a strap type Fall Absorber (2 - Fig. 2-55) before boarding the loader attachment or other unsecured areas on the excavator.

–

The Safety Harness is located in the cabinet in the operator’s cab.

–

The illustration (Fig. 2-55) shows the standard use of the safety harness with a strap type fall absorber.

Legend for Fig. 2-55: (1)

Safety Harness according to EN 361

(2)

Strap-Type Fall Absorber according to DIN EN 355

General Safety Version 22

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SPECIAL SAFETY EQUIPMENT

(3)

SAFETY

Swivel type ring bolt. Attachment point for strap-type fall absorber of the safety harness.

NOTICE HARNESS! Working in high places requires personal protection. DO NOT attach any other object to the ring bolts (3). Use only for attaching the strap-type fall absorber in connection with safety harness. (4)

Walkway on the boom

(A)

Shoulder Strap

(B)

Back Plate

(C)

Catching Hook

(D)

Shoulder-Strap Fixing

(E)

Belly Strap

(F)

Holding Hook

(G)

Hold-Back Hook

(H)

Pelvis Strap

(J)

Leg Strap

Only for the PC7000 The safety harness should be used when maintaining areas in the vicinity of the front of the car body on the PC7000 as shown on Fig. 2-56. The harness is to be attached to the handrails (1).

Fig. 2-56

2.7.5.2

INSTRUCTIONS FOR USE

Open the lock, lift the harness by the catch hook (C), ensuring the leg straps hang below (J). Pull the harness over the shoulders as you would a jacket. Insert the end of the belly strap (E) through the buckle and tighten securely, as shown in the illustration (Fig. 2-55). Prevent the shoulder straps from slipping by fastening the breast strap. Pull the leg straps (J) between the legs and securely buckle them at the front as illustrated. Adjust the harness so that it snugly fits the body ensuring that the catching hook (C) is in the center of the back. The safety harness is a personal accessory and should only belong to its owner. The safety harness should only be used together with connectors acc. to EN 354, and fall arrest acc. to EN 355, or fall protection devices acc. to EN 360.

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General Safety Version 22

SAFETY

SPECIAL SAFETY EQUIPMENT

The special attachment points for the safety harness should be used only, and the carrying capacity of the attachment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795. PRIOR TO USING THE HARNESS (1), THE WEARER SHALL –

Carry out a visual check of the system or component; correct functioning and perfect working order have to be assured.

–

Make sure that the recommendations for use with other components of the system be observed in conformity with the instructions for use.

The system or component must no longer be used, if there are any doubts in respect of its safe condition. The equipment has to be inspected by the manufacturer or by a qualified person. It is essential for safety reasons that a fall protection system or system component which has already been subjected to fall be removed from service and sent back to the manufacturer or an authorized qualified repair shop for maintenance and renewed testing. Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharpedged objects. Should the harness have become wet during use or cleaning, do not dry near a fire or other sources of heat, but rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up. When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest Systems" have to be observed for protection against danger. The safety harness and its components have to be inspected at least every 12 months by a competent person authorized by the manufacturer and maintained, if the manufacturer considers it necessary.

2.7.5.3

RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLDBACK HOOKS OF THE SAFETY HARNESS

The holding hooks should only be attached to the special attachment points (3) on the boom. Free-fall must be limited to 0.5m. With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs). The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be reached.

2.7.5.4

INSTRUCTIONS FOR USE

Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD) Use Within a fall-arrest system, the strap-type fall absorber (2) has to be used in conjunction with a safety harness (1) acc. to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a rope-shortening device has to be applied in addition. Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the safety harness. The special attachment points (3) should be used for this purpose attachment and the minimum carrying capacity of the strap-type fall absorber should be 10 KN, acc. to DIN EN 795. Only move when the fall absorber is attached to the attachment point. Disengage and only continue moving when the fall absorber is attached to the next point. The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor get them burnt by welding sparks.

General Safety Version 22

2 - 67

SPECIAL SAFETY EQUIPMENT

SAFETY

Storing and maintenance The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be ex-posed to acids, caustic chemicals, nor to an aggressive atmosphere, and contact with oils has to be avoided. If the strap-type fall absorber is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or other sources of heat). Protect it from sharp-edged objects. Inspection Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed from service immediately. The strap-type fall absorber must not be changed in any way.

2 - 68

General Safety Version 22

SAFETY WARNING SIGNS

2.8

SAFETY WARNING SIGNS

The warning signs and safety labels described in this section are used on this excavator. –

Be sure you fully understand the correct position and content of these safety labels.

–

To ensure that the labels and signs can be read properly, be sure that they are situated in the correct location and that they are clean. When cleaning them, use soap and water. Do not use organic solvents or gasoline. These may damage the labels and cause them to peel off.

–

There are also other labels in addition to the safety labels. Handle these labels in the same way.

NOTICE If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with your Komatsu distributor.

Safety Warning Signs Version 11

2 - 69

SAFETY WARNING SIGNS

2.8.1

LOCATION AND DESCRIPTION OF THE SIGNS

Fig. 2-57

2 - 70

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

SIGN PLATE IN THE OPERATOR’S CAB Fig. 2-57 1. Information on fire safety. Part number 518 661 98 For fire prevention procedures, actions in the event of fire and fire fighting procedures, refer to the operating manual. See "FIRE PREVENTION" on page 2-17 and the chapter "Fire Prevention" in the "Operation" section of the Operation and Maintenance Manual. 2. Risk of causing explosion. Part number 0984500480 There is a risk of explosion caused by active radio transmission at a blast zone. Locate the excavator a safe distance away from the blast zone or detonator.

WARNING RISK OF EXPLOSION! Transmitting two-way radio signals in a blast zone can result in an explosion that could result in serious injury or death. If the excavator is equipped with Komtrax Plus (with optional modem) two-way radio communication device, keep clear of the blast site. If the excavator must work within 12m (40 ft) of a blast zone, or an active blasting excavator, the wiring harness must be disconnected from the Komtrax Plus module.

3. Information on hydraulic oil. Part number 518 662 98 Refer to Operation and Maintenance Manual for further information on hydraulic oil. 4. Information for lubrication intervals Part number 518 676 98 Refer to Operation and Maintenance Manual for further information on points and areas of lubrication. 5. Keep clear of high voltage cables Part number 09801A0481 Do not travel or operate the excavator near electric cables. See "DO NOT GO CLOSE TO HIGH VOLTAGE CABLES" on page 2-22. 6. Ensure the excavator is locked down. Part number 09654A0481 Before leaving the operator’s seat, ensure the bucket is lowered, the key is removed and the lock lever is set. See "LEAVING OPERATOR’S SEAT WITH LOCK" and "LEAVING THE MACHINE" on page 2-21. 7. Read the Operation and Maintenance Manual. Part number 09691A0481 Read, understand and follow all precautions and warnings in this manual and on the excavator before operating and performing maintenance. 8. Sound the travel alarm when reversing. Part number 098021A0480 Before reversing the excavator, sound the signal horn. Refer to "PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE" on page 2-31 for further information. 9. Backwards caution (for vehicles with a rear view camera) Part number 09833AO881 Always be aware of the surrounding area and check all rear views. Do not rely too heavily on the rear view camera only.

Safety Warning Signs Version 11

2 - 71

SAFETY WARNING SIGNS

2.8.2

LOCATION AND DESCRIPTION OF THE SIGNS FOR PC3400

9 2 4

1 min

EURO

13 PC3400

Fig. 2-58

2 - 72

Safety Warning Signs Version 11

Z 32386-1

SAFETY WARNING SIGNS

3. Information on hydraulic oil. Part number 518 662 98 Refer to Operation and Maintenance Manual for further information on hydraulic oil. 4. Information for lubrication intervals Part number 518 676 98 Refer to Operation and Maintenance Manual for further information on points and areas of lubrication. 5. Keep clear of high voltage cables Part number 09801A0481 Do not travel or operate the excavator near electric cables. See "DO NOT GO CLOSE TO HIGH VOLTAGE CABLES" on page 2-22. 6. Ensure the excavator is locked down. Part number 09654A0481 Before leaving the operator’s seat, ensure the bucket is lowered, the key is removed and the lock lever is set. See "LEAVING OPERATOR’S SEAT WITH LOCK" and "LEAVING THE MACHINE" on page 2-21. 7. Read the Operation and Maintenance Manual. Part number 09651A0481 Read, understand and follow all precautions and warnings in this manual and on the excavator before operating and performing maintenance. 8. Sound the travel alarm when reversing. Part number 098021A0480 Before reversing the excavator, sound the signal horn. Refer to "PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE" on page 2-31 for further information. 9. Backwards caution (for vehicles with a rear view camera) Part number 09833A0881 Always be aware of the surrounding area and check all rear views. Do not rely too heavily on the rear view camera only.

Safety Warning Signs Version 11

2 - 73

SAFETY WARNING SIGNS

10. Seat belts Part number 09848A0480 Always use seat belt when operating the excavator to reduce risk of injury or death in case of roll-over. 11. Track Adjustment Part number 09657A0881 refer to operation and maintenance manual for track adjustments 12. Lock lever (PPC lock) Part number 21T0038450 It is impossible to slew, travel or operate the working equipment with lock lever (PPC lock) activated 13. Control Pattern Part number 2020021150 shows the operation pattern of the controls used on the excavator.

1. Emergency escape route from operator’s cab. Fig. 2-59 Part number 517 435 98 or 0984400050 for the PC3400 For information on escaping the operator’s cab in the event of an emergency, refer to the chapter "Emergency Escape Ladder" in the "Operation" section of the Operation and Maintenance Manual.

REMARKS: This label is placed on the right side window of the operator’s cab on the PC8000. The lower of the two signs is for the position for the PC3400 only.

Break the glass using the emergency escape hammer. 2. Activating the fire suppression system (if equipped). Part number 518 850 98 (35mm x 70mm), 518 668 98 (50mm x 100mm) In the event of fire, activate the fire suppression system by striking the actuator. Refer to the chapter "Fire detection and Suppression System" in the "Operation" section of the Operation and Maintenance Manual. Z 28651b

Fig. 2-59

2 - 74

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

No entry to the machinery house while the motor is running Fig. 2-60. Part number 518 659 98 Hot surfaces and rotating parts will cause injury.

Fig. 2-60 Always wear a safety harness Fig. 2-61 Part number 518 510 98 Before accessing the boom, ensure that a safety harness is worn at all times. Refer to "SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)" on page 2-48.

Fig. 2-61

Safety Warning Signs Version 11

2 - 75

SAFETY WARNING SIGNS

Beware of toxic gases. (Electrically driven excavators only) Fig. 2-62 Part number 518 690 98 Do not enter the cab base or the high voltage area after the fire suppression system has been activated as the inhaling of noxious gases from the suppression system is extremely harmful. REMARKS: This sign exists three times for the PC3000E and is also to find on the column between the double door entrance.

Fig. 2-62

1. Starter terminals are live Fig. 2-63 Part number 09842A0362 Never attempt to start the motor by shorting the starter terminals. For more information, see "PRECAUTIONS AT JOBSITE" on page 2-20 and the chapter "Starting the motors" in the "Operation" section of the Operation and Maintenance Manual.

PC 3400 2x 2

Avoid inadvertent contact with the starters. 1

2. Hot surfaces Part number 09817A01103 Positioned on each side of the engine manifold

Z 28655b

Fig. 2-63 2 - 76

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

1. Hot surfaces Fig. 2-64 Part number 0981701103 Positioned on each side of the housings of the exhaust system 6X 2. Hot spurting liquid Part number 09653A0481 Positioned on the protection cover to the cap of the radiator.

Fig. 2-64

Hot spurting liquid 1

Part number 09653A0481 1. Positioned near supply port for hydraulic tank 2. Positioned on oil cooler

3. Positioned on revolving frame REMARKS: On PC3400 only. Fig. 2-65 3

Z 32388

Fig. 2-65 Safety Warning Signs Version 11

2 - 77

SAFETY WARNING SIGNS

1. Hot surfaces Fig. 2-66 Part number 0981701103 Positioned on switch box in cab base on inside of door REMARKS: On PC3400 only

Z 32389

Fig. 2-66

Emergency escape route from machinery house Fig. 2-67 Part number 518 669 98 (left upwards) Part number 519 760 98 (to the right) For further information, refer to the chapter “Emergency Escape Ladders" in the "Operation" section of the Operation and Maintenance Manual.

Fig. 2-67

2 - 78

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

Emergency escape route from right side walkway Fig. 2-68 Part number 519 756 98 (Instructions for operating the emergency escape ladder) 1. Turn pin handle CW (clockwise) 2. Remove pin handle 3. Kick against bar to disengauge lever mechanism 4. Kick against bar to assist in lowering the ladder 5. Kick against angled section to push ladder downwards 6. Turn pin on latch on hand railing gateway CCW (counterclockwise) 7. Remove pin 8. Raise hand raining gateway Part number 520-135-98 (emergency escape ladder to the left) For further information, refer to the chapter “Emergency Escape Ladders in the “Operation” section of the Operation and Maintenance Manual.

Fig. 2-68

Safety Warning Signs Version 11

2 - 79

SAFETY WARNING SIGNS

Emergency escape route from machinery house roof or pedestal on oil cooler of the PC8000 Fig. 2-69 Part number 520 193 98 (upper sign) or 520 194 98 (lower sign) (Instructions for operating the emergency escape ladder) For upper release on roof 1. Locate the pin on the escape latch and pull it downwards. This unlocks the latching system. 2. Release the latching system by pushing firmly with your foot on the bar 3. Push the ladder away from the roof by pushing firmly with your foot against the angled plate . The ladder will fall under it’s own weight. 4. The gate on the handrail must be released to gain access to the stairway. 5. Grasp the handrail on the ladder and descend backwards. For lower release on pedestal 1. In emergency situations when escaping from the pump area of the machinery house, exit the door.

Fig. 2-69

2. Stand facing the wall on the platform. Suspended on the wall is the mechanism for releasing the emergency escape ladder 3. Pull the lever downwards to release the mechanism. 4. Only then is it possible to extract the hook mechanism. 5. Reach up with the hook mechanism in order to attach it to the bar on the release latch. 6. Pull down with the hook.

2 - 80

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

Emergency escape route from machinery house roof or operator’s cab to front ladder Fig. 2-70 Part number 519 756 98 (Instructions for operating the emergency escape ladder) 1. Turn pin handle CW (clockwise) 2. Remove pin handle 3. Kick against bar to disengauge lever mechanism 4. Kick against bar to assist in lowering the ladder 5. Kick against angled section to push ladder downwards 6. Turn pin on latch on hand railing gateway CCW (counterclockwise) 7. Remove pin 8. Raise hand railing gateway

Fig. 2-70

Emergency escape route from machinery house roof or operator’s cab to front ladder, PC3400 Fig. 2-67 Part number 2A2 00 21390 (Instructions for operating the emergency escape ladder) 1. Open the escape hatch 2. Release the rope ladder from fixed hooks 3. Pull up the handle Part number 520 135 98 (emergency escape ladder to the left)

Z 32426a Fig. 2-71

Safety Warning Signs Version 11

2 - 81

SAFETY WARNING SIGNS

Maximum permissible persons/weight Fig. 2-72 Part number 519 757 98 When the stairway is down, it may not be resting on the ground and may be suspended above an uneven surface. Only two people or maximum 200kg (440 lbs) are allowed on the stairway at one time.

Fig. 2-72

Emergency release of stairway/ladder when emergency stop chain or rope is activated Fig. 2-73 Part number 519 665 98

PC3000 PC5500 PC7000

PC8000

Shows the position of the chain or rope to activate a release causing the stairway to lower

PC3400

PC4000

Z 32429

Fig. 2-73

2 - 82

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

Keep clear of stairway Fig. 2-74 Part number 518 833 98 Always keep clear of the moving range of the stairway when it is being elevated or lowered.

Fig. 2-74

Keep clear of stairwayPC3400 Fig. 2-74 Part number 518 833 98 Always keep clear of the moving range of the stairway when it is being elevated or lowered.

Z 32427

Fig. 2-75

Safety Warning Signs Version 11

2 - 83

SAFETY WARNING SIGNS

1. Rotating parts Fig. 2-76 Part number 09667A0481 Ensure the belt drives of the alternator and the air-conditioning compressor are at standstill before working on them. 2. Rotating fans Part number 518 657 98 Do not work on the fans while they are rotating. 3. Rotating fans Part number 518 967 98 Do not work on the fans while they are rotating.

Fig. 2-76

1. Rotating parts, PC3400 Fig. 2-76 Part number 09667A0481 Ensure the belt drives of the alternator and the air-conditioning compressor are at standstill before working on them. 2. Rotating fans, PC3400 Part number 518 967 98 Do not work on the fans while they are rotating.

Z 32428a

Fig. 2-77

2 - 84

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

Please continue reading on the next page.

Safety Warning Signs Version 11

2 - 85

SAFETY WARNING SIGNS

Fig. 2-78

2 - 86

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

High Voltage appliances on the excavator. Fig. 2-78 Part number 517 425 98 On electrically driven excavators 1. On the door to the high voltage cabinet. 2. On the junction box of the cable drum unit 3. On the cable drum unit. 4. On the terminal box of the electric motor 5. On the capacitor’s cover 6. On the slip ring unit On all excavators 7. On the door to the cab base REMARKS: Refer to "PRECAUTIONS FOR HIGH VOLTAGE" on page 2-48.

Safety Warning Signs Version 11

2 - 87

SAFETY WARNING SIGNS

1. No naked flame Fig. 2-79 Part number 518 509 98 No fire, open flames or smoking on the excavator 2. Hazard strip Part number 518 677 98 Positioned on the bottom of the stairway and areas were there is a risk of hitting the head in low areas for example low hanging pipes in the machinery house etc.

Fig. 2-79 1. Keep clear of service arm Fig. 2-80 Part number 242 00 21460 Keep clear of the moving range of the service arm. 2. Traveling reflector strip Part number 518 907 98 (PCs 3000, 4000, 5500, 7000, 8000) and part number 2A20021470 (PC3400) This red reflecting strip is to ensure better visibility of the excavator in low ambient light.

Fig. 2-80

2 - 88

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

Ensure a safe distance from working area Fig. 2-81 Part number 09134A3281 Position on the stick of the attachment to warn of keeping clear of the moving range of the working equipment.

Fig. 2-81

Care when handling batteries Fig. 2-82 Part number 518 658 98 Care is to be taken when handling the batteries or the battery cables. Refer to "BATTERY HANDLING" on page 2-40. This sign is located under the access grip to the battery compartment under the walkway.

Fig. 2-82 Safety Warning Signs Version 11

2 - 89

SAFETY WARNING SIGNS

Z 32430

Fig. 2-83

2 - 90

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

1. Care when handling batteries, PC3400 Fig. 2-83 Part number 518 658 98 Care is to be taken when handling the batteries or the battery cables. Refer to "BATTERY HANDLING" on page 2-40. This sign is located on the battery box 2. Care when handling cables, PC3400 Fig. 2-83 Part number 09808A0881 Care is to be taken when handling the battery cables. Refer to "BATTERY HANDLING" on page 2-40. This sign is located under the access lid of the battery compartment and in the electronic box under the access steps 3. Care when handling battery, PC3400 Fig. 2-83 Part number 0966470011 Care is to be taken when handling the battery cables. Refer to "BATTERY HANDLING" on page 2-40. This sign is located on the battery

Safety Warning Signs Version 11

2 - 91

SAFETY WARNING SIGNS

Fig. 2-84 2 - 92

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

Risk of explosion. PCs 3000, 4000. 5500. 7000, 8000 Fig. 2-84 Part number 09659A0641 Handling the accumulators. Refer to "ACCUMULATOR" on page 2-43 1. Accumulators on the control and filter plates 2. Accumulator on the track tensioning system 3. Pulsation dampers on the distributor manifold or collector pipe (PC8000)

WARNING RISK OF EXPLOSION! The accumulators are charged with nitrogen and when mishandled can explode causing serious injury or death. Never carry out welding, soldering or mechanical work on a charged accumulator vessel. Before carry out work on the hydraulic systems, de-pressurize and secure against restarting.

Safety Warning Signs Version 11

2 - 93

SAFETY WARNING SIGNS

3 6

Fig. 2-85 2 - 94

Safety Warning Signs Version 11

Z 32431

SAFETY WARNING SIGNS

Risk of explosion. PC3400 Fig. 2-85 Part number 09659A057B Handling the accumulators. 1. Decal placed on the accumulators to show risk of explosion. 2. Accumulators in the pump area 3. Accumulators on the drain tank 4. Accumulators on the track tensioning system. 5. Accumulators on the control and filter plate 6. Accumulators on the emergence ladders (right side shown) 7. Accumulators on the track system

Safety Warning Signs Version 11

2 - 95

SAFETY WARNING SIGNS

No welding before reading the manual Fig. 2-86 Part number 518 660 98 Welding should only be carried out when the safety instructions have been fully complied with. Refer to "PRECAUTION WHEN WELDING" on page 2-44 and the section "Weld Repairs" in the "Maintenance" section of the Operation and Maintenance Manual.

Fig. 2-86

Keep clear of the excavator Fig. 2-87 Part number 09133A6481, 09133A3281 Always remain clear of the excavator when it is in operation.

Fig. 2-87 2 - 96

Safety Warning Signs Version 11

SAFETY WARNING SIGNS

Risk of falling Fig. 2-88 Part number 0985000481 Sign indicates a hazard of falling. Tie off a safety belt on the anchor point when working in high places.

Z 32432

Fig. 2-88

Safety Warning Signs Version 11

2 - 97

SAFETY WARNING SIGNS

2 - 98

Safety Warning Signs Version 11

3 OPERATION

3 -1

FOREWORD

3.1

OPERATION

FOREWORD

This Operation Manual contains the instructions for correct operation of your KOMATSU Mining excavator. It should always be ready for use in the Operator's cab. REMARKS: The information in this manual does not replace any safety rules or laws used in your area. Special safety regulations are given in the rules for the prevention of accidents. It is your responsibility to observe these rules. Carefully read the Safety Instructions → See page 2-23" Before operating the excavator, familiarize yourself with its instruments and controls. Observe the instructions in this manual for: –

your Personal SAFETY

–

Operating SAFETY, and

–

READY and EFFICIENT PERFORMANCE of your KOMATSU Mining excavator.

WARNING IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS INJURY OR DEATH! Please read and make sure that you fully understand the precautions described in this section and the safety labels on the excavator. When operating or servicing the excavator, always follow these precaution strictly.

REMARKS: Optional equipment and accessories are available. Disregard the instructions for equipment not on your excavator. Some illustrations are examples and may differ from the original.

3.1.1

CONNECTION OF CUSTOMER ELECTRICAL INSTALLATIONS TO THE EXCAVATOR

WARNING FIRE HAZARD! Incorrect electrical installation can cause fire. Only qualified electricians are allowed to perform electrical installations according to the electrical diagram of the excavator.

For customer-supplied electrical installations there are provided clamping points in the cab and in the cab base. Customer electrical installations may only be connected to these clamping points by a qualified electrician. Refer to the electrical diagram of the excavator for further information.

3 -2

OMM 06372-D-EN-6T2-1.0

Version 2021/02

OPERATION

CONSTRUCTION OF THE EXCAVATOR

3.2

CONSTRUCTION OF THE EXCAVATOR

3.2.1

OVERALL VIEW

Fig. 3-1 Legend for Fig. 3-1 (1)

Undercarriage

(5A)

Bottom dump bucket

(2)

Superstructure

(6)

Boom cylinders

(3)

Boom

(7)

Stick cylinders

(4)

Stick

(8)

Bucket cylinders

(5)

Backhoe bucket

(9)

Bucket opening cylinders

Version 2021/02

OMM 06372-D-EN-6T2-1.0

3 -3

CONSTRUCTION OF THE EXCAVATOR

3.2.2

OPERATION

UNDERCARRIAGE AND SUPERSTRUCTURE

Fig. 3-2 3 -4

OMM 06372-D-EN-6T2-1.0

Version 2021/02

OPERATION

CONSTRUCTION OF THE EXCAVATOR

Legend for Fig. 3-2 (1)

Final drive, hub type travel gear

(2)

Crawler carrier

(3)

Track roller

(4)

Carrier roller

(5)

Guide wheel

(6)

Travel motors

(7)

Center frame

(8)

Slew circle guard

(9)

Hydraulically operated access ladder, see page 3-10 for more information

(10)

Light switch for access area lighting

(11)

Pull chains for emergency lowering of the access ladder, see page 3-10 for more information. REMARKS: Whenever the access ladder has been lowered with one of the emergency chains (11), the switching valve has to be reset. Refer to chapter .

(12)

Battery main switches

(13A)

Control switch for access ladder at machinery house door

(13B)

Control switch for access ladder at operator’s cab

(14)

Fuel tank

(15)

Cab base, see page 3-100 for more information

(16)

Operator’s cab

(17)

Sliding window for emergency exit from operator’s cab, see page 3-16 for more information

(18)

Emergency escape ladder, see page 3-16 for more information

(19)

Exhaust muffler

(20)

Engine air cleaners

(21)

Machinery house door, see page 3-98 for more information

(22)

Radiator grill door

(23)

Counterweight

Version 2021/02

OMM 06372-D-EN-6T2-1.0

3 -5

CONSTRUCTION OF THE EXCAVATOR

3.2.2.1

OPERATION

SUPERSTRUCTURE - TOP VIEW

Fig. 3-3 3 -6

OMM 06372-D-EN-6T2-1.0

Version 2021/02

OPERATION

CONSTRUCTION OF THE EXCAVATOR

Legend for Fig. 3-3 (1)

Hydraulically operated access ladder, see page 3-11 for more information

(2)

Stair to operator’s cab

(3)

Operator’s cab door, see page 3-22 for more information

(4)

Operator’s cab, see page 3-22 for more information

(5)

Machinery house door, main access, see page 3-98 for more information

(6)

Coolant radiator

(7)

Diesel engine

(8)

Fire wall

(9)

Flexible coupling

(10)

PTO (pump distributor gear)

(11)

Main hydraulic pumps

(12)

Engine oil reserve tank only on excavators equipped with the Engine Oil Management System.

(13)

Radiator fan guard

(14)

Battery box below the walkway gratings

(15)

Front machinery house door

(16)

Main control valves

(17)

Return oil collector pipe

(18)

Back-pressure valve

(19)

Main hydraulic oil reservoir

(20)

Hydraulic oil cooler

(21)

Slew gear

(22)

Distributor manifold

(23)

Cab base door

(24)

Slewing connection

(25)

Emergency escape ladder, see page 3-16 for more information

Version 2021/02

OMM 06372-D-EN-6T2-1.0

3 -7

CONSTRUCTION OF THE EXCAVATOR

3.2.2.2

OPERATION

MACHINERY HOUSE

Fig. 3-4 3 -8

OMM 06372-D-EN-6T2-1.0

Version 2021/02

OPERATION

CONSTRUCTION OF THE EXCAVATOR

Legend for Fig. 3-4 1

Diesel engine

Water filters

Engine oil filters

First stage fuel filter

Second stage fuel filters

Suction oil reservoir

Main hydraulic pumps (three tandem swash plate type pumps)

PTO lubrication pump

Hydraulic pump for hydraulic oil cooler fan drive

Control oil pump (pilot oil circuit)

Suction oil reservoir

Coolant radiator

Exhaust muffler

Engine air cleaner

Elastic mounts

Flexible coupling

Version 2021/02

OMM 06372-D-EN-6T2-1.0

3 -9

CONSTRUCTION OF THE EXCAVATOR

OPERATION

Fig. 3-5 3 - 10

OMM 06372-D-EN-6T2-1.0

Version 2021/02

OPERATION

3.2.3 NOTE!

CONSTRUCTION OF THE EXCAVATOR

HYDRAULICALLY OPERATED ACCESS LADDER If so equipped, use a crane to move material to or from the excavator. Refer to chapter 3.22 for further information. Always maintain three-point contact (both feet and one hand, or both hands and one foot) while using the access ladder.

Legend for Fig. 3-5 (A)

Access ladder in lowered position

(B)

Access ladder in upper position (Working position)

(1)

Access ladder

(2)

Light switch for access area lighting

(3a,b)

Pull chains for emergency lowering of the access ladder Whenever the access ladder has been lowered with one of the emergency chains (3a,b), the switching valve (C) has to be reset. Refer to chapter 3.2.3.2. REMARKS: EMERGENCY USE ONLY! During normal operation use this chain only in emergency cases, when the Operator needs to escape the excavator.

(4A)

Control switch for access ladder at machinery house door

(4B)

Control switch for access ladder at operator’s cab

(5)

Switch direction for lifting the ladder

(6)

Switch direction for lowering the ladder

(7)

Sliding window for emergency exit from operator’s cab

(8)

Emergency escape ladder

(9)

Ladder pivot bracket

(10)

Monitor and control sensor (70B0S91). Function of sensor (70B0S91): This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (70B122) fails to function properly, the sensor (70B0S91) prevents unintended movement of the ladder.

(11)

Safety sensor (70B122, 70B122a redundant), located on ladder pivot bracket. Function of sensor (70B122): Cut out of the pilot control system and actuation of the hydraulic slew brake with the ladder in lowered position.

(12)

Lock nut for ladder pivot ball bearing

Version 2021/02

OMM 06372-D-EN-6T2-1.0

3 - 11

CONSTRUCTION OF THE EXCAVATOR

OPERATION

Fig. 3-6 3 - 12

OMM 06372-D-EN-6T2-1.0

Version 2021/02

OPERATION

3.2.3.1

CONSTRUCTION OF THE EXCAVATOR

STANDARD OPERATION OF THE HYDRAULIC ACCESS LADDER

WARNING OPERATING THE ACCESS LADDER IMPROPERLY IS HAZARDOUS! Operating the ladder improperly can result in serious injury or death. Wait until the ladder has lowered completely before climbing. Do not lift people or objects (tools) with the ladder. Make sure the moving range of the ladder is clear of people when raising or lowering.

REMARKS: If there are any obstacles within the moving range of the ladder, stop the ladder by setting the control switch to 0- position. Operating the hydraulic Access Ladder (continued) Fig. 3-6 Raising the ladder Enter the excavator with ladder in fully lowered position (A). Start the engine. REMARKS: For starting procedure → See "STARTING THE ENGINE" on page 3-118. Go back to the ladder control switch (4B). Raise the ladder by turning the switch to position (5), arrow up, and hold until the ladder is in fully lifted position (B). Lowering the ladder The ladder can be lowered with the engine running or with the engine at standstill. REMARKS: For stopping the engine→ See "STOPPING THE ENGINE" on page 3-152. Lower the ladder by turning the ladder switch (4A or 4B) to position (6), arrow down, and hold until the ladder is completely lowered in position (A). With the engine at standstill, it can be necessary to push the ladder slightly until it starts moving down by its own weight.

WARNING HAZARDOUS AREA! People moving within the area of the lowering range of the ladder can be injured. Make sure the moving range of the ladder is clear of all persons before lowering the ladder. Enter the ladder only after the ladder is in fully lowered position (A).

REMARKS: Check safety sensor (11) of access ladder for correct function after every 50 operating hours or once a week. Refer to Maintenance Section 4, for checking procedure.

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OPERATION

Fig. 3-7 3 - 14

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3.2.3.2

CONSTRUCTION OF THE EXCAVATOR

EMERGENCY OPERATION OF THE HYDRAULIC ACCESS LADDER

In cases of emergency or electrical fault on the excavator, the hydraulic access ladder can be lowered independently of all other electrical safety shut down systems. To access the excavator from the ground, pull down the chain (3b) in order to lower the ladder. To escape the excavator, pull down the chain (3a) in order to lower the ladder.

WARNING HAZARDOUS AREA! People moving within the area of the lowering range of the ladder can be injured. Make sure the moving range of the ladder is clear of all persons before lowering. Once the chain has been pulled, the ladder is lowered by gravity and cannot be stopped.

REMARKS: Whenever the access ladder has been lowered with the emergency chain (3), the switching valve (C) has to be reset. Reset switching valve: 1. Open the cover of switching valve. 2. Move the valve levers to the horizontal position shown in detail (C). 3. Close the cover of the switching valve.

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3.2.4

OPERATION

EMERGENCY ESCAPE LADDER

Fig. 3-8 3 - 16

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CONSTRUCTION OF THE EXCAVATOR

Legend for Fig. 3-8 (1)

Sliding window, serves also for emergency exit Use the emergency escape hammer located next to the window inside the cab for breaking the window glass.

CAUTION BEWARE OF GLASS! Broken glass can cause injuries. When escaping, remove the broken pieces of glass from the sash so that you will not cut yourself on them. Take care not to slip on the broken and scattered pieces.

If the operator’s cab is equipped with external metal sun visors, disengage the four catches and push out the sun visor panel. (2)

Release lever for hinged railing bar (3)

(3)

Hinged railing bar

(4)

Rigidly mounted emergency escape ladder. The rigidly mounted emergency escape ladder with rope ladder extension provides the means to go down to the ground.

(5)

Rope ladder. The upper end of the rope ladder is fixed onto the lower rung of the rigid escape ladder (4) by means of the fasteners (6), see detail (X). The lower end of the rope ladder is fixed on brackets (8) and secured with rubber fasteners (7), see section (A-A).

(6)

Hooks for fastening the rope ladder onto the rigid ladder (4)

(7)

Rubber fasteners for rope ladder in lifted position

(8)

Bracket for rope ladder in lifted position. The lower rung of the rope ladder is hooked up into the brackets (8)

(9)

Machinery house

Using the emergency escape ladder In case of emergency with normal walkways obstructed use escape ladder (4) and (5) for leaving the excavator. Proceed as follows: 1. Move up lever (2) and pull out. 2. Open the hinged railing bar (3). 3. Unhook fasteners (7) and take out rope ladder rung from brackets (8). 4. Let the rope ladder fall down to the ground. The upper end of the rope ladder is fixed onto the lower rung of the rigid ladder (4). 5. Use the rigid ladder (4) and then the rope ladder (5) for leaving the excavator.

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CONSTRUCTION OF THE EXCAVATOR

3.2.5

OPERATION

EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE

Fig. 3-9

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CONSTRUCTION OF THE EXCAVATOR

Legend for Fig. 3-9 (A)

View from rear machinery house doors onto the emergency escape ladder (1)

(B)

Top view of the machinery house roof

(1)

Emergency escape ladder in front of the rear machinery house doors

(2)

Emergency escape hatch

(3)

Rubber toggle

(4)

Safety rods of rear machinery house doors

Using the emergency escape ladder In case of emergency with normal walkways obstructed use escape ladder (1) and hatch (2) for leaving the machinery house. 1. Disengage toggle (3). 2. Open the hatch (2) and get up on the upper deck. 3. Depending on the situation, use the emergency escape ladder at the operator’s cab or the normal ground access ladder for leaving the excavator.

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CONSTRUCTION OF THE EXCAVATOR

3.2.6

OPERATION

EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM

Fig. 3-10

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3.2.6.1

CONSTRUCTION OF THE EXCAVATOR

ENGINE SHUTDOWN SYSTEM ACTUATED FROM GROUND MAN

REMARKS: This option needs to be activated in the Komtrax Plus menu. The alternative option is to activate the operator warning system, see chapter 3.2.6.2 for further information. Legend for Fig. 3-10 (1)

Actuating chains for shut down of the engine. To stop the engine, pull down one of the chains (1). To reactivate the stop function, pull the chain again.

(2)

Pull chain for emergency lowering of the access ladder

(3)

Komtrax Plus display on the instrument panel in the Operator’s cab. When one of the chains (1) is being pulled down from ground man, both engines will be stopped and a corresponding message will be displayed on the screen (3).

3.2.6.2

OPERATOR WARNING SYSTEM

REMARKS: This option needs to be activated in the Komtrax Plus menu. The alternative option is to activate the engine shutdown system actuated from ground man, see chapter 3.2.6.1 for further information. This option is used to inform the Operator that someone wants to enter the excavator or to draw the Operator’s attention to special circumstances requiring his action. Legend for Fig. 3-10 (1)

Actuating chains for operator warning

(2)

Pull chain for emergency lowering of the access ladder

(3)

Komtrax Plus display on the instrument panel in the Operator’s cab.

As soon as a chain (1) is pulled down, a corresponding message will be displayed informing the Operator that someone wants his attention. In such a case, the Operator should stop work until he has received the ground man’s request.

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CONSTRUCTION OF THE EXCAVATOR

3.2.7

OPERATION

OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)

Fig. 3-11

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CONSTRUCTION OF THE EXCAVATOR

Legend for Fig. 3-11

NOTICE FALLING OBJECTS! Any modifications on the steel structure of the cab are inadmissible. The Operator’s cab is equipped with an integrated Falling Object Protective Structure (FOPS) that meets the requirements of ISO 3449. Any modifications on the steel structure of the cab are inadmissible. Repairs on the FOPS must only be carried out by specialists having the authorization for repair work on Falling Object Protective Structures and in accordance with the manufacturer’s repair instructions. A

Left View of Operator’s Cab

(1)

Control switch for hydraulically operated access ladder

(2)

Door fastener, engages into the door latch when the cab door is fully opened.

(3)

Access door to the air filter of the operator’s cab

(4)

Release lever inside the cab for door fastener (2)

(5)

Portable fire extinguisher. Make sure the fire extinguisher is always charged and ready for use

(6)

Handle of the sliding window The sliding window serves as emergency exit and should always be closed when working with the excavator to prevent dust from getting into the cab. Operator’s console, see page 3-39 for more information.

(7) (8)

Lock lever. –

This lever locks the controls for working equipment, slew and travel drive when placed in the fully rear position (L).

–

Start the engine with lock lever in LOCKED position (L). Thereafter set the lock lever to free position (F) in order to enable operation of the hydraulic control system.

WARNING ACCIDENTAL USE OF THE CONTROLS! Inadvertently touching the controls when leaving the operator’s seat may lead to a serious accident. Before leaving the operator’s cab set the lock lever to LOCK position (L). (9)

Air conditioner condenser unit

(10)

Air flow control louvers adjustable

(11)

Air flow jets adjustable

(23)

Adapter for warning beacon

(24)

Aerial

(25)

Sun visor

(26)

Main wiper Motor

(27)

Main windshield wiper

(28)

Auxiliary windshield wiper

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OPERATION

Fig. 3-12 3 - 24

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Operator’s Cab (continued) Legend for Fig. 3-12 B

Top View of Operator’s Cab

(1)

Control switch for hydraulically operated access ladder

(2)

Door fastener, engages into the door latch when the cab door is fully opened.

(4)

Release lever inside the cab for door fastener (2)

(7)

Operator’s console

(8)

Lock lever

(12)

Light switch for access area lighting

(13)

Light switch for interior cab lighting

(14)

Co-driver’s seat, refer to page 3-28 for more information

(15)

Operator’s seat, refer to page 3-27 for more information

(16)

Left control lever REMARKS: Usually the excavator is equipped with an "EURO" control pattern. Before starting to work ensure that the control pattern has not been changed.

(17)

Right control lever REMARKS: Usually the excavator is equipped with an "EURO" control pattern. Before starting to work ensure that the control pattern has not been changed.

(18)

Control pedals for opening and closing of the bottom dump bucket (Front shovel only)

(19)

Travel control pedals

(20)

Slew brake pedal

(21)

Door opener push button, from inside the cab door.

(22)

Outside mirrors with integrated heaters.

–

Make sure the cab door is always closed when working with the excavator.

–

Lock the door in open position by engaging the door latch into fastener (2).

NOTICE FIRE HAZARD! Blocking the ventilation of the heater may result in fire. Do not place anything in front of the intake or output of the heating.

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CONSTRUCTION OF THE EXCAVATOR

OPERATION

Fig. 3-13

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3.2.7.1

CONSTRUCTION OF THE EXCAVATOR

OPERATOR’S SEAT ADJUSTMENT

Before operating the excavator adjust the seat and mirrors for Operators maximum comfort, visibility, and complete control of the excavator. Legend for Fig. 3-13 (1)

Seat suspension adjustment (firm to soft ride)

(2)

Height adjustment

(3)

Seat depth adjustment

(4)

Seat cushion tilt adjustment

(5)

Fore/aft adjustment

(6)

Not used on this model

(7)

Control lever carrier

(8)

Headrest (optional)

(9)

Seat heater switch (optional)

(10)

Lumbar support adjustment

(11)

Armrest, foldable

(12)

Armrest adjustment

(13)

Backrest adjustment

(14)

Fore/aft isolator Seat belt (not shown)

–

Use seat belt in accordance with the local safety regulations and laws.

–

Check condition and fastening of the seat belt. Replace any worn or damaged part of the seat belt system.

–

To ensure proper functioning of the seat belt replace the seat belt and securing parts after every three years.

REMARKS: For more information, refer to the separate Operating Instruction Manual ”AIR SUSPENSION SEAT” in volume 2 binder.

