Page 1 Operation & Maintenance Manual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
Page 3: Introduction
1. INTRODUCTION...
Page 4: Contents Of The Binder
1.1 CONTENTS OF THE BINDER INTRODUCTION CONTENTS OF THE BINDER Assembled in this file are the Operation-, Lubrication- and Mainte- nance Manuals for your KOMATSU Hydraulic Mining Shovel.
Page 5: Division Of The Binder
READY EFFICIENT PERFORMANCE your KOMATSU Hydraulic Mining Shovel. Periodic preventive inspections and maintenance are the surest means of keeping the machine 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.
Page 6: Designated Use Of The Shovel
1.3 DESIGNATED USE OF THE SHOVEL INTRODUCTION DESIGNATED USE OF THE SHOVEL This machine has been manufactured in accordance with advanced and up-to-date technology standards including recog- nized 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 machine and to other material property.
Page 7: Delivery Of The Shovel
In order to keep your Shovel 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 MINING GERMANY GmbH from any guarantee. SERVICE For all questions related to your Shovel please contact your local Service Center.
Page 8: Explanation Of Abbreviations
1.5 EXPLANATION OF ABBREVIATIONS INTRODUCTION EXPLANATION OF ABBREVIATIONS ABB. Definition Ampere Alternating Current American Petroleum Institute Centistoke °C Degree Celsius CENTRY Engine Electronic Control System Central Lubrication System Direct Current German Institute for Standardization Electronic Bucket Levelling System Electronic Control Module (Engine) Electronic Control and Monitoring System FGPS Front Guard Protective Structure...
Page 9: Table Of Contents
INTRODUCTION 1.6 TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION ................... 3 CONTENTS OF THE BINDER ......................4 DIVISION OF THE BINDER ....................... 5 DESIGNATED USE OF THE SHOVEL ....................6 DELIVERY OF THE SHOVEL ......................7 EXPLANATION OF ABBREVIATIONS ..................... 8 TABLE OF CONTENTS ........................
Page 10 1.6 TABLE OF CONTENTS INTRODUCTION ELECTRONIC MONITORING AND CONTROL SYSTEM ECS ............88 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING ........192 3.5.1 A - HEATING ........................192 3.5.2 B - COOLING ........................193 3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING ....... 193 POWER HOUSE ..........................
Page 11 INTRODUCTION 1.6 TABLE OF CONTENTS CARTRIDGES ON POWER HOUSE ROOF ..............265 3.18 CENTRAL REFILLING SYSTEM ....................266 3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM ..........267 3.18.2 OPERATING THE HYDRAULIC SERVICE ARM ............. 269 3.18.3 RECEIVER PANEL WITH MONITOR BOX ..............271 3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS ...
Page 12 1.6 TABLE OF CONTENTS INTRODUCTION 4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL ........309 4.6.6 MAINTENANCE OF THE ENGINES ................. 311 4.6.7 ENGINE FUEL FILTER LOCATIONS ................313 WHEN NECESSARY ........................314 4.7.1 ENGINE AIR CLEANER MAINTENANCE ................. 315 4.7.2 SWING CIRCLE TOOTHING LUBRICATION ..............
Page 13 INTRODUCTION 1.6 TABLE OF CONTENTS 4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE ............451 4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES ....453 4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES ....455 4.13 EVERY 2000 OPERATING HOURS OR YEARLY ................ 456 4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER ......................
Page 14 1.6 TABLE OF CONTENTS INTRODUCTION...
Page 15: Safety
2. SAFETY...
Page 16: Safety Instructions
2.1 SAFETY INSTRUCTIONS SAFETY SAFETY INSTRUCTIONS 2.1.1 WARNINGS AND SYMBOLS The following signs and designations are used in the manual to designate in-structions of particular importance. WARNING Refers to orders and prohibitions designed to prevent injury or extensive damage. CAUTION Refers to special information and/or orders and prohibitions directed towards preventing damage.
Page 17: Organizational Measures
SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.3 ORGANIZATIONAL MEASURES The Operation,- Lubrication and Maintenance Manual must always be at hand at the place of use of the machine, e. g. by stowing them in the box provided for such purpose. In addition to the Operation,- Lubrication and Maintenance Manual, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.
Page 18 2.1 SAFETY INSTRUCTIONS SAFETY Replace hydraulic hoses within stipulated and appropriate intervals even if no safety-relevant defects have been detected. Adhere to prescribed intervals or those specified in the Oper- ation,- Lubrication and Maintenance Manual for routine checks and inspections. For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indis- pensable.
Page 19: Selection And Qualification Of Personnel - Basic Responsibilities
SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES Any work on and with the machine must be executed by reli- able 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.
Page 20: Safety Instructions Governing Specific Operational Phases
2.1 SAFETY INSTRUCTIONS SAFETY 2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES STANDARD OPERATION Avoid any operational mode that might be prejudicial to safety. Before beginning work, familiarize yourself with the surround- ings and circumstances of the site, such as obstacles in the working and travelling area, the soil bearing capacity and any barriers separating the construction site from public roads.
Page 21 SAFETY 2.1 SAFETY INSTRUCTIONS Always keep at a distance from the edges of building pits and slopes. Avoid any operation that might be a risk to machine stability. Never travel across slopes; always keep the working equip- ment and the load close to the ground, especially when trav- elling downhill.
Page 22 2.1 SAFETY INSTRUCTIONS SAFETY The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The mar- shaller giving the instructions must be within sight or sound of the operator. For carrying out overhead assembly work always use spe- cially designed or otherwise safety-oriented ladders and working platforms.
Page 23: Warning Of Special Dangers
SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.6 WARNING OF SPECIAL DANGERS ELECTRIC ENERGY Use only original fuses and circuit breakers with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system. When working with the machine , maintain a safe distance from overhead electric lines.
Page 24 2.1 SAFETY INSTRUCTIONS SAFETY GAS, DUST, STEAM AND SMOKE Operate internal combustion engines and fuel operated heat- ing systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation. Observe the regulations in force at the respective site. Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.
Page 25: Transporting And Towing -Recommissioning
SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING The machine must be towed, loaded and transported only in accordance with the Operation,- Lubrication and Maintenance Manual. For towing the machine observe the prescribed transport position, admissible speed and itinerary. Use only appropriate means of transport and lifting gear of adequate capacity.
Page 26 2.1 SAFETY INSTRUCTIONS SAFETY LIGHTING The Shovel must only be operated when the operator has suffi- cient visibility in relation to the work area. Disturbing shady areas or dazzling effects must be avoided. If necessary, the Shovel must be retrofitted with lighting equip- ment (working lights) in order to ensure sufficient visibility condi- tions.
Page 27 SAFETY 2.1 SAFETY INSTRUCTIONS This page left intentionally blank...
Page 28 2.1 SAFETY INSTRUCTIONS SAFETY...
Page 29: Safety Harness In Conformity With En 361 (European Standard)
SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) WARNING Always use the Safety Harness (1) in conjunction with strap type Fall Absorber (2), illust. (Z 20885) before mounting onto the loader attachment or other unsecured places of the Shovel.
Page 30 2.1 SAFETY INSTRUCTIONS SAFETY...
Page 31 SAFETY 2.1 SAFETY INSTRUCTIONS INSTRUCTIONS FOR USE Open the lock, lift the harness by the catch hook (C), the blue straps (leg straps J) are below. The harness is being put on just like a jacket. Pull the belly strap (E) through the lock, as shown on the illustration, and secure it.
Page 32 2.1 SAFETY INSTRUCTIONS SAFETY...
Page 33 SAFETY 2.1 SAFETY INSTRUCTIONS 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 com- ponents of the system be observed in conformity with the instructions for use.
Page 34 2.1 SAFETY INSTRUCTIONS SAFETY...
Page 35 SAFETY 2.1 SAFETY INSTRUCTIONS INSTRUCTIONS FOR USE Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD) 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.
Page 36 2.1 SAFETY INSTRUCTIONS SAFETY...
Page 37: Operation
3. OPERATION...
Page 38: Foreword
3.1 FOREWORD OPERATION FOREWORD This Operation Manual contains the instructions for correct opera- tion of your KOMATSU Mining Shovel. It should always be ready for use in the Operator’s cab. WARNING The information in this manual does not replace any safety rules or laws used in your area.
Page 39: Construction Of The Shovel
OPERATION 3.2 CONSTRUCTION OF THE SHOVEL CONSTRUCTION OF THE SHOVEL 3.2.1 OVERALL VIEW Legend for illustration Z22874 Undercarriage (5A) Backhoe bucket Superstructure Boom cylinders Boom Stick cylinders Stick Bucket cylinders Bottom dump bucket...
Page 40: Undercarriage And Superstructure
3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE...
Page 41 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z22875 Final drive, hub type travel gear Crawler carrier Track roller Carrier roller Guide wheel Swing circle guard Hydraulically operated access ladder, see page 46 for more information Hydraulic cylinder for access ladder Control switch for access ladder (10) Battery main switches...
Page 42 3.2 CONSTRUCTION OF THE SHOVEL OPERATION SUPERSTRUCTURE - TOP VIEW...
Page 43 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z21711 Hydraulically operated access ladder, see page 46 for more information Lower deck Coolant radiator for front engine number 2 Hydraulic motor for radiator fan drive Front Diesel engine, designated as engine number 2 Flexible coupling, oil filled Front PTO (pump distributor gear) Main hydraulic pumps...
Page 44 3.2 CONSTRUCTION OF THE SHOVEL OPERATION MACHINERY HOUSE...
Page 45 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z22876 REMARK The upper part of the illustration shows the rear power unit, viewed from counterweight side. The lower part, view "A" shows the pump compartment of the Rear power unit (Rr), engine number 1, and the pump compart- ment of the Front power unit (Fr), engine number 2.
Page 46: Hydraulically Operated Access Ladder
3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...
Page 47 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z 23018 Access ladder in lowered position Access ladder in upper position (Working position) Stop bar Manual actuator for fire suppression system (if so equipped) Pull chain for emergency lowering of the access ladder CAUTION Use this chain only in emergency cases, when the Operator does not respond to other communication signals.
Page 48 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 49 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Operating the hydraulic Access Ladder, illust. (Z 23018) Raise the ladder Enter the Shovel with ladder in fully lowered position (A). Start the engine. F o r s ta r t i n g p r o c e d u r e → S e e " S TA R T I N G T H E ENGINES"...
Page 50: Emergency Escape Ladder
3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.4 EMERGENCY ESCAPE LADDER...
Page 51 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illust. Z24090 Sliding window, serves also for emergency exit Release lever for hinged railing bar (3) Hinged railing bar Rigidly mounted emergency escape ladder 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).
Page 52: Emergency Engine Shutdown From Ground Man Or Operator Warning System
3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...
Page 53 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Emergency Engine Shutdown System actuated from Ground Man (Special Equipment) Legend for illust. Z 21726 Actuating chains for emergency shut down of both engines. To stop the engines, pull down one of the chains (1). Actuating chain for hydraulically operated service arm.
Page 54: Operator's Cab With Integrated Falling Object Protective Structure (Fops)
3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
Page 55 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illust. Z 21418 Front View of Operator’s Cab Adapter for Warning Beacon Main Wiper Motor Aerial Main Working Lights, the four main working lights can be adjusted from inside the Cab, after removal of the upper panelling cover.
Page 56 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 57 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Operator’s Cab - Hand Wash Sink and Refrigerator Legend for illust. Z 21589 Hand wash sink Water-tap WARNING No drinking water. Use for hand washing only Water tank for hand wash sink. The capacity of the water tank is 50 liters.