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CONSTRUCTION OF THE EXCAVATOR

3.2.7.2

OPERATION

CO-DRIVER’S SEAT

Fig. 3-14 Legend for Fig. 3-14 (1)

Co-driver’s seat

(3)

Portable fire extinguisher

(2)

Seat belt

(4)

Cabinet door

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3.2.7.3

CONSTRUCTION OF THE EXCAVATOR

INSTRUCTIONS TO USING AND LOOKING AFTER THE SEAT BELTS

CAUTION CHECK SEAT BELT! A defective seat belt may not prevent injury when the excavator is involved in an accident or moves suddenly or unexpectedly as planned.

REMARKS: To ensure the seat belt functions properly, we recommend replacing the seat belt and securing parts 3 years after installation or 5 years after seat belt manufacture, whichever comes first. Before operating the excavator, adjust the seat comfortably and fasten the seatbelt. Adjust the seat belt to fit low around the hips to lessen the chance and severity of injury in the event of an accident. Do not adjust the seat belt around the abdomen. These instructions apply to both the main operator’s seat and the passenger’s jump seat. The condition of the seat belt, all seat belt components, the seat belt retractors and and the seat belt mounting hardware should always be checked before operating the excavator. Replace any defective parts immediately. Replace the seat belt if:–

The webbing material of the seat belt is overly worn, has a frayed appearance or has loose stitching.

–

The buckle and tongue fastening no longer click together closed or they show other signs of damage.

–

The retracting system does not pull the belt in.

–

The slack take-up system, if equipped, no longer operates.

Always: –

ensure that the seat belt mounting bolts are tight and are not in any way damaged.

–

ensure items with sharp edges are kept away from the seat belt webbing.

–

ensure the buckle and the tongue fastening are not lubricated.

–

make sure the belt is cleaned using only soapy water and a mild detergent. Never use bleach, color dye or solvents on the seat belt webbing.

–

ensure the seat belt is flat and not twisted when not in use.

–

use seat belt in accordance with the local safety regulations and laws.

CAUTION CHECK SEAT BELTS! Defective seat belts are a safety hazard. The seat belt should be completely exchanged, together with all seat belt components and the mounting hardware. The date of installation of the seat belt system should be marked and affixed where appropriate.

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OPERATOR’S CAB - CONTROLS

OPERATION

3.3

OPERATOR’S CAB - CONTROLS

3.3.1

CONTROLS WITH BACKHOE ATTACHMENT

Fig. 3-15

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3.3.1.1

OPERATOR’S CAB - CONTROLS

HYDRAULIC CONTROL SYSTEM

Usually the excavator is equipped with an "EURO" control pattern. Before starting to work ensure that the control pattern has not been changed. REMARKS: For more information → See "WORKING WITH THE ATTACHMENT" on page 3-139. NOTE!

Wrong operation of the controls can cause mechanical break-down, property damage, injury or death. Observe the Safety Instructions. Before starting the engine / motor, make sure you know the location and function of each control. Always sit in the Operator’s seat when operating this excavator.

3.3.1.2

SAFETY CIRCUIT FOR CONTROLS

(Pilot control system cut-out and actuation of hydraulic slew parking brake) This system is controlled through the Lock lever at the operator’s seat, the hydraulic access ladder and the service arm of the central refilling system. It prevents movements of the excavator and its attachment as long as the lock lever is in the upper locked position and/or the access ladder is in the lowered position or when the service arm of the central refilling system is in its lowered position.

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OPERATOR’S CAB - CONTROLS

OPERATION

Fig. 3-16

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3.3.1.3

OPERATOR’S CAB - CONTROLS

EURO CONTROL PATTERN

Legend for Fig. 3-16 (1)

Control lever for stick and slew machinery

(2)

Control lever for boom and bucket

(3)

Toggle switch for engine speed selection Low idle – High idle REMARKS: The engine will not respond when the toggle switch is set to low idle when the excavator is traveling or slewing

(4)

Push button for Truck counter. For counting loaded trucks press this button. The total number of trucks loaded is recorded in the Komtrax Plus system and can be called up, refer to page 3-46 for more information.

(5)

Signal horn button

(6)

Travel control pedal, left track forward - reverse

(7)

Travel control pedal, right track forward - reverse

(8)

Slew brake pedal

REMARKS: For more information → See "WORKING WITH THE ATTACHMENT" on page 3-139.

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OPERATOR’S CAB - CONTROLS

3.3.2

OPERATION

CONTROLS WITH BOTTOM DUMP BUCKET

Fig. 3-17

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3.3.2.1

OPERATOR’S CAB - CONTROLS

HYDRAULIC CONTROL SYSTEM

Wrong operation of the controls can cause mechanical break-down, property damage, injury or death.

–

Observe the Safety Instructions.

–

Before starting the engine / motor, make sure you know the location and function of each control.

–

Always sit in the Operator’s seat when operating this excavator.

3.3.2.2

SAFETY CIRCUIT FOR CONTROLS

(Pilot control system cut-out and actuation of hydraulic slew parking brake) This system is controlled through the lock lever at the operator’s seat, the hydraulic access ladder and the service arm of the central refilling system. It prevents movements of the excavator and its attachment as long as the lock lever is in the upper locked position and/or the access ladder is in the lowered position or when the service arm of the central refilling system is in its lowered position.

3.3.2.3

AUTOMATIC FLOAT POSITION FOR BOOM AND STICK

The excavator operates automatically with the float position for boom and stick activated. That means the lowering movement of boom and stick is always done in the float position. To deactivate the float position, press both buttons (3 and 4) and keep depressed as long as the float position shall be deactivated. When releasing the buttons the float position is activated again.

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OPERATOR’S CAB - CONTROLS

OPERATION

Fig. 3-18

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3.3.2.4

OPERATOR’S CAB - CONTROLS

EURO CONTROL PATTERN

Legend for Fig. 3-18 (1)

Control lever for stick and slew gear

(2)

Control lever for boom and bucket

(3)

Push button for deactivation of boom float position

(4)

Push button for deactivation of stick float position

(5)

Toggle switch for engine speed selection Low idle – High idle

(6)

Push button for Truck counter For counting loaded trucks press this button. The total number of trucks loaded is recorded in the Komtrax Plus system and can be called up, refer to page 3-46 for more information.

(7)

Signal horn button

(8)

Not used

(9)

Pedal for closing the bottom dump bucket

(10)

Pedal for opening the bottom dump bucket

(11)

Travel control pedal, left track forward - reverse

(12)

Travel control pedal, right track forward - reverse

(13)

Slew brake pedal

REMARKS: For more information → See "WORKING WITH THE ATTACHMENT" on page 3-139.

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OPERATOR’S CAB - CONTROLS

OPERATION

Fig. 3-19

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3.3.3

OPERATOR’S CAB - CONTROLS

OPERATOR’S CONSOLE

Legend for Fig. 3-19 (1)

Machine monitor The monitor (1) displays the condition of the excavator, the maintenance status, and messages for the operator and service man, and is also used to input the necessary data. The key pads below the monitor are used to switch the screen and for input of data. See chapter 3.4 for more information

(2)

Ashtray

(3)

Switch board, refer to next page for description of components

(4)

Control unit for air conditioning and heating, see chapter 3.6 for more information

(5)

Radio

(6)

Switch board lighting with flexible arm

(7)

Cigarette lighter

CAUTION CHECK SEAT BELT! A defective seat belt may not prevent injury when the excavator is involved in an accident or moves suddenly or unexpectedly as planned, resulting in injury. Check the condition and fastening of the seat belt. Replace any worn or damaged part of the seat belt system. To ensure proper functioning of the seat belt replace the seat belt and securing parts after every three years. Use seat belt in accordance with the local safety regulations and laws.

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OPERATOR’S CAB - CONTROLS

OPERATION

Fig. 3-20

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3.3.3.1

OPERATOR’S CAB - CONTROLS

CONTROL PANEL

Legend for Fig. 3-20 (1)

Acoustic warning signal This signal sounds for approximately 1 second when a fault message appears on the Komtrax Plus screen.

REMARKS: In case the hydraulic oil level is too low, this signal will sound continuously. Shut down the excavator, locate and correct the cause immediately. Fill up hydraulic oil to the correct level. For the correct checking procedure → See "CHECKS BEFORE STARTING THE ENGINE" on page 3-112. (2)

Switch for warning beacon on cab roof (if so equipped)

(3)

Switch for dashboard illumination

(4)

Switch for windshield washer

(5)

Enable switch for hydraulic service arm operation. Set this switch to ON position ”1” before lowering the service arm. With this switch in ON position, the pilot control system is made inoperative and the hydraulic slew brake is applied. After completion of replenishment procedure, swing back the service arm to its home position and set switch (12) to OFF position ”0”.

(6)

Switch for mirror heating

(7)

Toggle switch for slew parking brake – ”0” Parking brake released - UP – ”1” Parking brake applied - DOWN. REMARKS: The parking brake must only be applied with superstructure at complete standstill, except in case of emergency. Refer to chapter 3.13 for more information.

(8)

Strike button for emergency shut down of the engine and pilot control system cut out.

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OPERATOR’S CAB - CONTROLS

OPERATION

Fig. 3-21

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OPERATION

OPERATOR’S CAB - CONTROLS

Control Panel (continued) Legend for Fig. 3-21 (9)

Switch for main working lights

(10)

Switch for upper and lower windshield wiper Switch positions: 0 - Off 1 - Interval stage 2 - Slow stage 3 - Fast stage

(11)

Switch for cab ventilation blower. Blower runs with low speed, even with switch in”0” position. (Cab pressurizing prevents ingress of dust).

(12)

Switch for manual actuation of slew ring gear pinion lubrication system

(13)

Switch for manual actuation of central lubrication system

(14)

Rotary switch "Idling stop timer" REMARKS: When turning this switch to the right, the engine will idle without load as long as the time shown in the display has expired and stop afterwards.

(15)

Rotary switch for starting the engine

(16)

Key operated main switch

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OPERATOR’S CAB - CONTROLS

OPERATION

Fig. 3-22

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3.3.3.2

OPERATOR’S CAB - CONTROLS

REAR PANEL CONTROLS

Legend for Fig. 3-22 (1)

Control unit for air conditioning and heating, see page 3-86 for more information. A - Plus key B - Minus key C - Digital display D - Selector keys and LED indication

(2)

Radio

(3)

Plug socket (X27) for download of Komtrax Plus data from protocol and statistics memory

(4)

Plug socket (X13) for electronic pump control diagnostic, refer to service manual for more information.

(5)

Plug socket 24V DC

(6)

Flexible switch board lighting

(7)

Light switch

(8)

Cigarette lighter

(9)

Ashtray

REMARKS: For more information of the air conditioning refer also to the separate Instruction Manual Eberspächer filed in volume 2 binder.

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MACHINE MONITOR KOMTRAX PLUS)

3.4

OPERATION

MACHINE MONITOR KOMTRAX PLUS)

Fig. 3-23

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OPERATION

MACHINE MONITOR KOMTRAX PLUS)

Legend for Fig. 3-23 (1)

Monitor screen displays the condition of the excavator, the maintenance status, and messages for the operator and maintenance man.

(2)

Function key group for changing the screen and for settings in the user menu,

(3)

Key pad for entering data and Personal Identification Number (PIN)

(4)

Main key switch on dashboard

(5)

Opening message

(6)

Acknowledgment button for opening message

3.4.1

SEQUENCE OF DISPLAYS

When the main key switch (4), Fig. 3-23 is turned ON, the initialization screen (KOMATSU logo) Fig. 3-24 is displayed for approx. 3 seconds. The system offers three languages, for example ENGLISH GERMAN - SPANISH, according to Customer request. Changing of the present language can be carried out in the main menu Settings, see Fig. 3-31.

Fig. 3-24

3.4.2

OPENING SCREEN

The second display, see no. (5) in Fig. 3-23, is of general information for the operator. Press function key (6) to acknowledge this message, the display will change to the Main Gauge Screen 1, see Fig. 3-25 on page 3-48.

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MACHINE MONITOR KOMTRAX PLUS)

3.4.3

OPERATION

MAIN GAUGE SCREENS 1 TO 2

Fig. 3-25

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OPERATION

MACHINE MONITOR KOMTRAX PLUS)

Main Gauge Screen 1 of 2 °C 1/min

Celsius, ambient temperature Engine speed Time

Truck counter 1

Truck counter 2

Engine oil pressure

Engine coolant temperature

Hydraulic oil temperature

Fuel level

Main Gauge Screen 2 of 2

Battery charging current (A)

Board voltage (24V)

Engine oil temperature

Definition of the gauge range colors Green

Normal operating range

Red

Serious trouble, act immediately. Engine derate or shutdown may happen.

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MACHINE MONITOR KOMTRAX PLUS)

3.4.4

OPERATION

FUNCTION OF KEYS F1 TO F6

This button is used to scroll through the three Main Gauge Screens (1, 2 and 3). With other screens selected the function of this key changes accordingly, see examples on the following pages.

This button switches to Fuel Consumption screen, for details see page 3-53.

This button switches to Failure Message history screen for the operator. The color of the icon above this switch changes to yellow when a current message is available in the Failure Message history. The button remains yellow as long as the cause for the message exists, even if the message was canceled. For details see Failure Message screen on page 3-54.

This button switches to the Main Screen for changing the display from Time to Service Meter Reading or to Date and vice versa, for details see page 3-54.

This button switches to the Maintenance Monitor. The color of the icon above this switch changes to yellow or red when Maintenance is due, for details see Maintenance Monitor on page 3-55.

This button switches to the User Menu Settings for Operator, for details see page 3-56.

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Please continue reading on the next page.

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OPERATION

Fig. 3-26

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3.4.5

MACHINE MONITOR KOMTRAX PLUS)

FUEL CONSUMPTION SCREEN

Measuring fuel consumption Starting from one of the three Main Gauge screens press button F2, the screen changes to Fuel Consumption screen (1), Fig. 3-26. The fields in screen (1) can be either blank or filled with the data of the last measurement. If you want to start fuel consumption measurement, push the START button F1. The Date and local Time will be inserted into the Start Time field and the START button changes to STOP button, see screen (2). Push return button F5 to go back to the Main Gauge Screen 1. When the time period for fuel consumption measurement is over, for example after 10 hours, select the CONSUMPTION Screen from any of the three Main Gauge Screens by pushing the fuel consumption button F2. The displayed consumption screen shows the starting date and time of fuel consumption measurement. Push the STOP button. The current date and time is inserted into the Stop Time field and the split fuel consumption calculated during the time period is inserted into the Split Consumption field. The STOP button changes to START button, see screen (3). Push return button F5 to go back to the Main Gauge Screen 1.

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3.4.6

OPERATION

FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR

Failure history for Operator

The Failure Message history screen can be selected from the Main Gauge Screens 1, 2 or 3 by pressing the Message button F3. The color of the icon above this button changes to yellow when a current message is available in the failure message history for the operator.

Fig. 3-27 Legend for Fig. 3-27 F3

Scroll down button, shifts single messages

Scroll up button, shifts single messages

Standard monitor display button, switches back to the Main Gauge Screen 1.

When the cause for a message listed in the failure history has gone, the message will be removed from the failure history for operator and the time and date is added to the already stored message in the memory of the Failure History for Service.

3.4.7

MAIN SCREEN - CHANGE >TIME >SMR >DATE

Fig. 3-28 The button F4 switches to the Main Screen for changing the display from Time to Service Meter Reading (SMR) or to Date and vice versa. Push button F4 again to change the display from Time to Service Meter Reading. For display of the Date push the button F4 again. The selected display Time, SMR or Date will be shown on all three Main Gauge Screens. Fig. 3-28

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MACHINE MONITOR KOMTRAX PLUS)

MAINTENANCE MONITOR

Fig. 3-29 The Maintenance Monitor can be selected from the Main Gauge Screens 1, 2 or 3 by pressing the Maintenance button F5. The color of the icon above the button changes to yellow when maintenance is due. The color will change to red when maintenance is overdue. Fig. 3-29 shows a Maintenance Monitor of a new excavator which has been operated for 10 operating hours. There are 240 hours left before the 250 hour maintenance is due and 2990 hours before the 3000 hours maintenance is due. For returning to the Main Gauge Screen press button F5.

Fig. 3-29

Peculiarities to be observed: Higher maintenance also include lower maintenance. (Lower maintenance must also be carried out!) Exception: On performance of the 3000 h maintenance it is not necessary to also carry out the 2000 h maintenance. The maintenance cycles are rigidly linked to the running time meter. Only running time hours are taken into consideration (No minutes or seconds).

NOTICE REGULAR CHECKS AND INSPECTIONS! The routine visual checks and inspections after every 10 and 50 operating hours are not called up on the Maintenance Monitor. Carry out these checks and inspections according to the MAINTENANCE section 4 in this manual. The engine maintenance has to be carried out according to the separate Engine Operation and Maintenance Manual filed in volume 2 binder. On new excavators an INITIAL SERVICING after the first 250 and 1000 operating hours is required, in addition to the periodic maintenance intervals displayed on the monitor. Carry out all maintenance items according to the MAINTENANCE section 4 in this Manual. Missing or incomplete checks and inspections can cause damage to the excavator. Always perform all scheduled checks and inspections.

3.4.8.1

MAINTENANCE CONFIRMATION THROUGH SERVICE PERSONNEL

Maintenance indicated with yellow or red color of the icon above the maintenance key F5 should be confirmed through Service Personnel in the Service Menu subsequent to the execution of the maintenance. With the confirmation the actual value maintenance number is increased by 1. Thus, the length of the maintenance cycle is added to the display value and the gray color will appear on the maintenance icon. The message in the Service Menu for maintenance confirmation then turns white instead of yellow. For more information of maintenance confirmation refer to the Service Manual of the excavator.

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3.4.9

OPERATION

SETTINGS FOR OPERATOR

The User Menu Settings for Operator can be selected from the Main Gauge Screens 1, 2 or 3 by pressing the button F6. Main Screen Settings for Operator, Fig. 3-30

Fig. 3-30 Selection of Setting Screens The selection menu for settings offers seven possibilities of setting screens. Starting with USER ID and ending with Language selection. Use scroll button F3 or F4 for selection of the desired screen. Push acknowledge button F6 for switching over the selected setting screen. Button F5 switches back to Main Gauge Screen 1. The setting screens on the following pages appear in the same sequence as shown in the Main Setting Screen.

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3.4.9.1

SETTINGS FOR OPERATOR

3.4.9.2

USER ID SCREEN

Entry of the Operator identification number (USER ID), Fig. 3-31 To distinguish Operators, it is possible to enter a ten-digit Operator identification number by using key group (2). The screen changes from (1) to (3). Acknowledge ID number by pressing button F6, the display changes to Main Screen Settings. If ten numbers were entered each further entry will be ignored.

Fig. 3-31

3.4.9.3

RESET TRUCK COUNTER 1

With screen (1), Fig. 3-32 displayed press button F6 to reset truck counter 1 to zero. The screen switches back to the Main Screen Setting. If you don’t want to reset the truck counter press button F5 for going back to the Main Screen Setting. Truck counter 2 is reset in the same way.

Fig. 3-32

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3.4.9.4

OPERATION

SCREEN ADJUSTMENT

Screen adjustment Day and Night, Fig. 3-33

Fig. 3-33 Screen adjustment Day and Night The Day Screen (1) will be displayed during the day with the main working lights off. The screen changes automatically to Night when the main working lights are on, see screen (2). Adjustment of both screens is done in the same way.

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Explanation of key functions for screen adjustment, Fig. 3-33 F2

Button for automatic adjustment of Brightness, Contrast and Backlight

Button for decreasing Brightness, Contrast and Backlight

Button for increasing Brightness, Contrast and Backlight

Button for switching back to Main Screen Settings

Button for selection of Brightness, Contrast and Backlight

Screen adjustment –

Brightness shall be changed.

The first display of the screen shows the Brightness field highlighted. For increasing the Brightness push button F4 until the desired stage is obtained. For decreasing the Brightness push button F3 until the desired stage is obtained. –

Backlight shall be changed.

Push button F6 until the Backlight field in the third line is highlighted. For increasing the backlight push button F4 until the desired stage is obtained. For decreasing the backlight push button F3 until the desired stage is obtained. –

Contrast shall be changed.

Push button F6 until the Contrast field in the second line is highlighted. For increasing the Contrast push button F4 until the desired stage is obtained. For decreasing the Contrast push button F3 until the desired stage is obtained. After adjustment is done press button F5 for returning to the Main Screen Settings.

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3.4.9.5

OPERATION

DATE ADJUSTMENT SCREEN

The Date Adjustment Screen, Fig. 3-34 offers also the possibility to adjust the Time and the Daylight Saving Time. –

Date shall be changed.

The first display of the screen shows the Date and Year field highlighted. If, for example, the Month date shall be changed push button F1 once the Month field becomes highlighted, see screen (1). Use button F3 (down) or F4 (up) for changing the Month date. For changing the Day date push button F1 again the Day field will be highlighted. Use button F3 (down) or F4 (up) for changing the Day date. For returning to the Main Screen Settings push button F5. –

Time shall be changed.

Starting from screen (1) push button F1 three times the Time and Hours field will be highlighted, see screen (2). Use button F3 (down) or F4 (up) for changing the Hours. For changing the Minutes push button F1 again the Minute field will be highlighted. Use button F3 (down) or F4 (up) for changing the Minutes. For returning to the Main Screen Settings push button F5. –

Daylight Saving Time shall be changed.

Starting from screen (1) push button F1 five times the Daylight Saving Time field will be highlighted. Use button F3 or F4 for changing the Daylight Saving Time field from OFF to ON and vice versa.

Fig. 3-34

After adjustment is done press button F5 for returning to the Main Screen Settings.

3.4.9.6

CLOCK ADJUSTMENT SCREEN

The Clock Adjustment Screen offers basically the same settings as the Date Adjustment Screen. However, the display will start with the Time field highlighted. Settings are carried out in the same way as in the Date Screen.

3.4.9.7

LANGUAGE SELECTION SCREEN

Select the desired language with button F3 or F4, Fig. 3-35 and acknowledge the selection with button F6. The screen changes back to the Main Screen Settings.

Fig. 3-35

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MACHINE MONITOR KOMTRAX PLUS)

AUTOMATIC MESSAGES

If a failure or an information condition occurs during operation, the present display is automatically replaced by a message in text. If there are several messages at the same time, the system starts rolling up of all present messages and the present display. Each message is being displayed a few seconds. The message text informs the operator about the type of failure and the action to be taken. Carry out the action given on the screen. The headings of automatic messages have a background color indicating the severity of the condition as follows: RED YELLOW GREEN

Severe - act immediately. See page 3-62 for a typical message with red background. Caution - inform service, work can be continued. See page 3-63 for a typical message with yellow background. Information. See page 3-64 for a typical message with green background.

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3.4.10.1

OPERATION

AUTOMATIC MESSAGES

Example of a message with red background color of the top message, see Fig. 3-33

Fig. 3-36 Legend for illustration Fig. 3-36 and Fig. 3-37 1

Top message: Type of failure

Instruction message: Follow the displayed instructions

Message number (Error code): G = Excavator generated message C = engine 1 generated message

Order of occurrence of message now being displayed

Total number of existing messages

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AUTOMATIC MESSAGES

Legend for Fig. 3-36 and Fig. 3-37 continued F1

Cancel button: When this button is pressed, the displayed current message disappears and is listed in the failure history for operator. The message will be displayed again when a different Operator Identification number (ID) is entered.

Pause button (green): When this button is pressed, automatic rolling up of messages is stopped and the displayed message will be frozen on the screen for two minutes. Then the button changes to Reset (red) and automatic roll up of current messages starts again. New message will overwrite a frozen message.

Jump button: This button switches to the last displayed menu, normally the Main Gauge Screen 1. After two minutes the display jumps automatically back to the last displayed Automatic Message and rolling up of messages starts again. If a menu select button was activated during the two minutes standard Monitor display period, the display will also jump back to Automatic Message when the two minutes are over. New message will overwrite any menu display and rolling up of messages starts again.

Example of a message with yellow background color of the top message, see Fig. 3-37

Fig. 3-37

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3.4.10.3

OPERATION

AUTOMATIC MESSAGES

Example of an information message with green background color of the top message, see Fig. 3-38

Fig. 3-38 Legend for Fig. 3-38 1

Top message: Type of information

Explanation of condition

Message number (Error code): G = Excavator generated message C = engine 1 generated message

Order of occurrence of message now being displayed

Total number of existing messages

REMARKS: All messages available in the system are listed up on the following pages.

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TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM

REMARKS: The Instruction Messages belonging to the TOP Messages are listed in a separate Table, see page 3-76. The number shown in the Instruction Message column indicates the applying Instruction Message for the TOP Message. The table below also contains messages which do not apply to your excavator. These messages will not be displayed on the machine monitor.

Error code (Message number) G = Shovel C = Engine

Color code of TOP message: 0 = RED . 1 = YELLOW 2 = GREEN

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00001

G00002

Test speed 1800 1/min engine 1

G00003

Trouble pump controller

G00005

Low hydraulic oil level

G00006

Test speed 1800 1/min engine 2

G00007

G00012

Central lubrication system grease level too low

G00013

Slew ring gear lubrication system grease level too low

G00020

Trouble Shut-Off (gate) valve (Start blocked)

G00031

Set engine to low idle

G00032

Trouble starter

G00033

Trouble VHMS-Controller

G00034

Trouble VHMS-Display

G00035

Trouble totally loss gear oil (PTO 1)

G00036

Trouble totally loss gear oil (PTO 2)

G00037

Trouble monitoring, engine speed 2 too low

G00038

Trouble monitoring, engine speed 2 too high

G00039

Actuate engine speed selector switch

G00040

Emergency shut-down pump compartment

G00041

Emergency shut-down pump compartment

G00042

Trouble monitoring screen at hydraulic oil cooler entry

G00043

Trouble output short-circuit

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Trouble Shut-Off (gate) valve

Trouble hydraulic oil level

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Error code (Message number) G = Shovel C = Engine

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

OPERATION

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00044

Trouble monitoring oil filter pump control (B22-2)

G00045

Trouble oil filter pump control (B22-2)

G00046

Reverse travel cut out bypassed by horn

G00047

Travel cut out by cable drum

G00048

G00049

Trouble cab heating 1

G00050

Trouble cab heating 2

G00051

Trouble cab heating 1

G00052

Trouble cab heating 2

G00053

Reset emergency safety circuit

G00057

Fire in the cab base

G00058

Fire in the collector ring

G00059

Fire in the high voltage cabinet

G00060

Fire in the power house

G00061

Trouble monitoring, engine speed 1 too low

G00062

Trouble monitoring, engine speed 1 too high

G00063

Trouble monitoring hydraulic oil temp

G00064

Trouble monitoring hydraulic oil level

G00065

Very low hydraulic oil level

G00066

Trouble hydraulic oil temperature

G00067

Trouble battery voltage too high

G00068

Trouble gear lubrication (PTO 2)

G00069

Trouble monitoring oil temperature gear (PTO 1)

G00070

Trouble oil temperature gear (PTO 1)

G00071

Trouble gear lubrication (PTO 1)

G00072

Trouble monitoring hydraulic oil level

G00073

Trouble monitoring remote engine oil level 1

G00074

Trouble monitoring grease pressure (central)

G00075

Trouble monitoring grease pressure (slew ring gear)

G00076

Trouble monitoring pressure suction tank

G00077

Trouble monitoring grease level (central)

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Error code (Message number) G = Shovel C = Engine

MACHINE MONITOR KOMTRAX PLUS)

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00078

Trouble monitoring grease level (slew ring gear)

G00079

Trouble monitoring pressure oil cooler 1

G00080

Trouble monitoring pressure preload valve

G00081

Trouble lubrication system

G00082

Trouble monitoring remote engine oil level 2

G00083

Trouble monitoring oil temperature gear (PTO 2)

G00084

Trouble oil temperature gear (PTO 2)

G00085

Trouble monitoring pressure oil cooler 2

G00086

SHUTDOWN

G00089

EBL bypassed

G00090

Trouble power supply

G00091

Pilot control cut out

G00092

Emergency shut-down at access ladder

G00093

Emergency shut-down at valve block

G00094

Emergency shut-down at hydraulic control panel

G00095

Emergency shut-down in cabin

G00096

Pilot control cut out

G00097

Emergency shut-down at counterweight

G00098

Emergency shut-down at radiator

G00099

Trouble power supply

G00100

Maintenance Safety Switch

G00101

Faulty switch 20M007

G00102

G00103

Faulty switch 20M004

G00104

Trouble battery current

G00105

Trouble battery charging current too low

G00106

Faulty switch 20M007

G00107

Trouble slew parking brake control 56K250a

G00108

Trouble slew parking brake control Output to 56K250a

G00109

Trouble slew parking brake control 56K250b

G00110

Trouble slew parking brake control Output to 56K250b

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Switch off wiper

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Error code (Message number) G = Shovel C = Engine

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

OPERATION

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00111

Trouble travel parking brake control 56K251a

G00112

Trouble travel parking brake control Output to 56K251a

G00113

Trouble travel parking brake control 56K251b

G00114

Trouble travel parking brake control Output to 56K251b

G00115

Trouble slew hydraulic brake control 56K252a

G00116

Trouble slew hydraulic brake control Output to 56K252a

G00117

Trouble slew hydraulic brake control 56K252b

G00118

Trouble slew hydraulic brake control Output to 56K252b

G00133

Trouble monitoring 61B087e

G00134

Trouble monitoring 61B807f

G00135

Trouble monitoring 61B087g

G00136

Trouble monitoring 61B087h

G00137

Trouble monitoring 61B087i

G00138

Trouble monitoring 61B087j

G00139

Trouble monitoring X1-2 Pressure

G00140

Trouble monitoring X1-1 Pressure

G00141

Trouble monitoring X2-Pressure

G00142

Trouble monitoring pump support pressure X4-1

G00143

Trouble monitoring 61B087a

G00144

Trouble monitoring 61B087b

G00145

Trouble monitoring 61B087c

G00146

Trouble monitoring 61B087d

G00147

Trouble monitoring gear lubrication (PTO 1)

G00148

Trouble monitoring fuel level

G00149

G00150

Trouble monitoring gear lubrication (PTO 2)

G00151

Trouble monitoring gear (PTO) oil filter 1

G00152

Trouble monitoring oil filter pump lubrication

G00153

Trouble monitoring oil filter pump control

G00154

Trouble monitoring return oil filter

G00155

Trouble monitoring leak oil filter

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OPERATION

Error code (Message number) G = Shovel C = Engine

MACHINE MONITOR KOMTRAX PLUS)

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00156

Trouble monitoring oil filter radiator 2

G00157

Trouble monitoring oil filter radiator 1

G00158

Trouble monitoring oil filter fan drive oil cooler 1

G00159

Trouble monitoring breather filter

G00160

Trouble monitoring engine air cleaner 1

G00161

Trouble monitoring battery voltage

G00162

Trouble monitoring charging-/discharging current

G00163

Trouble monitoring pilot control

G00164

Trouble air cleaner 1

G00165

Trouble breather filter hydraulic oil tank

G00166

Trouble oil filter gear (PTO 1)

G00167

Trouble oil filter pump lubrication

G00168

Trouble oil filter pump control

G00169

Trouble return oil filter hydraulic oil tank

G00170

Trouble leak oil filter hydraulic oil tank

G00171

Trouble oil filter fan drive oil cooler 1

G00172

Trouble oil filter fan drive radiator 1

G00173

Trouble monitoring slew ring gear house brake

G00174

Trouble monitoring travel gear house brake

G00175

Trouble travel gear house brake

G00176

Trouble battery voltage

G00177

Trouble battery charging circuit

G00178

Trouble battery charging current to high

G00179

Trouble control pressure X1-1

G00180

Trouble pilot pressure X2 too low

G00181

Trouble pilot pressure X2 too high

G00182

Trouble control pressure X1-2

G00183

Trouble pump support pressure X4-1

G00184

Central lubrication system empty

G00185

Trouble central lubrication system

G00186

Trouble central lubrication system

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Error code (Message number) G = Shovel C = Engine

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

OPERATION

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00187

Slew ring gear lubrication system empty

G00188

Trouble slew ring gear lubrication system

G00189

Trouble slew ring gear lubrication system

G00190

Trouble oil filter fan drive radiator 2

G00191

Trouble oil filter gear (PTO 2)

G00192

Trouble oil filter fan drive oil cooler 2

G00193

Trouble monitoring gear (PTO) oil filter 2

G00194

Trouble monitoring oil filter fan drive oil cooler 2

G00195

Trouble pump support pressure X4-2

G00196

Trouble monitoring pump support pressure X4-2

G00197

Trouble monitoring engine air cleaner 2

G00198

Trouble air cleaner 2

G00201

Attachment lubrication system empty

G00202

Attachment lubrication system grease level too low

G00203

Trouble attachment lubrication system

G00204

Trouble attachment lubrication system

G00205

Trouble monitoring grease level (attachment)

G00206

Trouble monitoring grease pressure (attachment)

G00207

Engine remote oil-tank 1 empty

G00208

Engine remote oil-tank 2 empty

G00210

Trouble electric motor 1 winding temperature

G00211

Trouble electric motor 2 winding temperature

G00212

Trouble electric motor 1 bearing temperature

G00213

Trouble electric motor 2 bearing temperature

G00214

Trouble transformer 1 temperature

G00215

Trouble transformer 2 temperature

G00216

Trouble software not compatible

G00218

Switch off all motors for running transfer pump

G00219

Return oil tank empty

G00220

Trouble transfer pump motor overheated

G00221

Trouble slew direction module defect

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Error code (Message number) G = Shovel C = Engine

MACHINE MONITOR KOMTRAX PLUS)

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00223

Trouble starter control 51K001a-1

G00224

Trouble starter control Output to 51K001a-1

G00225

Trouble starter control 51K001b-1

G00226

Trouble starter control Output to 51K001b-1

G00227

Trouble starter control 51K001a-2

G00228

Trouble starter control Output to 51K001a-2

G00229

Trouble starter control 51K001b-2

G00230

Trouble starter control Output to 51K001b-2

G00231

Trouble pilot control lever 20S019

G00232

Trouble pilot control lever 20S020

G00233

Trouble pilot control 11Q045

G00234

Trouble pilot control 11K111a

G00235

Trouble pilot control Output to 11K111a

G00236

Trouble pilot control 11K111b

G00237

Trouble pilot control Output to 11K111b

G00238

Trouble supply by key switch 11Q044

G00239

Trouble electrical matter

G00240

Trouble hydraulic oil temperature

G00241

Motor 1 already running

G00242

Engine 1 already running

G00243

Fill up fuel tank

G00244

Motor shutdown from ground

G00245

Engine shutdown from ground

G00246

Hydraulic oil temperature

G00247

Slew ring gear house brake

G00248

Engine 2 already running

G00249

Hydraulic oil temperature

G00250

Motor 2 already running

G00251

VHMS is by-passed

G00252

Emergency shut-down at access ladder

G00253

Emergency shut-down at valve block

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Error code (Message number) G = Shovel C = Engine

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

OPERATION

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00254

Emergency shut-down at hydraulic control panel

G00255

Emergency shut-down in cabin

G00256

Operator warning system

G00257

Hydraulic oil temperature

G00258

Emergency shut-down at counterweight

G00259

Emergency shut-down at radiator

G00261

Maintenance Safety Switch

G00262

Trouble screen at hydraulic oil cooler entry clogged

G00263

Trouble monitoring motor 1 bearing temperature

G00264

Trouble monitoring motor 2 bearing temperature

G00265

Trouble monitoring emergency voltage

G00266

Trouble emergency voltage to high

G00267

Trouble emergency voltage to low

G00270

Trouble monitoring motor 1 current

G00271

Trouble monitoring motor 2 current

G00272

Trouble monitoring high voltage

G00274

Trouble monitoring motor 1 winding temperature

G00276

Trouble monitoring motor 2 winding temperature

G00277

Trouble high voltage capacitor 1

G00278

Earth fault tripped

G00279

Trouble oil filter hydraulic generator

G00280

Trouble monitoring oil filter hydraulic generator

G00281

Ground leakage tripped

G00282

Trouble low voltage system

G00283

Trouble monitoring motor 1 power

G00284

Trouble monitoring motor 2 power

G00285

Trouble motor 1

G00286

Trouble motor 2

G00287

G00288

Trouble restart motor 1, temperature to high.

G00289

Trouble restart motor 2, temperature to high.

3 - 72

Trouble 3 phase current rotation direction

OMM 06372-D-EN-6T2-1.0

Version 2021/02

OPERATION

Error code (Message number) G = Shovel C = Engine

MACHINE MONITOR KOMTRAX PLUS)

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00290

G00291

Reverse travel cut out by cable drum

G00292

Reverse travel left track cut out by cable drum

G00293

Reverse travel right track cut out by cable drum

G00294

Forward travel cut out by cable drum

G00295

Trouble temperature cab base

G00296

Trouble temperature high voltage cabinet

G00297

Trouble monitoring temperature main transformer 1

G00298

Trouble inverted rectifier

G00299

Trouble battery charger control voltage

G00300

Trouble battery charge emergency voltage

G00301

Trouble high voltage supply was interrupted

G00302

Trouble monitoring temperature main transformer 2

G00303

Trouble high voltage capacitor 2

G00304

Start Motor 1 blocked

G00305

Start Motor 2 blocked

G00306

G00307

G00308

Trouble CAN-Bus or CAN-Hardware

G00309

Trouble ladder up 56K253a

G00310

Trouble ladder up Output to 56K253a

G00311

Trouble ladder up redundant 56K253b

G00312

Trouble ladder up redundant Output to 56K253b

G00313

Trouble ladder down 56K254a

G00314

Trouble ladder down Output to 56K254a

G00315

Trouble ladder down redundant 56K254b

G00316

Trouble ladder down redundant Output to 56K254b

G00317

Trouble service arm up 56K255a

G00318

Trouble service arm up Output to 56K255a

G00319

Trouble service arm up redundant 56K255b

G00320

Trouble service arm up redundant Output to 56K255b

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Trouble motor main relay 1

Trouble motor main relay 2 Attention! Cable drum!

OMM 06372-D-EN-6T2-1.0

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MACHINE MONITOR KOMTRAX PLUS)

Error code (Message number) G = Shovel C = Engine

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

OPERATION

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00321

Trouble service arm down 56K256a

G00322

Trouble service arm down Output to 56K256a

G00323

Trouble service arm down redundant 56K256b

G00324

Trouble service arm down redundant Output to 56K256b

G00325

Trouble service arm Input

G00326

Trouble ladder Input

G00327

Trouble parking brake Input

G00328

Trouble start Input

G00329

G00330

G00331

Automatic after-running engine 1

G00332

Automatic after-running engine 2

G00333

Trouble battery charger relay

G00334

Trouble cab heater contactor

G00335

Trouble cab heater safety relay

G00336

Trouble monitoring slew speed

G00337

Trouble Motor on control 12K408a-1

G00338

Trouble Motor on control Output to 12K408a-1

G00339

Trouble Motor on control 12K408b-1

G00340

Trouble Motor on control Output to 12K408b-1

G00341

Trouble Motor on control 12K408a-2

G00342

Trouble Motor on control Output to 12K408a-2

G00343

Trouble Motor on control 12K408b-2

G00344

Trouble Motor on control Output to 12K408b-2

G00417

Communication failure PLC <=> VHMS-Controller

G00419

Source voltage error

G00420

Connector sel error

G00421

Farm sys error

G00422

Can-net sys (J1939)

G00423

Application sys error

G00424

Hot short ckt in buzzer

3 - 74

Protection switch tripped Trouble pilot control 11K111a, 11K111b

OMM 06372-D-EN-6T2-1.0

Version 2021/02

OPERATION

Error code (Message number) G = Shovel C = Engine

MACHINE MONITOR KOMTRAX PLUS)

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

G00425

Settings impossible to take over into the PLC

G00491

Communication failure MH800 <=> VHMS-Controller

MFA0

Manual Trigger

C112

Timing Fueling Mismatch

C115

Speed Signal Lost

C116

Timing Rail Press Ckt Failed High

C117

Timing Rail Press Ckt Failed Low

C124

High Boost LB

C143

Low Oil Press

C151

High Coolant Temp

C155

High IMT LBF

C158

High IMT LBR

C162

High IMT RBF

C165

High IMT RBR

C214

High Oil Temp

C2157

Rapid Rise in LBR IMT

C2158

Rapid Rise in RBF IMT

C2159

Rapid Rise in RBR IMT

C233

Low Coolant Press

C234

Engine Overspeed

C235

Low Coolant Level

C253

Oil Level Low

C254

FSOV Open Circuit

C259

FSOV Mech Stuck Open

C261

High Fuel Temp

C423

Timing Press Incorrect

C441

Low Battery Voltage

C442

High Battery Voltage

C455

Rail Actuator Open Ckt

C467

Desired Timing Not Achieved

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MACHINE MONITOR KOMTRAX PLUS)

Error code (Message number) G = Shovel C = Engine

Color code of TOP message: 0 = RED 1 = YELLOW 2 = GREEN

OPERATION

Instruction Message Number. Refer to separate Table

TOP Message with colored background Messages w/o color code are not displayed. These messages are stored in the history memory only.

C468

Desired Rail Pressure Not Achieved

C514

Rail Actuator Mech Stuck

C551

Throttle Validation Switch High Error

C553

Rail Press OOR High

C554

Rail Press Incorrect

C555

High Blowby Press

C612

High Oil Filter Rest

C641

High Exh Temp #1 LB

C642

High Exh Temp #2 LB

C643

High Exh Temp #3 LB

C644

High Exh Temp #4 LB

C645

High Exh Temp #5 LB

C646

High Exh Temp #6 LB

C647

High Exh Temp #7 LB

C648

High Exh Temp #8 LB

C651

High Exh Temp #1 RB

C652

High Exh Temp #2 RB

C653

High Exh Temp #3 RB

C654

High Exh Temp #4 RB

C655

High Exh Temp #5 RB

C656

High Exh Temp #6 RB

C657

High Exh Temp #7 RB

C658

High Exh Temp #8 RB

C783

Rapid Rise in LBF IMT

Table 3-1

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Version 2021/02

OPERATION

MACHINE MONITOR KOMTRAX PLUS)

Please continue reading on the next page.

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CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT)

3.5

OPERATION

CAMERA SYSTEM WITH MONITORS (SPECIAL EQUIPMENT)

Fig. 3-39 3 - 78

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Version 2021/02

OPERATION

3.5.1

CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT)

LOCATION OF MONITORS AND CONTROL UNITS

Legend for Fig. 3-39 -I-

Top view of Operator’s cab

(A)

Components of the camera system mounted on the left side of the superstructure, see page 3-85 for details.

(B)

Components of the camera system mounted on the counterweight

(C)

Components of the camera system mounted on the right side of the superstructure

(1)

Monitor for viewing the left area of the excavator

(2)

Monitor for viewing the rear area of the excavator

(3)

Monitor for viewing the right area of the excavator

(4)

Control unit for monitor (1)

(5)

Control unit for monitor (2)

(6)

Control unit for monitor (3)

REMARKS: Refer to page 3-81 for operating instructions of the monitors.

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CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT)

OPERATION

Fig. 3-40

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Version 2021/02

OPERATION

3.5.1.1

CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT)

OPERATING THE MONITORS

CAUTION CORRECT CAEMERA MODE! Ensure that the rear camera is set in mirrored mode. If the camera setting is in normal mode, obstacles will be displayed on the wrong side.

Legend for Fig. 3-40 A

Front view of the monitor

(1)

Power ON/OFF button

(2)

Volume button. This function is not used.

(3)

Camera position button. This function is not used.

(4)

Camera selection button. This function is not used.

(5)

Menu button

(6)

Brightness sensor (Day/Night automatic brightness control) The brightness of the display is automatically adjusted according to the light conditions.

(7)

Speaker

Rear view of the monitor

(8)

Input cable

(9)

Bracket rail

3.5.1.2

ADJUSTMENTS OF THE MONITOR

1. BRIGHTNESS SETTING –

Press the MENU button (5) less than 2 seconds.

–

Select menu item BRIGHT with buttons UP/DN (3) and acknowledge the selection with the MENU button (5).

–

Adjust the desired brightness by using the buttons +/- (2).

–

Press button MENU (5) to finish the set-up.

2. CONTRAST SETTING –

Press the MENU button (5) less than 2 seconds.

–

Select menu item CONTRAST with buttons UP/DN (3) and acknowledge the selection with the MENU button (5).

–

Adjust the desired contrast by using the buttons +/- (2).

–

Press button MENU (5) to finish the set-up.

3. COLOR SETTING –

Press the MENU button (5) less than 2 seconds.

–

Select menu item COLOR with buttons UP/DN (3) and acknowledge the selection with the MENU button (5).

–

Adjust the desired color by using the buttons +/- (2).

–

Press button MENU (5) to finish the set-up.

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CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT)

OPERATION

Fig. 3-41 4.

TINT SETTING

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OPERATION

CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT)

–

Press the MENU button (5) less than 2 seconds.

–

Select menu item TINT with buttons UP/DN (3) and acknowledge the selection with the MENU button (5).

–

Adjust the desired tint by using the buttons +/- (2).

–

Press button MENU (5) to finish the set-up.

REMARKS: For more information refer to the separate manual 7’’ Digital TFT LCD Color All Round Vision Monitor filed in volume 2 binder.

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CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT)

OPERATION

Fig. 3-42

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OPERATION

3.5.1.3

CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT)

TYPICAL ARRANGEMENT OF THE CAMERAS

Legend for Fig. 3-42 (A)

Camera mounted on the left side of superstructure

(B)

Camera mounted on the counterweight

(C)

Camera mounted on the right side of the superstructure

(1)

Camera bracket

(2)

Camera –

View angle 130°

REMARKS: Never remove the lens glass from the camera. The housing is filled with nitrogen which prevents moisture from getting into the camera. The nitrogen would escape if the lens glass is being removed.

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OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

3.6

OPERATION

OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

NOTICE REGULAR OPERATION OF THE AIR CONDITIONING UNIT! The air conditioning unit can be damaged if it is not used. Operate the air conditioning units at least once a month for a minimum of 30 minutes.

3.6.1

DIGITAL DISPLAY

Fig. 3-43 Function of Keys when "Engine On" and controller active. See Fig. 3-43 Key T1: Plus Key Increases interior temperature setpoint by one degree per stroke or increases manual blower speed, depending on displayed mode.

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OPERATION

OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

Key 2: Minus Key Decreases interior temperature setpoint by one degree per stroke or decreases manual blower speed, depending on displayed mode. Key T3: Recirculating Air/Fresh Air Switches from recirculated air to fresh air and vice versa. Key T4: Blower Control Switches on the manual blower control. Press plus/minus key to select the following speeds: 1*) -2-3-4-5. 1*) to 5: adjusts the blowers to speeds 20%, 40%, 60%, 80%, 100%. Off*): Switches off the blowers or switches to automatic. Automatic: The blowers are controlled automatically based on the interior temperature. Key T5: Automatic climate control Switches on the automatic temperature control. Key T2+T3: Temperature indication. Shows the inside temperature for 10 seconds. If pressed a second time, it shows the outside temperature for 10 seconds (optional) Key T3+T5: Reheat (optional) Starts reheat mode fro 3 minutes. (Duration adjustable) Key T3+T4: Controller OffSwitches of all control functions and the display. *) The following blower steps are disabled when the automatic climate control is on. 2-,3-Step: off continuously adjustable blower: Off, 1

Air Flow Control –

For defrosting the windshield close the slide in the seat base. The whole air flow is now directed to the windshield.

–

To direct the air flow to your feet, open the slide in the seat base.

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OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

OPERATION

Luminous Indication

Fig. 3-44 Function of Indication when"Engine On" and Controller active. See Fig. 3-44 LED Field L1: Standard indication is the setpoint temperature. LED Field L2: Fresh air operation (green) LED Field L3: Manual blower control "ON" (green) LED Field L4: Cooling/Heating mode (green) LED Field L5: Malfunction cooling unit (red). Operating Instructions. When the engine is running, press any key to activate the air conditioning control unit. All previous settings are reactivated. Display When the unit is ON, the display shows the interior setpoint temperature. When selecting individual functions, the display shows the corresponding information for a short period of time. The display is dark when engine or control unit are OFF.

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Version 2021/02

OPERATION

OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

Interior Temperature Control. When the unit is ON, select Automatic Climate Control (T5) to start interior temperature control. Press the plus (T2) or minus (T3) to set the required interior temperature. The temperature can be adjusted between 18° and 28°C. When outside temperatures are below 2°C (adjustable parameter), the cooling function remains disabled. Ventilation When the unit is operating in Automatic Climate Control mode, the blower speed is controlled based on the room temperature. However, the blowers may be switched to manual mode by pressing the blower key. Press the plus (T1) or minus (T2) keys to define one of five different blower settings. The blowers can not be switched OFF when Automatic Climate Control (T5) is ON. When Automatic Climate Control is OFF, the blowers stop when the manual blower control is turned to zero. Reheat (optional) The reheat mode is used to remove air humidity and to help defog the windshields. Press T3 and T5 (Fig. 3-44) at the same time to activate reheat. Heating and cooling will be active for 3 minutes (adjustable parameter) during which time the blowers must be switched to maximum speed and the fresh air flap is to be closed. When the windshields are defogged at the end of the preselected duration time, all functions are to be set to the previously selected settings. Reheat mode is disabled when outside temperatures are below 2°C (adjustable parameter) or when the sensor is not installed or is defective. Temperature indication Press T2 and T3 (Fig. 3-44) at the same time to display the inside temperature, eg. "i 22" for 10 seconds. Additionally, when pressing the keys a second time, the outside temperature can be displayed, eg. "o 19". A sensor malfunction is shown as "i--" or "o--".

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OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

OPERATION

Fig. 3-45

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Version 2021/02

OPERATION

3.6.2

OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

CONTROL MODULE FOR AUXILIARY CAB HEATER (IF SO EQUIPPED)

Legend for Fig. 3-45 (1)

Control module for the engine independent auxiliary cab heater (upper heater. see position 7 on Fig. 3-46). This module is used for switching the auxiliary cab heater ON and OFF during excavator operations with the diesel engine running. It is also used to preselect heater start times and heating duration periods whilst the engine is switched off. For detailed setting instructions for the control module, refer to the separate operating instructions in binder volume 2.

(2)

Control module for the engine independent auxiliary cab heater (lower heater. see position 8 on Fig. 3-46).

(3)

Display showing the operating condition of the heater

(4)

Button for actual time indication

(5)

Button for heating time preselection

(6)

Button for heating indication

(7)

Button for backward settings

(8)

Button for forward settings

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OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

OPERATION

Fig. 3-46

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Version 2021/02

OPERATION

3.6.3

OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED)

NOTICE FIRE RISK! Blocking the ventilation of the heater may result in fire. Do not place anything in front of the intake or output of the heating.

Legend for Fig. 3-46 (1)

Auxiliary heater unit mounted on RH cab side

(A)

View from inside cab onto the RH wall below co-drivers seat

(2)

Openings for cold air (C) to auxiliary heaters (7 and 8)

(3)

Air flow louvers adjustable for warm air (W) from the auxiliary heaters (7 and 8) into the cab

(B)

Auxiliary heater unit shown with covering removed

(4)

Fuel return tank

(5)

Fuel strainers

(6)

Fuel dosing pumps

(7)

Upper auxiliary cab heater

(8)

Lower auxiliary cab heater. Same type as number (7).

(9)

Exhaust silencer

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OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

OPERATION

Fig. 3-47

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OPERATION

3.6.4

OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED)

REMARKS: The auxiliary cab heater is located on the inside of the fuel tank. Fig. 3-47 shows the arrangement of components and the flow of water, fuel and air. Legend for Fig. 3-47 (1)

Fuel tank

(2)

Heater unit HYDRONIC 10. Refer to the separate operating manual HYDRONIC 10 for all operating and maintenance instructions. This manual is filed in binder volume 2.

(3)

Water supply line from engine

(4)

Water return line

(5)

Water line to auxiliary heater

(6)

Hot water line from auxiliary heater to cab heater

(7)

Fuel shut-off cock for fuel supply to heater

(8)

Fuel strainer

(9)

Fuel supply line

(10)

Fuel dosing pump

(11)

Combustion air intake line

12)

Exhaust

(13)

Heater supply

(14)

Heater return

(15)

Cab heater

(16)

Mechanical thermostat

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OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

OPERATION

Fig. 3-48

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OPERATION

3.6.5

OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING

FUEL PUMP ARRANGEMENT

Legend for Fig. 3-480 (1)

Fuel shut-off cock for fuel supply to heater

(2)

Fuel pump

(3)

Fuel supply line to heater

(4)

Auxiliary cab heater

(5)

Fuel line from fuel tank to pump

(6)

Heater unit HYDRONIC 10. Refer to the separate operating manual HYDRONIC 10 for all operating and maintenance instructions. This manual is filed in binder volume 2.

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MACHINERY HOUSE

3.7

OPERATION

MACHINERY HOUSE

Fig. 3-49

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Version 2021/02

OPERATION

3.7.1

MACHINERY HOUSE

EMERGENCY ENGINE SHUTDOWN SWITCHES

Legend for Fig. 3-49 (1)

Emergency engine shutdown switch in the cabin (20S036)

(2)

Emergency engine shutdown switch (61S033b) at the machinery house wall, opposite to the main control valves

(3)

Emergency engine shutdown switch (51S033d) in pump compartment

(4)

Light switch

(5)

Emergency engine shutdown switch at the machinery house door (51S033e)

(6)

Maintenance safety switch for start prevention of the engine (51S058)

(7)

Rotary switch

(8)

Fold up flap

(9)

Padlock holes on flap

(10)

Display of Komtrax Plus on the instrument panel in the Operator’s cab.

Emergency engine shut down switches (1, 2, 3, 5) Operating the emergency engine shutdown switches: –

In an emergency situation, push in the button (1, 2, 3, 5) to stop the engine. The fault message ’Engine shutdown: emergency stop switch activated’ is displayed on the screen (9).

–

To release button (1, 2, 3, 5) turn it to the right, the button returns to normal position. The engine can then be started in the normal way at the control panel in the operator's cab. The engine can not be started with button in depressed position.

Maintenance safety switch (6) Before beginning any maintenance operations set the rotary switch (7) to -0- position to prevent starting of the engine during maintenance. Fold up flap (8) and secure this position by inserting a padlock into the holes (9) of flap (8) and safety switch (6). Up to ten padlocks can be attached.

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ELECTRICAL EQUIPMENT IN CAB BASE

3.8

OPERATION

ELECTRICAL EQUIPMENT IN CAB BASE

Fig. 3-50

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OPERATION

ELECTRICAL EQUIPMENT IN CAB BASE

DANGER HIGH VOLTAGE! The cab base may contain high voltage electrical appliances which cause serious injuries or even death when handled incorrectly. Do not touch cables, their terminals and connected components. Always contact authorized electricians who are qualified to work on medium and high voltage systems. Access to the cab base for authorized service staff only.

REMARKS: There are additional components in the cab base for excavators equipped with electrical preheating systems. Refer to page 3-112 for more information. Legend for Fig. 3-50 (1)

Cab base door

(2)

Light switch

(3)

Pilot control frame

(4)

Box of the main switch board (X2). See page 3-105 for more information.

(5)

Compressor for signal horn

(6)

Signal horn

(7)

Controller (E61) for the electronic pump control system CR710

(8)

Controller Komtrax Plus

(9)

Data Communicator Komtrax Plus

(10)

Service monitor (provides documentation of the excavator)

REMARKS: For further information about Komtrax Plus contact your local dealer.

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ELECTRICAL EQUIPMENT IN CAB BASE

OPERATION

Fig. 3-51

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OPERATION

3.8.1

ELECTRICAL EQUIPMENT IN CAB BASE

ACCESS COVER FOR THE HEADLIGHTS MOUNTED ON CAB BASE

Legend for Fig. 3-51 (A)

View from inside the cab base

(1)

Head lights (Xenon) on cab base

(2)

Access cover to the headlights from inside the cab base

(3)

Headlight mounting bracket

(4)

Voltage amplifier for the headlights

(5)

Main switch board (X2)

For access to the headlights remove cover (2). When mounting the access cover (2) ensure that the power supply cables to the headlights are correctly routed through the slots in cover (2).

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ELECTRICAL EQUIPMENT IN CAB BASE

OPERATION

Fig. 3-52

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OPERATION

3.8.2

ELECTRICAL EQUIPMENT IN CAB BASE

SWITCH BOX (X2) IN CAB BASE

Legend for Fig. 3-52 (1)

Main switch board (X2)

(2)

Multi monitor for diagnostic of the electronic pump control system CR710 (11P046)

(3)

Hour meter for travel operation. The hour meter indicates the total number of hours of traveling operation (11P029). Service switches for the pump control system CR710: Service switch for the electronic pump control system CR710 (adjustment mode) (11S100) Service switch for the electronic pump control system CR710 (selection down) (11S101) Service switch for the electronic pump control system CR710 (selection up) (11S102) Service switch for the electronic pump control system CR710 (test mode selection position 2) (11S103) Service switch for the electronic pump control system CR710 (primary P-factor) (11S104) Service switch for Qmin position of main hydraulic pumps. Position 1 normal pump regulation. Position 2 Qmin position. (11S150)

REMARKS: The Service switches (11S100 to 11S150) are used for testing and adjustment procedures of the hydraulic system and should only be operated through authorized service personnel. For more information refer to the Service Manual PC3000-6.

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ELECTRICAL EQUIPMENT IN CAB BASE

OPERATION

Fig. 3-53

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OPERATION

3.9

PREHEATING SYTEM (OPTIONAL)

DANGER HIGH VOLTAGE! The cab base contains high voltage electrical appliances which cause serious injury or death when handled incorrectly. Access to the cab base for authorized service staff only.

General The preheating system is special equipment and can be installed in the factory or locally at site. Power supply to the preheating system is provided by an external power source. The following systems are equipped with heaters: –

Engine cooling system

–

Engine lubricating system

–

Hydraulic system (main and suction oil reservoir)

–

PTO’s (pump distributor gears)

–

Storage batteries

3.9.1

COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE

REMARKS: The auxiliary heater unit in the cab base (4) and the battery charger (2) are also connected to the external power supply. Legend for Fig. 3-53 (1)

Main switch board box (X2). See page 3-105 for more information

(2)

Battery charger 10T055

(3)

Fuse box with circuit breaker for battery charger

(4)

Heater unit for cab base

(5)

Wall bracket for heater unit

(A)

External power socket for battery charger

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Components of Electrical Preheating System in Cab Base (continued)

WARNING ELECTRIC SHOCK! Be sure to switch off main switch (3 Fig. 3-55) and switch for oil tank heating (9 Fig. 3-55). Disconnect the power supply cable from external power source before working on any part of the heating system.

Operating the Preheating System Use the preheating system during stand-still periods e.g. over night and low ambient temperatures. The heating system should be energized as soon as the engine is shut down. This allows the heating system to maintain the desired temperature with minimum power usage. Battery Charger (2) Power supply to the battery charger is provided by the generator set or an external power source connected to the 1X2 plug socket at the cab stairway. The batteries of the excavator are charged by the battery charger (2). The battery charger is switched ON and OFF with the switch on the front panel of the battery charger. REMARKS: For operating instructions refer to the separate Users Manual "MASTERVOLT" battery charger filed in volume 2 binder.

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PREHEATING SYTEM (OPTIONAL)

COMPONENTS OF ELECTRICAL PREHEATING SYSTEM ON THE COUNTERWEIGHT

Legend for Fig. 3-55 1)

Counterweight

(2)

Main switchboard for the preheating systems located on the inner wall of the counterweight

(3)

Extended rod for ON/OFF switch with external access switch (54Q201)

(4)

Preheater for engine coolant

Coolant supply line

(6)

Coolant return line

(7)

Cock for coolant supply line (located in the machinery house)

(8)

Cock for coolant return line (located in the machinery house)

(9)

Switch cabinet for oil tank heating with ON/OFF switch (54S267)

Before connecting the power supply cable to the external power source (see chap. 3.9.1), open the cocks for the coolant supply line (5) and the coolant return line (6). Close both cocks (5 and 6) after having disconnected the power supply cable for preheating.

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3.10

OPERATION

CHECKS BEFORE STARTING THE ENGINE

Fig. 3-56

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WARNING STARTING THE ENGINE IS HAZARDOUS! People on or about the excavator may be unaware that it is starting, and could be injured or killed as a result. Before starting the Engine, make sure that no one will be endangered.

3.10.1

CHECK THE FOLLOWING ITEMS

Legend for Fig. 3-56 (1)

Engine oil pan dipstick oil level gauge

(2)

Oil filler tube for engine oil pan

(3)

Coolant expansion tank of engine radiator

(4)

Coolant level sight gauge on coolant expansion tank

(5)

Cover plate on power house roof above the radiator pressure cap

(6)

Radiator pressure cap

Walk-around Inspection Make a ”Walk-around” inspection of the excavator. Refer to Maintenance Section 4 for the daily inspection items. Check engine oil level in oil pan Check oil level with Shovel standing on level ground. Check oil level in engine oil pan with the dipstick oil gauge (1). For accurate readings, the oil level should not be checked until the oil has settled into the oil pan after the engine has been shut down (about 5 minutes). Check engine oil level on shovels equipped with the engine oil reserve system The oil level in the engine oil pan can vary between the MIN and MAX marking on gauge (1) depending on the operating condition of the reserve system when the engine was stopped. With sufficient oil in the reserve tank and with the reserve system in proper working order, there is no need to fill the engine oil pan even with the oil level at the MIN mark on gauge (1). If the oil level is below the MIN marking on the gauge, corrective action must be taken. Fill the reserve tank and check the reserve system. The function of the reserve system is monitored by an indicator light located on the “X2” switch board in the cab base. See section "SWITCH BOX (X2) IN CAB BASE" on page 3-105 for more information.

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Fig. 3-57

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3.10.1.1

CHECKS BEFORE STARTING THE ENGINE

COOLANT LEVEL

CAUTION SCALDING FLUIDS! Removing the radiator pressure cap (6 Fig. 3-57) when the engine is hot can result in serious burns from heated coolant spray or steam. Wait until the temperature is below 50°C before removing the pressure cap (6).

Turn the radiator cap (6) slowly counterclockwise to the safety stop to allow the pressure to escape, then continue to turn until cap is free to be removed. The coolant level should be in the upper field of the sight gauges (4). If necessary add coolant. REMARKS: Refer to the Engine Manual for the correct coolant composition. Fill Engine Fuel Tank

WARNING RISK OF EXPLOSION! Engine fuel is flammable and can cause a fire or an explosion and may seriously injure or kill. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigar or cigarettes, etc.

Fill the fuel tank at the end of the of the shift to prevent condensation from forming. See engine operation and maintenance manual for fuel specifications. Be sure to install and lock the fuel filler caps after refueling. Check the breather filter at the filler neck and clean if necessary.

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Fig. 3-58

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CHECKS BEFORE STARTING THE ENGINE

HYDRAULIC SYSTEM - CHECK OIL LEVEL

General Information The hydraulic oil level in the main oil reservoir fluctuates depending on the oil temperature and the position of the loader attachment (hydraulic cylinders retracted / extended). Legend for Fig. 3-58 (1)

Main hydraulic oil reservoir

(2)

Hydraulic oil level sight gauge

(3)

Oil level plate

(4)

Oil filler plug

For checking the oil level lower the attachment (backhoe or bottom dump bucket) onto the ground in a position as shown in Fig. 3-58. Depending on type of attachment and the present oil temperature, select the applying oil level range on plate (3). Be sure to use the correct marking on oil level plate (3). Add hydraulic oil as necessary. REMARKS: Make sure that all doors of the machinery house, cab base and cab are securely closed before starting the engine.

3.10.1.3

OPERATOR’S SEAT ADJUSTMENT

Before operating the excavator adjust the seat and mirrors for Operators maximum comfort, visibility, and complete control of the excavator. REMARKS: Use seat belt in accordance with the local safety regulations and laws. See also page 3-27 for more information.

Fig. 3-59

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OPERATION

STARTING THE ENGINE

Fig. 3-60

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3.11.1

STARTING PROCEDURE

REMARKS: Excavators destined for areas with very low ambient temperatures are equipped with electronic preheating systems. These preheating systems have to be activated as soon as the engine has been stopped. Before starting, read the Engine Operation Manual. Observe the instructions for starting the Engine. –

After repairs on the Diesel Engine or Starter Motor, make sure that the ground cables are correctly connected before starting the Engine.

–

Start the engine from the operator’s seat only. Never attempt to start the engine by shorting across starter terminals. This can cause fire, serious injury or death.

–

Before each start, ensure that all controls are in neutral position.

–

Be sure to sound the signal horn before starting, in order to make your intention clear.

REMARKS: Before starting the engine and again before starting work, pay attention to the hydraulic oil temperature. Refer to the paragraph "Hydraulic Oil Warm-up" in this section. Legend for Fig. 3-60 (1)

Key operated main switch

(2)

Acoustic warning signal

(3)

KOMTRAX text display input buttons

(4)

Engine speed selector switch –

Low idle - High idle

(5)

Signal horn button

(6)

Rotary switch - engine start

(8)

Rotary switch "Idling stop timer" REMARKS: When turning this switch to the right, the engine will idle without load as long as the time shown in the display has expired and stop afterwards.

(9)

Strike button - emergency engine shutdown and cut-out of pilot control system

(10)

Komtrax Plus text display

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Fig. 3-61

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STARTING THE ENGINE

STARTING PROCEDURE AT AMBIENT TEMPERATURE UP TO -25°

REMARKS: If the ambient temperature is below -25°C proceed according to chapter "Cold Weather Starting at ambient Temperatures below –25°C" on page 3-123. 1. Insert battery main switch keys and turn to operating position. REMARKS: Start the engine with the lock lever in the fully rear LOCKED position. When the engine is running, move the lock lever to the front in the FREE position. 2. Insert key into the switch (1), Fig. 3-61 and turn to operating position. The warning buzzer (2) must give an acoustic test signal. If the buzzer fails to function, corrective action must be taken. 3. Observe Komtrax display (3). Normally the basic display appears on screen (3). If a FAULT message or INFORMATION item is displayed, proceed according to section "MACHINE MONITOR KOMTRAX PLUS)" on page 3-46. 4. Set toggle switch (4) to low idle speed position. 5. Sound the signal horn (5). 6. Start the engine by turning starter switches (6). REMARKS: The engine is equipped with a prelubrication system which is activated by the starter switch (6). Turning and holding the switch in the start position sends current to the prelubrication starter solenoid which then prelubricates the engine. This solenoid timer prevents current from flowing to the conventional starting motor until 17 kPa (2.5 psi) oil pressure has been achieved in the cam oil rifle. After a subsequent 3 second delay, current is then directed to the starting motors for cranking the engine.

3.11.2.1

COLD WEATHER STARTING AT AMBIENT TEMPERATURES BELOW 0°C TO -25°C

To facilitate starting at low outside temperatures (below 0° C) and with the engine cold, use the cold starting aid. Take into account, that the prelubrication period will be longer at low ambient temperatures. Inject starting fluid only after the prelubrication period is finished and the engine starts to crank. Engage the starter and while cranking, apply metered amounts of starting fluid using switch until the engine idles smoothly. REMARKS: Use the cold starting aid only during starting and with the engine cold.

NOTICE CRANKING THE ENGINE! Starting the engine improperly could damage the excavator. Never operate the starter longer than 30 seconds at a time in order to avoid damage. If the engine does not start within the first 30 seconds, wait 2 minutes before cranking again. As soon as the engines are running, check display (3) for messages.

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Fig. 3-62

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3.11.2.2

STARTING THE ENGINE

COLD WEATHER STARTING AT AMBIENT TEMPERATURES BELOW –25°C

NOTICE COLD WEATHER STARTING AT EXTREMELY LOW TEMPERATURES! If the following cold weather start-up procedure for extremely low temperatures is not properly carried out, the reliability of the excavator and equipment will be seriously impaired. The hydraulic system should be filled with one of the specified hydraulic oils listed on page 4-4, "FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES".

1. Record the Outside Ambient Temperature. If it is colder than –40°C, then DO NOT start the Excavator and keep the electrical preheating systems activated. If the customer decides to start the excavator at temperatures below –40°C it will be at the customer’s own risks in terms of potential structural damages and components failures. It must be understood, that Komatsu Germany will decline any warranty claims which would result from starting or operating the excavator when the ambient temperatures are below –40°C. 2. If the Outside Ambient Temperature is between –40°C and –25°C, then check that the preheating systems are duly energized and that all the heaters are functioning properly. Also close the radiator shutters (if so equipped). 3. Let the preheating systems warm the hydraulic oil and the engine coolant up to a temperature of –25°C or warmer. These temperatures are indicated on the temperature gauges on the dashboard. (With Heaters properly functioning, these temperatures should never fall below –25°C). –

If the preheating systems were not energized during the Standstill Period, the warm-up phase may last several hours, depending on the actual ambient temperature the excavator was exposed to, and the length of time the excavator stood still, until the minimum starting temperature of –25°C for the hydraulic oil and engine coolant is reached.

–

If the outside ambient temperature is below –40°C, warm up the entire excavator, using any safe means of heat generation such as hot air blower in connection with air-borne parachute, and/or any other appropriate means, before start-up, especially when the excavator has been shutdown for a long period, moreover when the preheating systems were not energized during the standstill period.

4. When the hydraulic oil, for example Shell Tellus S4 VX 32, and the engine coolant have been warmed-up to the minimum starting temperature of –25°C, switch off the engine coolant preheating systems. All other heating systems remain active. REMARKS: If a different hydraulic oil with a different viscosity is in the system, the minimum starting temperature may change. Refer to chapter "Hydraulic Oil Viscosity and Temperature Chart" on page 3-127 for the permissible starting temperatures. 5. When the hydraulic oil and the engine coolant have been warmed-up to the minimum starting temperature of – 25°C, switch off the engine coolant preheating systems. All other heating systems remain active.

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Fig. 3-63

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6. Crank the engine up to three times without activating the starting aid fluid switch. 7. If the Engine does not start, activate the Diesel starting aid fluid switch, while cranking. 8. Release immediately the starting aid fluid switch once the Engine starts. 9. If Engine fails to start, go back to step 5. 10. Once the Engine is started, keep it at low idle speed for five minutes, then shift Engine to high idle speed in order to warm-up the Engine. 11. Once the Engine is up to working temperature, switch OFF the remaining electrical preheating systems and, if an external power source is used, disconnect the power supply cable. Carefully start moving the attachment by operating controls very slowly. Follow the steps below: – Raise the attachment slightly off the ground and start by holding the clam closed function over relief. Keeping in mind not to hold over relief for long periods of time as it may damage the relief valve due to overheating. – After holding clam closed function over relief, slowly open clam and hold open function over relief. Continue working clam and holding over relief until the hydraulic oil temperature gauge begins to move and then proceed on to the bucket functions. – While holding the bucket functions over relief, continue to work the clam to keep the oil flowing through the circuit. – As the temperature of the hydraulic oil rises, move on to the stick and then to the boom functions, keeping other functions in motion as well. Once the hydraulic oil temperature is approximately +30°C, start adding slew functions into motion. – Once the hydraulic oil is close to working temperature slew over one track, raise the track off of the ground with the attachment, and slowly rotate the raised track to remove cold oil from the circuit. The running surfaces of track pads must be unobstructed with dirt, mud, or other debris. Once the track has been rotated in both directions for a few minutes, lower the track and repeat the same procedure with the opposite track. 12. Operate the excavator normally but smoothly, avoiding shocks and jerky movements, as hydraulic hoses may burst when the outside ambient temperature is extremely low. Operators must be more careful as temperature goes down to the limit of –40°C. REMARKS: Continuous operation with low coolant temperature below +60°C can damage the engine. To increase coolant temperature switch on the heater blowers in the machinery house. Load the hydraulic system.

NOTICE TEMPERATURES BELOW -40°C! Operating the excavator at temperatures below -40°C can cause damage to the excavator. If during operation, the ambient temperature drops below 40°C, stop work, move the loader attachment to the correct parking position, shut down the engine and switch on the electrical preheating system.

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Fig. 3-64

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STARTING THE ENGINE

HYDRAULIC OIL VISCOSITY AND TEMPERATURE CHART Rated viscosity at 40° C of hydraulic oil grade:

Starting temperature (max. 1000 cSt) -1-

Operating range (100 - 10 cSt) -2-

ISO VG

°C

Shell Tellus S4 VX 32 *1)

- 32

10 - 85

Shell Tellus S4 VX 32 *2)

- 34

5 - 81

HLP 22

-20

8 - 55

HLP 32

-14

16 - 70

HLP 46

-6

25 - 80

HLP 68

32 - 85

HLP 100

39 - 85

*1)

Temperature values for new oil (freshly filled in).

*2)

Temperature values for used oil. This temperature value has to be adjusted when the viscosity of the hydraulic oil has decreased by 10 to 12 percent compared with new oil. The determination of the hydraulic oil viscosity should be carried out in the course of the regular oil analysis procedure.

REMARKS: The starting and operating temperatures in the above chart depend on the hydraulic oil viscosity grade used in the system. Refer to section KOMTRAX menu control chart II for the viscosity grade of the present oil filling. For example: Hydraulic system filled with ISO VG 22 viscosity grade oil. 1. Lowest permissible starting temperature: -20°C, see column "1" 2. Operating temperature: min. + 8° C max. + 55° C, see column ”2”

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MOVING THE EXCAVATOR

OPERATION

3.12

MOVING THE EXCAVATOR

3.12.1

TRAVEL CONTROL WITH FOOT PEDALS

REMARKS: Traveling directions with cab in normal working and travel position i.e. cab above idler wheel. Counter weight above drive sprockets.

2 3

6 5 1

4 Z 33209

Fig. 3-65 Legend for Fig. 3-65 (1)

Left pedal, inside cab

(4)

Right pedal, inside

(2)

Left track forward

(5)

Right track forward

(3)

Left track reverse

(6)

Right track reverse

WARNING INTERFERENCE TO THE ELECTRONIC CONTROL SYSTEM! The interference of electromagnetic radiation can cause the excavator to respond in an unexpected manner which could lead to serious injury or death. In the event of unexpected movement, release all control levers and pedals and strike the emergency shut-down button.

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WARNING MAKE SURE THE AREA AROUND THE EXCAVATOR IS CLEAR! Anyone in the area of the excavator must be warned that it is about to move, otherwise serious injury or death may occur. Before moving, sound the signal horn in order to make your intentions clear.

2 3

6 5 1

4 Z 33209

Fig. 3-66 Regulate travel speed by depressing the pedals more or less. Apply slew circle brake as necessary. On excavators with two-speed range travel drive, select normal or fast speed range according to ground conditions. For braking the excavator release pedals (1 and 4 Fig. 3-66).

WARNING TRAVELING ON SLOPES! There is the risk that the excavator may tip over when traveling on slopes causing serious injury or death. Traveling on a slope requires special care. Plan your work so that the excavator travels up- and downhill parallel to the grade. The superstructure must be parallel with the undercarriage and the working attachment must face to the front in travel direction. The travel gears must be at the rear in the direction of travel. DO NOT use the FAST TRAVEL SPEED RANGE when traveling on a grade. For maximum stability carry the bucket as close to ground level as possible. Operate the travel control pedals sensitively. Avoid jerky acceleration and deceleration of travel motions. Travel speed must be conform to the ground conditions.

NOTE!

For safety reasons, the engine will not switch to low idle when the toggle switch on the control lever is set to the low idle position during traveling.

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OPERATION

Two Speed Range Travel Drive REMARKS: If the excavator is equipped with a Two Speed Range travel drive, always use the low speed range when traveling on a slope. Never go downhill with fast speed range engaged. The low travel speed range must also be used during cornering. PARKING BRAKE The excavator is equipped with spring loaded disk type parking brakes. These brakes engaging and releasing automatically. They are arranged between the hydraulic motors and travel gears. When the motor/engine is running the parking brakes are automatically released by pilot oil pressure. With the motor/engine at standstill the parking brakes are engaged.

3.12.1.1

TRAVEL ALARM / BACK-UP ALARM

(Special equipment) The excavator can be equipped with one of the above alarm systems. The back-up alarm will sound at reverse travel. The travel alarm will sound at forward and reverse travel.

3.12.2

TRAVELING INSTRUCTIONS

– Never travel the excavator without first making certain that no one will be endangered. – Be sure to sound the signal horn before starting to drive to make your intention clear. – Before traveling long distances slew the superstructure parallel to the undercarriage and apply the slew brake. – When traveling over inclines and gradients raise the working attachment only to such a height, that the bucket has sufficient ground clearance. – Do not travel crossways to slope. – Whenever possible operate the excavator with the sprockets to the rear in the direction of travel. – On steep terrain make sure that the final drives are at the rear in relation to travel direction. – Before traveling over a bridge find out whether its bearing capacity is sufficient for the operating weight of the excavator. – Check for sufficient clearance and use a spotter. – Pay attention to high voltage lines. On rough terrain observe movement of the boom. – Travel speed must conform to local conditions so that the excavator can be stopped at any time. – Change traveling direction only after the excavator is stopped. – In order to avoid damage to track rollers and links, never turn the undercarriage over ditches and troughs. – When working attachment is removed, the reduced stability of the excavator has to be considered during traveling or slewing and when basic boom is operated. The stability can be improved, when the final drives are positioned opposite to counterweight. – Observe permissible tilt angle of the Diesel engine when traveling uphill or downhill (superstructure must be in line with the undercarriage). REMARKS: Refer to Engine Operation Manual for the respective data.

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Please continue reading on the next page.

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Z34195

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3.12.2.1 TRAVELING During travel, high loads and uneven ground cause vibrations which can cause damage to the mounting bolts of the attachment or the hydraulic system. Keep the attachment in a neutral position outside the end position of the cylinders and attachment. The attachment must be hydraulically fixed and must not be controlled by mechanical end-stops of cylinder or attachment stop.

WARNING RISK OF UNEXPECTED MOVEMENT! If the controls of the operator’s cab are left unattended, there is the risk that the excavator may move unexpectedly, resulting is serious injury or death. Do not leave the operator’s cab when the engine is running.

Bring the work equipment in a neutral position as shown on Fig. 3-67. REMARKS: The pistons should be about 150mm from the end-stop. Move the cylinder carefully to final stop and from there about 150mm back. Carefully lift the boom if there is not enough space between the attachment and the ground when traveling.

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3.12.2.2 TRAVELING LONG DISTANCES The maximum permissible operating temperature of traveling gear components is 60°C. In order to prevent the overheating of traveling gear components when traveling with the excavator over extended distances above 500m, observe the following precautions. 1. After traveling 500m, stop the excavator and check the temperature of the following components (see A on Fig. 3-68) : – Bottom rollers – Guide wheels – Top rollers – Travel park brake housing. 2. If the temperature of the components is within the permissible range, continue traveling for a further 500m. 3. Stop the excavator and check the temperature again, as the temperature has a tendency to develop. If the temperature of one of the components is near maximum, cool down to a temperature of at least 20°C below the maximum permitted 60°C. If the temperature of the components is within the permissible range, continue traveling for a further 500m. 4. Repeat the 500m stops and temperature measurements. 5. If the temperature of at least one of the above listed components is higher than 60°C, park the excavator for at least 10 minutes and cool down the components with water. 6. When the final destination of the excavator is reached, shut down the excavator and check the above listed components for leakages and other irregularities. 7. Take action as necessary. It is good practice to keep the attachment near to the excavator when traveling (center of gravity) and to make stationary turns rather than traveling a continuous curve (see B on Fig. 3-68). This practice reduces strain on traveling gear components.

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SLEWING AND BRAKING THE SUPERSTRUCTURE

OPERATION

3.13

SLEWING AND BRAKING THE SUPERSTRUCTURE

3.13.1

SLEWING THE SUPERSTRUCTURE

3.13.1.1

EXCAVATORS WITH "EURO" CONTROL

Legend for Fig. 3-69 ”L” CCW- Lever (1) to the left ”L” ”N” Neutral position ”R” CW- Lever (1) to the right ”R”

WARNING SLEWING! People in the area of the excavator can be seriously injured or killed when slewing. Be sure everyone is in the clear before slewing the superstructure. Never slew or position the attachment or load over persons or vehicle cabs. Never allow anyone to walk or work under the Shovel or load while the Shovel is operating.

NOTE!

For safety reasons, the engine will not switch to low idle when the toggle switch on the control lever is set to the low idle position during slewing. Fig. 3-69

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3.13.1.2

SLEWING AND BRAKING THE SUPERSTRUCTURE

BRAKING THE SUPERSTRUCTURE

Braking of the superstructure from a slewing movement is carried out first by returning the control lever (1) or (2), Fig. 3-70 to the neutral position (N). This procedure can be shortened by depressing pedal (3).

Fig. 3-70

3.13.2

SLEW PARKING BRAKE

The parking brake for the slew gears is a spring loaded disk type brake. This brake is switched ON and OFF with toggle switch (4), Fig. 3-71.

NOTICE PROPER USE OF SLEW PARKING BRAKE! The slew parking brake must only be applied with the Superstructure at complete standstill. Applying the parking brake with superstructure still slewing may result in severe damage to the brake. Use the slew parking brake only in an emergency situation for stopping the rotating superstructure. If the parking brake has been used for emergency stopping, it is necessary to shut down the Excavator and to have the parking brake of each slew gear inspected and repaired if necessary. Contact your Komatsu dealer for support. Be sure to release the slew parking brake before slewing the superstructure.

Fig. 3-71 Switch Positions, Fig. 3-70 –

”0” Parking brake OFF

–

”1” Parking brake ON

Applying the Parking Brake Pull out toggle switch (4) against spring force and move down to position ”1”.

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OPERATION

Releasing the Parking Brake Move up toggle switch (4) to position ”0”. In this position the switch is automatically pulled down by spring force.

3.13.2.1

HYDRAULIC SLEW BRAKE ACTUATED BY HYDRAULIC ACCESS LADDER AND SERVICE ARM OF CENTRAL REFILLING SYSTEM

The hydraulic slew brake will be applied automatically when the access ladder and/or the service arm of the central refilling system is not in its completely lifted position.