Page 58 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 59 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Operator’s Seat Adjustment Before operating the Shovel adjust the seat and mirrors for Oper- ators maximum comfort, visibility, and complete control of the Shovel. Legend for illust. (Z 21420): Seat suspension adjustment (firm to soft ride) Height adjustment Seat depth adjustment Seat cushion tilt adjustment...
Page 60 3.2 CONSTRUCTION OF THE SHOVEL OPERATION Co-driver’s Seat Legend for illust. Z 21421 Seat suspension frame Back rest Folding seat Adjust Seat Position A - Fold down seat to sitting position. The seat will automatically move up when released. B - To swing the seat out, towards the front, first lift seat suspen- sion frame (1) and then swing seat to the front;...
Page 61 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL This page left intentionally blank...
Page 62: Engine Oil Management System
3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.7 ENGINE OIL MANAGEMENT SYSTEM...
Page 63 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Engine Oil Management System The engine oil management system of each engine combines the automatic engine oil supply system "Reserve" and the oil burning system "Centinel" in connection with the "Eliminator" oil filtra- tion system. Reserve System Oil Flow Schematic, illust.
Page 64 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 65 ON position. Turn starter switch of the concerned engine and release. Once the correct fault code is identified, refer to the Mas- ter Repair Manual CENTINEL filed in volume 2 binder for fault code explanation, and inform your Komatsu Service Organization about the trouble condition.
Page 66 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 67 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Clearing Active Faults and Reset the Centinel System to Operational Condition Legend for illust. (Z 23056) The illustration shows the terminal configuration on the (X2) switch board for the FRONT ENGINE 2 Calibration Plug for Engine Oil Quality Bridge wire for resetting the Centinel system to oper- ational condition Resetting of the Centinel system is necessary:...
Page 68 3.2 CONSTRUCTION OF THE SHOVEL OPERATION Oil Burning System "Centinel" combined with Oil Supply System "Reserve" Legend for illust. Z 21473 (schematic illustration) Engine oil reserve tank (10) Fuel/lube oil blend return to fuel tank Oil filters (11) System function indicator LED’s Pump unit (12) Oil level gauge...
Page 69 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Eliminator Engine Oil Filtration System Legend for illust. Z 21541 (schematic illustration) Oil inlet from engine (100%) Oil flow to engine oil pan (5%) Stainless steel filter removes particles as Oil outlet to engine (95%) small as 20 µm Centrifugal separator removes particles up to Backflush oil (5%) for cleaning the filter...
Page 70: Operator's Cab - Controls
3.3 OPERATOR’S CAB - CONTROLS OPERATION OPERATOR’S CAB - CONTROLS 3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...
Page 71 Hydraulic Control System There are two control patterns of levers (1 and 2) available: ”EURO” control pattern and ”KMG” (Komatsu Mining Germany) control pattern Your Shovel is equipped with the EURO control pattern for levers (1 and 2). For more information → See "WORKING WITH THE ATTACHMENT"...
Page 72 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 73 OPERATION 3.3 OPERATOR’S CAB - CONTROLS EURO Control Pattern Legend for illustration (Z 22463) Control lever for stick and swing machinery Control lever for boom and bucket Toggle switch for engine speed selection Low idle – High idle Push button for Truck counter. For counting loaded trucks press this button.
Page 74: Controls With Bottom Dump Bucket Attachment
3.3 OPERATOR’S CAB - CONTROLS OPERATION 3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT...
Page 75 Hydraulic Control System There are two control patterns of levers (1 and 2) available: ”EURO” control pattern and ”KMG” (Komatsu Mining Germany) control pattern Your Shovel is equipped with the EURO control pattern for levers (1 and 2). For more information → See "WORKING WITH THE ATTACHMENT"...
Page 76 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 77 OPERATION 3.3 OPERATOR’S CAB - CONTROLS EURO Control Pattern Legend for illustration (Z 21542.1) Control lever for stick and swing machinery Control lever for boom and bucket Push button for deactivation of boom float position Push button for deactivation of stick float position Toggle switch for engine speed selection Low idle –...
Page 78 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 79 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Operator’s Console Legend for illust. Z 22478 Operator’s cab door Light switch, interior cab lighting Light switch, access area lighting Operator’s console Text display with key board of the Electronic Control and Monitoring System "ECS". Refer to page 88 for more information.
Page 80 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 81 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Control Panel Legend for illust. Z 22464 NOTICE The items (A, B, C, D and E) are part of the Elec- tronic Monitoring and Control System, refer to page 88 for more information. The screen (A) displays the condition of the machine, the maintenance status, and messages for the operator and service man.
Page 82 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 83 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Switch Board Legend for illust. Z 22464 (14) Switch, interior illumination (15) Switch, dashboard illumination (16) Switch, warning beacon on cab roof *) (17) Switch, main working lights (1) (18) Switch, cab ventilation blower. Blower runs with low speed, even with switch in ”0”...
Page 84 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 85 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Switch Board (continued) Legend for illust. Z 22464 (28) Strike button, emergency shut down of both engines and pilot control system cut out. WARNING In case of emergency push in this button to stop the Die- sel engines and to cut out the pilot control circuit.
Page 86 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 87 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Controls for Heater, Air Conditioning and Special Equipment Legend for illust. Z22465 Control unit for engine-independent auxiliary cab heater. This unit is used to control the auxiliary cab heater during standstill periods when an exter- nal power source is connected and the KIM Hotstart system is activated Be sure to set the standard heater control to maximum heating position when the auxiliary cab heater is switched on with control unit (1).
Page 88: Electronic Monitoring And Control System Ecs
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION ELECTRONIC MONITORING AND CONTROL SYSTEM...