3.13.2.2

IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE

WARNING DO NOT slew over persons or over the unprotected cab of a truck. DO NOT level the ground in front of the Shovel by turning superstructure back and forth. DO NOT jump off the rotating superstructure. Never slew against the wall of a pit. First raise the attachment out of the pit and then start rotating the superstructure. Start digging only after finishing the slewing operation.

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3.14

WORKING WITH THE ATTACHMENT

NOTICE UNEXPECTED CONTROL OF THE EXCAVATOR! An incorrect control pattern will result in the excavator reacting unexpectedly. The control pattern shown is set as standard ex-works (Euro). Variations may exist. Please check and con-firm if the control pattern is implemented on your excavator.

Backhoe LH control lever – A - Extending stick – B - Retracting stick RH control lever – C - Filling bucket (roll back) – D - Emptying bucket (roll forward) – E - Lifting boom – F - Lowering boom

Fig. 3-72

Front shovel LH control lever – A - Extending stick – B - Retracting stick RH control lever – C - Emptying bucket (roll back) – D - Filling bucket (roll forward) – E - Lifting boom – F - Lowering boom Fig. 3-73 Version 2021/02

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WORKING WITH THE ATTACHMENT

OPERATION

REMARKS: The raised working attachment can also be lowered with the ENGINE at standstill. If, for example, the engine stalls with the working attachment in a raised position, lowering of the working attachment is possible by moving control lever (2) to position (A). The necessary oil pressure for shifting the spools of the main control valves is provided by a pressure accumulator in the pilot oil circuit. After stopping the engine, relieve the pressure in the hydraulic system. For more information → "STOPPING THE ENGINE" on page 3-152.

3.14.0.1

FRONT SHOVEL BUCKET

OPERATING THE BUCKET CLAM Fig. 3-74 A - Opening the bottom dump bucket: Depress RH pedal B - Closing the bottom dump bucket: Depress LH pedal

NOTICE OPERATION WITH BUCKET COMPLETELY CLOSED! As soon as the bucket is completely closed, release pedal B otherwise the pressure relief valve of the bucket closing circuit will open resulting in unnecessary loading of the hydraulic system.

Fig. 3-74

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3.14.1

WORKING WITH THE ATTACHMENT

COMBINED OPERATION CYCLES

With each of the control levers, two operation cycles can be initiated simultaneously. In order to obtain efficient operation, always select intermediate control lever positions in relation to work load.

Fig. 3-75 shows the pattern for the right hand control lever.

Fig. 3-75

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WORKING WITH THE ATTACHMENT

OPERATION

Legend for Fig. 3-75 (N)

Neutral position

(5)

Raising boom

(1)

Lowering boom

(6)

Raising boom and filling bucket

(2)

Lowering boom and emptying bucket

(7)

Filling bucket

(3)

Emptying bucket

(8)

Lowering boom and filling bucket

(4)

Raising boom and emptying bucket

Fig. 3-76 shows the pattern for the left hand control lever. .

Fig. 3-76 Legend for Fig. 3-76 (N) 3 - 142

Neutral position

(5)

Retracting stick

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WORKING WITH THE ATTACHMENT

(1)

Extending stick (away from excavator)

(6)

Retracting stick and slewing to the left

(2)

Extending stick and slewing to the right

(7)

Slewing to the left

(3)

Slewing to the right

(8)

Extending stick and slewing to the left

(4)

Retracting stick (towards excavator) and slewing to the right

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OPERATION

3.15

WORKING INSTRUCTIONS

3.15.1

STABILITY OF THE EXCAVATOR

WARNING CHECK SURROUNDING AREA FOR STABILITY! Unsafe ground may cause the excavator to tip over, causing serious injury or death. Before beginning work prepare a suitable excavator base to ensure adequate stability for safe working of the excavator.

The stability of the excavator is determined according to DIN 24087 “’Determination of the stability of Excavators’. The excavator must therefore be operated in such away, that it’s stability is always ensured and the danger of tipping over is avoided.

Fig. 3-77

When slewing the superstructure, take into account that the stability of the excavator is reduced when the superstructure (bucket) is turned in a 90° direction to the undercarriage.

Fig. 3-78

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WORKING INSTRUCTIONS

A - Avoid working with the crawler tracks across a slope, as this reduces stability and increases the tendency for the excavator to slide or to tip over. B - Operation on a slope requires special care. Plan your work so that the excavator travels uphill and downhill parallel to the gradient. Do not turn on slopes. Always travel straight up or down a slope ensuring that the sprocket and travel system faces down the hill to the operator. C - The excavator’s stability is reduced when operating on a slope. If the excavator has to work on a slope, pile the loose earth to make a platform that will keep the excavator as horizontal as possible. Fig. 3-79

The illustration shows a few examples of operating and working conditions which can reduce the stability of the excavator: A - Overloading of the shovel (bucket overfilled). B - Ground conditions such as loose sand or wet soil (possibly from a cave in). C - Jerky acceleration or deceleration of working- and travel motions.

Fig. 3-80

A - Do not work below overhanging rocks or earth masses. B - Always keep a safe distance to the edge of an excavation where bank cave-ins are possible.

Fig. 3-81 –

When working with the loader attachment, switch-off the fast speed range (if equipped).

–

Do not jerk the operate control levers and always keep the shovel under control.

–

Know the shovel’s limits - and do not exceed them.

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WORKING INSTRUCTIONS

3.15.2

OPERATION

FURTHER OPERATING PRACTICES

DO NOT use the loader attachments to "sweep" an area in front of the shovel clean as this may result in severe damage on slew gear components.

Fig. 3-82

DO NOT use the bucket clam for loosening or removing anchored rocks or other solid objects since such operations may result in severe damage to the clam pivot bearings.

Fig. 3-83

When cleaning a facing slope, ensure the material is loose (blasted). If the slope is not loose, ensure that the shovel on the attachment does not scrape over protruding rocky outcrops which will cause the attachment to jerk downwards. Do not hammer on to protruding material. These actions will cause sever damage to the attachment components.

Fig. 3-84

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WORKING INSTRUCTIONS

Do not attempt to excavate hard and rocky ground with the working attachment. It is better to excavate it after breaking up by different means.

Fig. 3-85

Do not operate the hydraulic cylinders of the working attachment to the end of their strokes. This will bring excessive force onto the inner stoppers of the cylinders and will reduce the lifetime of the cylinders. To prevent this, move the control levers to neutral position before the cylinders reach their end of stroke.

Fig. 3-86

When working with the bucket in the longitudinal direction, the final drives should be in the rear position for the following reasons: – The travel motors and travel gears are protected from falling rocks etc. – When the shovel is operated on muddy ground and the tracks are covered with mud, the sprocket runs on a clean track when backing up.

Fig. 3-87

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OPERATION

When working with the loader in a cross direction to the track group, be sure that the track is not raised off the ground. This can cause the track to dis-attach from the rollers when it is lowered down on the ground. Also the flanges of the track rollers and the track shoes can be bent by the excessive load.

Fig. 3-88

Do not use the dropping force of the shovel attachment for digging, or use the dropping force as a hammer or breaker. This will drastically reduce the life of the shovel.

Fig. 3-89

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WORKING INSTRUCTIONS

Fig. 3-90

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WORKING INSTRUCTIONS

3.15.3

OPERATION

LOADING TRUCKS

See Fig. 3-90 1. Position the truck as closely as possible to the shovel. 2. Do not slew the attachment over unprotected driver cabs. Slew the attachment at a sufficient height over the loading platform 3. Always keep the shovel as close as possible to the work area. Short boom trips - high efficiency. 4. Distribute material evenly on loading platform. Do not overload the truck. 5. When turning into a pit, the rotating motion must not be stopped by the walls of the pit. 6. Only a bucket with a complete set of teeth and cutting edges in good condition ensures efficient performance. Correct bucket size and properly adjusted equipment prevents overloading and ensures maximum operating efficiency of the Shovel. 7. Loosen hard material and rocks with the bucket, not with the stick crowding thrust.

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3.16

PARKING THE excavator

PARKING THE EXCAVATOR

Park the excavator at a safe place on level and solid ground. –

Lower the working attachment onto the ground in a position as shown in Fig. 3-91.

–

Stop the engines and relieve the pressure in the hydraulic system, refer to section 3.17 on page 3-152 for more information.

Move the lock lever fully to the rear in locked position.

Fig. 3-91

WARNING RISK OF UNEXPECTED MOVEMENT! If the controls in the operator’s cab are left unattended, there is the risk that the excavator may move unexpectedly, resulting in serious injury or death. Do not leave the operator’s cab when the engine is running.

– Be sure to lock the operator’s cab door before leaving the excavator. – If the excavator has to be parked on steep terrain, the track groups must be secured with wedges. – Before leaving the excavator make sure that the parked excavator does not impair local requirements, have consideration for other mining traffic.

3.16.1

CLEANING THE TRACK GROUPS

Fig. 3-92 Under working conditions with excessive material build up on the crawler components, cleaning of the crawlers is very important to prevent damage. Material build up on guide wheels, drive sprockets and tracks can lead to over tensioning of the tracks, resulting in severe damage to these components. If there is danger of frost, the tracks must also be cleaned.

Fig. 3-92 REMARKS: Use a suitable cleaning device for removing dirt, mud and debris from the tracks, rollers, guide wheels and sprockets.

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STOPPING THE ENGINE

3.17

OPERATION

STOPPING THE ENGINE

Fig. 3-93

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STOPPING THE ENGINE

NOTICE STOPPING THE ENGINE FROM FULL LOAD! If a hot engine is shut down without previous idling period of three to five minutes, the temperature in certain engine parts rising sharply after the cooling system ceases to function. The resulting thermal stress, especially in the turbochargers, may cause serious damage. Never stop the engines when the excavator is fully loaded except in cases of emergency! For EMERGENCY STOP of the Engine, use STRIKE BUTTON (9). Additional emergency shut-down switches are located on the power house. For more information → See "MACHINERY HOUSE" on page 3-98.

Stopping procedure, see Fig. 3-93. 1. Park the excavator at a safe place on level and solid ground. –

For more information → See page 3-151.

2. Deposit the working attachment onto the ground, proceed as follows: – A - Backhoe Attachment Lower the backhoe attachment fully extended onto the ground in a position as shown on the oil level plate at the hydraulic oil reservoir, refer to page 3-117 for more information. – B - Bottom Dump Bucket Attachment Lower the bottom dump bucket attachment onto the ground in a position as shown on the oil level plate at the hydraulic oil reservoir, i.e. the stick cylinders are fully retracted and the bucket is fully rolled back so that the bucket back wall contacts the stick. The positions A or B are necessary to prevent unintentional movement of the working attachment when the pressure in the hydraulic system is relieved and for correct checking procedure of the hydraulic oil level. 3. Move all controls into neutral position. 4. Set toggle switch (4) to low idle speed position. 5. Turn switches (8) clockwise to stop position. After the engine has come to standstill, relieve the pressure in the hydraulic system. 6. After the engine has come to standstill, relieve the pressure in the hydraulic system, see chapter "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM" on page 3-155" for more information.

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STOPPING THE ENGINE

OPERATION

Fig. 3-94

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3.17.1

STOPPING THE ENGINE

RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM

REMARKS: With the engine at standstill and main switch (1 Fig. 3-94) in ON position, move all controls for working attachment and crawlers several times through all shift positions to relieve the pressure in the hydraulic system. The necessary oil pressure for shifting the spools of the main control valves is provided by a pressure accumulator in the pilot oil circuit. The pressure accumulator in the pilot oil circuit serves also for lowering a raised working attachment to the ground with the engine at standstill. If, for example, the engine stalls with the working attachment in a raised position, lowering of the working attachment is possible by operating the respective control lever. 1. Set main switch key (1) to ”0” position and remove. 2. Set lock lever to the rear in LOCKED position. 3. Switch off the battery main switches and remove keys.

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AUTOMATIC LUBRICATION SYSTEMS

3.18

OPERATION

AUTOMATIC LUBRICATION SYSTEMS

Fig. 3-95

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3.18.1

AUTOMATIC LUBRICATION SYSTEMS

OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS

The excavator is equipped with two automatic lubrication systems: 1. Central Lubrication System (CLS) for lubrication of the attachment bearings, the slewing connection bearing and the slew gear bearing. 2. Slew ring gear pinion Lubrication System (SLS) for lubrication of the slew ring teeth. These systems work automatically as soon as the engine is running at high idle speed. The slew ring gear lubrication system is only activated during slewing movement of the superstructure. The Komtrax system monitors the function of both lubrication systems. Trouble conditions of the lubrication systems are indicated through fault messages on the Komtrax display. Legend for Fig. 3-95 Electrical components of the Central Lubrication System (CLS) located on the X2 switch board in the cab base 11K103

Pause time relay, factory setting 60 minutes

11K104

Monitoring time relay, factory setting 3 minutes

11K139

Time relay for switching off the bucket motion if the lubrication system fails to function over a period longer than 4.2 hours

11K028

Relay initiates a fault message if power supply to the lubrication system is interrupted

11K030

Relay initiates a fault message if the lubrication cycle is not carried out in the adjusted time period

11K136

Relay initiates a fault message if the grease barrel is empty Electrical components of the Slew ring gear Lubrication System (SLS)

11K007

Pause time relay, factory setting 9 minutes

11K008

Monitoring time relay, factory setting 2 minutes

11K140

Time relay for switching off the bucket motion if the lubrication system fails to function over a period longer than 4.2 hours

11K035

Relay initiates a fault message if power supply to the lubrication system is interrupted

11K037

Relay activates the slew ring gear lubrication system during slewing of the superstructure

11K038

Relay initiates a fault message if the lubrication cycle is not carried out in the adjusted time period

11K138

Relay initiates a fault message if the grease barrel is empty

80B043

Line pressure switch of CLS interrupts lubrication cycle

62B046

Line pressure switch of SLS interrupts lubrication cycle

20S24

Rotary switch for manual actuation of the CLS

20S26

Rotary switch for manual actuation of the SLS

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OPERATION

Fig. 3-96

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AUTOMATIC LUBRICATION SYSTEMS

Operation of the automatic Lubrication Systems (continued) REMARKS: If one of the automatic lubrication systems fails to work for a period longer than 4.2 hours automatic bucket motion cut off will happen. Repair the system as soon as possible. For more information regarding inspection, trouble shooting and maintenance of the lubrication systems, refer to the separate manual LUBRICATION SYSTEMS in volume 2 binder.

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FIRE DETECTION AND SUPPRESSION SYSTEM

3.19

OPERATION

FIRE DETECTION AND SUPPRESSION SYSTEM

(Special Equipment)

Fig. 3-97

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3.19.1

FIRE DETECTION AND SUPPRESSION SYSTEM

FIRE DETECTION AND SUPPRESSION SYSTEMS

REMARKS: Contact certified Ansul Service for maintenance. The mining excavator is equipped with the following systems: –

CHECKFIRE SC-N ELECTRIC DETECTION AND ACTUATION SYSTEM

–

DRY CHEMICAL FIRE SUPPRESSION SYSTEM LT-A-101

–

LIQUID AGENT FIRE SUPPRESSION SYSTEM LVS

The CHECKFIRE SC-N system provides automatic fire detection and automatic or manual actuation of the fire suppression systems. If the CHECKFIRE SC-N system detects a fire it will automatically actuate the suppression systems in two steps. First the DRY CHEMICAL FIRE SUPPRESSION SYSTEM LT-A-101 will be actuated and after a 20 second delay the LIQUID AGENT FIRE SUPPRESSION SYSTEM LVS will be actuated. The dry chemical portion of the twin agent system is primarily responsible for the suppression. Although the LVS wet chemical solution is primarily intended for cooling, it can also aid in suppression by two means: –

The water content of the solution cools the fuel and the surroundings surface areas. Cooling the surrounding surface areas minimizes the change for reflash.

–

Forming a film over the fuel, which aids in securing against reflash.

WARNING THE FIRE SYSTEM MUST BE OPERABLE AT ALL TIMES! In the event of a fire, an inoperable fire detection and suppression system may lead to serious injury or death. Before operating the excavator, make sure the systems function correctly. Carry out inspection and maintenance according to the separate manuals CHECKFIRE SC-N ELECTRIC DETECTION AND ACTUATION SYSTEM and FIRE SUPPRESSION SYSTEMS in volume 2 Binder.

REMARKS: This section covers only such information necessary for the operator to understand operation of the fire detection and actuation system. Further information can be found in the separate manual filed in Vol. 2.

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OPERATION

Fig. 3-98

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FIRE DETECTION AND SUPPRESSION SYSTEM Legend for Fig. 3-98 (1)

Control module of the fire detection and actuation system. Refer to the separate Manual CHECKFIRE SC-N ELECTRIC DETECTION AND ACTUATION SYSTEM for all information concerning Operational Modes, Daily Inspection, Maintenance and System Conditions -.

(2)

Ring pin. For manual actuation of the fire suppression system, pull out this ring and then strike button (3)

(3)

Strike button for manual actuation of the fire suppression system

(4)

Manual / automatic actuator

(5)

LT-5-R cartridge

(6)

Manual actuator switch at the radiator door

(7)

Manual actuator switch at the rear power house door

(8)

High level alarm on operator’s cab

(9)

Pressure switch - DPST located in the cab base. This switch shuts off the engine immediately when the fire detection system has a fire detected. The reset plunger (10) moves out into its upper position. When the fire suppression system has been recharged, push in the reset plunger.

(10)

Reset plunger, be sure to push in this plunger as soon as the fire suppression system has been recharged after actuation of the system.

(11)

Extinguishing agent tanks of the dry chemical fire suppression system LT-A-101 located on power house roof

(12)

Nitrogen expellant gas cartridge for tanks (11)

(13)

Extinguishing agent tank of the liquid agent fire suppression system LVS located on power house roof

(14)

Nitrogen expellant gas cartridge for tank (13)

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OPERATION

Fig. 3-99

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3.19.2

FIRE DETECTION AND SUPPRESSION SYSTEM

HIGH LEVEL ALARM -FIRE-

The high level alarm (8), Fig. 3-99 will sound approximately 15 seconds before discharge of the fire suppression system in case of automatic actuation of the system. Act according to the circumstances and the applying safety regulations. Evacuate area to lessen risk of injury from flames.

3.19.3

ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE

The fuel shut-off solenoid valve for the engine is actuated through pressure switch (9), Fig. 3-99. When the fire detection system detects a fire, the valve will be closed shutting-off fuel supply to the engine (Shutdown of the engine).

3.19.4

ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM

3.19.4.1

MANUAL ACTUATION

Via strike button (3) in operator's cab or strike button of switches (6) on radiator door and (7) at the rear power house door.

WARNING STOP EXCAVATOR BEFORE ACTUATING THE FIRE SYSTEM! Manual actuation will result in immediate system discharge which may obscure vision and result in an accident that could cause serious injury. Make certain the excavator is stopped safely before manually actuating the system. Manual actuation will bypass all auxiliary shutdown and alarm functions.

REMARKS: For manual actuation via switches (4, 6 or 7), pull ring (2/A) and strike button (3/B).

3.19.4.2

AUTOMATIC ACTUATION

Via detection wires routed through the engine room - and hydraulic pump compartment.

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FIRE DETECTION AND SUPPRESSION SYSTEM

OPERATION

Fig. 3-100

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3.19.5

FIRE DETECTION AND SUPPRESSION SYSTEM

INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM

Alarm to Shutdown Period - The RED alarm LED and the audio alarm will pulse at a rate of 2 times per second. Shutdown to Discharge Period - The RED alarm LED and the audio alarm pulses "on" four times per second. Timer Setting (factory adjustment) –

Alarm to Shutdown: 5 seconds

–

Shutdown to Discharge: 10 seconds

WARNING FIRE! Fire can cause serious injuries or death. Act according to the circumstances and the applying safety regulations. Evacuate area to lessen risk of injury from flames, heat, hazardous vapors, explosions, or other hazards that may be created. Evacuate endangered Persons. Inform the fire brigade. Fight the fire.

WARNING FIRE SYSTEM MUST BE OPERABLE AT ALL TIMES! Never operate the excavator with an exhausted fire system. Further fires may cause serious injury or death. For continued protection, the Detection and Actuation System and the Fire Suppression System must be recharged through authorized Service Personnel immediately after operation.

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FIRE DETECTION AND SUPPRESSION SYSTEM

OPERATION

Fig. 3-101

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3.19.6

FIRE DETECTION AND SUPPRESSION SYSTEM

LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF

Legend for Fig. 3-101 -A-

Components of the dry chemical fire suppression system LT-A-101

-B-

Components of the liquid agent fire suppression system LVS

(1)

Extinguishing agent tank assembly of the dry chemical suppression system LT-A-101

(2)

Name plate

(3)

Fill cap

(4)

Extinguishing agent tank assembly of the liquid agent fire suppression system LVS

(5)

Relief valve

(6)

Manual actuator switch at the radiator door

(7)

Manual actuator switch at the rear power house entrance

(8)

From automatic detection system

(9)

Extinguishing agent outlet to nozzle

(10)

Pressure switch for engine shutdown

(12)

Mounting clamp

(15)

Expellant gas Nitrogen cartridge

(20)

Pneumatic actuation line

REMARKS: Check Extinguishing agent tank assemblies (1 and 4) and Expellant gas cartridges (15) for good condition and proper mounting. Check filling level of Extinguishing agent tank assembly (1) of the dry chemical suppression system LT-A-101 according to the instructions in the separate Inspection and Maintenance manual LT-A-101 VEHICLE FIRE SUPPRESSION SYSTEM. When checking the filling level, make sure the extinguishing powder is not compacted. Stir up the extinguishing powder with a suitable stick until it is in a free flowing condition. Check filling level of Extinguishing agent tank assembly (4) of the liquid agent fire suppression system LVS according to the instructions in the separate Inspection and Maintenance manual LVS LIQUID AGENT SYSTEM.

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CENTRAL REFILLING SYSTEM

3.20

OPERATION

CENTRAL REFILLING SYSTEM

Fig. 3-102

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3.20.1

CENTRAL REFILLING SYSTEM

SYSTEMS CONNECTED TO THE REFILLING SYSTEM

The following systems are connected to the receiver panel (5) of service arm (3), Fig. 3-102: –

Fuel Tank

–

Engine Oil Pan

–

Engine Oil Reserve Tank (if so equipped)

–

Engine Coolant Radiator

–

Main Hydraulic Oil Reservoir

–

Central Lubrication System (CLS)

–

Slew circle pinion Lubrication System (SLS)

Legend for Fig. 3-102 (1)

Enabling switch for hydraulic service arm operation

(2)

Actuating chain for lowering and lifting of hydraulic service arm (3)

(3)

Service arm, hydraulically operated

(4)

Monitoring and control box

(5)

Receiver panel

(6)

Actuating chains for Operator Warning System or Emergency Stop of the Engine (if so equipped).

(7)

Actuating chain for emergency lowering of the access ladder

3.20.1.1

OPERATION OF THE HYDRAULIC SERVICE ARM

WARNING SERVICE ARM! Death or serious injury can result when care is not taken around the service arm. Never enter, or allow anyone else to enter the moving range of the service arm (3). Death or serious injury can result.

WARNING HIGH PRESSURE FLUID! High pressure fluid can cause serious injuries. DO NOT loosen any connections on the hydraulic circuit of the service arm. The circuit is under pressure. Lower the service arm completely before carry out any work on the hydraulic circuit.

REMARKS: With Enabling switch (1) in ON position ”1” and/or Service Arm (3) not in fully lifted home position, the pilot control system is inoperative i.e. no excavator movement possible.

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CENTRAL REFILLING SYSTEM

OPERATION

Fig. 3-103

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3.20.2

CENTRAL REFILLING SYSTEM

OPERATING THE HYDRAULIC SERVICE ARM

A - Diesel Engine OFF The Service Arm can only be lowered. Proceed as follows: 1. Turn main key switch to ON position. 2. Turn enabling switch (1), Fig. 3-103 to ON position ”1”. 3. For lowering the Service Arm (3) pull down chain (2). 4. Release chain (2) when arm (3) is in fully lowered position. REMARKS: To stop lowering movement of the Service Arm in any position release chain (2). 5. Before leaving the excavator turn enabling switch (1) to OFF position ”0” and remove the main switch key. B - Diesel Engine running Control the Service Arm as follows: 1. Turn enabling switch (1), Fig. 3-103 to ON position ”1”. 2. To lower the service arm (3) pull chain (2) and hold until the service arm is in fully lowered position. For reversing moving direction of service arm release the chain (2) to stop service arm movement and then pull chain (2) again. When lowering the service arm, the superstructure must always be aligned parallel to the tracks. 3. To lift the service arm pull chain (2) and hold until the service arm is completely lifted into its home position. NOTE!

Be sure the Service Arm is completely lifted to its home position otherwise the proximity switch in the guide frame of the service arm will not release the pilot control system.

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CENTRAL REFILLING SYSTEM

OPERATION

Fig. 3-104

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3.20.3

CENTRAL REFILLING SYSTEM

RECEIVER PANEL WITH MONITOR BOX

Legend for Fig. 3-104 3

Service arm, hydraulically operated

Monitoring and control box

Push button for testing lamps (7, 8, 9 and 10). Push the button, all lamps must light up. If a lamp does not light up, corrective action must be taken.

Indicator lamp, grease container of Central lubrication System FULL. (H76)

Indicator lamp, grease container of Slew circle pinion Lubrication System FULL.(H78)

Indicator lamp, main hydraulic oil reservoir FULL. Recheck hydraulic oil level at the sight gauge before operating the excavator. (H52)

Indicator lamp, engine oil reserve tank FULL. (H142)

Receiver panel

Fuel filling adapter REMARKS: The fuel nozzle cut-out pressure should be adjusted to 0,38 bar. If this pressure is too low for filling the fuel tank up to the correct level, gradually increase the cut-out pressure until the pressure is sufficient for filling up to the correct level The maximum flow rate depends on the fuel refilling equipment used.

Adapter for filling the grease container of the Central Lubrication System (CLS). Before filling the grease container make sure the grease filter in the filling line is not obstructed. Observe lamp (7).

Adapter for filling the grease container of the Slew circle pinion Lubrication System (SLS). Before filling the grease container make sure the grease filter in the filling line is not obstructed. Observe lamp (8).

Adapter for evacuation and filling of the main hydraulic oil reservoir. After the oil is completely evacuated, drain the oil from suction oil reservoir, collector pipe and back-pressure valve pipe. Refer to maintenance section, item hydraulic oil change for draining procedure. Open the shut-off valve between main oil reservoir and suction oil reservoir. Fill the hydraulic reservoir and observe indicator lamp (9).

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OPERATION

Fig. 3-105

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CENTRAL REFILLING SYSTEM

Legend for Fig. 3-105 16

Oil evacuation and filling adapter for engine oil pan. Monitor oil level at level gauge.

Radiator coolant draining and filling adapter. Monitor coolant level at radiator sight gauge. REMARKS: The two-loop type cooling system of the engine is equipped with two radiators. One radiator for the engine crankcase and cylinder heads and one radiator for the low temperature aftercooler (LTA) system. The radiators are connected with a pipe on the bottom side. This pipe contains a check valve which allows coolant flow from rear radiator to the front LTA radiator only. For draining the coolant from the front mounted LTA radiator, it is necessary to open the shut-off cock in the draining/filling hose line just below the radiators. Refer to the engine Operation and Maintenance Manual in volume 2 binder for the maintenance instructions of the cooling system. Be sure to close the shut-off cock on the bottom side of the radiators as soon as the maintenance of the cooling system is finished.

Engine oil evacuation and filling adapter for the reserve tank. Observe the indicator lamp (10).

Refilling Procedure: REMARKS: Refer to Maintenance section 4, for the correct lubricant specifications and filling capacities. For Engine Lubricants and Coolants refer to the separate Engine Operation & Maintenance Manual in volume 2 binder. 1. Connect supply lines to the respective adapters. 2. Monitor the respective fluid/lubricant level at the indicator lights (7, 8, 9 and 10). 3. After finishing the refilling operation, cover the adapters with the protection caps provided and swing back hydraulic service arm (3) to its home position.

NOTICE SUFFICIENT FLUID LEVELS! Insufficient fluid supply can cause damage. Recheck fluid levels before operating the excavator.

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OPERATION

Fig. 3-106

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3.20.4

CENTRAL REFILLING SYSTEM

REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS

Legend for Fig. 3-106 (1)

Grease pressure gauges

(2)

Grease filter for central lubrication system. Before filling the grease container make sure the filter is not obstructed. Service the filter element according to the instructions in the maintenance section 4.

(3)

Grease container of the central lubrication system

(4)

Breather filter

(5)

Grease filter for slew circle pinion lubrication system. Before filling the grease container make sure the filter is not obstructed. Service the filter element according to the instructions in the maintenance section 4.

(6)

Grease container of the slew circle pinion lubrication system

(7)

Grease filter

(8)

Level indicator, grease barrel full

(9)

Level indicator, preliminary warning that grease level is low in barrel

(10)

Level indicator, grease barrel empty

(11)

Dipstick Before reinserting the dipstick, clean its insertion opening and make sure that the dipstick is free of any kind of contamination.

Refill the respective grease container, when the Fault message ”Central lube system grease container empty” or ”Slew circle lube system grease container empty” is displayed on the Komtrax Plus monitor. REMARKS: The central lubrication system and the slew circle pinion lubrication system have to be filled with different types of grease. Select the correct greases according to the Lubricant Charts in volume 2 binder. As soon as a grease container is filled up to the correct level the corresponding indicator lamp (see Fig. 3-105) lights up and the signal horn sounds. In order to ensure proper operation of the lubrication systems carry out the periodic maintenance of the grease filters (2 and 5 Fig. 3-106). REMARKS: Refer to maintenance section 4 for more information. After finishing the refilling operation, cover the adapters with the protection caps provided. Carry out a test-run of the lubrication systems by actuating the switches on the instrument panel.

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TRANSFER PUMP FOR HYDRAULIC OIL

3.21

OPERATION

TRANSFER PUMP FOR HYDRAULIC OIL

Special Equipment

Fig. 3-107

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3.21.1

TRANSFER PUMP FOR HYDRAULIC OIL

OPERATING THE TRANSFER PUMP

Legend for Fig. 3-107 REMARKS: The illustration shows the transfer pump arrangement viewed from center of the platform. (1)

Transfer pump with electric motor

(2)

Cock for suction oil reservoir

(3)

Cock for return oil collector pipe –

C - Closed

–

O - Open

(4)

Operating switch for transfer pump

(5)

Suction line to suction oil reservoir

(6)

Suction line to return oil collector pipe

(7)

Feed back line to main oil reservoir

(8)

Hand wheel of main shut-off valve between suction oil reservoir and main oil reservoir –

To OPEN the valve turn hand wheel (8) CCW to the stop.

–

To CLOSE the valve turn hand wheel (8) CW to the stop.

A proximity switch located on the gearbox of the shut-off valve monitors the valve position. With the valve not fully open a corresponding message will be displayed on the Komtrax Plus screen in the Operator’s cab. REMARKS: Before starting the engine make sure the shut-off valve is completely open by turning hand wheel (8) fully to the left (CCW). (9)

3.21.2

Oil level sight gauge

FUNCTIONS OF THE TRANSFER PUMP

A - Transfusing oil from the suction oil reservoir into the main oil reservoir. Necessary for evacuation of the suction oil reservoir, when changing the hydraulic oil (the main oil reservoir will be evacuated via service arm connector, see page 3-171 for details). Before servicing the main hydraulic pumps it is advisable to empty the suction oil reservoir partially. B - Transfusing oil from return oil collector pipe into main oil reservoir. Necessary when changing the hydraulic oil and prior to servicing the high pressure filters or the main control valves (oil return system). REMARKS: Before operating the transfer pump lower the attachment onto the ground in a position as shown on the oil level plate. Shut down the engine.

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OPERATION

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TRANSFER PUMP FOR HYDRAULIC OIL

A - Pumping the oil from the Suction Oil Reservoir into the Main Oil Reservoir 1. Close main valve (8), Fig. 3-108 2. Open cock (2), position (O). REMARKS: In order to prevent build-up of a vacuum in the suction system, open the vent plug on the suction pipe of each main hydraulic pump. 3. Switch on pump (1) with switch (4). When changing the hydraulic oil, be sure to evacuate the main oil reservoir via the service arm connector simultaneously with the transfusion procedure. Otherwise overfilling of the main oil reservoir. Observe oil level at sight gauge (9). 4. When the suction oil reservoir is empty or after completion of the maintenance job switch off transfer pump (1) with switch (4). Close cock (2), position (C) and open main valve (8). 5. With the main shut-off valve (8) open, the suction oil reservoir will be filled with oil from the main oil reservoir. Let the vent plugs on the main pumps open to allow the air to escape from the suction oil reservoir and hoses. 6. The suction oil reservoir and the suction hoses are filled, when bubble free oil flows out at the vent plugs on each main pump. Close the vent plugs. 7. Check oil level in the main reservoir. Fill up with new hydraulic oil as necessary.

NOTICE NO ENGINE START WITH EMPTY SUCTION OIL RESERVOIR! Hydraulic components can be damaged. Ensure that the suction oil reservoir is sufficiently filled with hydraulic oil.

8. Start the engine and run at low idle speed to allow trapped air to be removed from the hydraulic system. B - Pumping the Oil from the Return Oil Collector Pipe into the Main Reservoir 1. To empty the return oil collector pipe, open cock (3). Open a vent plug on the return oil collector pipe. 2. Switch on transfer pump with switch (4). 3. Observe oil level at sight gauge (9). As soon as the oil level remains constant the return oil collector pipe is empty. Now switch off the transfer pump (1) and close cock (3). Close the vent plug on the return oil collector pipe. REMARKS: During normal operation the valves (2 and 3) must be in closed position (C).

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OPERATION

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3.22

SERVICE CRANE (SPECIAL EQUIPMENT)

Carry out inspection and maintenance according to the separate Crane Instruction Manual "REID" in Vol. 2. Legend for Fig. 3-109 (1)

Service crane (weight 22,5 kg)

(2)

Chain hoist

NOTICE MAXIMUM LOAD! The chain hoist delivered with the machine can be loaded with a maximum of 150 kg. This weight must not be exceeded, otherwise the chain hoist may break. (3)

Column

(4)

Socket extension (weight 15 kg)

(5)

Socket

(6)

Strap

(7)

Ring bolt

(8)

Storage box for service crane and chain hoist

NOTICE DISASSEMBLE THE CRANE DURING THE OPERATION OF THE EXCAVATOR! The crane is not designed to be on the counterweight during the operation of the excavator. It may only be used with the excavator at standstill.

NOTE!

Make sure everyone is in the clear before lifting or lowering a load with the crane. Never slew or position a load over personnel. DO NOT exceed the maximum permissible working load limit of 500 kg for the crane and 150 kg for the chain hoist.

Use of the crane: 1. Ensure that the excavator has stopped operation. 2. Take the crane and the chain hoist out of the storage box (8). Assemble the crane according to the instructions "REID" filed in Vol. 2. Before releasing the jib retaining strap, hang on the chain hoist onto the crane shackle. Observe also the crane operation instructions. 3. After having finished work disassemble the crane and chain hoist accordingly and put it back to the storage box on the machinery house roof (8). Secure the crane in place with straps. 4. Fix the socket extension (4) on the socket (5) with the strap (6) through the ring bolt (7).

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WORK ON THE LOADER ATTACHMENT

3.23

OPERATION

WORK ON THE LOADER ATTACHMENT

WARNING TRAINED PERSONNEL ONLY! Inexperienced workers working on the attachment and who are unaware of the dangers can cause serious accidents, resulting in personal injury. Work on the loader attachment must be carried out only by personnel with special knowledge of the excavator. Improper working on the attachment can cause severe accidents with personal injury. If you are not sure how to carry out the work on the attachment contact your local Komatsu Service Station for support.

3.23.1

OBSERVE THE FOLLOWING INSTRUCTIONS

–

Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this necessary.

–

Provide hoists of sufficient capacity to lift heavy units. Refer to the separate booklet ”Specifications” in volume 2 binder for weight specifications.

–

Be sure to observe the instructions in the ”Assembly Procedure Manual” which is also attached in volume 2 binder.

–

Before working on the loader attachment lower it to the ground, stop the engine and cycle all hydraulic control levers to relieve all pressure before disconnecting hydraulic lines.

–

For more information → See "STOPPING THE ENGINE" on page 3-152.

–

Lifting gear, tools and other suspension systems must be in good condition and of sufficient lifting capacity.

–

Be sure hydraulic cylinders and attachment components are properly supported from hoist and securely fastened before removing supporting pins.

–

Floors must be clean and dry. After draining operations be sure all spillage is cleaned up.

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3.24

TRANSPORTATION AND LIFTING OF THE excavator

TRANSPORTATION AND LIFTING OF THE EXCAVATOR

WARNING CORRECT PROCEDURES! Disassembling, Lifting or Transporting this excavator poses inherent risks, which may lead to serious injury or death. Contact your local Komatsu Service Station for all the necessary instructions for safe and economic disassembling, lifting and transportation procedures of your excavator.

3.24.1

DISASSEMBLING OF THE EXCAVATOR

The excavator is transported disassembled into its main components.

REMARKS: The sequence of disassembly can be derived from the Assembly Procedure Manual in volume 2 binder. Disassembling is basically the reverse order of the assembling procedure.

3.24.2

TRANSPORTATION AND LIFTING

REMARKS: The transport dimensions and weights of the excavator’s components are listed in the separate booklet "Specifications" in volume 2 binder. Observe the operating permits of the low loader used for transportation. They contain the permissible load, loading width and height. –

Observe the federal, state and local laws and regulations for transportation of heavy units. Know the safety rules and laws before you transport this excavator.

–

Make sure the low loader and the components of the excavator are equipped with the correct safety devices.

–

Secure the excavator and all components transported on the low loader against movement.

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RETRIEVAL PROCEDURE

3.25

OPERATION

RETRIEVAL PROCEDURE

–

Before starting retrieval measures, inform the responsible safety department.

–

Check whether fuel or oil has flown out.

–

Observe the local fire prevention- and safety regulations.

REMARKS: Contact your local Komatsu service station for all the necessary instructions for safe and economic retrieval procedures of your excavator. Select the sequence of retrieval steps with regard to the stability of the excavator. It must be prevented that the removal of main components impairs the stability of the excavator.

3.25.1

GENERAL

REMARKS: The ”Assembly Procedure Manual” in volume 2 binder contains information for lifting the main components of the excavator. Provide adequate crane and lifting gear with sufficient lifting capacity, refer to the separate booklet ”Specifications” in volume 2 binder for component weights.

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excavator STORAGE

3.26

EXCAVATOR STORAGE

3.26.1

GENERAL

Storage periods up to 30 days require no special preservation when the unit is stored in a protected place. When the excavator is placed in storage for 30 days or more follow the procedure below. REMARKS: The description below includes special equipment which may not be installed in your excavator.

3.26.2

PREPARING FOR STORAGE

1. Clean the excavator thoroughly, lubricate all points according to the lubrication chart. Move the excavator to a protected place or cover the excavator with a tarpaulin. Retract all hydraulic cylinders as far as possible. Cover the protruding piston rods with grease. 2. Refer to Engine Operation and Maintenance Manual for Engine storage procedure. 3. Fill up cooling system with anti-freeze and coolant. Observe instructions in the Engine Manual. 4. Service the engine air cleaner. 5. Drain condensation from fuel tank and fill the fuel tank with a mixture of 90% Diesel fuel and 10% protection oil, e.g. Shell Ensis 20. 6. Seal the engine air intake, exhaust outlet, electrical components, fuel tank ventilation and breather on the hydraulic oil reservoir to prevent dirt and moisture from entering. 7. Remove the batteries and store them in a cool, dry place (0 to 10° C) to minimize self discharge. Be sure the batteries are fully charged. Never allow batteries to run down below ¾ full charge. 8. Loosen all drive belts. 9. Repaint areas that have paint damage with a good quality paint. Grease all machined unpainted surfaces with good quality grease to prevent rust. 10. Drain condensation from hydraulic oil reservoir. If necessary, add hydraulic oil. 11. Attach a tag to the instrument panel to indicate what work has been done.

3.26.3

ONE MONTH REPETITIVE SERVICE PERIOD

1. Service the engine according to the engine manual. 2. Check coolant level and cooling systems for leakage. 3. Check all oil levels according to the lubrication chart. 4. Drain condensation from fuel tank and hydraulic oil reservoir. 5. Operate air conditioning for approx. ½ hour.

3.26.4

SIX MONTH REPETITIVE SERVICE PERIOD

1. Perform steps 1 through 4 of the one month repetitive service period. 2. Lubricate the excavator according to lubrication chart (manual lubrication only). 3. Completely fill the fuel tank.