Page 89 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS INTRODUCTION The Electronic Monitoring and Control System ECS incorporates the following two main functional groups: 1. TEXT DISPLAY (A) with INTEGRATED KEY BOARD (B), illustration Z 22466 2. SERVICE FUNCTIONS operated with KEY GROUP (D) and KEY SWITCH (C) TEXT DISPLAY and KEY BOARD 1.1 Text Display (A)
Page 90 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 91 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS SERVICE FUNCTIONS operated with KEY GROUP (D) and KEY SWITCH (C), illustration Z22466, continued Display of ”INPUTS-OUTPUTS”. This section is basically used for Testing procedures through authorized service staff and therefore locked dur- ing normal operation by the software program.
Page 92 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 93 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Legend for illust. Z 22466 Display with basic information Key board with 8 keys. For the function of the keys refer to page 95. (C)) Key operated switch for enabling access to the INPUT-OUTPUT levels and input of operational data.
Page 94 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 95 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Function of the keys (1 to 8) of Keyboard (B): Text display of that page, which was selected from the Text store, Record memory or Statistics memory. Shifting to the mode ”leaf through” of current messages. ME S S AGE Acknowledgement of changed settings.
Page 96 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 97 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Operating the Electronic Monitoring System 1.0 TEXT DISPLAY (A) with integrated KEY BOARD (B) illust. Z 22466 After switching on the Shovel’s key operated main switch, the fol- lowing introductory messages will be displayed on screen (A): .
Page 98 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 99 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Basic Display The basic display in system level -0- is for general information during operation and shows the Date, the Time of Day, the Oper- ating Hours (h) and the speed of engine 1 (M1) and engine 2 (M2).
Page 100 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 101 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Automatic Display of Messages on Screen (A), illust. Z 22466 The messages of the ECS system are divided into three main cat- egories as follows: Category I: Information messages indicating an operating condition, e.g. ”# swing Parking Brake Applied”...
Page 102 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 103 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Automatic Display of Messages If a fault or an information condition occurs during operation, the basic display is automatically replaced by a message in text. If a further condition occurs, another message is displayed so that the operator is always shown the latest message.
Page 104 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 105 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Message Classification All messages filed in the text store of the text display are listed in Section ”Table of messages” on page 168 in sequence of their page numbers and are divided into the following 4 groups: Group 1 Fault Messages of message text pages number 500 - 739.
Page 106 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 107 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Emergency Indication of Operating Conditions. The ECS system is equipped with an emergency indication. In case the text display (A) fails to work, it indicates faults in impor- tant operating systems of the Shovel. The indication is effected by means of LED’s at the Programmable Logic Controller ”PLC”...
Page 108 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 109 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS TEXT DISPLAY (A), illust. Z 22466 Several messages are present at the same time: The last input message is displayed. The number of all current messages is indicated by a flashing number in the second text line.
Page 110 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 111 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Display of message pages without present mes- sage. If there is a statistics print out and the individual Nos. of the mes- sage pages cannot be adjoined to the message text, the message text can be called up as follows.
Page 112 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 113 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Display the Contents of Record (PROTOCOL) Memory, illust. Z 22466 Press to display Protocol memory. PR O Last entry of the protocol memory Fault message going will be displayed first. Higher num- bers indicating older entries.
Page 114 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 115 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Display the Contents of Statistics Memory, illust. Z 22466 Press to display statistics memory. S T A Display: STATISTICS Appeared: 4 = 80.0% Error : 644 Elapsed : 00:02:40 = 100.0% Press to leaf through all recorded messages. DOWN Indication in percent how often the Example:...
Page 116 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 117 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS How to print out Contents of Record (PROTOCOL) Memory: Print out the complete Contents of Record (PROTOCOL) Memory Display: Press until the maximum amount of entries (39) is reached PR O DAT A OU T DOWN Print from the last >...
Page 118 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 119 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS . Possibility - The last (X) Entries of a certain Message (X) = desired number of the last entries e.g. 10. This print shows, whether the desired message appeared within the last 10 entries. Press until the desired nos.
Page 120 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Explanation of the statistics print-out You receive for example the following print-out: Column Good = 0.0 % 02:00:00 33.3% 524: = 14.3 % 01:00:00 25.0% 578: = 14.3 % 01:00:00 25.0% 590: = 42.6 % 02:30:00 62.5%...
Page 121 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Time Diagram of Statistics Print The diagram below shows an example, how the time without faults (Good) and the time with faults (Err) could be distributed within the total operating time of the ECS. E: Total operating time of the ECS 524/578/590/608: Total time of a message Err: Total time of all messages...
Page 122 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 123 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Return to SYSTEM level: Display of the Last Message Received or Menu (Standard Display) Operation of the keyboard (B) has no influence to the recording of input messages. For example, if the record memory is called up via keyboard (B), the ECS switches back to SYSTEM level after a period of 20 seconds when no further key is actuated within this period.
Page 124 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 125 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 2.0 Service Functions and Menu Control Menu Control operated with Key Switch (C) and Key Group (D), illust. Z 22466 The menu controls are structured hierarchically. The highest-level menu is designated ”LEVEL 0” and is accessed by depressing the ”RET”...
Page 126 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 127 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Menu Control with Key Switch (C) and Key Group (D) Display of Menu Options, see Menu Control Chart I (Z23063) EXAMPLE: Display of TRUCK COUNTER READING, starting from basic display on level -0- Proceed as follows: 1.
Page 128 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 129 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Display of Service *POWER CHECK* continued, see menu control chart II, illustration (Z 23064) 6. Press key (10) for display of the present system pressures in level 4. 7. For returning to the standard display level -0- press “RET” key (9) four times.
Page 130 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 131 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Menu Control with Key Switch (C) and Key Group Setting of Operational Data, menu item Service *SETTINGS* Example: Changing the pause time of the Central Lubrication System (on machines with factory installed lube systems only). Starting from the menu level -1-, *SERVICE* see menu control charts I and III (Z 23065).
Page 132 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 133 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Menu Control with Key Switch (C) and Key Group Setting of Operational Data, menu item Service *SETTINGS* Example: Changing the pause time of the Central Lubrication System 12. After the numerical values have been changed, press key (1) one time (Acknowledgement of new setting).
Page 134 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 135 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Menu Control with Key Switch (C) and Key Group Display of Menu Options Example: Display of INPUTS-OUTPUTS, starting from basic display on level -0-, see Menu Control Charts I and IV (Z 23066). The main group *INPUTS-OUTPUTS* is basically used for Test- ing procedures through authorized service staff and therefore locked during normal operation.
Page 136 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 137 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Menu Control with Key Switch (C) and Key Group (D). Display of INPUTS-OUTPUTS Example: Display of menu items in the group *ANALOG-INPUTS*, starting from menu level -2-, see Menu Control Chart IV (Z23066). The following menu items shall be displayed: Hydraulic oil temperature Grease barrel filling level of Central Lubrication System.
Page 138 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 139 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Menu Control with Key Switch (C) and Key Group (D). Display of DIGITAL-INPUTS (continued) 2. Press ”QUI” key (10) the starting menu item ”B1-1 (E11.5):” in level -3- appears on the display. 3.
Page 140 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 141 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Menu Control with Switch (C) and Key Group (D). Display of DIGITAL-OUTPUTS Example: You want to display the condition of the Central Lubri- cation System (solenoid valve Y7 / Y7A) in the group *DIGITAL- OUTPUTS*, starting from menu level -2-, see Control Chart V.
Page 142 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 143 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Menu Control with Switch (C) and Key Group (D). Acknowledgement of carried out Maintenance according to dis- played MAINTENANCE CALL, see Menu Control Chart I and VI. Example: The Maintenance call *INITIAL 250h MAINTENANCE* is dis- played.
Page 144 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 145 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Data Transfer from Protocol and Statistics Memory to various Downloading Equipment The illustration (Z 20731) shows typical arrangement of several downloading equipment connected to the text display interface plug socket (X27). Legend for illust. (Z 20731) Text display unit on instrument panel (E35) Plug socket (serial interface X27) for connecting data transfer cable to units (4, 5, 6 or 9)
Page 146 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 147 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Graphical Diagram see illustration Z21737 This illustration shows the components and the signal flow of a typical ECS-System for Shovels powered by two Diesel engines. Overall View of Menu Control All items of the Menu Control are listed up on page 148 in sequence of their Menu Levels.
Page 148 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Menu Control of the E C S The Menu Control is carried out with the Service Keys. (Four control keys and one key switch). QUIT-Key Access to a lower level (-1- = > -2-) Acknowledgement of new oil viscosity RETURN-Key Return to previous level (-2- = >...
Page 149 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Introductory Messages # Bitte arbeiten Sie sicherheitsbewußt! Please be Safety Conscious when working! Did you check the Operating Safety of the Shovel ? Did you do Maintenance according to the Service Literature ? Date M1 *1) 1/min: Time...
Page 150 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 0: Cockpit - Display # no messages / messages Date M1 *1) 1/min: Time M1 *2) 1/min: - 0 - Gear oil (< °C) M1 : °C - 0 - Gear oil (< °C) M2 : °C - 0 - Hydraulic oil (<...
Page 151 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 2: Service - 2 - Service * LANGUAGE * - 2 - Service * POWER CHECK * - 2 - Service * MAINTENANCE * - 2 - Service * SETTINGS * - 2 - Service (Menu item) * INPUTS - OUTPUTS ON / OFF * - 2 - Service...
Page 152 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 4: Service / Power check / FAN DRIVE RADIATOR, min- imum / maximum speed - 4 - Fan drive radiator min / max OPERATE KEY SWITCH - 4 - min / max | Y14A-1: | Y14B-1: | 0 | 1 |...
Page 153 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 3: Service / SETTINGS - 3 - Settings * PTO-GEAR - OIL VISCOSITY * - 3 - Settings * HYDRAULIC - OIL VISCOSITY * - 3 - Settings * CENTRAL LUBRICATION SYSTEM * - 3 - Settings * SWING RING GEAR LUBE SYSTEM * - 3 - Settings...
Page 154 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 4: Service / Settings / CENTRAL LUBRICATION SYS- TEM (CLS) - 4 - Settings (minutes) * PAUSE TIME : * - 4 - Settings (minutes) * MONITORING TIME : * - 4 - Settings (minutes) * PRESSURE RELIEVE TIME : * - 4 - Settings * LUBE CYCLE COUNTER : *...
Page 155 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 4: Service / Settings / SWING RING GEAR LUBE SYS- TEM (SLS) - 4 - Settings (minutes) * PAUSE TIME : * - 4 - Settings (minutes) * MONITORING TIME : * - 4 - Settings (minutes) * PRESSURE RELIEVE TIME : * - 4 - Settings...
Page 156 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 3: Service / Settings / DATE - 3 - Settings OPERATE KEY SWITCH date: new date: Level 3: Service / Settings / TIME - 3 - Settings OPERATE KEY SWITCH time: new time: Level 3: Service / Settings / OPERATING HOURS - 3 - Settings...
Page 157 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 3: Service / MESSAGES ON / OFF - 3 - Messages OPERATE KEY SWITCH - 3 - Messages ⎜ 0 ⎜ 1 ⎜ Condition : Level 3: Service / EVALUATION ON / OFF - 3 - Evaluation OPERATE KEY SWITCH - 3 - Evaluation...
Page 158 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 3: Inputs - Outputs / ANALOG-INPUTS B14-1 Coolant temperature M1 (EW1.1): °C B14-2 Coolant temperature M2 (EW1.2): °C B15 Hydraulic oil temperature (EW2.1): °C B49-1 PTO - gear oil temperature M1 (EW1.3): °C B49-2 PTO - gear oil temperature M2...