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excavator STORAGE

OPERATION

4. Check hydraulic system and all gear boxes for leakage. If necessary - fill up the units with the specified lubricant. Repaint surfaces that have paint damage. 5. Prepare the engine for operation according to the engine manual. Tighten all drive belts. Install fully charged batteries. Make sure the alternator is correctly connected. 6. Remove coverings from engine air intake, exhaust outlet, electrical components, fuel tank ventilation and breathers on the hydraulic reservoir. 7. Start the engine and run at low idle a few minutes to allow distribution of lubricating oil. DO NOT increase engine speed until normal oil pressure and temperature are reached. 8. Operate heater unit and air conditioning. 9. Operate the central lubricating system and slew ring gear lubrication system. Check the lubrication results at the respective lubrication points. 10. Carry out several complete working cycles with the loader attachment. 11. Stop the engine, observe the cooling down period. Install all coverings which have been removed according to step 6. Service the engine according to the engine manual. Lubricate all machined surfaces. Remove Batteries and store as described under "Preparing for Storage". Loosen all drive belts. Fill up the fuel tank.

3.26.5

PREPARING FOR OPERATION

1. Remove grease from all machined unpainted surfaces (piston rods). 2. Install fully charged batteries. 3. Remove all coverings. 4. Fill up fuel tank with an approved Diesel fuel. 5. Check cooling system for leaks, loose connections and coolant level. Check mixture ratio of antifreeze, refer to the engine manual for details. 6. Service the engine according to the engine manual. Tighten all drive belts. Make sure the alternator is correctly connected. 7. Carry out the maintenance according to the lubrication and maintenance manual of the excavator. 8. Start the engine and run at low idle speed until the normal oil pressure and temperature are reached. DO NOT place the excavator under load before the normal values are indicated. 9. If the engine is misfiring or loss of power is evident, check the fuel system for restriction or loose parts. 10. Carry out several complete working cycles. Check the function of special equipment (central lubricating system, slew circle pinion lubricating system, fire detection and suppression system etc.).

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TROUBLE SHOOTING

3.27

TROUBLE SHOOTING

3.27.1

GENERAL

The following charts list a number of the most common problems encountered in operation. Some of the faults may be due to careless handling or operation, improper maintenance or the use of lubricating oils other than specified. The “Probable Cause” column is formulated in such a way as to imply the answer to particular failure. For repairs requiring expert knowledge and tools, consult authorized service personnel.

3.27.2

ENGINE

Problem

Probable cause

Engine will not start

–

Fuel tank empty or filter clogged

–

Fuel supply system air-bound or clogged

–

Fuel filters not sealed properly

–

Engine speed control system defective

–

Cold starting aid, fluid container empty

–

Fuel filters clogged

–

Air in fuel system

–

Engine speed governor defective

–

Coolant supply insufficient

–

Fan belt slipping

–

Coolant passages in cooling system clogged with dirt or scale

–

Radiator air passages clogged with dirt

–

Exhaust pipe or muffler restricted

–

Thermostat defective

–

Air cleaner clogged

–

Fuel filters clogged

–

Exhaust pipe or muffler restricted

–

Engine speed control system incorrectly adjusted

–

Valve (s) faulty

–

Fuel lines restricted

–

Turbocharger faulty, or inoperative

–

Oil filter (s) clogged

–

Low oil level

–

Poor quality oil

–

Oil pressure switch defective

–

Oil pump filter screen clogged

–

Dirt in regulating valve

–

Crankshaft, connecting rod or camshaft bearing (s) worn excessively.

Uneven engine operation

Engine overheats

Engine does not develop full power

Loss of oil pressure

REMARKS: Refer to the engine manual for more detailed information.

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3.27.3

OPERATION

HYDRAULIC SYSTEM

Problem

Probable cause

Poor hydraulic system performance

–

Hydraulic oil not at operating temperature.

–

Engine speed too low.

–

Reservoir low on oil

–

Restrictions in lines

–

Cooling circuit, pump control system and/or pilot control circuit defective.

–

Internal leakage (control blocks, valves or power units.)

–

Pressure lines twisted or kinked

–

Spool not in full stroke.

–

Relief valve defective, or out of adjustment.

–

Worn cylinders.

–

Defective hydraulic pump.

–

Low oil level

–

Incorrect viscosity or type of oil

–

Hydraulic oil cooler clogged with dirt.

–

Oil cooler fan defective or wrong speed.

–

Cooling circuit defective

–

Pump control system defective

–

Spool not in full stroke.

–

Internal leakage (control blocks, valves or power units)

–

Worn pump components

–

Job conditions (high temperature of materials being handled)

–

Piston rod bent

–

Piston sticking

–

Inside diameter of cylinder tube partially increased or scored

–

Air in control circuit

–

Oil too cold

–

Valve spool sticking, centering springs defective

–

Pump and/or engine control system defective

–

Valve of power circuit defective

–

Insufficient lubrication of slew ring gear and/or slewing connection.

–

Slewing connection mounting bolts loose

–

Drive pinion worn

–

Slew gear bearings worn

–

Sun gear or planetary pinions worn

–

High pressure circuit valves defective

–

Anti-cavitation valves sticking

Excessive oil temperature

Jerky motion of power cylinders

Noise when slewing

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TROUBLE SHOOTING

Excessive oil foaming

3.27.4

Air in hydraulic system

–

Poor quality oil

–

Excessive by-passing of oil over relief valves

–

Pressure hoses badly twisted or kinked

–

Restricted oil flow due to foreign matter

–

Breather on the reservoir clogged.

–

Relief valve improperly adjusted

FINAL DRIVES AND SLEW GEAR

Noisy operation

3.27.5

–

Incorrect lubricant or oil level too low

–

Bearings scored or damaged.

–

Sun gear teeth excessively worn or damaged

–

Bearings of planetary pinions worn

CRAWLER TRACKS

Excessive track wear

Excessive wear on drive sprocket

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–

Wrong track tension

–

Track roller loose or out of alignment

–

Track shoes loose

–

Track links stuck

–

Worn drive sprocket

–

Wrong track tension

–

Track links (pins/bores) Excessively worn

–

Sprocket, rollers and guide wheel out of alignment

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4 MAINTENANCE

4 -1

FOREWORD

MAINTENANCE

4.1

FOREWORD

This section contains instructions for the correct care and maintenance of your excavator. REMARKS: Since this section covers also special equipment and accessories, you may find illustrations and descriptions which do not apply to your excavator. Some illustrations are examples and may differ from the original.

4.1.1

DEFINITIONS

Service point Unit or system where the prescribed maintenance work has to be performed (e.g. engine, hydraulic, PTO etc.). Service intervals Number of operating hours after which the maintenance work has to be performed (e.g. “Every 10 Operating Hours”, at 10, 20, 30 etc.; “Every 250 Operating Hours”, at 250, 500, 750 etc.).

4.1.2

GENERAL RECOMMENDATIONS

Thoroughly clean all grease fittings, caps and plugs before lubricating. Seals must be replaced when oil drain plugs and oil level plugs have been opened. Fill-up fuel tank at the end of the shift to prevent condensation of moisture. It is recommended to carry-out oil change in assemblies when they are still at operating temperature to speed up draining.

CAUTION BEWARE OF HOT OIL! Hot oil can cause serious personal injury. Avoid direct contact of hot oil with your skin.

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4.2

PRECAUTIONS FOR MAINTENANCE

–

Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 2-23.

–

Park the Excavator at a safe place on level ground. Proceed according to the instructions on page 3-151. ”Parking the Excavator”. Lower the attachment flat onto the ground. Move all control levers to neutral position.

–

Stop the engine and move all control levers through their shift positions to relieve the pressure in the hydraulic system. Refer to chapter "STOPPING THE ENGINE" on page 3-152 for detailed description of the stopping procedure.

–

A warning plate ”CAUTION MACHINE MAINTENANCE” must be fixed in the Operator’s cab before any lubrication or maintenance work is started.

–

Before any maintenance work is started, set the maintenance safety switch to 0 position. Refer to page 3-99 for location of the maintenance safety switch. In the 0 position the engine can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten padlocks can be attached to the holes provided.

REMARKS: Some checks and adjustments can only be done with the engine running. For such jobs two men are necessary. Thereby, the controls must not be left unattended, while the other man carries out checks and adjustments. The man in the operator’s seat must keep constant visual contact with the other one and they must agree on suitable communication signals before they start their work. –

Block the excavator to prevent excavator movement.

–

Always use safety devices to block hydraulic cylinders. Never rely on the excavator hydraulic system to hold when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidently strike the control levers causing the loader to fall.

–

Relieve all pressure in the hydraulic system before servicing the hydraulic system.

–

Oily cloth and flammable material must be removed from the excavator. Clean the excavator before starting maintenance work.

–

Switch-off battery main switch and remove key, before working on the electrical system.

–

Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this necessary. Observe the local safety rules.

–

Never allow unauthorized persons access to the excavator during lubrication and maintenance work.

–

After servicing, remove oily cloth, flammable material and all tools from the excavator.

–

Clean the Excavator with a steam jet, especially after servicing fuel system, engine and hydraulic system.

CAUTION BEWARE OF STEAM! Hot steam can cause serious personal injury. When using a steam cleaner, wear safety glasses and protective clothing.

–

For cleaning the Excavator and its components use only fresh water with a salt content of less than 0.05%.

–

For cleaning the headlights, DO NOT use steam jet, high pressure cleaning device or strong water jet.

–

Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the excavator.

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FLUIDS AND LUBRICANTS

MAINTENANCE

4.3

FLUIDS AND LUBRICANTS

4.3.1

FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES

Point of Lubrication

Lubricant

Engines

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for Specifications of Engine Oil, Coolant and Fuel. *4)

Hydraulic System

Hydraulic oil HLP or HLPD with ZINC anti-wear additives *1)

Travel gears, Final drives and Slew gear

Brake housings and Motor adapter housings of Travel Gears and Slew Gear *3) PTO (Pump distributor gear)

Ambient Temperature °C

Viscosity Grades

- 20 to + 11

-14 to + 21

- 6 to + 31

0 to + 40

+ 5 to + 48

100

Gear oil CLP *2)

-15 to + 50

CLP 220

Engine oil

all

SAE 10

or Hydraulic oil

Quality Grades DIN/API

DIN 51524 T.2

DIN 51517 3 - CLP

HLP 22 or HLP 32

DIN 51524T.2 and T.3HVLP

Gear oil CLP *2)

-15 to + 50

CLP 150

DIN 51517 3 - CLP

Pump drive shaft housings

Hydraulic oil

all

HLP 32

DIN 51524T.2 and T.3HVLP

Fan bearing housings of Hydraulic oil cooler

Gear oil CLP

all

CLP 220

DIN 51517 3 - CLP

Grease Fittings (manual lubrication)

Multi-Purpose Grease ”MPG”

Refer to the Lubricant Chart in volume 2 binder for the recommended Multi-Purpose Greases. The part numbers of recommended MultiPurpose Greases are listed in the Parts Catalog.

Adhesive Lubricant

Refer to PARTS & SERVICE NEWS, Bulletin No. AH11501 for the recommended Adhesive Lubricants.

Central Lubrication System Slew Circle Teeth (manual lubrication) Slew Circle Pinion Lubrication System

The part numbers of the recommended Adhesive Lubricants are listed in the Parts Catalog.

Track rollers and Carrier rollers

Grease

-40 to +40

Castrol Tribol GR 3020/1000-000 PD *5)

Idler wheels

Gear oil ”CLP"

all

CLP 220

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Ambient Temperature °C

Viscosity Grades

Quality Grades DIN/API

Point of Lubrication

Lubricant

Air conditioning system

Refrigerant

R 134a

Refrigerant

Special oil

compressor

See Note below.

The Air Conditioning is prepared for Refrigerant ”R134a” only. Observe Notice below.

–

*1) DO NOT mix ZINC-FREE Hydraulic oils with Hydraulic oils containing Zinc. DO NOT mix Mineral Hydraulic oils with Synthetic Hydraulic oils. Mixing of the above oils, will reduce anti wear properties and oxidation stability of the oil. Quick plugging of the oil filters in the hydraulic system will occur.

–

*2) Refer to the chart GEAR OILS filed in volume 2 binder for the released gear oil qualities and viscosity grades.

–

*3) Brake housings of slew gears type 2063 have no separate oil compartment, as brake disks are lubricated by splash oil from gear box.

–

*4) Komatsu Super Coolant AF-NAC is acceptable to be used as antifreeze in the cooling system of the engines.

–

*5) The Castrol Tribol GR 3020/1000-000 PD is now yellow in color when new and no longer red. Red however may still exist.

–

The lubricating instructions in this book refer to the recommended grade specifications. Damages caused by using lubricants other than specified are not covered by the manufacturer's warranty.

NOTICE USE CORRECT REFRIGERANT FOR AIR CONDITIONING! The Air Conditioning must be filled with refrigerant ”R134a” through authorized Service Specialists only. DO NOT use refrigerant ”R12”, otherwise serious damage on system components could occur. The lubrication oil for the refrigerant compressor must be compatible with ”R134a” refrigerant.

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FLUIDS AND LUBRICANTS

4.3.2

MAINTENANCE

LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES

Lubrication Point

Lubricant

Ambient Temperature °C

Hydraulic System (preheated)

Komatsu Mining Arctic *6) Mobiltrans AST 20

- 50 to + 35 - 45 to + 28

Travel Gears

Shell Omala S4 GX 220

All seasons

Final Drives

Shell Omala S4 GX 220

All seasons

Slew Gear

Shell Omala S4 GX 220

All seasons

Track rollers and Carrier rollers

Grease

-40 to +40

Idler wheels

Gear oil ”CLP"

all

Pump Distributor Gear

Shell Transaxle Oil 75W-90

All seasons

(preheated)

Transmission SYN FE 75W-140

- 45 to + 35

Pump drive shaft housings

Komatsu Mining Arctic *6)

-50 to +35

Brake housings and Motor adapter housings of Gears

Komatsu Mining Arctic *6)

-50 to +35

Fan Bearing Housings of Hydraulic Oil Cooler

Shell Omala S4 GX 220

All seasons

Central Lubrication System

Fuchs Stabyl L-TS MO

- 10 to + 35

Shell Gadus S5 U100D1

- 30 to + 35

Fuchs Urethyn HGO

- 50 to - 10

Shell Gadus S2 OG 80

- 10 to + 35

Shell Gadus S2 OG 15

- 30 to

Fuchs Urethyn HGO

- 50 to - 10

Refrigerant Lubricant

Shell Clavus Oil R 68

- 50 to + 35

Refrigerant

Shell R 134 a

- 50 to + 35

Engine Oil

SAE15W-40 API Category CG-4SJ

All seasons

Engine Coolant and Fuel

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for Specifications.

Slew Circle Lubrication System

*6) Please refer to section 4.3.2.1 on page 4-7 for recommended hydraulic oil products. This hydraulic oil is also known as Shell Tellus S4 VX 32.

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4.3.2.1

FLUIDS AND LUBRICANTS

RECOMMENDED HYDRAULIC OILS

Komatsu Germany recommends using Komatsu Genuine Hydraulic Oil in the hydraulic system as it is formulated especially for Komatsu using the latest tribological technology. It is designed to maintain the reliability and durability of Komatsu excavators, ensuring extended fluid lifetimes and improved anti-wear characteristics of metallic hydraulic components.

Hydraulic System using Komatsu Genuine Hydraulic Oil according to DIN 51524 part 2 (HLP) and part 3 (HVLP) and KES 07.841.1

Environment acceptable oil (according to ISO 15380 HEES)

Komatsu Lubricant

Ambient Temp. °C

Komatsu Mining Arctic

-50°C to +35°C

HO-MVK

-30°C to +50°C

HO46-HM

-20°C to +50°C

HO68-HM

0°C to 40°C

HO100-HM

+5°C to +50°C

BO46-G3A

-20°C to +50°C

BO46-G4

-20°C to +50°C

NOTICE CORRECT USE OF FLUIDS! Incorrect use of fluids can cause damage. Please note the following information: *1) DO NOT mix ZINC-FREE Hydraulic oils with Hydraulic oils containing Zinc. DO NOT mix Mineral Hydraulic oils with Synthetic Hydraulic oils. Mixing of the above oils, will reduce anti wear properties and oxidation stability of the oil. Quick plugging of the oil filters in the hydraulic system will occur. *2) Refer to the chart GEAR OILS filed in volume 2 binder for the released gear oil qualities and viscosity grades. *3) Brake housings of slew gears type 2063 have no separate oil compartment, as brake disks are lubricated by splash oil from gear box. The lubricating instructions in this book refer to the recommended grade specifications. Damages caused by using lubricants other than specified are not covered by the manufacturer's warranty. The Air Conditioning must be filled with refrigerant ”R134a” through authorized Service Specialists only. DO NOT use refrigerant ”R12”, otherwise serious damage on system components could occur. The lubrication oil for the refrigerant compressor must be compatible with ”R134a” refrigerant.

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FLUIDS AND LUBRICANTS

4.3.2.2

MAINTENANCE

GENERAL INFORMATION TO SELECTING HYDRAULIC OILS

Hydraulic oil can be viewed as an essential excavator component and therefore constitutes careful and correct selection. General Information The make up of hydraulic oil can be broken down as so:Base oil + additives = hydraulic oil API Oil Categories Base oils can be made from mineral oils or synthetic oils. Type

Category

Refinery process

Viscosity index

Mineral

Solvent refined

80-120

Hydrotreated

80-120

III

Hydrocracked

>120

Synthetic

Polyalphaolephins (PAOs)

All other base oils not included in groups I, II, III and IV

Additives There are a variety of additives that are added to the base oil when blending hydraulic oils. These serve definitive required purposes. –

Foaming resistance and air release

–

Thermal, oxidation and hydrolytic stability

–

Anti-wear performance

–

Filterability

–

Demulsibility (water release capabilities)

–

Rust and corrosion inhibition

–

Viscosity improvement

The range and difference of one hydraulic oil to the next could therefore be great, and the mixing of them in a hydraulic system could be potentially catastrophic to the hydraulic components. Example: Hydraulic oil 1 - Made up of a group II base oil (hydrotreated mineral oil) with a foam resistance additive, water separation capabilities and a zinc containing anti-wear additive. Hydraulic oil 2 - made up of a group IV base oil with a foam resistant additive, water separation capabilities, viscosity improvers and a zinc-free (ashless) anti-wear additive There may be reasons why these two examples of hydraulic oils may be incompatible. – The incompatibility of the mineral oil (group II) with the synthetic based oil (group IV) – The incompatibility of the anti-wear additives (zinc containing with zinc free) – Different anti-foam agents when mixed may actually contribute to an increase in foaming. – Different water separating characteristics may actually cause water to separate too much, leading to increased emulsion formation.

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Conclusion The minimum requirement from Komatsu Germany is that the hydraulic oil must conform to DIN 51524 Part 2 (HLP) or part 3 (HVLP) and fulfill the viscosity requirements for the prevailing ambient temperature at the site of operation. We state that: –

Mixing of zinc containing with zinc-free (ashless) hydraulic oils is not allowed, even in small amounts.

–

Mixing of mineral based hydraulic oils with synthetic based hydraulic oils is not allowed.

It is essential that the customer queries the hydraulic oil producer to the compatibility and miscibility of hydraulic oils before changing or employing them in the hydraulic system of the excavator. All recommendations for miscibility and compatibility are entirely the responsibility of the lubricant manufacturer and for the implementation of those recommendations, entirely the responsibility of the customer using the guidelines given above by Komatsu Germany. Komatsu Germany will not accept liability for any damage to the hydraulic components resulting from the incorrect mixing of hydraulic fluids.

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FILLING CAPACITIES

4.4

MAINTENANCE

FILLING CAPACITIES

Unit or System

Liter (approx.)

Engine cooling system

360.0

Engine oil pan

190.0

Engine oil reserve tank (special equipment)

510.0 (424.0 Refill)

Fuel tank

4500.0

Hydraulic oil reservoir

2900,0

Hydraulic system

4400.0

PTO type 2063

87.0

PTO type 631650

64.0

Pump drive shaft housings on PTO

*1)

Slew gear type 2063

42.0

Motor adapter housing

0.6

Slew gear type 632770

60.0

Motor adapter housing

0.6

Brake housing

0.3

Grease container

165

Motor adapter housing

1.5

Brake housing

0.6

Travel gears, each: Planetary gear housing

60.0

Spur gear housing

7.5

Motor adapter housing

1.5

Brake housing

0.12

Track rollers, each

1.25

Guide wheels, each

2.7

Support rollers, each

2.8

Water tank for windshield washer system

7.0

REMARKS: Capacities listed above are approximate values. For proper checking use level plugs, dipsticks, and inspection openings, provided for this purpose. *1) Fill up to lower edge of level plug opening.

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4.5

STANDARD TORQUE LIST

NOTICE GENUINE KOMATSU BOLTS! When using or replacing bolts, always ensure that the bolt is compatible to the component, is in no way damaged or faulty, and is a genuine Komatsu replacement part.

Wrench size (mm)

Tightening torque MA (Nm)

Bolt size (mm)

Quality Grades 8.8

10.9

12.9

M 8

M 10

M 12

108

127

M 14

118

173

202

M 16

179

265

310

M 18

255

360

425

M 20

360

510

600

M 22

485

690

810

M 24

620

880

1030

M 27

920

1310

1530

M 30

1250

1770

2080

M 33

1690

2400

2800

M 36

2170

3100

3600

2800

4000

4700

3500

4950

5800

4350

6200

7200

5200

7500

8700

6700

9600

11200

8400

12000

14000

10400

14800

17400

12600

17900

20900

100

15200

21600

25500

M 39 M 42

M 45 M 48

M 52 M 56

M 60 M 64 M 68

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STANDARD TORQUE LIST

4.5.1

MAINTENANCE

TORQUE FOR FLANGE JOINTS

Fig. 4-1 Reference

Connection

Connecting parts

Tightening torque

Quality

M12 = 108 Nm

10.9

Tube to tube

4 x Bolt and nut

M14 = 173 Nm

10.9

Tube to connector plate

4 x Cylinder head screw

M16 = 265 Nm

10.9 10.9

M20 = 510 Nm

Reference

Connection

Connecting parts

Tightening torque

Quality

M12 = 074 Nm

8.8

Hose to tube

4 x Cylinder head screw and nut

M14 = 118 Nm

8.8

Hose to connector plate

4 x Cylinder head screw

M16 = 179 Nm

8.8

M20 = 360 Nm

8.8

NOTICE BOLT TORQUE! The torque values given in these charts are only valid for bolts manufactured according to DIN (German Standard). Threads and bolt heads must be lubricated with a multi-purpose grease (MPG - as found for example, in the Central Lubricating System grease barrel) except connections for the slew circle and the car body. These must be lubricated with Detroit Diesel International Compound #2® only. The contact surfaces of parts which should be screwed together have to be free of grease. For other special tightening torques, please refer to the Parts & Service News AH00521.

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4.5.2

STANDARD TORQUE LIST

TORQUES FOR SPECIAL COMPONENTS

1. Transmission oil pump with aluminium housing (PC3000-6 only)

Fig. 4-2

2. Spool cover for main control block for PC3000 and PC4000 (MO 40)

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STANDARD TORQUE LIST

MAINTENANCE

3. Spool cover for main control block for PC5500 and PC8000 (MO 52)

Fig. 4-4 4. Electrical connections (medium-high voltage) at contact bars The following tightening torques are valid for direct current and alternating current to 60 Hz. The threads and the heads have to be lubricated with multi-purpose grease Size

Tightening Torque

15Nm

M10

30Nm

M12

60Nm

M16

120Nm

5. Tightening torque for electrical isolators (threads of brass) Size

Tightening Torque

6Nm

15Nm

M10

32Nm

M12

45Nm

M16

110Nm

M20

220Nm

M24

295Nm

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4.6

LUBRICATION AND MAINTENANCE SCHEDULE

4.6.1

INITIAL SERVICING

NOTICE INITIAL SERVICE! The initial service described here is of vital importance for proper operation and long service life of the excavator.

4.6.1.1

INITIAL RUNNING-IN

Check the functionality of the greasing systems. For the CLS greasing system, check the injectors and greasing points on the attachment, the carbody and the inner raceway of the slew circle. For the SLS greasing system, check the injectors for the flywheel of the teething of the slew gear. Regarding the slew circle, check the torque of the bolt connections and regarding the crawler carrier, retighten the mounting bolts. See page 4-28 for further information.

4.6.1.2

AFTER THE FIRST 250 OPERATING HOURS

Change oil in Slew gear, Travel gears and PTO (pump distributor gear). Thereafter every 3000 hours, but at least once a year. An oil sample analysis should be made every 1000 operating hours. Hydraulic system: Replace return oil filter elements and leakage oil filter element. Inspect return oil strainers. Thereafter every 1000 hours. REMARKS: During the initial 250 hours of operation, an increased amount of wear materials may collect on the return oil and leakage oil filter elements. This is a normal occurrence caused during the running-in of the excavator and does not effect the quality of the hydraulic oil or the operative capabilities of the hydraulic components. The tightening torques of all critical bolt connection, except the undercarriage to car body bolts and the slew circle mounting bolts, are to be checked after the initial 250 operating hours. Flexible coupling: Inspect visually, for further information refer to separate Manual CENTA Coupling filed in volume 2 binder.

4.6.1.3

AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT

Check tightening torque of critical bolt connections. Thereafter every 1000 hours. –

The mounting bolts of the left and right crawler carrier to the undercarriage carbody have to be retightened only after the first 1000 operating hours, see page 4-37 for retightening procedure.

–

The slew circle connection bolts need only to be checked after the first 1000 operating hours in accordance with PARTS&SERVICE NEWS No. AH00511.

–

The tightening torques of all critical bolt connections are to be checked after the initial 1000 operating hours.

–

All critical bolt connections are to be checked immediately in cases of unexpected impacts, collisions or when loosening is suspected (peeling paint on the screws or obvious signs of unscrewing). It is strongly recommended to use new bolts when attaching replacement components.

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LUBRICATION AND MAINTENANCE SCHEDULE

4.6.2

MAINTENANCE

SERVICING THE CRITICAL BOLT CONNECTIONS

over a 6000 hour operating period Bolt Connection

250h

2000h

3000h

4000h

5000h

6000h

check

visual

check

visual

check

Counterweight

check

Slew gears

check

Undercarriage to car body

check first 1000h only

Slew circle connections Radiators, oil tank, fuel tank, walkways, machinery house, gears etc Cabin to cabin base

4.6.3

1000h

Initial Check

PERIODIC SERVICING INTERVALS

All following intervals of time between services are based on average operating conditions. Under unusually severe conditions of operation, reduce the interval of time between services.

4.6.4

PERIODIC SERVICING SCHEDULE

4.6.4.1 WHEN NECESSARY Service Point

Service

See

Engine Air Cleaners

Maintenance

page 4-43

Slew circle toothing

Immediately apply grease if bare spots are visible

page 4-47

Automatic lubrication systems

Fill grease containers Clean or replace filter elements

page 4-49

Guide wheels

If leakage occurs replace floating seals and fill with gear oil CLP 220

page 4-51

Cold starting aid

Replace fluid cartridge

page 4-53

Cylinder rod protection

Exchange cylinder protection sliding blocks

page 4-121

Complete excavator

Clean

page 4-55

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4.6.4.2 EVERY 10 OPERATING HOURS OR DAILY Service Point

Service

See

Excavator

Walk-around inspection

page 4-59

Air cleaner

Clean precleaner

page 4-65

Radiator

Check coolant level

page 4-67

Track groups

Clean, especially in winter

page 4-67

Fuel system water separator

Drain water

page 4-69

Ground cables for engine and cab

Check connection

page 4-63

Electrical Equipment

Visual check

page 4-71

Emergency escape from cabin

Visual check

page 4-73

Engine

Check oil level

(1)

Fire detection and actuation system

Inspections

(2)

4.6.4.3 EVERY 50 HOURS OR WEEKLY Service Point

Service

See

Slew gear and Motor adapter housing

Check oil levels

page 4-75

Travel gears, Brake housings and Motor adapter housings

Check oil levels

page 4-79

PTO (Pump distributor gear)

Check oil level

page 4-83

Hydraulic access ladder

Check safety sensor

page 4-85

Hydraulic oil cooler and radiator

Check and clean as necessary

page 4-87

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MAINTENANCE

4.6.4.4 EVERY 250 HOURS OR MONTHLY Service Point

Service

See

Refrigerant compressor

Check drive belt tension

page 4-89

Radiator fan belt and automatic belt tensioner

Maintenance check

page 4-91

Generator

Check drive belt tension

page 4-95

Signal horn compressor

Lubricate

page 4-97

Oil cooler fans

Check condition and fastening

page 4-97

Automatic lube systems

Clean breather filter

page 4-99

Cab, air filter

Clean or replace filter element

page 4-101

Windshield washer reservoir

Check fluid level

page 4-103

Air conditioning for Operator's cab

Inspection

page 4-105

Engine

Maintenance

(1)

Fire suppression system

Inspection

(2)

Eliminator filter

Maintenance check

(4)

4.6.4.5 EVERY 500 HOURS OR QUATERLY Service Point

Service

See

Batteries

Check fluid level

page 4-107

Fuel tank

Drain condensation

page 4-109

Crawler tracks

Inspection

page 4-111

Automatic lubrication systems

Check grease injector pins for proper function (move in and out freely). Remove excess grease.

page 4-116

Emergency lowering of access ladder

Test functionality

page 4-119

Cylinder rod protection (if equipped)

Inspect

page 4-121

Fire detection and actuation system

Maintenance

(2)

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4.6.4.6 EVERY 1000 HOURS OR 6 MONTHLY Service Point

Service

See

Critical bolt connections for cabin mounting, for counterweight and for slew gears

Check for correct tightening torque and security

page 4-123

Hydraulic system

- Replace return and leakage oil filter elements - Clean or replace pressure filter elements - Clean or replace high pressure filter elements - Replace breather filter elements - Drain sediments

page 4-129

PTO (Pump distributor gear) Slew gear and Travel gears

Oil sample analysis

page 4-147

Signal horn compressor

Clean and lubricate

page 4-149

Hydraulic track tensioning system

Check pressure accumulators

page 4-151

Hydraulic oil cooler doors and machinery house doors

Inspect and lubricate door hinges

page 4-153

Emergency engine shutdown switches

Test functionality

page 4-155

Engine shutdown pull chains

Test functionality

page 4-157

Electrical equipments

Maintenance

page 4-159

Air cleaners

Inspect and lubricate door hinges

page 4-161

Oil separator element

Replace breather filter

page 4-163

Engine

Maintenance

(1)

Fire suppression system

Maintenance

(2)

Air conditioning

Inspect the complete system

(3)

4.6.4.7 EVERY 2000 HOURS OR YEARLY Service Point Hydraulic system

Service Change oil (*)

See page 4-165

Replace suction strainers (*) Replace pulsation damper Emergency escape ladder

Inspect

page 4-179

Preventative Maintenance (PM) Test

Perform test

page 4-181

Hydraulic hoses, attachment

Check

page 4-183

Emergency escape from cabin

Check functionality

page 4-185

Fire detection and actuation system

Maintenance

(3)

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MAINTENANCE

4.6.4.8 EVERY 3000 HOURS HOWEVER AT LEAST ONCE A YEAR Service Point

Service

See

Slew gear and Motor adapter housing

Change oil

page 4-187

Travel gears, Brake housings and Motor adapter housings

Change oil

page 4-195

PTO (Pump distributor gear)

Change oil

page 4-199

Critical bolt connections (6)

Check for correct tightening torque and security

page 4-203

Oil separator element

Replace

page 4-221

Engine

Maintenance

(1)

Flexible coupling

Inspect

(5)

4.6.4.9

EVERY 6000 HOURS OPERATING HOURS OR AT LEAST ONCE A YEAR Service Point

Service

See

Automatic lubrication systems

Change filter

page 4-223

Coolant radiator fan drive bearing

Check

page 4-225

(1)

Perform inspections according to the separate Manuals ”FIRE DETECTION AND ACTUATION SYSTEM” filed in volume 2 binder.

(2)

Perform maintenance according to separate Motor Maintenance Manual filed in volume 2 binder.

(3)

Perform inspections according to the separate Manual ”OPERATING INSTRUCTIONS AC” filed in volume 2 binder.

(4)

The hydraulic oil change intervals can be extended for a further time period, when an oil sample analysis shows a positive result. When extending the oil change interval, it is necessary to carry out an oil sample analysis after every 1000 operating hours. However, it is recommended to change the hydraulic oil after 6000 operating hours at the latest. The pulsation damper of the hydraulic oil cooler circuit must be replaced after every 2000 operating hours. REMARKS: Information to the Komatsu Germany recommended used oil limits can be found in the separate manual "Oil Analysis & Condition Monitoring" filed in the Operation & Maintenance Manual Volume 2 binder.

(5)

Perform inspections according to separate Manual CENTA Coupling filed in volume 2 binder.

(6)

All bolt connections should be lubricated with multi purpose grease (MPG - as found for example, in the CLS grease barrel) except the bolt connections for the slew ring and the carbody. These should be lubricated with the greasing procedures according to AH11507 ’ Bolted Undercarriage’ and AH00511 ’Procedures for Slew Circle’. Contact surfaces must be metallically blank and free of grease.

Sufficient lubrication will show a small collar of grease on the bearing points, especially on the attachment. On the slew circle grease points, sufficient lubrications will show a small collar of grease between the upper and lower body part of the excavator. This should be checked from inside. Check that all lines and joints to and from the injectors and the injectors themselves are attached correctly, are undamaged, and do not leak.

REMARKS: The Lubrication oil Pump for Pump Distributor Gear Lubrication should be replaced with a new pump after every 10000 OPERATING HOURS.

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4.6.5

LUBRICATION AND MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM

REMARKS: Always replace the seal kits when exchanging or inspecting the filters and screens. A - Hydraulic filters Interval

Element

Action

Comments

1000 hrs

Return & leakage oil Filters

Replace elements

3 return oil filters 1 leakage oil, see page 4-129

1000 hrs

Hydraulic pressure Filters

Clean

PTO oil filters can not be cleaned and must be replaced. See page 4-139 for information.

1000 hrs without oil sample

High pressure Filter

Clean

See page 4-135 for information.

1000 hrs

Breather Filter

Replace elements

See page 4-133

1000 hrs

Return & leakage oil screen

Clean

3 return oil filters 1 leakage oil, seepage 4-129

2000 hrs with oil sample

High pressure Filter

Clean

See page 4-135 for information.

2000- 6000 hrs (*)

Pulsation Damper

Replace together with O-ring

See page 4-165 for information

2000- 6000 hrs (*)

Suction strainer of suction oil reservoir

Replace together with gaskets

See page 4-165 for information

2000- 6000 hrs (*)

Suction Strainer of main hydraulic pumps

Replace together with gaskets

Replace with hydraulic oil change. See page 4-165

6000 hrs

Hydraulic pressure Filters

Replace together with gaskets

PTO oil filters can not be cleaned and must be replaced. See page 4-146 for information.

6000 hrs

High pressure Filter

Replace together with gaskets

See page 4-135 for information.

6000 hrs

Return & leakage oil screen

Replace together with gaskets

3 return oil filters 1 leakage oil, see page 4-129

6000 hrs

Return oil strainer of oil cooler circuit

Replace together with gaskets

Also after major repairs, see page 4-165

(*)

Replacement interval of the strainers depends on the hydraulic oil change interval which can, after a positive oil sample result, be extended up to 6000 hour.

B - Grease Filters Interval

Element

Action

Comments

250 hrs

Breather Filter

Clean

See page 4-99 for information.

6000 hrs

Pump outlet filter

Replace

See page 4-223 for information

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4.7

SAFETY CRITICAL PARTS

4.7.1

REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES

Hydraulic hoses and fuel hoses are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years.

NOTICE HYDRAULIC HOSE STORAGE! Hose lines considered as Safety Critical Parts have to be replaced earlier, see page 4-23 for more information. The maximum permissible storage time of hydraulic hoses and fuel hoses is 2 years. This storage period is part of the usable lifetime and must be considered when a new hose line is being installed. If, for example, a hose line with a one year storage time is to be installed, the remaining service life of the hose line is 5 years. All hose lines are marked with the date of production. All hydraulic hoses lines are marked with the date of production. All hydraulic hoses of the excavator have to be replaced after every 6 years at the latest, even if there is no visible damage.

WARNING REPLACE - DO NOT REPAIR! Repaired hydraulic hoses and fuel hoses are unsafe and can lead to serious injury due to high pressure oil or fuel. Replace all defective hoses using ONLY GENUINE Komatsu Germany replacement hose lines.

4.7.2

INSPECTION OF HOSE LINES

Inspect all hoses, hose lines and fittings during the course of the daily walk-around inspection. Check for leaks and damages. Replace damaged parts without delay. Hydraulic fluid escaping under pressure can cause serious injuries. Fuel and oil leaks can cause fires. Some examples of faults on hydraulic hoses and fuel hoses requiring replacement of the concerned part: –

Damage to the outer layer (e.g. chafed spots, cuts or scratches).

–

Brittle top layers. Flaws on the hose material

–

Distortion of the hose line (strong deviation from the original shape) under pressurized and pressureless conditions or when kinked or crushed, e.g. disintegration of hose layers or blistering.

–

Leaks

–

Detachment of hose and fitting. Damaged hose fitting.

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SAFETY CRITICAL PARTS

PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS

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Safety critical parts No.

Safety critical parts for periodic replacement

Hydraulic system

1.1

High pressure hoses

1.1.1

Hoses between main pumps, pressure filters and main control blocks

1.1.2

Hoses between manifold and return oil collector pipe (secondary relief valve lines)

1.1.3

Hoses between manifold and all attachment cylinders

1.1.4

Slew circuit hoses

1.1.5

Travel circuit hoses

1.2

Accumulator for pilot control circuit

Replacement intervals

Every 6000 operating hours or every 2 years, whichever comes first 2.

Fuel system

2.1

Fuel supply hoses

2.2

Fuel return hoses

2.3

Fuel drain hoses

2.4

Fuel refilling hoses

2.5

Fuel cooler hoses (if so equipped)

Turbocharger lubrication system

3.1

Oil supply hose

3.2

Oil drain hose

Seat belts *1)

Every 3 years after initial commissioning of the excavator and thereafter every 3 years.

Portable fire extinguishers

Observe the instructions on the maintenance sticker affixed to the fire extinguisher container.

Automatic fire detection and suppression system

Follow the instructions given in the manufacturer’s maintenance manual.

*1) Recommended interval. Exchange the seat belts immediately if they show signs of damage such as worn or damaged hardware, nicked or frayed straps, loose stitching or retractor malfunctions or if they have been used in an accident situation. Replace the seat belt if:- 'There is significant bleaching due to ultra-violet sunlight exposure, has become stiff or leaves a powdery residue’.

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Please continue reading on the next page.

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MAINTENANCE

Fig. 4-5

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4.7.4

SAFETY CRITICAL PARTS

VENTING THE AIR FROM THE FUEL FILTERS

This image represents a generalized view of the engine. The actual engine variation may differ. REMARKS: Do not prefill the fuel filters. Legend for Fig. 4-5 (1)

Fuel tank

(2)

First stage fuel filter(s)

(3)

Second stage fuel filters

(4)

Tube from connection block to first stage fuel filters

(5)

Connection block

(6)

Tube from air bleed check valve

(7)

Air bleed check valve

1. Ensure that the fuel tank (1) is full. 2. Loosen tube (4) on connection block (5) that runs from the first stage fuel filter(s) (2). 3. Ensure that the magnet valve is activated by very briefly turning the engine over. This ensures that fuel is flowing into the engine. 4. Retighten tube (4) to connection block (5). 5. Remove tube (6) from air bleed check valve (7). 6. Wait until bubble (air) free fuel runs out. 7. Reattach tube (6). 8. Start engine using starting procedure according to the engine maintenance manual filed in Volume 2. REMARKS: For further detailed procedures to venting the air from the fuel filters, refer to the engine maintenance manual filed in Volume 2.

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INITIAL SERVICING

4.8

MAINTENANCE

INITIAL SERVICING

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4.8.1

INITIAL SERVICING

WORKING ATTACHMENT - INITIAL CHECKS FOR PROPER LUBRICATION

The volume of injected grease is set to maximum in the factory. The pause time is set to 10 min (minimum setting). These settings are used for the initial (40 h) running-in time of the excavator. After 20 working hours, check the settings of the lubrication system and ensure all points of lubrication have a well balanced quantity of grease. Fine Adjusting the Pause Time and Injectors The amount of grease to be injected is dictated by the working environment and conditions. To fine adjust the injectors and the pause time, proceed as follows: 1.

Find the lubrication point (bearing seal or open bearing) with the lowest quantity of grease. This is the point of reference that will determine the following pause time setting.

If any of the bearing points have too much grease, adjust the injectors gradually to lower the volume. Do this by rotating the output adjusting screw (2) a maximum of 1-2 turns clockwise. Wait at least 40 hours and observe lubricated areas. Care must be taken while turning the screw (2) as turning too much will block the movement of the injector.

Reduce the quantity of grease by extending the pause time gradually, in steps of about 2-5 minutes, until only a small amount of fresh grease appears on the open bearing or bearing seal that is used as the reference point. Between each step, wait at least 40 hours while observing the lubricated areas daily.

NOTICE CHECK THE GREASE! Insufficient or inappropriate lubrication causes damage. Always operate the excavator with a sufficient amount and the recommended type of grease. If there is too little grease or the wrong type, correct this immediately.

REMARKS:

There are two types of grease injectors installed “SL1” and “SL11” injectors, see Fig. 4-2.

Visually check grease injectors and grease connections. Sufficient lubrication will show a small collar of grease on the bearing points. Check that all lines and joints to and from the injectors and the injectors themselves are attached correctly, are undamaged, and do not leak. See page 4-116 for information on inspecting and maintaining the grease injectors. Legend for Fig. 4-2

Injectors on bucket

(2)

Output adjusting screw

Injectors on stick

(3)

Protection cap

Injectors on boom

(4)

Grease fitting

(1)

Indicator stem for visual indication of injector operation

(5)

Backhoe bucket wishbone

WARNING RISK OF FALLING! Falling from the boom can cause serious injury or death. Always ensure that the safety harness is worn according to the instructions in "SPECIAL SAFETY EQUIPMENT" on page 2-56 when accessing the boom, and that the special attachment points (as shown on page 4-71) are utilized for the fall absorber.

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MAINTENANCE

Fig. 4-7

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4.8.2

INITIAL SERVICING

SLEW CIRCLE - CHECK GREASE INJECTORS

Legend for Fig. 4-3 (D)

Injectors on slewing connection

(1)

Indicator stem for visual indication of injector operation

(2)

Output adjusting screw

(3)

Protection cap

(4)

Grease fitting

REMARKS: If the failure is caused through a defective central lubrication system, manually lubricate at grease fittings (4) after removal of caps (3). Visually check grease injectors and grease connections.

NOTICE CHECK GREASE ON EXCAVATOR AND INJECTORS! Sufficient lubrication will show a small collar of grease on the bearing points, especially on the attachment (see Fig. 4-2). On the slew circle grease points, sufficient lubrications will show a small collar of grease between the upper and lower body part of the excavator. This should be checked from inside. Check that all lines and joints to and from the injectors and the injectors themselves are attached correctly, are undamaged, and do not leak.

Seepage 4-116 for information on inspecting and maintaining the grease injectors.

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MAINTENANCE

Fig. 4-8

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4.8.3

INITIAL SERVICING

CAR BODY AND RACEWAY OF SLEW RING

Legend for Fig. 4-4 (1)

Slew gear

(2)

Bearing point for boom cylinder

(3)

Bearing point for boom

(4)

Mounting plate of grease injectors

(5)

Raceway of slew gear

Visually check grease injectors and grease connections.

See page 4-116 for information on inspecting and maintaining the grease injectors.

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MAINTENANCE

Fig. 4-9

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4.8.4

INITIAL SERVICING

SLEW CIRCLE - CHECK TORQUE OF BOLT CONNECTIONS

Fig. 4-9 Check tightening torque of inner and outer mounting bolts (02 and 04) according to PARTS & SERVICE NEWS, No. AH00511. REMARKS: Checking/retightening of slew circle mounting bolts is only necessary after the first 1000 operating hours. Check condition and fastening of slew circle guard (10) and bolts (15).

NOTICE CHECK BOLT CONNECTION! A visual check of the security and the conditions of the bolt connections must be performed every 1000 hours.

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MAINTENANCE

Fig. 4-10

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4.8.5

INITIAL SERVICING

RETIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS

NOTICE BOLT TORQUE! The required tightening torque for the mounting bolts of the crawler carriers has been determined and applied during the assembling procedure of the excavator at the mine site. This procedure has to be repeated one time after the first 1000 operating hours through your Komatsu dealer.

General The required tightening torque for all mounting bolts (M48), Fig. 4-10 has to be determined with the four measuring bolts (7), which dimension is analogous to the mounting bolts. The required axial tensioning force of the bolts (M48) is determined by means of the elongation of the bolts. For determination of the tightening torque, two especially prepared measuring bolts (7) are installed on each crawler carrier (A). The measuring bolts can be identified by the centering dot at the bolt head and at the shaft end. Necessary equipment for the retightening procedure: –

Measuring device (1 - 6) delivered with the new excavator, see table below.

–

Special hydraulic torque wrench, see Fig. 4-12 on page 4-40. This tool will be provided by your Komatsu dealer.

REMARKS: Refer to Parts & Service News AH11507 or contact your local dealer for further information. Measuring Device Position

Part name

Qty.

Angle bar

Dial gauge

Screw M5x16

Feeler

Bolt M10x25

Washer

Measuring bolt (installed)

REMARKS: Fig. 4-10 shows the left crawler carrier seen from the carbody side.

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MAINTENANCE

Fig. 4-11

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Critical Bolt Connections (continued) Procedure for determination of the tightening torque for the crawler carrier mounting bolts after the first 1000 operating hours, see Fig. 4-11 1. Loosen the two measuring bolts (7) at the left crawler carrier and the two measuring bolts at the right crawler carrier. Do not lubricate the measuring bolts. 2. Tighten the four measuring bolts (7) with 150 Nm. 3. Attach the measuring device (1 - 6). 4. Set the dial gauge (2) to the zero position. 5. Attach the special hydraulic torque wrench (1), see Fig. 4-12 on page 4-40 to the measuring bolt (7). 6. Increase the pressure at the hydraulic torque wrench until a torque of 2100 Nm is reached and tighten the measuring bolt. 7. Record the pressure and the change of the bolt length in a table. 8. Increase the pressure further by steps of 10 bar until the required elongation of 0.93 mm of the measuring bolts (7) is reached. 9. Record the corresponding hydraulic pressures in a table. 10. Repeat this procedure on all four measuring bolts (7). 11. Add the 4 determined hydraulic pressures and then divide by 4 to obtain an average value. 12. Now loosen one of the mounting bolts (M48) and tighten up to the determined average pressure. REMARKS: DO NOT loosen more than one bolt at the same time. DO NOT lubricate the bolts (M48). 13. Repeat this procedure at all bolts (M48) step by step.

NOTICE CHECK BOLTS! A visual check of the security and the conditions of the bolt connections must be performed every 1000 hours.

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MAINTENANCE

Fig. 4-12

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Critical Bolt Connections (continued) Special hydraulic torque wrench Legend for Fig. 4-12 (1)

Application of the hydraulic torque wrench

(2)

Special wrench socket with supporting bar (P/N 793 376 73)

(3)

Hydraulic wrench (P/N 793 374 73)

(4)

Electro-hydraulic pump set (P/N 793 375 73)

The equipment shown in Fig. 4-12 will be provided by your Komatsu dealer. Location of the four measuring bolts (7), Fig. 4-13

Fig. 4-13

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WHEN NECESSARY

4.9

MAINTENANCE

WHEN NECESSARY

Fig. 4-14

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4.9.1

WHEN NECESSARY

ENGINE AIR CLEANER MAINTENANCE

Servicing the main filter elements, Fig. 4-14:

NOTICE SERVICING HINTS FOR THE MAIN FILTER ELEMENT! Before servicing the filter elements clean dust cups of the precleaners. Never service air cleaner while engine is running. Clean main filter elements when the fault message "Air cleaner element restricted" is displayed on the Komtrax screen. Replace elements after 6 cleanings or annually, whichever occurs first.

1. Remove elements in sequence of reference numbers (1 to 4). 2. Clean and check respectively. replace main filter element. Wipe out filter housing with a clean cloth. 3. Element cleaning methods: Clean main element by one of the following methods. Compressed air or washing: Compressed air is recommended when element will be reused immediately because a washed element must be dried before reuse. Compressed air: Direct air through element in the direction opposite to normal air flow through the element. Move nozzle up and down while rotating element. Keep nozzle at least one inch from pleated paper. Maximum air pressure to prevent damage of element is 100 P.S.I. (6 bar). Washing: 1. Soak element 15 minutes or more in cleaning solution. See package for full instructions. 2. Rinse until water is clear maximum water pressure 40 P.S.I. (2.5 bar). 3. Air-dry or use warm flowing air, max. 160° F (+70° C). Do not use compressed air or light bulbs. REMARKS: Before installing main elements (4) check service indicator (6) of safety element (7). If a red signal is shown, replace safety element (7). Clean indicator (6) then suck on the outer side of the indicator to reset signal to green indication. 4. Install main filter elements (4).

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MAINTENANCE

Fig. 4-15

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WHEN NECESSARY

Air Cleaner Maintenance (continued) Fig. 4-15 REMARKS: If the fault message "Air cleaner element restricted" is again displayed on the Komtrax screen after installation of a new main filter element the safety-filter element has also to be replaced. If faulty service or a defect has been detected while servicing the main filter element also the safety filter element has to be replaced. After having the main filter element cleaned three-times or replaced also the safety filter element has to be replaced. Replacing the safety filter element (7): 1. Remove element in sequence of ref. no. (1 to 7). 2. Cover air intake opening. 3. Install new safety filter element (7). REMARKS: The safety filter element may not be cleaned and reused 4. Remove cover from air intake opening. 5. Install safety and main filter element, take care service indicator (6) is correctly secured by cotter pin (5).

4.9.1.1

GENERAL SERVICE TIPS

The air cleaners should be inspected periodically to maintain maximum engine protection and maximum service life. These inspections should include the following points. 1. Inspect the air transfer duct between the air cleaner and the engine to be sure all clamps are tight, all flange joints are tight, and there are no cracks in the ducting. 2. Air cleaner mounting bolts and clamps must be tight to hold the air cleaner securely. 3. Check the dust cup to make sure it is sealing 360° around the air cleaner body. 4. Automatic dust unloader valve (if so equipped) must be in place, not inverted or damaged, and free from obstruction.

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MAINTENANCE

Fig. 4-16

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4.9.2

WHEN NECESSARY

SLEW CIRCLE TOOTHING LUBRICATION

See Fig. 4-16 All teeth of the gear ring (3) must be completely covered with grease. If the teeth are not completely covered with grease, they have to be lubricated immediately using special adhesive spray grease, Fig. 4-16, or spread-type adhesive grease as specified in the parts catalogue. The spread type grease can be applied, for example, with a brush. Observe the instructions on the grease container for correct use of the lubricant. REMARKS: If the excavator is equipped with gear ring guard (6), remove covers (7) for slew circle teeth inspection. If the automatic lubrication system of the slew circle toothing fails to function for more thanone shift, lubricate manually (using spray grease) and remove the lube pinion (5), to prevent serious damage. In order to ensure proper adherence of the lubricant, clean and dry the ring gear prior to lubrication. In most cases it is sufficient to rotate the superstructure several times in order to move moisture from the gear teeth. Make sure that the multi-purpose grease of the slew circle bearing does not come in contact with the teeth of the slew circle because this will diminish lubrication capability of the slew circle teeth lubricant. If necessary remove excessive multi-purpose grease from the slew circle above the dust seal ring.

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MAINTENANCE

Fig. 4-17

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4.9.3

WHEN NECESSARY

AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS

Fill the grease containers of the Central Lubrication System and Slew circle pinion Lubrication System when the corresponding message "grease container empty" is displayed on the Komtrax screen. Make sure the grease filters in the filling lines are not obstructed. If necessary service the Grease Filters. Refer to chapter "CENTRAL REFILLING SYSTEM" on page 3-170 for further information. Legend for Fig. 4-17

–

(1)

Grease level gauges for manual checking of the grease level

(2)

Grease filter for central lubrication system. Before filling the grease container make sure the filter is not obstructed. Service the filter element according to the instructions on next page.

(3)

Grease container of the central lubrication system

(5)

(6)

Grease container of the slew circle pinion lubrication system

Fill the grease containers according to the instructions on page 3-179.

REMARKS: Check condition and fastening of both grease containers.

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MAINTENANCE

Fig. 4-18

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4.9.3.1

WHEN NECESSARY

SERVICE THE GREASE FILTERS FOR REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SLEW CIRCLE PINION LUBRICATION SYSTEM

Fig. 4-18 1. Screw off filter case. 2. Remove element assy. (02) and clean. Take care not to contaminate the ”Clean” inside of the element when flushing. REMARKS: Carefully inspect elements for damage. Always install new elements if ruptures or other damages are found. 3. Inspect O-rings (03 and 05) and back-up ring (04). Replace if necessary. 4. Fill filter case half way up with the specified grease. 5. Installation sequence vice versa. Take care for proper position of filter element (02). REMARKS: Replace element (02) after three cleanings or after every 5000 operating hours, whichever occurs first.

Fig. 4-19

4.9.4

GUIDE WHEELS - REPLACE FLOATING SEALS

Legend for Fig. 4-19 (1)

Guide wheel,

(2)

Floating seal

The Guide wheels are filled with a gear oil CLP 220. If leakage occurs, replace floating seal (2).

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MAINTENANCE

Fig. 4-20

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4.9.5

WHEN NECESSARY

COLD STARTING AID, REPLACE FLUID CYLINDER

Legend for Fig. 4-20 (1)

Rear exhaust muffler

(2)

Engine air cleaner

(3)

Cold starting aid mounted on the air cleaner frame

(4)

Electrically operated valve

(5)

Mounting clamp

(6)

Cold start fluid cylinder

WARNING HAZARDOUS FLUID! Starting fluid is poisonous and flammable Do not store replacement cylinders in living areas Do not smoke while changing cylinders Use only in well ventilated areas Use with care to avoid fires Avoid breathing of vapors or repeated contact with skin Do not puncture or burn cylinders Discard cylinders in a safe place Keep fluid container away from heat, sparks, open flame, or open sunlight. It may explode Observe instructions on the container Do not store or use at temperatures above 93° C (200° F)

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MAINTENANCE

Fig. 4-21

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WHEN NECESSARY

4.9.6

CLEANING THE EXCAVATOR

4.9.6.1

PRECAUTIONS FOR CLEANING

WARNING WORKING ON THE EXCAVATOR CAN BE EXTREMELY HAZARDOUS! Apply the recommended safety instructions contained within the Operation and Maintenance Manual before starting any lubrication or maintenance (and cleaning) work, read the fundamental safety instructions in the chapter "SAFETY" on page 2-23.

–

Park the excavator at a safe place on level ground. Proceed according to the instructions below.

–

Stop the engine, (key switch is on, the service arm is up and lock lever is in the operating position) and move all control levers through their shift positions to relieve the pressure in the hydraulic system. Refer to chapter "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM" on page 3-171 for detailed description.

–

Before any maintenance work is started, set the maintenance safety switch to 0 position. Information is on the following page. In the 0 position the engines can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten padlocks can be attached to the holes provided.

–

A warning plate ”CAUTION EXCAVATOR MAINTENANCE” must be fixed in the operator’s cab before any lubrication or maintenance work is started.

–

Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this necessary. Observe the local safety rules.

–

Never allow unauthorized persons access to the excavator during cleaning work.

–

After cleaning, remove oily cloth, flammable material and all tools from the excavator.

Park the excavator at a safe place on level and solid ground. –

Lower the working attachment onto the ground.

–

Stop the engines and relieve the pressure in the hydraulic system.

Z 33251

Fig. 4-22

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–

MAINTENANCE

Move the lock lever fully to the rear in locked position.

Fig. 4-23

–

Apply the maintenance safety switch in the machinery room.

Fig. 4-24 –

Remove any obvious signs of dirt on or in the excavator.

–

Do not use petrol or diesel fuel for cleaning.

–

Do not use undiluted detergents or other non-compatible detergents. Use the compatible ones according to the manufactures specifications.

When cleaning with high pressure water or steam REMARKS: Make certain that the distance to the surface that is to be high pressure cleaned is not less than 50cm (6) and the water temperature is no higher than 60°C. The water pressure should not be higher than 80 bar (1160PSI). The salt content of the water should be less than 0.05% Make certain there is no direct jet from a high pressure cleaner in the following areas. See Fig. 4-21 –

seals, bearings and joints on the attachment (1).

–

electrical fittings and appliances (2).

–

fire warning systems (linear detectors in engine/motor room or fire extinguishers) (3).

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–

the seals between cylinders and piston rods (4).

–

air filters (breather filters) (5 as an example).

–

Always clean from top to bottom

If grease catchers are installed near the A-frame, these have to be emptied.

The excavator must always be re-greased after pressure washing or steam cleaning. This means all general areas (door hinges for example) should be re-greased with a grease gun and all areas that use the CLS grease system (the bearings of the attachment for example) should be cycled.

Fig. 4-25

NOTICE PRECAUTIONS! Flammable particles may combust when they come into contact with extremely hot areas. They must not be allowed to accumulate. Always use local regulations when disposing of debris, oils or greases created by excavator cleaning.

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EVERY 10 OPERATING HOURS OR DAILY

4.10

MAINTENANCE

EVERY 10 OPERATING HOURS OR DAILY

Fig. 4-26

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4.10.1

EVERY 10 OPERATING HOURS OR DAILY

WALK - AROUND INSPECTION

WARNING CHECK ALL SAFETY FEATURES ON THE EXCAVATOR BEFORE MAINTENANCE! Defective safety equipment on the ladder can lead to serious injury or death. Before carry out any maintenance on this excavator, make sure the mounting ladder, handrails and walkways are properly installed and in good condition. Keep the ladder, steps, handrails and walkways free of mud, oil and grease. Always use the ladder, handrails and steps to get on or of the excavator. Jumping on or off the excavator can cause injury.

For a comprehensive and detailed procedure of the checks that are to be performed on a daily basis, refer to the Daily Inspection Sheets filed in the binder Operation & Maintenance Manual Volume 2. Legend for Fig. 4-26 (1)

Working attachment. Check overall condition. Inspect for loose or missing securing parts.

(2)

Hydraulic cylinders. Check cylinders, hydraulic lines and connections for leakage and damage.

(3)

Check bucket teeth for proper mounting. Inspect for loose or missing securing parts. Check condition of the loader bucket. Both loader bucket versions, bottom dump bucket and backhoe bucket are equipped with wear protection packages as specified in the contract. These wear packages protect the base body of the bucket from premature wear and tear. Therefore it is important to check the condition of the wear protection elements regularly. Worn or damaged protection elements should be replaced at an early stage in order to prevent damage to the base body of the bucket. In case the bucket base is already weakened, reconditioning measures will be necessary. Contact your Komatsu dealer for support.

(4)

Check guide wheels for leakage.

(5)

Check carrier rollers for leakage.

(6)

Check track rollers for leakage.

NOTICE LEAKAGE ON GUIDE WHEELS! If leakage is found on guide wheels or rollers inspect the floating seals of the respective unit (see AH05511), replace if necessary. Check also that the plugs are operable and tightened (see AH00521) Fill the unit with the correct gear lubricant. (7)

Check final drives and hydraulic motors for leakage. Check hydraulic hoses, hose lines and fittings for leakage and damage.

(8)

Check slew circle toothing for adequate lubrication.

(9)

Check condition, fastening and security of access ladders.

(10)

Check condition, fastening and security of all walk-ways, steps, railings and hand rails.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 59

EVERY 10 OPERATING HOURS OR DAILY

MAINTENANCE

Fig. 4-27

4 - 60

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 10 OPERATING HOURS OR DAILY

Walk-around Inspection (continued) (11)

Check condition, fastening and security of emergency escape ladder

(13)

Check condition and fastening of exhaust mufflers

(14)

Check condition, fastening and security of the automatic lubrication system grease container.

(15)

Make a visual inspection of the engine room. Check engine oil level and coolant level. Check engine for good condition and security. Check for oil and fuel leakages. Check fuel hoses, hose lines and fittings for leakage and damage. Engine mounts, check for good condition and correct fastening. Check radiator coolant level. Check cooling system for leakage, damaged hoses and connections. Check housing of radiator fan bearing for leakage. Check fan guards and coverings for correct installation, good condition and security. Check flexible coupling between engine and PTO for leakage. Check condition and mounting of PTO and hydraulic pumps. Check hydraulic hoses, hose lines and fittings for leakage and damage. Check housing of oil cooler fan bearing for leakage. Check fan guards and coverings for correct installation, good condition and security. Check hydraulic hoses, hose lines and fittings for leakage and damage. Check hydraulic oil cooler for plugged cores. Check hydraulic oil level. Check hydraulic oil reservoir for leakage, damaged hoses and connections. Check condition and fastening of control valves. Check hydraulic hoses, hose lines and fittings for leakage and damage. Check engine for good condition and security. Check for oil and fuel leakages. Check fuel hoses, hose lines and fittings for leakage and damage. Check that the oil level gauge of the return oil chamber is free of bubbles and completely filled with oil. Refer to chap. 4.14.3 for further information.

REMARKS: If any damages, failures or wrong condition, have been found during the inspection, corrective action must be taken.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 61

EVERY 10 OPERATING HOURS OR DAILY

MAINTENANCE

Fig. 4-28

4 - 62

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.10.1.1

EVERY 10 OPERATING HOURS OR DAILY

GROUND CABLES - CHECK CONNECTION POINTS

Legend for Fig. 4-28 (1)

Ground cable from alternator to platform

(2)

Alternator

(3)

Ground cable from operating panel in cabin to floor of cabin support

(4)

Contact point and ground bolt

Check that the contact between ground cables and ground bolts is secure and shows no defects.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 63

EVERY 10 OPERATING HOURS OR DAILY

MAINTENANCE

Fig. 4-29

4 - 64

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 10 OPERATING HOURS OR DAILY

4.10.2

AIR CLEANER - CLEAN PRECLEANER

4.10.2.1

CLEAN DUST CUPS OF PRECLEANERS

Legend for Fig. 4-29 (1)

Roof mounted air cleaner units

(2)

Air intake screen

(3)

Clamps

(4)

Dust cups

(5)

Jet tubes

1. Provide suitable container for collecting the dust before opening the dust cups (4). 2. Loosen the clamps and swing down dust cups (4). 3. Remove dust from precleaner dust cups. 4. Check condition of the dust cup gaskets and replace if necessary. 5. Swing back dust cups (4) to closed position and secure with the clamps provided. 6. Check air cleaner mounting parts for tight fit and security.

NOTICE IN CASE OF VERY DUSTY CONDITIONS! When operating the excavator under very dusty conditions, check precleaner jet tubes (5) for plugging. Dust plugging of tubes can be removed with a stiff fiber brush. Never clean tubes with compressed air unless both the primary and safety elements are installed in the air cleaner. Do not steam-clean tubes.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 65

EVERY 10 OPERATING HOURS OR DAILY

MAINTENANCE

Fig. 4-30

4 - 66

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.10.3

EVERY 10 OPERATING HOURS OR DAILY

RADIATOR - CHECK COOLANT LEVEL

Legend for Fig. 4-30 (6)

Coolant expansion tank of the engine radiator

(7)

Coolant level sight gauge on coolant expansion tank

(8)

Cover plate on power house roof above the radiator pressure cap

(9)

Radiator pressure cap

WARNING RISK OF SCALDING! The radiator pressure cap, when removed, can cause serious burns due to escaping steam or spray. DO NOT remove the radiator pressure cap (9), Fig. 4-30 when the engine is hot. Wait until the temperature is below 50°C before removing the pressure cap (9). Press button in center of cap to allow the pressure to escape, then turn the cap until it is free to be removed.

The coolant level should be in the upper field of the sight gauges (7). If necessary add coolant. REMARKS: Refer to the Engine Operation and Maintenance Manual for the correct coolant composition.

4.10.4

TRACK GROUPS - CLEAN

See (10), Fig. 4-30. Under working conditions with excessive material build up on the crawler components, cleaning of the crawlers is very important to prevent damage. Material build up on guide wheels, drive sprockets and tracks can lead to over tensioning of the tracks, resulting in severe damage to these components. If there is danger of frost, the tracks must also be cleaned. REMARKS: Use a suitable cleaning device for removing dirt, mud and debris from the tracks, rollers, guide wheels and sprockets.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 67

EVERY 10 OPERATING HOURS OR DAILY

MAINTENANCE

Fig. 4-31

4 - 68

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.10.5

EVERY 10 OPERATING HOURS OR DAILY

FUEL SYSTEM WATER SEPARATOR - DRAIN WATER

Special Equipment Legend for Fig. 4-31 (A)

Front view of the engine

(B)

Top view of engine compartment

(1)

Fuel tank

(2)

Fuel shut-off solenoid valve. This solenoid valve cuts-off fuel supply to the engine when the stop switch on the instrument panel is actuated.

(3)

Water separator filter

(4)

Fuel shut off cock

(5)

Counterweight

Draining Water Frequency of water draining is determined by the contamination of the fuel. Inspect or drain the collection bowl of water daily or as necessary. The collection bowl must be drained before contaminants reach the top of the turbine. REMARKS: Refer to separate Instruction booklet -Fuel Filter/Water Separator- filed in volume 2 binder for draining procedure. Filter Element Replacement Frequency of element replacement is determined by the contamination of the fuel. Replace the elements after every 500 operating hours, if power loss is noticed or annually, which ever comes first. REMARKS: Refer to separate Instruction booklet -Fuel Filter/Water Separator- filed in volume 2 binder for replacement procedure.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 69

EVERY 10 OPERATING HOURS OR DAILY

MAINTENANCE

Fig. 4-32 4 - 70

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.10.6

EVERY 10 OPERATING HOURS OR DAILY

BOOM - CHECK LADDER AND WALKWAY

Check all bolts and and clamps on the ladder, walkway and catwalk and make sure they are secure and show no signs of damage. Legend for Fig. 4-32 A

Boom for backhoe

Boom for front shovel

(1)

Access ladder for boom

(2)

Walkway to catwalk

(3)

Catwalk

(4)

Attachment points for the fall protection of the safety harness

NOTE!

Before accessing the boom, wear a safety harness as described in the chapter "SPECIAL SAFETY EQUIPMENT" on page 2-52, and only attach it to the attachment points (4) on the boom.

NOTICE USE ONLY FALL PROTECTION! DO NOT attach any other object to the ring bolts of the attachment points. Use only for attaching the strap type fall absorber in connection with safety harness. Any inappropriate use may damage the components on the boom.

4.10.7

ELECTRICAL EQUIPMENT - CHECK VISUALLY

Visually check all electrical equipment and components daily. Note any obvious signs of decay, breakage, loose fittings and excess dirt. Defective equipment must be repaired or replaced immediately.

Fig. 4-33

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 71

EVERY 10 OPERATING HOURS OR DAILY

MAINTENANCE

Fig. 4-34 4 - 72

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.10.8

EVERY 10 OPERATING HOURS OR DAILY

EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB

Legend for Fig. 4-34 (1)

Operator’s cab

(2)

Operator’s cab view from inside when entering

(3)

Detachable sun visor

(4)

Emergency escape hammer

(5)

Release catches on sun visor

(6)

Emergency escape route sign

Perform a visual check of the escape route from the cabin. Visually check that the emergency escape hammer (4) is hanging in the appropriate place in the cabin. Check the condition of the release catches (5) of the sun visor panel (3). Check the sun visor panel (3) for obvious signs of damage. Check that the emergency escape route sign (6) is in good condition and can be easily read Check that the general escape route is free from obstacles.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 73

EVERY 50 OPERATING HOURS OR WEEKLY

4.11

MAINTENANCE

EVERY 50 OPERATING HOURS OR WEEKLY

Fig. 4-35

4 - 74

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.11.1

EVERY 50 OPERATING HOURS OR WEEKLY

SLEW GEAR AND MOTOR ADAPTER HOUSING - CHECK OIL LEVEL

REMARKS: The excavator can be equipped either with a slew machinery type 2063 or with type 632770. Refer to the data plate on each slew machinery housing to find out which slew machinery is installed.

4.11.1.1

SLEW GEAR MANUFACTURED TYPE 2063

Legend for Fig. 4-35 Slew gear (A)

Position of oil level gauge for checking the oil levels

(1)

Oil level gauge

(2)

Oil filler plug

(3)

Breather filter

(7)

Drain coupling or evacuation nozzle for Wiggins system

Motor Adapter Housing (4)

Oil level gauge and filler opening. This opening can also be used for connecting a suction pump when changing the oil.

(5)

Breather filter

(6)

Oil drain plug

CHECK SLEW GEAR OIL LEVEL Remove oil level gauge (1), Fig. 4-35 and wipe it clean. Insert the gauge, see detail ”A”. Remove the gauge. The oil level should be at the upper mark of gauge (1). If necessary add the specified gear oil through filler opening (2). Remove breather filter (3). Blow out with compressed air from inside to outside and reinstall. CHECK MOTOR ADAPTER HOUSING OIL LEVEL Remove oil level gauge (4) and wipe it clean. Insert the gauge, see detail ”A”. Remove the gauge. The oil level should be at the upper mark of gauge (4). If necessary add the specified oil through filler opening (4). Remove breather filter (5). Blow out with compressed air from inside to outside and reinstall.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 75

EVERY 50 OPERATING HOURS OR WEEKLY

MAINTENANCE

Fig. 4-36

4 - 76

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.11.1.2

EVERY 50 OPERATING HOURS OR WEEKLY

SLEW GEAR TYPE 632770

Legend for Fig. 4-36 (A)

Position of oil level gauge for checking the oil level in slew gear and motor adapter housing

(B)

Position of oil level gauge for checking the oil level in brake housing

(1)

Slew gear

(2)

Brake housing

(3)

Compensator oil tank for slew gear

(4)

Oil level gauge for slew gear

(5)

Oil drain plug for motor adapter housing

(6)

Oil level gauge for motor adapter housing

(7)

Breather filter for brake housing

(8)

Oil level gauge for brake housing

(9)

Oil drain plug for brake housing

(10)

Breather filter

CHECK SLEW GEAR OIL LEVEL Remove oil level gauge (4) and wipe it clean. Insert the gauge but DO NOT screw in, see detail -A-. Remove the gauge. The oil level should be at the upper mark of gauge (4). If necessary add the specified gear oil through filler pipe. Remove breather filter (10). Blow out with compressed air from inside to outside and reinstall. CHECK BRAKE HOUSING OIL LEVEL Remove oil level gauge (8) and wipe it clean. Insert the gauge and tighten, see detail -B-. Remove the gauge. REMARKS: The upper mark (W) on gauge (8) indicates the correct oil level with the oil warm. The lower mark (C) indicates the correct oil level with the oil cold. With cold oil, the oil level should be at the lower mark of gauge (8). With warm oil, the oil level should be just below the upper mark of gauge (8). If necessary add engine oil SAE 10 or hydraulic oil HLP 32 through filler opening.

NOTICE DO NOT OVERFILL THE BRAKE HOUSING Overfilling the brake housing with oil could damage the brake due to overheating. Therefore ensure correct oil level of brake housing.

Remove breather filter from pipe (7). Blow out with compressed air from inside to outside and reinstall. CHECK MOTOR ADAPTER HOUSING OIL LEVEL Remove oil level gauge (6) and wipe it clean. Insert the gauge but DO NOT screw in, see detail -A-. Remove the gauge. The oil level should be at the upper mark of gauge (6). If necessary add engine oil SAE 10 or hydraulic oil HLP 22 or HLP 32 through filler opening.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 77

EVERY 50 OPERATING HOURS OR WEEKLY

MAINTENANCE

Fig. 4-37

4 - 78

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.11.2

EVERY 50 OPERATING HOURS OR WEEKLY

TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS

–

Planetary Gear Box

–

Spur Gear Box

–

Brake Housing

–

Motor Adapter Housing

Legend for Fig. 4-37 Planetary gear box: (1)

Oil level plug on travel gears

(2)

Oil filler plug

(3)

Drain plug

(13)

Breather filter, the breather filter is located inside the center frame.

Spur gear box: (4)

Oil level plug

(5)

Oil filler plug

(6)

Oil drain plug

Brake housing: (7)

Oil level plug

(8)

Oil filler plug

(9)

Oil drain plug

Motor adapter housing: (10)

Oil level plug

(11)

Connector for breather filter line, the breather filter is located inside the center frame. The port of connector (11) is also used as oil filler opening.

(12)

Oil drain plug

4.11.2.1

PLANETARY GEAR BOX - CHECK OIL LEVEL

Move the Excavator so, that the planetary gear box is in a position as shown in Fig. 4-37. The filler plug (2) is in 12 o’clock position and the level plug (1) is above the center line of the gear box. Remove plug (1). The oil level should be at lower edge of opening (1). If necessary add oil through filler opening (2). Insert both plugs (1 and 2) and tighten securely.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 79

EVERY 50 OPERATING HOURS OR WEEKLY

MAINTENANCE

Fig. 4-38

4 - 80

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.11.2.2

EVERY 50 OPERATING HOURS OR WEEKLY

SPUR GEAR BOX - CHECK OIL LEVEL

Check oil level by removing oil level plug (4). Oil level should be at lower edge of opening (4), if necessary add oil through filler opening (5). Install level and filler plug (4 and 5). Check breather filter (13) for restriction. If necessary, remove breather filter, blow out with compressed air from inside to outside and reinstall.

4.11.2.3

BRAKE HOUSINGS - CHECK OIL LEVEL

Check oil level by removing oil level plug (7). Oil level should be at lower edge of opening (7). If necessary Add oil through filler openings (8) and install plugs (7) and (8).

4.11.2.4

MOTOR ADAPTER HOUSING - CHECK OIL LEVEL

Check oil level by removing oil level plug (10). Oil level should be at lower edge of opening (10). If necessary, remove connector (11) for breather filter line and add oil through filler opening. Install level plug (10) and screw in breather filter line connector (11). Check breather filter inside the center frame for restriction. If necessary, remove breather filter, blow out with compressed air from inside to outside and reinstall.

4.11.2.5

MILEAGE INDICATOR (SPECIAL EQUIPMENT)

The mileage indicator is fitted to the center bore of the spur gear box. REMARKS: Travel gears, Brake- and Motor adapter housings have to be filled with different types of oil. Refer to page 4-4 for the correct oil specifications.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 81

EVERY 50 OPERATING HOURS OR WEEKLY

MAINTENANCE

Fig. 4-39

4 - 82

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.11.3

EVERY 50 OPERATING HOURS OR WEEKLY

PTO (PUMP DISTRIBUTOR GEAR) - CHECK OIL LEVEL

Legend for Fig. 4-39 (1)

Oil level gauge on PTOs type 2063

(2)

Oil filler plug

(3)

Breather filter

(4)

Oil drain plug

(5)

Adapter housings for main hydraulic pumps

(6)

Adapter housing for pilot oil pump

(7)

Oil level plug

(8)

Oil filler plug with breather pipe

(9)

Oil drain plug

(10)

Positions of oil level gauges on PTOs type 631650

REMARKS: Check PTO oil level just after the engine is stopped and with the oil at operating temperature. 1. Unscrew level gauge (1/10) and wipe it clean. Insert gauge (1/10), but DO NOT tighten, see detail (A). Remove level gauge and read the oil level. The oil level should be between the “MIN” and “MAX” mark. If necessary, add oil through filler opening (2) up to the “MAX” mark on gauge (1/10).

NOTICE CHECK OIL LEVEL! If the oil level is above the “MAX” mark, drain the oil down until the oil level is at the “MAX” mark. Too much oil in the pump distributor gear will cause aeration of the oil.

2. Insert gauge (1/10) and tighten securely. Remove breather filter (3). Blow out with compressed air from inside to outside and reinstall.

4.11.3.1

MAIN HYDRAULIC PUMPS - CHECK OIL LEVEL IN DRIVE SHAFT HOUSINGS

The Oil level should be at the lower edge of level plug opening (7). If necessary remove filler plug with breather pipe (8) and add Gear Oil through the filler opening up to the level opening (7). Reinstall plugs (7 and 8) and tighten securely. Check breather pipe for obstruction. If necessary, blow out with compressed air. If pump removal becomes necessary, drain the drive shaft housing oil by removing drain plug (9). Be sure to fill the drive shaft housing up to the filler opening (7) after mounting of the pump.

NOTICE OIL LEAKAGE! If oil starts dropping out at one of the breather pipes (8), the oil seal ring of the respective pump drive shaft must be checked and replaced if necessary.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 83

EVERY 50 OPERATING HOURS OR WEEKLY

MAINTENANCE

Fig. 4-40

4 - 84

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.11.4

EVERY 50 OPERATING HOURS OR WEEKLY

HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR

Legend for Fig. 4-40 (A)

Access ladder in lowered position

(B)

Access ladder in upper position (Working position)

(1)

Access ladder

(2)

Light switch for access area lighting

(3a,b)

Pull chains for emergency lowering of the access ladder REMARKS: Whenever the access ladder has been lowered with one of the emergency chains (11), the switching valve has to be reset. Refer to chapter 3.2.3.2. NOTE!

Use this chain only in emergency cases, when the operator needs to escape the excavator.

(4A)

Control switch for access ladder at machinery house door

(4B)

Control switch for access ladder at operator’s cab

(5)

Switch direction for lifting the ladder

(6)

Switch direction for lowering the ladder

(7)

Sliding window for emergency exit from operator’s cab

(8)

Emergency escape ladder

(9)

Ladder pivot bracket

(10)

(11)

Safety sensor (70B122) . (70B122a redundant), located on ladder pivot bracket. right and left side. Function of sensor (70B122): Cut out of the pilot control system and actuation of the hydraulic slew brake with the ladder in lowered position.

(12)

Lock nut for ladder pivot ball bearing

Check Safety Sensors (11) With the ladder completely lowered (position A) start the engine. Move the bucket control lever to ROLL BACK position. The bucket must NOT start to move. If the bucket starts to move, the safety sensor and/or its circuit is defective. –

Inform the Service Staff about the malfunction of the ladder sensor.

–

DO NOT operate the Excavator before the failure has been eliminated and the sensors function properly.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 85

EVERY 50 OPERATING HOURS OR WEEKLY

MAINTENANCE

Fig. 4-41

4 - 86

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.11.5

EVERY 50 OPERATING HOURS OR WEEKLY

HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY

See Fig. 4-41 –

Provide adequate working platform for safe access to the hydraulic oil coolers.

–

Before removing mounting bolts (1) of the hydraulic oil cooler door (2) check to make sure that all door hinges are in good condition and properly fastened on their carrier frames. If cracks are found at the welded joints of the hinges, DO NOT remove mounting bolts (1) otherwise the cooler door may become detached and fall off. Danger of accidents. Have the damage repaired as soon as possible.

NOTICE CLEANING! Never clean the oil coolers with the engine running or with the cooler fans still rotating.

1. Loosen mounting bolts (1). Open door (2) –

Details (A and B) show LH hinge mounted oil coolers. The description below applies also to RH mounted oil coolers.

2. Swing out oil coolers (4 and 5) and secure door (2) and oil coolers (4 and 5) with locking bars (7, 8 and 9). 3. Clean the oil coolers with compressed air, hot pressure water or steam cleaner. Use only clear water for cleaning the coolers. Direct the flow from inside to outside. When using hot pressure water, operate the cleaner at a pressure of max. 150 bar and and keep the nozzle at a distance of at least 20 cm.

WARNING RISK OF SCALDING AND INJURY FROM FLYING PARTICLES! Hot steam/water and flying particles can cause serious personal injury. When cleaning the oil cooler, always wear safety glasses and protective clothing.

4. After cleaning, bring back the oil coolers to their home position. PROCEED AS FOLLOWS Disengage locking bars (7, 8, 9). Put them in storage position (10). Swing back inner cooler (5). Take care guide pin (A) fits into hole (B) of main frame (6). Swing back outer cooler (4); observe (A - B). Close door (2); observe (B - A). Install mounting bolts (1) and tighten securely. REMARKS: When cleaning the oil coolers, also inspect laying and fastening of the hydraulic oil lines.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 87

EVERY 250 OPERATING HOURS OR MONTHLY

4.12

MAINTENANCE

EVERY 250 OPERATING HOURS OR MONTHLY

Fig. 4-42

4 - 88

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.12.1

EVERY 250 OPERATING HOURS OR MONTHLY

AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION

WARNING ROTATING PARTS! Serious personal injury can occur when the drive belt is moving. Be sure to set the maintenance safety switch to 0 position before starting the checking procedure. Refer to page 3-99 for the location of the maintenance safety switch. In the 0 position the engines can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to three padlocks can be attached to the holes provided.

–

Open the radiator fan guard door as shown on page 4-91.