Page 159 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 3: Inputs - Outputs / DIGITAL-INPUTS B1-1 (E11.5): B1-2 (E11.6): (E9.8): B5-1 (E9.1): B5-2 (E9.4): B6-1 (E9.2): B6-2 (E9.5): B7-1 (E9.3): B7-2 (E9.6): (E3.3): B17-1 (E3.1): B17-2 (E3.2): B18-1/B19-1 B18-2/B19-2 (E4.1): (E4.2): B21-1 (E4.5): B21-2 (E4.6):...
Page 160 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 3: Inputs - Outputs / DIGITAL-INPUTS K73 (E8.5): (E8.6): K125 (E8.4): (E8.1): S4.1 (E2.1): S4.2 (E2.2): S5.1 (E2.3): S5.2 (E2.4): S7 (E14.5): (E2.7): S24 (E5.3): (E5.6): S27 (E8.2): S28 (K119) (E2.6): S30 (E2.5): (E9.7): S33a (E6.4):...
Page 161 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 3: Inputs - Outputs / DIGITAL-OUTPUTS -3- * K164-2 RELAY ENGINE OIL TANK 2 EMPTY * -3- * Y6a-1 VALVE FAN DRIVE 1 OIL COOLER (minimum speed)* -3- * Y6a-2 VALVE FAN DRIVE 2 OIL COOLER (minimum speed)* -3- * Y6b-1 VALVE FAN DRIVE 1 OIL COOLER (medium speed) *...
Page 162 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / H22 ACOUSTIC SIGNAL -4- Output signals OPERATE KEY SWITCH -4- Acoustic signal | 0 | 1 | H22 (A5.1): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / H52 H76 H78 H139 SIGNAL LAMP TANK FULL -4- Output signals OPERATE KEY SWITCH...
Page 163 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / K45 RELAY ENGINE SPEED SHIFTING -4- Output signals OPERATE KEY SWITCH -4- Relay engine speed shifting | 0 | 1 | K45 (A1.3): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / K50 RELAY BUCKET CUT-OFF -4- Output signals OPERATE KEY SWITCH...
Page 164 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / K122 RELAY STAB. CURRENT SUPPLY -4- Output signals OPERATE KEY SWITCH -4- Relay stab. current supply | 0 | 1 | K122 (A1.7): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / K164-1 RELAY ENGINE OIL TANK 1 EMPTY -4- Output signals OPERATE KEY SWITCH...
Page 165 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y6b-1 VALVE FAN DRIVE 1 OIL COOLER (medium speed) -4- Output signals OPERATE KEY SWITCH -4- Valve fan drive 1 oil cooler | 0 | 1 | Y6b-1 (A3.3): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y6b-2 VALVE FAN DRIVE 2 OIL COOLER...
Page 166 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y14b-1 VALVE FAN DRIVE 1 RADIATOR (medium speed) -4- Output signals OPERATE KEY SWITCH -4- Valve fan drive 1 radiator | 0 | 1 | Y14b-1 (A3.7): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y14b-2 VALVE FAN DRIVE 2 RADIATOR...
Page 167 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y101 VALVE OIL COOLER BACK-PRESSURE -4- Output signals OPERATE KEY SWITCH -4- Valve oil cooler back-pressure | 0 | 1 | Y101 (A5.4): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y124a VALVE SERVICE ARM LIFT -4- Output signals OPERATE KEY SWITCH...
Page 168 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Fault and Information Message List The messages are divided into four groups as follows: Group 1 Message Text Pages: The fault messages of group 1 will be stored and result 500 - 739 Start blocked condition or Automatic engine speed reduction to low idle or Automatic shutdown of the Shovel or...
Page 169 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault and Information Message List GROUP 1 Fault Message Texts of message pages No. 500 - 739 Fault No. 500: Start blocked through main Shut-Off (gate) (503) *1) valve Limit switch S31 not closed. Help: - Check for broken cables to switch S31.
Page 170 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Faulty monitor channel oil pressure of engine 1 at Fault No. 536: high idle (with engine running, message no. 1286 dis- (539) played) Sensor B30-1 shows inadmissible values Help: - Check sensor and cables. Fault No.
Page 171 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault No. 584: (587) Help: Fault No. 590: Shutdown: (593) Hydraulic oil level too low - Fill up hydraulic oil. Help: - Check level sensor B4 and B50. Fault No. 596: Faulty monitor channel engine speed 2 (599) Frequency converter E8-2 for speed of engine 2 shows Help:...
Page 172 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Fault No. 626: Start of engine 1 blocked by high pressure filter 2 (629) Differential pressure switch B6-1 not closed. Help: - Check cables to differential pressure switch B6-1. Fault No. 632: Fire in the power house (Shutdown) (635) Fire suppression system 9K1 actuated.
Page 173 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault No. 668: High pressure filter 3 restricted. Stop the engine 1 (671) Differential pressure switch B7-1 not closed. Help: - Clean or replace filter element. - Check pump Fault No. 674: High pressure filter 4 restricted.
Page 174 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Fault No. 710: (713) Help: Fault No. 716: Shut down of engine 2: oil pressure at low idle too (719) Help: Message through Sensor B1-2. Fault No. 722: (725) Help: Faulty monitor channel for oil pressure of engine 2 Fault No.
Page 175 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS GROUP 2 Fault Message Texts of message pages No. 740 - 1309 will be stored Fault No. 740: Faulty pressure switch for strainer oil cooler (743) Closed contact of pressure switch B165 for return oil Help: strainer with switched off engine.
Page 176 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Fault No. 782: Shutdown through emergency stop switch S33B (785) Emergency stop switch S33B at control valves actuated. Help: - Find cause Fault No. 788: Shutdown through emergency stop switch S33D. (791) Emergency stop switch S33D at counterweight actuated.
Page 177 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault No. 824: Faulty pressure switch for leak oil filter (827) Closed contact of pressure switch B25 for leak oil filter with Help: switched off Engine. - Check pressure switch and cables. Fault No.
Page 178 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Fault No. 872: Return oil filter restricted (875) Help: - Replace filter elements. Fault No. 878: Leak oil filter restricted (881) Help: - Replace filter element. Fault No. 884: Faulty monitor channel for charge- /discharge cur- (887) rent.
Page 179 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault No. 920: Faulty monitor channel for oil temperature of PTO (923) gear 2 Temperature sensor B49-2 for PTO gear oil shows inad- Help: missible values. - Check sensor and cables. Fault No. 926: Oil temperature of PTO gear 2 too high (929) - Check gear oil cooling circuit.
Page 180 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Fault No. 962: Control pressure X1-1 for the main pumps too high (965) - Check / adjust electronic pump regulation. Help: - Check / adjust pressure reduction valve. Fault No. 968: Pilot pressure X2 too low. (971) Help: - Check / adjust pressure relief valve.
Page 181 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault No. 1010: Board net voltage too low (1013) - Check batteries Help: - Check generator. Fault No. 1016: Faulty monitor channel for X1-2-pressure (1019) Pressure pick up B85-2 for the X1-2-pressure shows inad- Help: missible values.
Page 182 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Fault No. 1052: Swing ring gear lube system failure (1055) Lube cycle is not performed at the given time. Help: - Check lube system for defects. - Check lube times. Fault No. 1058: Swing ring gear lube system failure (1061) The lube lines are not relieved at the given time.
Page 183 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault No. 1094: PTO gear 2 oil filter restricted (1097) Help: - Replace filter element. Fault No. 1100: Fan drive oil filter for oil cooler 2 restricted (1103) Help: - Replace filter element. Fault No.
Page 184 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Fault No. 1142: Lubrication system failure of PTO gear 2 (1145) Oil pressure for lubrication of PTO gear 2 insufficient. Help: - Check lubrication oil pump and connected lines. Fault No. 1148: Pump back-up pressure X4-1 failure (1151) Back-up pressure for pumps on engine 1 insufficient...
Page 185 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault No. 1190: Faulty monitor channel for X1-1-pressure (1193) Pressure pick up B85-1 for the X1-1-pressure shows inad- Help: missible values. - Check sensor and cables. Fault No. 1196: Faulty monitor channel for X2-pressure (1199) Pressure pick up B86 for the X2-pressure shows inadmis- Help:...
Page 186 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Fault No. 1232: Shutdown through emergency stop switch S36. (1235) Emergency stop switch S36 in the cab actuated. Help: - Find cause Fault No. 1238: Shutdown through maintenance safety switch S58. (1241) Maintenance safety switch S58 in machinery house actu- Help: ated.
Page 187 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault No. 1274: Problems pump control. (1277) Problem in the pump control. Help: - If the fault further exist, inform service. Fault No. 1280: Shutdown through emergency stop switch S33C. (1283) Help: Emergency stop S33C in pump compartment actuated.
Page 188 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Information No. 1316: (1317) ? 2000 h Maintenance performed Information No. 1318: (1319) ? 3000 h Maintenance performed GROUP 4 Information Message Texts of message pages No. 1320 - 1535 will not be stored Information No.
Page 189 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Information No. 1338: # Fill up fuel tank (1339) Information No. 1340: # Actuate engine speed selector switch (1341) Information No. 1342: # Engine shutdown has been actuated from (1343) ground man Information No.
Page 190 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION # Maintenance safety switch S58 in the Information No. 1370: power house was actuated. (1372) Unlock before restarting. Information No. 1374: # Operator warning system actuated from (1376) ground man. # Swing ring gear lube system grease container Information No.
Page 191 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Information No. 1440: # Remark to Maintenance calls. (1445) The maintenance calls integrated in the ECS system are to be performed according to the maintenance section in the operation and main- tenance manual. The routine visual checks, lubrication work and engine maintenance are not called up.
Page 192: Operating The Heater, Ventilation And Air Conditioning
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING OPERATION OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING Legend for illustration Z 21748 Switch, cab ventilation blower. Cab heater temperature control Cab heater blower control Air conditioning blower control knob Indicator light, air conditioning blower ON Air conditioner temperature control knob REMARK To lower the cab air temperature (maximum...
Page 193: B - Cooling
OPERATION 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 3.5.2 B - COOLING 1. Set blower switch (4) to high stage. 2. Rotate the air conditioner control knob (6) to the desired tem- perature level. NOTICE When the air-conditioning is in operation the door and win- dows should be closed to ensure maximum cooling perfor- mance.
Page 194: Power House
3.6 POWER HOUSE OPERATION POWER HOUSE...
Page 195: Emergency Engine Shutdown Switches
OPERATION 3.6 POWER HOUSE 3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES Legend for illustration Z22877 Pulling chains for emergency shut down from ground man (special equip- ment). When one of the chains (1) is being pulled down for emergency shut down of both engines, the Operator will be informed by the following message, displayed on the ECS screen: "...
Page 196 3.6 POWER HOUSE OPERATION...
Page 197: Control And Filter Panel Of Rear- And Front Power Unit
OPERATION 3.6 POWER HOUSE 3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT Legend for illustration Z22479 (Rr.1) Control and filter panel of rear power unit, engine 1 (Fr.2) Control and filter panel of front power unit, engine 2 Change over valve for operation mode of pump con- trol system for rear power unit, engine 1.
Page 198: Electrical Equipment In Cab Base
3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION ELECTRICAL EQUIPMENT IN CAB BASE...
Page 199 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE WARNING The cab base may contain high tension electrical appliances. Access to the cab base for authorized service staff only. Legend for illustration Z 22480 Mounting location of main switch board "X2". See page 201 for more information.
Page 200 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 201: Switch Board (X2) In Cab Base
OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE 3.7.1 SWITCH BOARD (X2) IN CAB BASE Legend for illustration Z 23071 Emergency By-pass switch for the shutdown f unc- (S27) tion of the PLC (E6). If an automatic shutdown is ini- tiated by Shovel systems , with a dangerous situation for man or machine, which needs the Shovel to be operable to over-come the dangerous situation, actuate this switch to override the shutdown function...