Legend for Fig. 4-42 (1)

Refrigerant compressor

(2)

Electromagnetic clutch

(3)

Compressor carrier

(4)

Swivel bracket

(5)

Pivot bolt, loosen for adjusting belt tension

(6)

Drive belts

(7)

Lock nut

(8)

Adjusting bolt for belt tension

Check tension of each belt The tension is correct if the belt can be depressed with 110 N (25 lb.) force approximately 15 to 20 mm midway between the belt pulleys. Excessive belt tension causes undue wear on the bearings. After a new belt has been in use for approximately 20 minutes, check the tension and adjust again if necessary. REMARKS: Always replace the belts in complete sets. Adjust belt tension 1. Loosen pivot bolt (5) 2. Loosen lock nut (7) 3. Turn adjusting bolt (8) until correct belt deflection is obtained. Tighten lock nut (7) 4. Tighten pivot bolt (5) and check the belt adjustment. 5. Close the radiator fan guard door, see page 4-91 for details.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 89

EVERY 250 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-43

4 - 90

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.12.2

EVERY 250 OPERATING HOURS OR MONTHLY

RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER MAINTENANCE CHECK

REMARKS: Before starting the maintenance check, set the maintenance safety switch to 0. Refer to page 3-99 for location. In the 0 position the engine cannot be started. Secure by inserting a padlock into the holes of the switch. Up to ten padlocks can be attached. Legend for Fig. 4-43 (1)

Radiator fan guard door

(2)

Nuts

(3)

Stud for fastening the guard door in open position

(4)

Fan hub carrier

(5)

Fan belt

(6)

Fan belt tensioner spring

(7)

Control rod (turn buckle) of the fan belt tensioner

(8)

Grease fitting for lubrication of the belt tensioner spring

(9)

Grease fitting for lubrication of the fan hub

(10)

Grease fitting for lubrication of the engine support bracket

(11)

Sump for collecting excess lubricant

Fan Belt Inspection 1. Remove nuts (2) and open the fan guard door (1) until the upper hole (2) engages on stud (3). Fasten the door in this position by attaching one of the removed nuts to stud (3). 2. Check the Poly-Vee belt (5) for intersecting cracks. Longitudinal (direction of belt length) cracks that intersect with transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces of material missing. REMARKS: Refer to the Engine Manual filed in volume 2 binder for replacement procedure. Fan Bearing Lubrication The bearings of fan hub can be lubricated via grease fitting (9). Lubrication should only be done, if there are signs of grease loss. Before removing the sump (11), clear the area of excess or overflowing grease. Emptying sump (11) and reinstall. Apply grease gun to the fitting (9) and fill the bearing with one or two strokes of the grease gun. REMARKS: DO NOT overfill with grease otherwise the seal ring of the hub could be damaged.

Version 2021/02

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4 - 91

EVERY 250 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-44

4 - 92

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 250 OPERATING HOURS OR MONTHLY

RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER - MAINTENANCE CHECK (continued) Automatic Belt Tensioner Inspection Check belt tensioner pulley, spring assembly (6) and control rod (7) Fig. 4-44) for good condition and alignment. If a pulley is worn or damaged, it should be replaced.

WARNING ROTATING PARTS! The fan belt tensioner pulley is under tension and can lead to serious personal injury to hands and arms. Do not allow hands to get between the pulley, fan or the fan hub.

When replacing belt and pulleys, pulley alignment must be checked under belt tensioned condition. A misalignment that can be detected by the naked eye is detrimental to belt performance. REMARKS: Refer to the Engine Operation and Maintenance Manual filed in volume 2 binder for adjustment, repair and replacement procedures. Lubrication of Tensioner Spring Assembly and Engine Support Bracket Lubricate the spring assy (6) via grease fitting (8) and the engine support bracket via grease fitting (10) after every 1500 operating hours or once a year whichever comes first. REMARKS: See Engine Operation and Maintenance Manual filed in volume 2 binder for lubrication procedure and grease specification. Be sure to close the fan guard door (1) after finishing the maintenance check. Secure the closed door with the two nuts (2).

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4 - 93

EVERY 250 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-45

4 - 94

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.12.3

EVERY 250 OPERATING HOURS OR MONTHLY

GENERATOR - CHECK BELT TENSION

REMARKS: For the correct belt tension and belt tension gauge refer to the Drive Belt Tension Chart in the Engine Operation and Maintenance Manual, Section V, page 19. The engine can be equipped with one of the two versions of belt tensioning systems. Version A with turn buckle, Fig. 4-45 Adjustment: 1. Remove generator belt guard. 2. Loosen bolts (1 and 2). 3. Loosen lock nuts (3) and adjust belt tension with turn buckle (4). 4. Tighten lock nuts (3) and bolts (2 and 1) in this sequence. 5. Install generator belt guard. Version B with slotted bar, Fig. 4-45 Adjustment: 1. Remove generator belt guard. 2. Loosen bolts (1 and 2). 3. Pull the generator until the required belt tension is obtained and tighten bolts (2 and 1) in this sequence. 4. Install generator belt guard. REMARKS: Check the belt tension after 10 minutes running time and readjust if necessary.

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4 - 95

EVERY 250 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-46

4 - 96

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.12.4

EVERY 250 OPERATING HOURS OR MONTHLY

SIGNAL HORN COMPRESSOR - LUBRICATE

See Fig. 4-46 The compressor (2) is located in the cab base. Fill 4 to 6 drops of thin oil into the lubricator (1). The oil must be free from resin and acid and must have the lowest solidifying-point possible (below - 40° C). REMARKS: If the Excavator is equipped with a second signal horn there is also a second compressor which has to be lubricated in the same way as the first one.

4.12.5

HYDRAULIC OIL COOLER FAN - CHECK CONDITION AND FASTENING

Legend for Fig. 4-46 (1)

Oil cooler carrier

(2)

Cooler fan

(3)

Mounting bolt

(4)

Thrust block

(5)

Mounting bolt

(6)

Hydraulic motor

(7)

Mounting bolt

Check condition of cooler fan (2). Make sure all bolts (3) are in place and correctly tightened. Check hub mounting bolt (5) for correct tightening torque. Check hydraulic motor (6) for leakage. Make sure all bolts (7) are in place and correctly tightened. REMARKS: Refer to Standard Torque List on page 4-11 for bolt tightening torques.

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4 - 97

EVERY 250 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-47

4 - 98

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.12.6

EVERY 250 OPERATING HOURS OR MONTHLY

AUTOMATIC LUBRICATION SYSTEMS - CLEAN BREATHER FILTER

Legend for Fig. 4-47 (1)

Pump station of automatic lubrication system

(2)

Breather Filter

NOTICE REMOVE IGNITION KEY BEFORE SERVICING! Before servicing stop the motor and remove ignition key in order to prevent operation of the system. Be sure to vent system pressure before removing the breather filler plug (2).

Check breather filter (2): Check condition and fastening of breather filter (2). If necessary clean the breather filter with compressed air. Check the correct fitting of all connections: Check the fitting and condition of all gaskets, bolts, hoses and cables of the automatic lubrication systems. Tighten loose connections and replace defective or worn parts.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 99

EVERY 250 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-48

4 - 100

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.12.7

EVERY 250 OPERATING HOURS OR MONTHLY

CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT

Legend for Fig. 4-48 (1)

Access door to cab air cleaner

(2)

Air cleaner housing

(3)

Filter element

(4)

Carrier

(5)

Seal ring

(6)

Cab blower

(6)

Blower housing

(7)

Air conditioning condenser

(8)

Access door to the water tank of the windshield washer system and to the dryer cartridge of the air conditioning

(9)

Cover grid for the air conditioner filter mat

(10)

Air conditioner filter mat

(11)

Condenser blower for air conditioning

4.12.7.1

CLEAN AND INSPECT FILTER ELEMENT (3) AS FOLLOWS:

1. Open door (1). 2. Remove air cleaner housing (2). 3. Remove and inspect element (3). If any rupture, holes or damaged gaskets are discovered replace the element. 4. If the element is usable clean with compressed air from inside to outside and reinstall. REMARKS: When installing the filter, ensure that the foldings of the filter are aligned vertically downwards. 5. Inspect seal ring (5) and replace if necessary. 6. Check blower (6) for correct fastening and tightness. Clean and inspect filter element (10) as follows: 1. Unscrew cover grid (9). 2. Remove and inspect filter mat (10). If any rupture, holes or damaged is discovered replace the element. 3. If the element is usable, clean and reinstall.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 101

EVERY 250 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-49

4 - 102

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.12.8

EVERY 250 OPERATING HOURS OR MONTHLY

WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL

Legend for Fig. 4-49

–

(1)

Access door to the water reservoir of the windshield washer system and to the dryer cartridge of the air conditioning

(2)

Water reservoir for windshield washer

(3)

Cab air filter

(4)

Cab blower

(5)

Dryer cartridge of the air conditioning

(6)

Sight glass for checking refrigerant filling

(7)

Shut-off valve for dryer cartridge replacement

(8)

Condenser blower

(9)

Evaporator

Fill the water reservoir (2) with clear water, add antifreeze and cleaning agent as necessary. Filling capacity of the reservoir approximately 7 liter. Check washer and wiper system for leakages and carry out a functional test of both systems.

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4 - 103

EVERY 250 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-50

4 - 104

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.12.9

EVERY 250 OPERATING HOURS OR MONTHLY

AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL

Fig. 4-50: –

Switch on air conditioning equipment and run at maximum capacity for approx. 5 minutes.

–

Observe inspection glass (6). A refrigerant flow loaded with bubbles or foam indicates a lack of refrigerant. In this case well equipped refrigeration specialists must check the circuit for tightness and must add the missing quantity or refrigerant.

–

If more than 200 grams per year are lost, the oil level of the refrigerant compressor must also be checked. This is a special procedure and must be carried out by refrigeration specialists only. Isolated small bubbles in the inspection glass may be neglected. Even with an absolutely tight equipment a certain amount of refrigerant is lost through the walls of the hoses. Therefore a small annual replenishment of the refrigerant quantity is normal.

–

The dryer cartridge (5) must be replaced after every 1000 operating hours or once a year by refrigeration specialists.

–

Clean the filter mat of condenser blowers (8).

–

Clean or replace the filter mat in the evaporator (9). To clean the evaporator filter map, remove bolts on the RH side of the intake grid and open.

REMARKS: Servicing of the air conditioning systems is restricted to workshops especially equipped for this purpose. Refer to AH06521b for more information.

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4 - 105

EVERY 500 OPERATING HOURS OR MONTHLY

4.13

MAINTENANCE

EVERY 500 OPERATING HOURS OR MONTHLY

Fig. 4-51

4 - 106

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.13.1

EVERY 500 OPERATING HOURS OR MONTHLY

BATTERIES - CHECK FLUID LEVEL

See Fig. 4-51 A - Top view of access area

WARNING RISK OF EXPLOSION! Batteries give off highly flammable gas! Never allow sparks or open flame near the batteries! Avoid spilling any electrolyte on hands or clothing. Repair or replace all broken wires immediately. All terminals must be clean and securely fastened; never paint connections. DO NOT short across or ground any terminals of the batteries.

NOTICE SAFE HANDLING OF BATTERIES! Care must be taken that the batteries are not overfilled as the electrolyte will expand and overflow when the temperature rises. On removal always disconnect the ground (-) cables first. When reinstalling the batteries connect the positive (+) cables first.

Check electrolyte level: REMARKS: The batteries are located below the walkway floor in two separate boxes. To get access to the batteries remove floor plate fastening bolts and open the hinged floor plates. Secure the open floor plates against falling down with the safety chains provided. 1. Remove the two battery main switch keys (1). 2. Open floor plates (2). 3. Check electrolyte level (4) of batteries (3). 4. If necessary remove filler and breather caps and top up with clean distilled water. 5. See that contact surfaces of battery terminals are bright. Clean if necessary and apply some vaseline to the terminal posts.

Version 2021/02

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4 - 107

EVERY 500 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-52 4 - 108

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.13.2

EVERY 500 OPERATING HOURS OR MONTHLY

FUEL TANK - DRAIN CONDENSATION

Legend for Fig. 4-52 (A)

Rear view of fuel tank

(B)

Left view

(C)

Top view

(1)

Fuel tank

(2)

Fuel return port (engine fuel pump return line)

(3)

Drain coupling

(4)

Fuel outlet port for auxiliary user (Generator set)

(5)

Fuel outlet port to engine fuel pump

(6)

Stair to cab

(7)

Pressure transducer for level indication

(8)

Mounting brackets

(9)

Cover

(10)

Fuel filler neck

(11)

Shut-off cock for pressure transducer (7). Close this cock when replacing the pressure transducer (7).

WARNING RISK OF EXPLOSION! Flammable fuels can ignite causing serious injury or death. DO NOT smoke or use an open flame when working around flammable fuels.

Drain Water and Sediments from Fuel Tank. Open the hinged cover below the fuel tank. Attach drain hose and open drain coupling (3). Collect outflowing sediments in a suitable container. REMARKS: A solenoid valve mounted to port (5) shuts off fuel supply to the engine as soon as the engine stop switch or any emergency stop switch is actuated.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 109

EVERY 500 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-53 4 - 110

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 500 OPERATING HOURS OR MONTHLY

4.13.3

CRAWLER TRACK - INSPECTION

4.13.3.1

CHECK ADJUSTING RANGE OF GUIDE WHEELS

(Track retensioning range) GENERAL The hydraulic track tensioning system, Fig. 4-53 maintains the correct track tension automatically. The pilot pressure oil of the travel brake release circuit is used, to pressurize the four adjusting cylinders (10) and (11). The resulting force moves the guide wheels toward the front, until the correct track tension is obtained. External forces acting upon the guide wheels are absorbed through the pressure accumulators (8A) and (8B). Legend for Fig. 4-53 (1)

Rotary distributor

(2)

Supply line, pilot pressure from travel brake release circuit

(3)

Return oil line (leakage oil)

(4)

Valve block

(5)

Pressure relief cock for hydraulic track tensioning system. “C” - Closed (Normal working position) “O” - Open

(6)

Shut-off cock in supply line (if so equipped) “O” - Open (Normal working position) “C” - Closed

(7)

Two stage pilot pressure operated relief valve

(8A)

Pressure accumulator, high pressure (150 bar)

(8B)

Pressure accumulator, low pressure (31 bar)

(9)

Shutoff cocks, RH & LH “O” - Open (Normal working position) “C” - Closed

(10)

Track adjusting cylinders, inner

(11)

Track adjusting cylinders, outer

(12)

Test connectors and vent valves

CAUTION HIGH PRESSURE! Before working on the hydraulic track tensioning system, relieve all pressure in the system by opening cock (5), position ’0’. After finishing the service work close the pressure relief cock (5), position ’C’.

Version 2021/02

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4 - 111

EVERY 500 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-54 4 - 112

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.13.3.2

EVERY 500 OPERATING HOURS OR MONTHLY

CHECK ADJUSTING RANGE FOR GUIDE WHEELS

Legend for Fig. 4-54 (1)

Guide wheel

(2)

Slide block

(3)

Stop plate

“X” Adjusting range for track tension The adjusting range for track tension is the distance “X” between guide wheel slide block (2) and stop plate (3). Depending on lengthening of the track the slide block (2) may come in contact with stop plate (3). In such a case, it must be ensured that the track does not become too loose, Depending on track condition, the removal of one track pad will restore the adjusting range “X”. If necessary contact our Service Department for more information.

–

If removal of a track pad becomes necessary, it must be done on both tracks in order to maintain the same length of both tracks.

–

During operation, the pressure relief cock (5) must always be in CLOSED position. Open cock (5) for pressure relieve prior servicing any part of the system, e.g. removal of a track pad.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 113

EVERY 500 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-55 4 - 114

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.13.3.3

EVERY 500 OPERATING HOURS OR MONTHLY

CHECK ADJUSTING RANGE FOR GUIDE WHEELS

NOTICE CHECK THE POSITION OF THE COCKS! The cocks (9), Fig. 4-55 must always be in OPEN position. Close only in such cases, when the adjusting cylinders (10 and 11) must remain under pressure while servicing other components of the system.

4.13.3.4

BLEEDING THE SYSTEM

1. Make sure pressure relief cock (5) Fig. 4-55 is in closed position “C”; and shutoff cocks (6 and 9) are in open position “O”. 2. Start the engine/motor. 3. Slowly open vent valves (12) on all four adjusting cylinders until bubble free oil flows out. Close the vent valves (12). 4. Move the excavator forward and reverse to distribute tension. 5. Check adjusting range “X” according to Fig. 4-54 on previous page. 6. Check the complete system for leakages. REMARKS: Further track group inspection and wear measurement procedures should be carried out according to Parts and Service News Bulletin No. AH02521.

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OMM 06372-D-EN-6T2-1.0

4 - 115

EVERY 500 OPERATING HOURS OR MONTHLY

4.13.3.5

MAINTENANCE

GREASE INJECTORS - CHECK INDICATOR STEMS

See page 4-29 for more information Check operation of all grease injectors by visually watching the cycle indicator stem (1) while operating the central lubrication system manually. Stem (1) must move in and out once a complete lubrication cycle. If a cycle indicator (1) does not move during a lubrication cycle, grease supply to the lubrication point of the concerned injector is interrupted, proceed according to paragraph CORRECTIVE ACTIONS.

NOTICE WHEN DEFECTIVE! If the failure is caused through a defective central lubrication system, manually lubricate at grease fittings (4) after removal of caps (3). g .F i4 -5 6Fig. 4-57

4.13.3.6

CORRECTIVE ACTIONS

1. Check to make sure grease supply through inlet line is provided. 2. Disconnect the outlet line of the respective injector. 3. Operate the central lubrication system manually. – A - If now the injector works, i.e. cycle indicator stem (1) moves in and out the disconnected line or the grease passage at the lubrication point is damaged or blocked by foreign matter. Repair as necessary. – B - If the injector does not work, i.e. cycle indicator stem (1) stationary, replace the respective injector. 4. Operate the central lubrication system and recheck operation of the grease injectors. If the failure is caused through a defective central lubrication system, manually lubricate at grease fittings (4) after removal of caps (3). REMARKS: If necessary, remove all excess grease from the injectors.

4 - 116

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MAINTENANCE

EVERY 500 OPERATING HOURS OR MONTHLY

Please continue reading on the next page.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 117

EVERY 500 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-58

4 - 118

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.13.4

EVERY 500 OPERATING HOURS OR MONTHLY

EMERGENCY LOWERING OF ACCESS LADDER - TEST FUNCTIONALITY

Legend for Fig. 4-58 (1)

Access ladder

(2)

Lowering chain on superstructure

(3)

Lowering chain for man on ground near counterweight

(4)

Lever on valve

Test the pull chains (2) and (3) for emergency lowering of the access ladder (1) successively according to the following procedure:

WARNING HAZARDOUS AREA! People moving within the area where the stairway will lower could be injured. Make sure the whole area is clear before lowering. Once the chain has been pulled, the ladder is lowered by gravity and cannot be stopped.

1. Pull chain. 2. If the ladder lowers, the test is successful. If not, call service. 3. Reset the function of the ladder by raising the lever on the valve (4). Refer to chapter "Emergency Lowering of the Access Ladder" on page 3-13 for more information. 4. Check if the chain (2 and 3) and the parts of the mechanical lever (4) are in good and serviceable condition. REMARKS: EMERGENCY USE ONLY! During normal operation use this chain only in emergency cases, when the Operator needs to escape the excavator.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 119

EVERY 500 OPERATING HOURS OR MONTHLY

MAINTENANCE

Fig. 4-59

4 - 120

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.13.5

EVERY 500 OPERATING HOURS OR MONTHLY

CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS

Legend for Fig. 4-59 (1)

Gap between stop plate and U-profile

(2)

U-profile

(3)

Stop plate

(4)

Sliding stones

(5)

Position of contracted cylinder rod

(6)

Sliding block retaining screws

(7)

Stop plate retaining screw

(8)

Bolt

(9)

Split pin

If the gap (1) between the U-profile (2) and the stop plate (3) is smaller than 1mm, the sliding blocks (4) have too much wear and must be exchanged.The wear that is shown by looking at the gap (1) can depend on which cylinder, and therefore in which position the cylinder rod protection is (bucket cylinder on backhoe excavators for example, or boom cylinders on front shovel excavator). –

Ensure the cylinder rod is completely retracted as shown on (5)

–

Secure the cylinder at the front and back with slings. In positions where the cylinder can not be kept in a horizontal position, the cylinder rod protection must be secured against falling.

–

Loosen the screws (6) that hold the sliding stones (4) in place. (Note - only loosen. Do not remove)

–

Secure the stop plate (3) in place with the screw (7)

–

Remove the splint (9) from the bolt (8) that holds the rod protection to the cylinder.

–

Remove bolt (8)

–

Move the protection forward so that the sliding stones (4) are easily accessible.

–

Unscrew the screws completely (5) that hold the sliding stones (4) in place.

–

Exchange the sliding stones (4) with new ones and screw in the screws (6) hand tight only.

–

Assemble the whole protection in reverse order ensuring the split pins (9) are replaced with new ones.

–

Tighten the screws (6) with 40 Nm

–

Remove slings

NOTICE LUBRICATION! Never lubricate the sliding stones or the area of sliding. The sliding stones are self-lubricating.

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4 - 121

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

4.14

MAINTENANCE

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

Fig. 4-60 4 - 122

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.1

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

CRITICAL BOLT CONNECTIONS

Check mounting of Operator’s cab Legend for Fig. 4-60 (1)

Cab brackets

(2)

Cab carrier plates

(3)

Viscous mounts, filled with silicon oil

(4)

Support bars with inner thread on cab base

(5)

Cab base

(6)

Mounting bolts carrier plates (2) to support bars (4)

(7)

Resilient sleeves

(8)

Mounting bolts cab brackets (1) to viscous mounts (3)

(9)

Resilient sleeves

(10)

Mounting bolts for viscus mounts

–

Check all mounting bolts for correct tightening torque.

–

Retighten loose mounting bolts and replace missing or damaged bolts.

–

Check the silicone oil filled viscous mounts (3) for leakage and signs of fatigue.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 123

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-61

4 - 124

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

Critical Bolt Connections (continued) Check tightening torque of the counterweight mounting bolts (2), Fig. 4-61 Reference No.:

Bolt size mm

Grade

M42

10.9

SW * mm

Tightening torque

4950

Qty.

(1) Counter weight (2) Mounting bolts

(3) Instruction label (4) Fastening points for horizontal transport (5) Fastening points for vertical transport (6) Fastening points for raising up the counter weight * SW = Wrench size –

Check all mounting bolts (2) for correct tightening torque.

–

Retighten loose mounting bolts and replace missing or damaged bolts.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 125

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-62

4 - 126

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

Critical Bolt Connections (continued) Check condition and fastening of the slew gear (2) and slew motor (1), Fig. 4-62 * SW = Wrench size Reference No.:

Bolt size mm

Grade

SW * mm

Tightening torque Nm

Qty.

(1)

M 16

10.9

265

(2) Socket head cap screw

M 24

12.9

1030

–

Check all mounting bolts (1 and 2) for correct tightening torque.

–

Retighten loose mounting bolts and replace missing or damaged bolts.

REMARKS: After checking and retightening of slew gear mounting bolts (2), attach protection caps (3) onto the bolt heads.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 127

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-63

4 - 128

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.2

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

HYDRAULIC SYSTEM - FILTER SERVICE

Legend for Fig. 4-63 R

Return of filter location

Leakage oil filter location

(1)

Mounting bolt

(2)

Filter cover retainer

(3)

Filter cover assy

(4)

Return- and leakage filter unit

(5)

Oil filler plug

(6)

O-ring

(7)

Breather filter

(8)

Cover

(9)

Gasket

REMARKS: The description of the hydraulic filters appears in the following sequence: –

Return- and Leakage oil filters, see page 4-131

–

Breather filter, see page 4-133

–

High pressure filters, see page 4-135

–

Pressure filters on central control and filter frame, see page 4-139

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 129

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-64

4 - 130

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.2.1

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

FILTER SERVICE

–

Replace return oil filter elements. Bleed return oil chamber afterwards, see chapter 4.14.3

–

Replace leakage oil filter element

–

Check filter screens

Follow the steps shown in Fig. 4-64: 1.

Loosen bolt (1).

Turn retainer (2).

Remove cover assy (3). Inspect O-ring (4) and replace if necessary.

Lift out element assy (5).

Disassemble filter assy (5) in sequence of ref. nos. (6 to 12)

Discard element (8)

Inspect screen (11) and clean if necessary.

REMARKS: Take care not to contaminate the clean inside of the screen when flushing. 8.

Inspect screen (11) and O-ring (12) for damage replace if necessary. Install screen (11) use new sealing washer (10) and self locking nut (9). Tighten nut with 14 Nm +2.

Reassemble filter assy (5) with new element (8) according to step 5. Use new self locking nuts (6). Tighten nuts with 12 Nm +2.

10.

Install filter assy use new gasket (7). Torque bolt (1) to 850 Nm.

–

After each repair of the hydraulic system the elements (8) should be replaced after about 50 operating hours.

–

The filter elements must also be replaced when the fault message "Filter restriction" is displayed on the Komtrax screen.

–

Replace screens (11) every 6000 operating hours at the latest.6000

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4 - 131

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-65

4 - 132

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

FILTER SERVICE (continued) –

Replace breather filter element

–

Drain water and sediments from hydraulic oil tank

Legend for Fig. 4-65 (1)

Hand wheel of main shut-off valve located between suction oil reservoir and main oil reservoir To OPEN the valve, turn hand wheel (1) CCW to the stop To CLOSE the valve, turn hand wheel CW to the stop A proximity switch located on the gearbox of the shut-off valve monitors the valve position. With the valve not fully open, a corresponding message will be displayed on the Komtrax screen in the Operator’s cab. Before starting the motor, make sure the shut-off valve is completely open by turning hand wheel (1) fully to the left (CCW).

(2)

Breather filter

Replace Element (C) of Breather Filter (2). 1. Remove nut (A). 2. Remove cover (B). 3. Remove filter element (C). 4. Insert new filter element and reassemble the breather filter (2). Drain Water and Sediments Drain water and sediments with excavator standing an level ground and when excavator was out of operation for some time. Refer to Operation section on page 3-164 for evacuation procedure.

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EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-66

4 - 134

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Version 2021/02

MAINTENANCE

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

FILTER SERVICE (continued) High Pressure Filters "HPF", Fig. 4-66 The filter reference numbers (1 - 3) correspond to the numbering of the main pumps. Legend for Fig. 4-66 (1)

HPF for pump 1

(2)

HPF for pump 2

(3)

HPF for pump 3

(4)

Main control valve I

(5)

Main control valve II

(6)

Main control valve III

(7)

Drain plug

(8)

Filter case

(9)

Hexagon

(10)

Filter element

(11)

Packing ring

(12)

O-ring

(13)

Back-up ring

(14)

O-ring

(15)

Filter header

1. Place working attachment on the ground and shut-off the engines. Relieve pressure in the hydraulic system with several movements of the control levers. (System must be depressurized.) 2. Check the outside of the filter elements for obvious signs of damage. Clean where necessary. (A handy tip is to mark the body of filter case and filter head with a marking line to help with ease during a visual check) 3. Place a suitable container below the filter in order to collect outflowing oil. Dispose of oil according to local safety regulations. 4. Remove plug (7) and drain the oil. 5. Unscrew the filter case (8) and remove the filter element (10). Place on clean surface. Check for wear elements. If none, or only minor wear elements are present, clean the filter with appropriate cleaning agents. If major contaminating wear elements are present, an investigation must take place of the corresponding pump as shown in the above legend to the illustration and the filter must be replaced together with all seals and gaskets. 6. Reassemble the filter unit in reverse order of the above using fresh seals and gaskets.

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EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

6.Reassemble the filter unit in reverse order of the above using fresh seals and gaskets.

Fig. 4-67

4 - 136

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EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

FILTER SERVICE (continued) High Pressure Filters "HPF", Fig. 4-67 REMARKS: Carefully inspect elements for damage. Always install new elements if ruptures or other damages are found. 7. Remove element (10) and clean. Take care not to contaminate the "Clean" inside of the element when flushing. 8. Inspect O-rings (12 and 14) and back-up ring (13). Replace if necessary. 9. Install drain plug (7) with new packing ring (11). Fill filter case (8) half way up with clean hydraulic oil and reassemble the filter. Make sure element (10) is properly seated in the filter head. 10. After short operating period check filter units for leakage. REMARKS: In case filter element (10) is soiled by metal chips, examine hydraulic pump for damages. Install new element (10).

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4 - 137

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-68

4 - 138

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Version 2021/02

MAINTENANCE

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

FILTER SERVICE (continued) Clean or replace filter elements of the hydraulic oil pressure filters REMARKS: When a fault message "Pressure Filter restricted" is displayed, stop work and clean replace element of the corresponding pressure filter. Legend for Fig. 4-68 (1)

Central control and filter panel

(2)

Valve bank

(2.1)

Valve block, hydraulic swing down service arm circuit

(2.2)

Valve block, hydraulic access ladder circuit

(2.3)

Valve block, slew circuit

(2.4)

Valve block, travel brake circuit

(2.5)

Valve block, pilot oil circuit

(3)

Pressure oil filter for pump distributor gear PTO lubricating oil. Filter restriction monitored by differential pressure switch B27.

(4)

Pressure oil filter for pilot- and pump control oil circuit. Filter restriction monitored by differential pressure switch B22.

(5)

Pressure oil filter for fan drive motor of hydraulic oil cooler . Filter restriction monitored by differential pressure switch B28.

(6)

Pressure accumulator for pilot oil circuit

REMARKS: The pressure filter (3) for PTO gear lubrication can not be cleaned. This element must be replaced.

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4 - 139

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-69

4 - 140

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

FILTER SERVICE (continued) Clean or replace pressure filter elements, Fig. 4-69, as follows: 1. Place working equipment on the ground and shut-off the motor. Relieve pressure in the hydraulic system according to page 3-148 in the operation section. 2. Place a suitable container below the filter in order to collect outflowing oil. 3. Remove plug (A) and drain the oil. 4. Unscrew case (C) of the respective filter and clean the filter case. REMARKS: Carefully inspect elements for damage. Always install new elements if ruptures or other damages are found. 5. Remove element (F) and clean. Take care not to contaminate the "Clean" inside of the element when flushing. 6. Inspect O-rings and back-up ring. Replace if necessary. 7. Install drain plug (A) with new packing ring (B). 8. Lubricate the thread at the filter head and at filter case (C) with multi-purpose grease K2K. 9. Insert the cleaned element or a new element (F) with new O-ring (G). 10. Fill the case (C) half way up with clean hydraulic oil. 11. Screw the case (C) into the head and tighten. 12. After short operating period check filter for leakage. 13. Check restriction indicator (H) for proper mounting and good condition. REMARKS: Replace elements (F) after three cleanings or after every 6000 operating hours, whichever occurs first.

Version 2021/02

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4 - 141

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-70 4 - 142

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.3

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

BLEEDING RETURN OIL CHAMBER (IF EQUIPPED WITH OIL LEVEL GAUGE)

REMARKS: If the return oil chamber is not equipped with an oil level gauge, refer to Parts & Service News AH20845. Contact Komatsu Service if necessary.

NOTICE BLEED AIR FROM THE RETURN OIL CHAMBER! Air in the hydraulic system can cause damage on hydraulic components. Always bleed return oil chamber if the oil level gauge (2) is not completely filled with oil.

Fig. 4-70 (1)

Hydraulic oil reservoir

(2)

Oil level gauge for return oil chamber

(3)

Oil bleeding plug with integrated lock valve

(4)

Protection cover

(5)

Protection cover of coupling

(6)

Hose connector

(7)

Bleeding hose

Ensure that everything is properly installed at the hydraulic reservoir. 1. Open protection covers (4) and (5). 2. Hang the open end of the hose (7) into a suitable container (min. 2l). Connect the bleeding hose (6) to the oil bleeding plug (3) and tighten securely by hand. 3. Start the motor. REMARKS: Run Diesel engine at low idle. 4. Wait until oil flows continuously out of the hose. 5. While the motor is running, remove the bleeding hose (6) to lock the internal valve. 6. Stop the motor. 7. Wait 10 minutes to ensure that oil foaming and degassing has stopped. 8. Start the motor. REMARKS: Run Diesel engine at low idle. When connecting bleeding hose to bleeding plug with the engine at standstill, air will enter the return oil chamber. 9. Hang the open end of the hose (7) into a suitable container (min. 2l). Connect the bleeding hose (6) to the oil bleeding plug (3) and tighten securely by hand. 10. Wait until oil flows continuously out of the hose. 11. While the motor is running, remove the bleeding hose( 6) to lock the internal valve.

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4 - 143

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-71 4 - 144

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

12. Stop the motor. 13. Wait 10 minutes to ensure that oil foaming and degassing has stopped. 14. Check the oil level gauge (2). If the oil level gauge is not free of air bubbles or the oil level is low, repeat this bleeding procedure (step 8-14) accordingly until the oil level gauge (2) is completely filled with oil. 15. Reinstall the protection covers (5) and (4) properly.

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4 - 145

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-72

4 - 146

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.4

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

PTO (PUMP DISTRIBUTOR GEAR), SLEW GEAR AND TRAVEL GEARS - OIL SAMPLE ANALYSIS

The oil sample analysis gives information about the grade of contamination and aging of the gear oils. Refer to the tables below for limits of contamination. Refer to the separate manual "Oil Analysis and Condition Monitoring” filed in the volume 2 binder for limits of contamination.

4.14.4.1

OIL DRAIN PLUGS

Fig. 4-72 (1)

PTO (Pump distributor gear)

(2)

Slew gear

(3)

Travel gears, planetary box

(4)

Travel gears, spur gear box

REMARKS: If the grade of contamination approaches to the “critical” values in the above tables, change the gear oil. However, the regular oil changes must be carried out every 3000 operating hours or once a year, whichever occurs first.

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4 - 147

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-73

4 - 148

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.5

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE

See Fig. 4-73 Unscrew collector protection cap (2). Unscrew ball bearing cover and fill it half way up with grease. If the fins of the collector are very strongly blackened or coated with verdigris, clean them with emery cloth.

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4 - 149

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-74

4 - 150

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.6

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS

CAUTION HIGH PRESSURE! Before working on any part of the hydraulic track tensioning system relieve all pressure in the system by opening pressure relief cock (5), Fig. 4-74.

REMARKS: For checking the charging pressure a special testing and filling device must be used. This device can be ordered from your Komatsu Dealer. The testing and filling procedure of the pressure accumulators has to be carried out in accordance with Service Bulletin No. AH01531. Legend for Fig. 4-74 (1)

Rotary distributor

(2)

Supply line, pilot pressure from travel brake release circuit

(3)

Return oil line (leakage oil)

(4)

Valve block

(5)

Pressure relief cock for hydraulic track tensioning system. “C” - Closed (Normal working position) “O” - Open

(6)

Shut-off cock in supply line (if so equipped) “O” - Open (Normal working position) “C” - Closed

(7)

Two stage pilot pressure operated relief valve

(8A)

Pressure accumulator, high pressure (150 bar)

(8B)

Pressure accumulator, low pressure (31 bar)

(9)

Shutoff cocks, RH & LH “O” - Open (Normal working position) “C” - Closed

(10)

Track adjusting cylinders, inner

(11)

Track adjusting cylinders, outer

(12)

Test connectors and vent valves

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4 - 151

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-75

4 - 152

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Version 2021/02

MAINTENANCE

4.14.7

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES

–

Provide adequate working platform for safe access to the hydraulic oil cooler (1).

–

Check all door hinges (4) for good condition and proper fastening to their carrier frames. If cracks or distortion at the weld area of the hinges are found corrective action must be taken. DO NOT try to open the cooler doors before the damage has been repaired otherwise the cooler door may become detached and fall off. Danger of accidents.

Legend for Fig. 4-75 (1)

Hydraulic oil cooler

(2)

Rear door of machinery house

(3)

Radiator door

(4)

Hinges

(5)

Grease fitting

(6)

Cotter pin

–

Lubricate all cooler hinges (4) at grease fittings (5).

–

Check to make sure that the hinge pins are properly secured with cotter pins (6).

4.14.8

MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES

–

Provide adequate working platform for safe access to the rear machinery house door (2).

–

Check all door hinges (4) for good condition and proper fastening to their carrier frames. If cracks or distortion at the weld area of the hinges are found corrective action must be taken.

–

Lubricate all door hinges (4) at grease fittings (5).

–

Check to make sure that the hinge pins are properly secured with cotter pins (6).

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 153

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-76

4 - 154

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.9

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

EMERGENCY ENGINE SHUTDOWN SWITCHES - TEST FUNCTIONALITY

Legend for Fig. 4-76 (1)

Emergency engine shutdown switch in the cabin (20S036)

(2)

Emergency engine shutdown switch (61S033b) at the machinery house wall, opposite to the main control valves

(3)

Emergency engine shutdown switch (51S033d) in pump compartment

(4)

Light switch

(5)

Emergency engine shutdown switch at the machinery house door (51S033e)

(6)

Maintenance safety switch for start prevention of the engine (51S058)

(7)

Rotary switch

(8)

Fold up flap

(9)

Padlock holes on flap

(10)

Display of Komtrax Plus on the instrument panel in the Operator’s cab.

Test all emergency engine shutdown switches (20S036, 61S033b,51S033d, 51S033e) successively according to the following procedure: 1. Start the engine and run at low idle. For further information about starting the engine refer to section 3.11 on page 3-118.

NOTICE STOPPING THE ENGINE FROM FULL LOAD! Never stop the engine from a full load except in cases of emergency. If a hot engine is shut down without previous idling period of three to five minutes, the temperature in certain engine parts rising sharply after the cooling system ceases to function. The resulting thermal stress, especially in the turbochargers, may cause serious damage.

2. Push the emergency engine shutdown button. If the engine stops and a corresponding fault message is displayed on the screen (9), the test is successful. If the engine keeps running and no fault message is displayed on the screen, call service. 3. To release the activated emergency engine shutdown switches, turn the button to the right. Test maintenance safety switch (51S058): Engine has to be off. 1. Set rotary switch (6) horizontally to -0- position as shown in Fig. 4-76. 2. Fold up flap (7) and secure this position by inserting a padlock into the holes (8) of flap (7) and safety switch (6). 3. Try to start the engine. For further information about starting the engine refer to section 3.11 on page 3-118. If the engine does not start, the test is successful. If the engine starts, call service.

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4 - 155

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-77

4 - 156

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.10

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) TEST FUNCTIONALITY

REMARKS: The engine shutdown pull chain function is an option which has to be selected in the Komtrax controller. Legend for Fig. 4-77 (1)

Actuating chains for shut down of the engine (special equipment). To stop the engine, pull down one of the chains (1).

(2)

Pull chain for emergency lowering of the access ladder

(3)

Display of the Komtrax Plus on the instrument panel in the Operator’s cab.

Test both chains for shut down of the engine successively according to the following procedure: 1. Start the engine and run at low idle. For further information about starting the engine refer to section 3.11 on page 3-118.

2. Pull the engine shutdown chain. If the engine stops and a corresponding fault message is displayed on the screen (3), the test is successful. If the engine keeps running and no fault message is displayed on the screen, call service.

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4 - 157

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-78 4 - 158

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.11

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

ELECTRICAL EQUIPMENT - MAINTENANCE

–

Check all cables and components of the electrical equipment on the excavator (working lights, signal horn, sensors, switches etc.).

–

Repair any loose connections

–

Check and repair any defects on the protective coverings especially in areas where the cables are likely to rub.

–

Check for deteriorating and broken cables, especially in conditions of high ambient and local heat, or areas of extreme external contamination or dirt.

–

Check switches, lamps and buttons for functionality and correct movement.

–

Check connections for water and/or dampness and dry where necessary.

–

Inspect plugs and sockets for functionality.

–

Any electrical components, cables, plugs or sockets that do not work or have deteriorated or are defective, must be replaced immediately by a qualified electrician.

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OMM 06372-D-EN-6T2-1.0

4 - 159

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-79

4 - 160

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.14.12

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

ENGINE AIR CLEANERS- INSPECT AND LUBRICATE HINGES

Legend for Fig. 4-79 (1)

Air cleaner on roof

(2)

Flaps to remove dirt/dust from the air cleaners

(3)

Hinges (with greasing nipple)

–

Ensure there is safe access to the hydraulic air cleaners (1) on roof.

–

Check all hinges (3) for good condition and proper fastening to their flaps (2). If cracks or distortion at the weld area of the hinges (3) are found corrective action must be taken. DO NOT try to open the flaps (2) before the damage has been repaired.

–

Lubricate all flaps (2) by attaching a grease gun to the grease fittings on the hinges (3). Grease will be pumped through the grease nipples into the hinges (3).

–

Check to make sure that the hinges (3) are properly secured.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 161

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

MAINTENANCE

Fig. 4-80

4 - 162

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Version 2021/02

MAINTENANCE

4.14.13

EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH

OIL SEPARATOR ELEMENT - REPLACE BREATHER FILTER

Legend for Fig. 4-109 (1)

Hydraulic oil tank

(2)

Oil separator

(3)

Breather filter

(4)

Bolt, M8 x 20, Grade 8.8

(5)

Oil separator element

(6)

O-ring

Replace breather filter of oil separator elements 1. Loosen bolts (4) and carefully remove cover with breather filter (3). 2. Replace breather filter (3) and O-ring (6) by new ones. 3. Carefully reinstall cover with breather filter (3) and tighten the bolts (4).

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4 - 163

EVERY 2000 OPERATING HOURS OR YEARLY

4.15

MAINTENANCE

EVERY 2000 OPERATING HOURS OR YEARLY

Fig. 4-81

4 - 164

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Version 2021/02

MAINTENANCE

4.15.1

EVERY 2000 OPERATING HOURS OR YEARLY

HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER

–

The hydraulic oil change intervals can be extended for a further time period, when an oil sample analysis shows a positive result. When extending the oil change interval, it is necessary to carry out an oil sample analysis after every 1000 operating hours. Information to the Komatsu Germany recommended used oil limits can be found in the separate manual "Oil Analysis & Condition Monitoring" filed in the Operation & Maintenance Manual Volume 2 binder. However, it is recommended to change the hydraulic oil and the suction strainers after 6000 operating hours at the latest.

–

The pulsation damper must be replaced after every 2000 operating hours.

Legend for Fig. 4-81 (1)

Main oil reservoir

(2)

Hand wheel of main shut-off valve

(3)

Compensator. Check condition and tightness of compensator and connected parts.

(4)

Intermediate pipe

(5)

Suction strainer

(6)

Suction strainer flange

(7)

Gaskets

(8)

Suction oil reservoir

(9)

Strainer for reducing air bubbles

4.15.1.1

SEQUENCE OF SERVICING

–

Evacuate main hydraulic oil reservoir. Proceed according to section "CENTRAL REFILLING SYSTEM" on page 3-170.

–

Drain the oil from return oil manifold, see page 4-167 for more information.

–

Drain the oil from suction oil reservoir, see page 4-169 for more information.

–

Replace main suction strainer (5) with gaskets (7), Fig. 4-81.

–

Replace suction strainers of the hydraulic pumps, see page 4-169 for more information.

–

Replace oil cooler strainer and pulsation damper, see page 4-167 for more information.

–

Check the strainer of the main hydraulic reservoir (9) visually. If necessary, replace by a new one.

REMARKS: With hydraulic oil reservoir empty, service the return oil filters and leakage oil filter. Inspect the reservoir for sediments. Clean the reservoir if necessary.

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4 - 165

EVERY 2000 OPERATING HOURS OR YEARLY

MAINTENANCE

Fig. 4-82

4 - 166

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 2000 OPERATING HOURS OR YEARLY

HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER (continued) Legend for Fig. 4-82 (1)

Main hydraulic oil reservoir

(2)

Back-pressure valve

(3)

Slew gear location

(4)

Return oil collector manifold

(5)

Drain coupling of the return oil collector manifold

(6)

Branch pipe

(7)

Strainer of the oil cooler circuit

(8)

Intermediate pipe

(9)

Differential pressure switch

(10)

Pulsation damper

(11)

Distributor manifold

(12)

Oil flow to cooler

–

Drain the oil from manifold (4) by attaching the drain hose (part of tool set) to coupling (5).

–

Remove pipe (8) with strainer (7). Insert new strainer and install pipe (8) with new gaskets.

–

Remove pulsation damper (10) and install new pulsation damper with new O-ring.

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4 - 167

EVERY 2000 OPERATING HOURS OR YEARLY

MAINTENANCE

Fig. 4-83

4 - 168

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 2000 OPERATING HOURS OR YEARLY

HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER (continued) Legend for Fig. 4-83 (1)

Main hydraulic pump -1-

(2)

Main hydraulic pump -2-

(3)

Location of main hydraulic pump -3- (shown on next page)

(4)

Hydraulic oil cooler fan drive pump

(5)

Flexible hoses

(6)

Flange

(7)

O-rings

(8)

Suction strainer

(11)

Suction oil reservoir

(12)

Drain coupling

Drain oil from suction reservoir Drain the oil from suction reservoir (11) by attaching the drain hose (part of tool set) to coupling (12). Replace suction strainers of the hydraulic pumps 1. Remove mounting bolts of flange (6). 2. Move away flexible hose (5) with flange (6). 3. Remove strainer (8) with O-rings (7) and discard. 4. Install new strainer (8) with new O-rings (7). 5. Locate flange (6) above the strainer and tighten the mounting bolts of flange (6). 6. Check to make sure that the hose clamps of the suction hoses are in good condition and properly fitted.

Version 2021/02

OMM 06372-D-EN-6T2-1.0

4 - 169

EVERY 2000 OPERATING HOURS OR YEARLY

MAINTENANCE

Fig. 4-84

4 - 170

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

EVERY 2000 OPERATING HOURS OR YEARLY

HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER (continued) Legend for Fig. 4-84 (3)

Main hydraulic pump -3-

(5)

Flexible hoses

(6)

Flange

(7)

O-rings

(8)

Suction strainer

(9)

Control oil pump (pilot oil circuit)

(10)

PTO gear lubrication pump

(11)

Suction oil reservoir

(12)

Drain coupling

Replace Suction Strainer of Main Pump (3) 1. Remove mounting bolts of flange (6). 2. Move away flexible hose (5) with flange (6). 3. Remove strainer (8) with O-rings (7) and discard. 4. Install new strainer (8) with new O-rings (7). 5. Locate flange (6) above the strainer and tighten the mounting bolts of flange (6). 6. Check to make sure that the hose clamps of the suction hoses are in good condition and properly fitted.

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MAINTENANCE

Fig. 4-85

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EVERY 2000 OPERATING HOURS OR YEARLY

HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER (continued)

4.15.1.2

FILLING THE HYDRAULIC SYSTEM

1. Make sure main shut-off valve (2), see Fig. 4-81 on page 4-164, is in open position. 2. Check to make sure that all connections are securely tightened. REMARKS: Select hydraulic oil viscosity grade according to ambient temperatures. If the new hydraulic oil has a different viscosity grade compared with the drained oil it is necessary to adjust the temperature switch units according to the table on page 4-175. 3. On excavators equipped with Central Refilling System fill main hydraulic oil reservoir according to section "CENTRAL REFILLING SYSTEM" on page 3-170. On excavator without central refilling system fill main oil reservoir through opening (4), Fig. 4-85. Depending on type of attachment and the present oil temperature, select the applying oil level range on plate (3). Be sure to use the correct marking on oil level plate (3). 4. Remove the air from the hydraulic system according to the instructions on page 4-177. Legend for Fig. 4-85 (1)

Main hydraulic oil reservoir

(2)

Hydraulic oil level sight gauge

(3)

Oil level plate

(4)

Oil filler plug

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MAINTENANCE

Fig. 4-86

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MAINTENANCE

4.15.1.3

EVERY 2000 OPERATING HOURS OR YEARLY

HYDRAULIC OIL VISCOSITY AND ADJUSTMENT OF TEMPERATURE SWITCH UNITS

If the new hydraulic oil has a different viscosity grade compared with the drained oil it is necessary to adjust the temperature limit values at switch units (11K026, 11K039 and 11K100), Fig. 4-86 in accordance with the viscosity grade of the new hydraulic oil. The switch units are located in the X2 switch box in the cab base. Legend for Fig. 4-86 11K026 - Switch unit for hydraulic oil cooler fan speed control. 11K039 - Switch unit for hydraulic oil temperature warning message “Hydraulic Oil Temperature too high“. 11K100 - Switch unit for preload of hydraulic oil cooler circuit Adjust switch units to the respective oil viscosity grade as follows: Oil viscosity grade according to ISO

VG 22

VG 32

VG 46

VG 68

VG 100

Shell Tellus S4 VX 32

-K26- Adjust temperature limit value to switching point °C

+32°

+41°

+50°

+58°

+67°

+39°

-K39- Adjust temperature limit value to switching point °C

+58°

+69°

+79°

+85°

+81°

-K100- Adjust temperature limit value to switching point °C

+9°C

+16°C

+25°C

+32°C

+39°C

+5°C

Adjustment procedure for (11K026, 11K039 and 11K100): Adjust the temperature limit value at the cogwheel next to the drum scale on switch unit front cover. REMARKS: Turn the cogwheel sensitively. DO NOT turn beyond the STOP marking, otherwise the internal potentiometer driver pin will disengage resulting in wrong value transmission. Refer to Service Bulletin No. AH02508b for functional test of the switch unit. The switch units (11K143) and (11K182) are used for adjustment of the pump distributor gear oil viscosity.

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MAINTENANCE

Fig. 4-87

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MAINTENANCE

4.15.1.4

EVERY 2000 OPERATING HOURS OR YEARLY

VENT SUCTION OIL RESERVOIR AND HYDRAULIC PUMPS

Fig. 4-87 1. Loosen vent plugs (A1 and A2) of suction oil reservoir (1). Retighten vent plugs (A1 and A2) when the outflowing oil is free of air bubbles. 2. Vent main pump (2) by opening first vent plug (B) at the suction pipe just below the pump flange. When the outflowing oil is free of air bubbles close vent plug (B). Open vent valve (C) and loosen leakage oil line connector (D). Retighten (C) and (D) when the outflowing oil is free of air bubbles. 3. Vent main pump (3) by opening first vent plug (B) located at the RH side of the suction pipe just below the pump flange. When the outflowing oil is free of air bubbles close vent plug (B). Open vent valve (C) and loosen leakage oil line connector (D). Retighten (C) and (D) when the outflowing oil is free of air bubbles. 4. Vent oil cooler fan drive pump (4) by loosening leakage oil line connector (E). Retighten (E) when the outflowing oil is free of air bubbles. 5. Vent control oil pump (5) by loosening vent plug (F) at the suction line flange. Retighten (F) when the outflowing oil is free of air bubbles. 6. Vent main pump (6) by opening first vent plug (G) at the suction pipe just below the pump flange. When the outflowing oil is free of air bubbles close vent plug (G). Open vent valve (H) and loosen leakage oil line connector (J). Retighten (H) and (J) when the outflowing oil is free of air bubbles. 7. Start the engine and run at low idle for five minutes. Stop the engine. 8. Loosen vent valves (C and H) of main pumps (2, 3 and 6) by one or two turns and close the valves when the outflowing oil is free of air bubbles. 9. Check hydraulic oil level and the whole hydraulic system for leakage. 10. At the first start up after an oil change carry out several operating cycles of all hydraulic movements without load. Operate the cylinders slowly. Do not operate the cylinders to stroke end. REMARKS: After changing the oil of the PTO gear vent the PTO lubrication pump (7) by opening vent plug (K) at the suction hose flange. Retighten (K) when the outflowing oil is free of air bubbles.

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MAINTENANCE

Fig. 4-88

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MAINTENANCE

4.15.2

EVERY 2000 OPERATING HOURS OR YEARLY

EMERGENCY ESCAPE LADDERS - INSPECTION

See Fig. 4-88 (1)

Sliding window, serves also for emergency exit

(2)

Rigidly mounted emergency escape ladder

(3)

Rope ladder. The upper end of the rope ladder is fixed onto the lower rung of the rigid escape ladder (2) by means of the fasteners (4), see detail (X). The lower end of the rope ladder is fixed on brackets (6) and secured with rubber fasteners (5), see section (A-A).

(4)

Hooks for fastening the rope ladder onto the rigid ladder (2)

(5)

Rubber fasteners for rope ladder in lifted position

(6)

Bracket for rope ladder in lifted position. The lower rung of the rope ladder is hooked up into the brackets (6)

(7)

Machinery house

–

Check rigidly mounted emergency escape ladder (2) for good condition and proper fastening.

–

Check rope ladder (3) for good condition and proper fastening.

–

If any damage or bad condition is found replace the concerned parts without delay.

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MAINTENANCE

Fig. 4-89

4 - 180

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MAINTENANCE

4.15.3

EVERY 2000 OPERATING HOURS OR YEARLY

PREVENTATIVE MAINTENANCE (PM) CLINIC - PERFORM TEST

NOTICE QUALIFIED PERSONNEL ONLY! Preventative Maintenance is to be performed by Komatsu qualified personnel only.

For cost effective help in minimizing excavator downtime, the Preventative Maintenance (PM) Clinic Test is a tool that ensures the excavator is regularly checked before a failure can occur. PM Clinics are excavator-specific, comprehensive inspections where the individual test results are noted on a multi-sided chart which is designed to monitor the performance of the excavator. By monitoring key diagnostic measurements, such as engine speeds and hydraulic pressures, it is possible to track trends and make recommendations to enhance the excavator’s performance. (1) on Fig. 4-89 shows an example of a PM-Clinic as a ’BH’ Parts & Service News as it can be obtained your Komatsu distributor. This document describes the procedure for performing a Preventative Maintenance (PM) test and also provides the PM Data Sheets that are to be filled out with the values collected during the test. See (2) on Fig. 4-89. The test form can be used in two ways. It can be printed out (4) and the values manually entered during the test or it can be electronically used directly from a laptop computer. If it is manually filled out, the values should be transfered to the electronic version after the test has been completed. The PM Test can then be saved (5) to a file and emailed (6) directly to the Komatsu Germany Service Department. These options can be found on the last page (3) of the PM Clinic document.

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MAINTENANCE

Fig. 4-90

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MAINTENANCE

EVERY 2000 OPERATING HOURS OR YEARLY

4.15.4 HYDRAULIC HOSES - CHECK CONDITION Legend for Fig. 4-90 (1)

Boom of attachment

(2)

Hydraulic hoses from main excavator body to attachment boom.

(3)

stabilizing ledge of hoses

–

Check the condition of the hoses (2), especially the boom arch hoses that lead from the excavator main body to the attachment boom. There should be no signs of rubbing, crimping, of overstretch, fatigue or leakage.

–

Check the condition of the stabilizing ledges (3). Ensure that there are no signs of loosening, slippage or movement.

NOTICE AVOID SURFACE CONTACT! Ensure that the stabilizing edge is positioned in such a way as to prevent contact with the protective bar on the top of the control block unit. This must be checked and adjusted if necessary during the regular PM tests.

REMARKS: If damage is apparent, repair or replace immediately as required. Be aware of tightening torques for hose connections. See page 4-12 for more information. Hose lines are considered safety critical parts. See page 4-22 for further information.

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EVERY 2000 OPERATING HOURS OR YEARLY

MAINTENANCE

Fig. 4-91

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MAINTENANCE

4.15.5

EVERY 2000 OPERATING HOURS OR YEARLY

EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB

Legend for Fig. 4-91

–

(1)

Operator’s cab

(2)

View of operator’s cab from entrance door

(3)

Emergency escape hammer

(4)

Sun visor panel

(5)

1 of 4 release catches of sun visor

Perform a visual check of the escape route from the cabin as shown on page 4-73.

4.15.5.1

FUNCTIONALITY

In order to test the functionality of the escape route, detach the sun visor panel (4) from the operator’s cab window. –

Clean contact surface on the frame as well as the detached sun visor panel (4).

–

Lubricate the release catches (5) with an adequate lubricant. The release catch (5) must move easily and freely and must be protected against corrosion and dust contamination especially in strong environmental conditions (e.g. dusty areas, wet or very cold areas)

REMARKS: The lubricant must effectively provide anti-seizure characteristics and prevent rusting of release catch components and any contact surfaces. An effective escape from the operator’s cabin must always be ensured. If the sun visor panel (4) or the release catches (5) are in any way damaged or defective, replace these components immediately. If the emergency escape hammer (3) is missing, put a new one in place immediately.

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4.16

MAINTENANCE

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

Fig. 4-92

4 - 186

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MAINTENANCE

4.16.1

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

SLEW GEAR AND MOTOR ADAPTER HOUSING - CHANGE OIL

4.16.1.1

SLEW GEAR TYPE 2063

Legend for Fig. 4-92 Slew gear (A)

Position of oil level gauge for checking the oil levels

(1)

Oil level gauge

(2)

Oil filler plug

(3)

Breather filter

(7)

Drain coupling or evacuation nozzle for Wiggins system

Motor Adapter Housing (4)

Oil level gauge and filler opening. This opening can also be used for connecting a suction pump when changing the oil.

(5)

Breather filter

(6)

Oil drain plug

Slew Gear, change oil: 1. Use adequate working platform for draining the oil. Place receptacles of sufficient capacity (approx. 60 liter) below drain couplings (7). Attach drain hose (part of tool set) to drain coupling (7). Remove parts (1, 2 and 3) to speed up draining. On slew gears with evacuation nozzle (7), use the Wiggins system for changing the oil. 2. Clean breather filter (3) with compressed air from inside to outside and reinstall. 3. After the oil is completely drained, flush the gear with the regular gear oil. 4. Remove drain hose from coupling (7) and attach the protection cap onto the drain coupling. 5. Fill gear housing through filler opening (2) up to the "MAX" mark on level gauge (1) with fresh oil and reinstall plug (2). REMARKS: For checking the oil level insert the level gauge (1) in, see detail (A). 6. After short operating period check oil level and housing for leaks.

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EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-93

4 - 188

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MAINTENANCE

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

Motor Adapter Housing, Change Oil Fig. 4-93 1. Remove level gauge (4) and breather filter (5). Insert the hose of a suction pump into the gauge pipe (4) until the hose end just touches the bottom of the T-union. Place the oil outlet hose of the suction pump into a receptacle. Switch on the pump and completely suck off the oil from the motor housing. If a suction pump is not available, place a receptacle below drain plug (6). Remove plug (6) and drain the oil completely. 2. Clean breather filter (5) with compressed air from inside to outside and reinstall. 3. If removed, install drain plug (6) and fill-up gear oil through filler opening (4), up to the "MAX" mark on level gauge (4) and install the level gauge. 4. After short operating period check oil level and housing for leaks.

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EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-94

4 - 190

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MAINTENANCE

4.16.1.2

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

SLEW GEAR TYPE 632770

Legend for Fig. 4-94 (A)

Position of oil level gauge for checking the oil levels

(1)

Slew gear

(2)

Brake housing

(3)

Compensator oil tank for slew gear

(4)

Oil level gauge for slew gear

(5)

Oil drain plug for motor adapter housing

(6)

Oil level gauge for motor adapter housing

(7)

Breather filter for brake housing

(8)

Oil level gauge for brake housing

(9)

Oil drain plug for brake housing

(10)

Breather filter

(11)

Drain coupling or evacuation nozzle for Wiggins system

SLEW GEAR - CHANGE OIL 1. Use adequate working platform for draining the oil. Place receptacles of sufficient capacity (approx. 70 liter) below drain coupling (11). Attach drain hose (part of tool set) to drain coupling (11). Remove parts (4 and 10) to speed up draining. 2. Clean breather filter (10) with compressed air from inside to outside and reinstall. 3. After the oil is completely drained, flush the gear with the regular gear oil. 4. Remove drain hose from coupling (11) and attach the protection cap onto the drain coupling. 5. Fill gear housing through filler opening up to the "MAX" mark on level gauge (4) with fresh oil and reinstall oil filler plug See detail A. 6. After short operating period check oil level and housing for leaks.

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EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-95

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MAINTENANCE

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

Brake Housing - Change Oil 1. Remove level gauge (8), Fig. 4-95, drain plug (9) and breather filter (7). Drain the oil into a receptacle of approx. 5 liter capacity. 2. Clean breather filter (7) with compressed air from inside to outside and reinstall. 3. Install drain plug (9) and fill-up engine oil SAE 10 or hydraulic oil HLP 32 through filler opening up to the lower mark on level gauge (8) and install the level gauge. DO NOT overfill the brake housing, otherwise the brake could be damaged due to overheating. See detail B 4. After short operating period check oil level and housing for leaks. REMARKS: Be sure to fill the brake housing and motor adapter housing with engine oil or hydraulic oil as specified onpage 4-4. Motor Adapter Housing - Change Oil 1. Remove level gauge (6) and drain plug (5). Drain the oil into a receptacle of approx. 5 liter capacity. 2. Install drain plug (5) and fill-up engine or hydraulic oil through filler opening, up to the "MAX" mark on level gauge (6) and install the level gauge. 3. After short operating period check oil level and housing for leaks.

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EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-96

4 - 194

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MAINTENANCE

4.16.2

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS CHANGE OIL

–

Planetary Gear Box

–

Spur Gear Box

–

Brake Housing

–

Motor Adapter Housing

Legend for Fig. 4-96 Planetary gear box (1a)

Oil level plug on travel gears

(2)

Oil filler plug

(3)

Drain plug

(13)

Breather filter, the breather filter is located inside the center frame.

Spur gear box (4)

Oil level plug

(5)

Oil filler plug

(6)

Oil drain plug

Brake housing (7)

Oil level plug

(8)

Oil filler plug

(9)

Oil drain plug

Motor adapter housing (10)

Oil level plug

(11)

Connector for breather filter line, the breather filter is located inside the center frame. The port of connector (11) is also used as oil filler opening.

(12)

Oil drain plug

REMARKS: Planetary gear and spur gear stage have separate oil compartments.

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EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-97

4 - 196

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MAINTENANCE

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

TRAVEL GEARS - CHANGE OIL Fig. 4-97 1. Move the Excavator so, that the drain plug (3) is in the lowest and filler plug (3) is in the uppermost position. The oil level plug (1) is then correctly positioned. 2. Place suitable receptacles below drain plugs (3 and 6). 3. Remove filler, level and drain plugs (1 - 6) and drain the oil completely into the receptacles. 4. After the oil is completely drained, flush both gear boxes with the regular gear oil. 5. Install drain plugs (3 and 6). 6. Fill planetary gear box with specified gear oil through filler opening (2) up to level opening (1). Install plugs (1 and 2). 7. Fill spur gear box with specified gear oil through filler opening (5) up to level opening (4). Install plugs (4 and 5). 8. Remove breather filter (11) and blow out with compressed air from inside to outside. Install breather filter (11). BRAKE HOUSINGS - CHANGE OIL REMARKS: The brakes must be released for changing the oil. 1. Place wedges at front and rear side of both crawlers. 2. Start the engine and lower the bucket onto the ground. 3. Have a second person for control in the operator’s cab. 4. Change the oil. Remove parts (7 to 9) and drain the oil. Install plug (9) and fill in fresh engine or hydraulic oil up to level openings (7). Install plugs (7 and 8). 5. Shut down the engine. REMARKS: Be sure to fill the brake housings and motor adapter housings with engine oil or hydraulic oil as specified onpage 4-4. MOTOR ADAPTER HOUSINGS - CHANGE OIL 1. Remove plugs (10 to 12) and drain the oil completely. 2. Install drain plug (12) and fill-up engine or hydraulic oil to level openings (10). Install plugs (10 and 11).

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EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-98

4 - 198

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MAINTENANCE

4.16.3

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL

Legend for Fig. 4-98 (1)

Oil level gauge

(2)

Oil filler plug

(3)

Breather filter

(4)

Oil drain plug

(5)

Adapter housings for main hydraulic pumps

(6)

Adapter housing for pilot oil pump

(7)

Oil level plug

(8)

Oil filler plug with breather pipe

(9)

Oil drain plug

Gear Oil Viscosity Select gear oil viscosity grade according to ambient temperatures. If the new gear oil has a different viscosity grade compared with the drained oil it is necessary to adjust the temperature switch units according to the table on page 4-201. REMARKS: Before opening the access covers from below the pump distributor gear provide an adequate working platform with sufficient space for the oil collecting container (approx. 100 liters). Change the Oil 1. Remove drain plug (4), gauge (1) and filler plug (2). 2. Remove breather filter (3), blow out with compressed air from inside to outside and reinstall. 3. After the oil is completely drained, flush the gear with the regular gear oil and reinstall drain plug (4). 4. Fill in new oil through opening (2) up to the “MAX” mark on gauge (1). 5. Reinstall parts (1 and 2). 6. Vent the PTO lubrication pump, see page 4-177 for more information. 7. After short operating period, check oil level and housing for leakage. REMARKS: If the oil level is above the "MAX" mark, drain the oil down until the oil level is at the "MAX" mark. Too much oil in the pump distributor gear will cause aeration of the oil.

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4 - 199

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-99

4 - 200

OMM 06372-D-EN-6T2-1.0

Version 2021/02

MAINTENANCE

4.16.4

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

PTO GEAR OIL VISCOSITY AND ADJUSTMENT OF TEMPERATURE SWITCH UNITS

If the new gear oil has a different viscosity grade compared with the drained oil it is necessary to adjust the temperature limit values at switch units (11K143 and 11K182), Fig. 4-99 in accordance with the viscosity grade of the new gear oil. The switch units are located in the X2 switch box in the cab base. Legend for Fig. 4-99 11K143 - Switch unit for gear oil temperature warning message "PTO oil Temperature too high“. 11K182 - Switch unit for preload of gear oil cooler circuit Adjust switch units to the respective oil viscosity grade as follows: Oil viscosity grade according to ISO

HLP T32

CLP 150

SAE 75W-90

-11K143- Adjust temperature limit value to switching point °C

+60°

+95°

-K182- Adjust temperature limit value to switching point °C

+48°

+15°

+54°

Adjustment procedure for (11K143 and K182): Adjust the temperature limit value at the cogwheel next to the drum scale on switch unit front cover. REMARKS: Turn the cogwheel sensitively. DO NOT turn beyond the STOP marking, otherwise the internal potentiometer driver pin will disengage resulting in wrong value transmission. Refer to Service Bulletin No. AH02508b for functional test of the switch unit.

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4 - 201

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-100

4 - 202

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Version 2021/02

MAINTENANCE

4.16.5

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

CRITICAL BOLT CONNECTIONS - CHECK TORQUE LOAD

Check critical bolt connections and securing elements for damage and looseness. If any damages, failures or wrong condition are found, corrective action must be taken. –

If the torque load is not stated otherwise refer to standard torque chart for torque data.

–

Bolts inserted with Multi-Purpose Grease MPG, KP2K on thread and head.

REMARKS: When selecting the tightening torque observe quality grade and bolt size Hydraulic Access Ladder, Fig. 4-100 (1)

Ladder

(2)

Ladder lifting cylinder

(3)

Ladder bearing assembly

(4)

Self locking nut

(5)

Pivot pins

(6)

Railings, steps and platforms

(7)

Emergency escape ladder

–

Check condition and fastening of ladder (1), bearing assembly (3) and hydraulic cylinder (2). Make sure the self locking nuts (4) are correctly tightened and have not lost their clamping torque.

–

Lubricate both eyes of hydraulic cylinder (2). Make sure both pivot pins (5) are properly secured with cotter pins. Check hydraulic lines for leakage and damage. Replace as necessary.

Check fastening and condition of all railings, steps and platforms (6) and of emergency escape ladder (7). –

Retighten loose mounting bolts and replace missing or damaged mounting bolts.

–

Make sure the rope wire emergency escape ladder (7) is in place and correctly fastened.

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EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-101

4 - 204

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MAINTENANCE

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

Critical Bolt Connections (continued) Check fastening and condition of –

Cab base (1)

–

Fuel tank (2)

–

Hydraulic oil cooler carrier (3) and

–

Main hydraulic oil reservoir (4)

see Fig. 4-101 Reference No.:

Bolt size mm

Grade

SW * mm

Tightening torque

(5 and 6)

M36

(7 and 8)

Qty.

10.9

3100

M30

10.9

1770

(9 and 10)

M30

10.9

1770

(11 and 12

M30

10.9

1770

* SW = Wrench size* –

Check all mounting bolts for correct tightening torque.

–

Retighten loose mounting bolts and replace missing or damaged bolts.

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4 - 205

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

MAINTENANCE

Fig. 4-102

4 - 206

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MAINTENANCE

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

Critical Bolt Connections (continued) Check mounting and security of the Diesel engine and pump distributor gear, Fig. 4-102 –

Check all flexible bearings (1) for engine and pump distributor gear. – Check the flexible bearings for damage and signs of fatigue. Make sure that there is no contact between the upper and lower metal brackets of the flexible bearings (1). Replace the bearings if necessary. After new flexible bearings have been installed, check distance (A) on both torque supports.

REMARKS: All flexible bearings (1) and all rubber-bounded metal bars (4) should be replaced during engine overhaul. –

Check distance (A) between torque support and stop bolt (8). – With setting of the flexible engine bearings (1) the distance (A) increases and must be adjusted. To do this, loosen lock nut (9) and tighten stop bolt (8) until the correct distance (A) is obtained. Tighten lock nut (9) and recheck distance (A). If new flexible engine bearings (1) have been installed, replace also cup springs (7) and adjust distance (A) to 29 mm.

–

Check tie bolts (3) on front and rear carrier units for looseness. – Check to make sure that the self locking retainer nuts (5) are tight and that there is no gap between nut and rubber-bounded metal bar (4). If necessary retighten retainer nuts (5) snugly. Check rubber-bounded metal bars (4) for signs of fatigue and damage. Replace as necessary.

–

Check all bolt connections for correct tightening torque.

Check condition of engine carrier and brackets. If any damages, failures or wrong condition are found, corrective action must be taken.

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MAINTENANCE

Fig. 4-103

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Critical Bolt Connections (continued) –

Check fastening and condition of main hydraulic pumps (1-3), Fig. 4-103.

–

Check fastening and condition of auxiliary pumps (4 - 6).

Legend for Fig. 4-103 (1-3)

Main hydraulic pumps, swash plate type for all working and traveling motions.

(4)

Control oil pump (pilot oil circuit)

(5)

Hydraulic oil cooler fan drive pump

(6)

PTO lubrication oil pump

(7)

Mounting bolts, main pumps

(8)

Mounting bolts, control oil pump

(9)

Mounting bolts, hydraulic oil cooler fan drive pump

(10)

Mounting bolts, PTO lubrication oil pump

(11)

PTO (pump distributor gear)

(12)

Drain coupling with protection cap

–

Check all mounting bolts (7, 8, 9 and 10) for correct tightening torque.

–

Retighten loose mounting bolts and replace missing or damaged bolts.

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MAINTENANCE

Fig. 4-104

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Critical Bolt Connections (continued) Check fastening and condition of control valve carrier (01), main control valves (04 - 06) and hose support (02), Fig. 4-104 * SW = Wrench size Reference No.:

Bolt size mm

Grade

SW * mm

Tightening torque Nm

Qty.

(17)

M12

8.8

(19)

M16

8.8

179

(20)

M16

8.8

179

(30)

M20

10.9

510

–

Check all mounting bolts (17, 19, 20 and 30) for correct tightening torque.

–

Retighten loose mounting bolts and replace missing or damaged bolts.

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MAINTENANCE

Fig. 4-105

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Critical Bolt Connections (continued) Center frame (1), check condition and fastening of swivel joint (2), Fig. 4-105 * SW = Wrench size Reference No.:

Bolt size mm

Grade

SW * mm

Tightening torque Nm

Qty.

(3)

M 16

10.9

265

(4)

M 16

10.9

265

–

Check all mounting bolts (3 and 4) for correct tightening torque.

–

Retighten loose mounting bolts and replace missing or damaged bolts.

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MAINTENANCE

Fig. 4-106

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Critical Bolt Connections (continued) Excavators with Electric Prime Mover Check condition and fastening of slip ring unit (01), Fig. 4-106 Check all mounting bolts (04, 05 and 07) for correct tightening torque.

–

Reference No.:

Bolt size mm

Grade

SW * mm

Tightening torque Nm

Qty.

((04)

M16

10.9

265

(05)

M16

8.8

180

(07)

M16

8.8

180

Retighten loose mounting bolts and replace missing or damaged bolts.

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MAINTENANCE

Fig. 4-107

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Critical Bolt Connections (continued) Check condition and fastening of travel gears, sprockets and travel motors Legend for Fig. 4-107 (1)

Crawler carrier

(2)

Travel gear

(3)

Sprocket

(4)

Travel motor

(5)

Mounting bolts for sprocket to travel gear

(6)

Mounting bolts for travel gear to crawler carrier

(7)

Mounting bolts for travel motors

Reference No.:

Bolt size mm

Grade

SW * mm

Tightening torque Nm

Qty.

(5)

M36

10.9

3100

(6)

M36

10.9

3100

(7)

M20

10.9

510

* SW = Wrench size –

Check all mounting bolts (5, 6 and 7) for correct tightening torque.

–

Retighten loose mounting bolts and replace missing or damaged bolts.

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MAINTENANCE

Fig. 4-108

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Critical Bolt Connections (continued) Check condition and fastening of railings (01/02) and of steps (03, 04, 05 and 23). See details (A - D) for mounting parts arrangement.

WARNING RISK OF FALLING! Falling from high places can result in serious injury or death. Always use the safety harness in conjunction with the strap type fall absorber when mounting onto the loader attachment. See section SAFETY INSTRUCTIONS on page 1-1 for more information.

Legend for Fig. 4-108

–

(A)

Mounting assembly for steps (03) to steel pipe, version I

(B)

Mounting assembly for railing posts to steps (03)

(C)

Mounting assembly for steps (03) to boom welded brackets

(D)

Mounting assembly for steps (03) to steel pipe, version II

Retighten loose mounting bolts and replace missing or damaged bolts.

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Fig. 4-109

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4.16.6

EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR

OIL SEPARATOR ELEMENT - REPLACE

Legend for Fig. 4-109 (1)

Hydraulic oil tank

(2)

Oil separator

(3)

Breather filter

(4)

Bolt, M8 x 20, Grade 8.8

(5)

Oil separator element

(6)

O-ring

Replace oil separator elements: 1. Loosen bolts (4) and carefully remove cover with breather filter (3). 2. Remove oil separator element (5) and O-ring (6). 3. Install new oil separator element (5) and new O-ring (6). 4. Carefully reinstall cover with breather filter (3) and tighten the bolts (4).

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4.17

MAINTENANCE

EVERY 6000 HOURS OR AT LEAST ONCE A YEAR

Fig. 4-110

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4.17.1

EVERY 6000 HOURS OR AT LEAST ONCE A YEAR

AUTOMATIC LUBRICATION SYSTEMS - REPLACE GREASE FILTERS

REMARKS: In extremely humid and dusty environments or in case of grease contamination as a result of improper filling, the filter change interval can be shorter.

NOTICE ALWAYS USE SERVICE ARM! Always fill the grease barrels using the service arm. The filling filters (see page 3-283 for further information) always have to be installed and clean. If the refilling procedure is, other than intended use, not performed using the service arm and without clean grease filters, the grease can get contaminated and cause damage to the system.I

Legend for Fig. 4-110 (1)

Control and filter block

(2)

Plug screw

(3)

O-ring

(4)

Filter

(5)

Pressure relief valve

(6)

2/2-way valve

NOTICE REMOVE IGNITION KEY! Before servicing stop the motor and remove ignition key in order to prevent operation of the system.

Replace the grease filter of the central lubrication system and the slew circle pinion lubrication system as follows: 1. Open plug screw (2). 2. Remove O-ring (3). 3. Take out filter (4) and insert new one. 4. Install plug screw (2) with new O-ring (3).

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Fig. 4-111

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4.17.2

EVERY 6000 HOURS OR AT LEAST ONCE A YEAR

CHECK FAN DRIVE BEARING OF COOLANT RADIATOR

Legend for Fig. 4-111 (1)

Coolant radiator

(2)

Drive belt

(3)

Belt tension pulley

(4)

Fan

(5)

Pulley

(6)

Flange shaft

(7)

Pulley bracket

Recommended mounting position of dial gauge

Recommended position for starting the measurement with dial gauge

Check condition and fastening of the coolant radiator fan drive bearing as follows: 1. Open the belt tension pulley (3). 2. Demount fan (4) and remove the drive belt (2). 3. Rotate the pulley (5) to check if there is an abnormality, e. g. if the bearing is sluggish or damaged, if there is a noise, vibration or leakage of grease. Using a dial gauge check the distance between pulley (5) and pulley bracket (7) This clearance has to be 0,05 mm. 4. If necessary replace the fan drive bearing. 5. Reassemble in reverse order.

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FIRE PREVENTION

4.18

MAINTENANCE

FIRE PREVENTION

Fig. 4-112

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4.18.1

FIRE PREVENTION

PRECAUTIONS

See Fig. 4-112 In order to prevent risks of possible fire break out observe the following items: 1. Keep the excavator clean, especially from flammable materials. Clean the excavator after servicing the hydraulic system, engine and fuel system by means of a steam jet. 2. Clean engine compartment, hydraulic pump compartment and service platform of the superstructure. Thereafter check fuel lines, engine oil lines and hydraulic oil lines for leakage, loose fastenings and damage. If any leakage, damage or loose fastening is found, corrective action must be taken immediately. 3. Check all electrical cables, terminals and connections for loose fastenings, damage and wear. Replace or repair defective or worn parts without delay. 4. Check the turbocharger for correct mounting and tight exhaust, intake and lube oil connections. Carry out all necessary repairs without delay. 5. On excavators equipped with a fire detection, actuation and suppression system: Refer to the manufacturers service manuals in volume 2 binder for correct maintenance and inspection of the systems. When checking the filling level of the dry chemical tanks, make sure that the extinguishing powder (Ansul FORAY dry chemical agent) is not compacted. Stir up the extinguishing powder with a suitable stick until it is in a free flowing condition.

NOTICE CARE WHEN CLEANING! When cleaning the power house take care the heat detection sensors do not come in contact with hot steam or other hot agent. Otherwise the fire suppression system may be triggered.

6. Make sure fire extinguishers are charged and ready for use. REMARKS: After cleaning lubricate all lubrication points by means of central lube system or manually. Lubricate slew circle gear after drying by means of the automatic lube system or manually.

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WELD REPAIRS

4.19

MAINTENANCE

WELD REPAIRS

Fig. 4-113

NOTICE CONTACT KOMATSU SERVIE DEPARTMENT BEFORE WELDING! Before carry out weld repairs, contact our Service Department EXCAVATORS in order to avoid improper welding procedures. Weld repairs can cause severe damage to an entire structure if performed incorrectly. If cracks are found in the steel construction of your excavator, please inform our Service Department as soon as possible. Attach suitable information material (photos, catalog drawings etc.) showing the location and nature of the crack.

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4.19.1 A.

WELD REPAIRS

GENERAL PROTECTIVE MEASURES Observe the prevailing safety and fire prevention regulations. Before any weld repair is started, a survey should be made of the area and all safety considerations satisfied such as fuel tanks, oil lines, electrical cables and synthetic materials. Attach the welding ground directly to the part that is being repaired. Do not allow welding current to go through bearings. Welding current could arc the bearings, resulting in severe damage to the bearing.

4.19.2

WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR

4.19.2.1

COUNTERWEIGHT

WARNING RISK OF EXPLOSION! The chambers of the counterweight are filled with a mixture of concrete, granulated ore and steel pellets. This mixture can create explosive gases which will accumulate in the chambers of the counterweight. Before any welding, flame-cutting, grinding or drilling procedures are carried out on the counterweight it is vital to expel these gases from the counterweight chambers. Failure to properly expel the gases from the counterweight chambers can result in an explosion with serious personal injury or death. Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases from the counterweight chambers.

Legend for Fig. 4-113 (1)

Undercarriage, refer to page 4-231 for protective measures.

(2)

Loader attachment, refer to page 4-233 for protective measures.

(3)

Superstructure, refer to page 4-235 for protective measures.

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WELD REPAIRS

MAINTENANCE

Fig. 4-114

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4.19.3

WELD REPAIRS

PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE

See Fig. 4-114 On standard Excavators there are no special protective measures necessary. However, the general protective measures (A and B) must be observed. On Excavators with a power unit (generator set) mounted to the undercarriage, all electrical connections between the Excavator and the power unit have to be disconnected.

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WELD REPAIRS

MAINTENANCE

Fig. 4-115

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4.19.4

WELD REPAIRS

PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT

Legend for Fig. 4-115 (1)

Electrical cable connector of the end-line pressure switch for the central lubrication system

(2)

Plug socket

(3)

Protection cap for (2)

(4)

Protection cap for (1)

(5)

Switch box of the electronic bucket leveling system ”EBL”, (Special Equipment)

(6)

Bucket position detector box for the ”EBL” system (Special Equipment)

NOTICE DISCONNECT BEFORE WELDING! If weld repairs have to be carried out on the Loader Attachment (Bucket, Stick and/or Boom) disconnect the end line pressure switch cable connector (1) from socket (2) and close the openings with caps (3 and 4). If the Excavator is equipped with an electronic Bucket Leveling System, disconnect also the cable connector on switch box (5). Be sure to disconnect electrical connections of working lights and other electrical equipment mounted on the loader attachment.

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WELD REPAIRS

MAINTENANCE

Fig. 4-116

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4.19.5

WELD REPAIRS

PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE

Legend for Fig. 4-116 (A)

Top view of access area

(1)

Battery main switch keys

(2)

Battery box cover underneath the cat walk

(3)

Batteries

(4)

Fluid level

Remove keys (1) of the two battery main switches.

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WELD REPAIRS

MAINTENANCE

Fig. 4-117

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4.19.5.1

WELD REPAIRS

ELECTRICAL UNITS IN CAB BASE

Fig. 4-117 1. Switch off all circuit breakers in the X2 switch box (1). 2. Open the three screws and loosen the multi monitor (2) carefully. Disconnect all plugs on the back of the multi monitor. 3. Remove the wiring harness connector from electronic pump controller CR710. For location refer to the chapter "ELECTRICAL EQUIPMENT IN CAB BASE" on page 3-100. Be sure to isolate Electronic Components of Special Equipment.

4.19.5.2

ENGINE ELECTRONICS

Disconnect the two Deutsch connectors (C5 and C6), Fig. 4-118. The connectors are located on the LH engine side near.the flywheel housing. REMARKS: For more information refer to the Operation and Maintenance Manual CENTRY System, filed in Volume 2 Binder. 1) - Engine harness (2) - Excavator harness

Fig. 4-118

4.19.6

AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE

After finishing the weld repairs connect all cable connectors which have been disconnected. When connecting the two Deutsch connectors (C5 and C6), make sure you hear a click. When all electrical connections are established insert the battery main switch keys.

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WELD REPAIRS

4 - 238

MAINTENANCE

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REVISION

5 REVISION

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REVISION TABLE

5.1 Revision

5 - 240

REVISION

REVISION TABLE Description

Date

OMM 06372-D-EN-6T2-1.0

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