Page 202 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 203 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Switch Board "X2" in Cab Base (continued) Service Switch for ”QMIN” and ”QMAX” Control of the Main Hydraulic Pumps (S155), illustration Z 23071 CAUTION The Service switch ”S155” is used for testing and adjustment procedures of the hydraulic system and should only be oper- ated through authorized service personnel (S155)
Page 204 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 205 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Emergency Indication of Operating Conditions The ECS system is equipped with an emergency indication via LED’s on the Programmable Logic Controller ”PLC” (E6), illust. Z21753. In case of a malfunction of the text display in the operator’s cab, the LED’s in the fifth column (A13/A7) of the ”PLC”...
Page 206 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 207 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE High Pressure Filter "HPF" Identification Codes of LED H31 The LED ”H31”, illust. Z 21753, monitors all six high pressure fil- ters. If a failure condition of a high pressure filter occurs, the LED ”H31”...
Page 208 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 209 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Preheating System for Oil, Coolant and Batteries General The preheating system is a special equipment and can be installed in the factory or locally at site. Power supply to the pre- heating system must be provided through an external power source.
Page 210 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 211 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Preheating System for Oil, Coolant and Batteries (continued) Engine Coolant and Engine Oil Heatings Legend for illustration Z 21724 Coolant heating systems, installed on RH and LH side member of the main frame. Switch, coolant heater ON/OFF.
Page 212 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 213 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Preheating System for Oil, Coolant and Batteries (continued Junction Box for Hydraulic Oil Heating and Location of Heat- ers and Thermostats, illustration Z 21755 Junction box for hydraulic oil heating Switch, hydraulic oil heating ON/OFF. Warning light, heating system failure, Indicator light, hydraulic oil heating ON.
Page 214: Checks Before Starting The Engines
3.8 CHECKS BEFORE STARTING THE ENGINES OPERATION CHECKS BEFORE STARTING THE ENGINES...
Page 215 OPERATION 3.8 CHECKS BEFORE STARTING THE ENGINES CAUTION Before starting the Engines, make sure that no one will be endangered when starting the Engines. CHECK THE FOLLOWING ITEMS Legend for illustration Z 22468 Engine oil pan dipstick oil level gauge Oil filler tube for engine oil pan Coolant expansion tank of front and rear engine radi- ators...
Page 216 3.8 CHECKS BEFORE STARTING THE ENGINES OPERATION...
Page 217 OPERATION 3.8 CHECKS BEFORE STARTING THE ENGINES Coolant Level WARNING DO NOT remove the radiator pressure cap (6), illust. Z22468 from a hot engine. Wait until the temperature is below 50°C before removing the pressure cap (6). Failure to do so can result in personal injury from heated coolant spray or steam.
Page 218 3.8 CHECKS BEFORE STARTING THE ENGINES OPERATION...
Page 219 OPERATION 3.8 CHECKS BEFORE STARTING THE ENGINES HYDRAULIC SYSTEM - CHECK OIL LEVEL General Information The hydraulic oil level in the main oil reservoir fluctuates depend- ing on the oil temperature and the position of the loader attach- ment (hydraulic cylinders retracted / extended). Legend for illustration Z22878 Main hydraulic oil reservoir Hydraulic oil level sight gauge...
Page 220: Starting The Engines
3.9 STARTING THE ENGINES OPERATION STARTING THE ENGINES...
Page 221 OPERATION 3.9 STARTING THE ENGINES NOTICE Before starting read the Engine Operation Manual. Observe the instructions for starting the Engines. WARNING After repairs on the Diesel engines or starter motors, make sure that the ground cables are correctly con- nected before starting the engines. Loose or missing ground cables can cause fire, serious injury or death.
Page 222 3.9 STARTING THE ENGINES OPERATION...
Page 223: Starting Procedure
OPERATION 3.9 STARTING THE ENGINES 3.9.1 STARTING PROCEDURE REMARK Start the engines one after another, e.g. first rear engine (1) then front engine (2). Both engines are started in the same way. 1. Insert battery main switch keys and turn to operating position. 2.
Page 224 3.9 STARTING THE ENGINES OPERATION...
Page 225 OPERATION 3.9 STARTING THE ENGINES After starting observe the following: The ECS System monitors the Shovel’s functions and provides information about the appropriate operational data. If a FAULT message is displayed on screen (3), the acoustic warning signal (2) will sound simultaneously for approximately 1 second.
Page 226 3.9 STARTING THE ENGINES OPERATION...
Page 227 OPERATION 3.9 STARTING THE ENGINES Emergency By-pass Switch for the ECS- Shut-down Func- tion. The unit is equipped with an Emergency By-pass Switch for the ECS-system. This switch is located on the ”X2” switch board in the cab base compartment and marked with ”S27”. If an automatic shut-down of the Shovel happens, with a danger- ous situation for man or machine, which needs the Shovel to be operable to overcome the dangerous situation, actuate this switch...
Page 228 3.9 STARTING THE ENGINES OPERATION...
Page 229 OPERATION 3.9 STARTING THE ENGINES Messages displayed with hydraulic oil too cold: Hydraulic oil far below operating temp. Fault No. 842: Wait for warm-up phase! The machine was taken into operation although the Help: start viscosity was not attained. - Preheat hydraulic oil! # Hydraulic oil not at operating temp.! Information Operate with reduced power!
Page 230 3.9 STARTING THE ENGINES OPERATION Hydraulic Oil Viscosity and Temperature Chart Rated Starting Operating range viscosity temperature (100 - 10 cSt) at 40° C of (max. 1000 cSt) hydraulic oil grade: ISO VG °C °C HLP 22 8 - 55 HLP 32 16 - 70 HLP 46...
Page 231: Moving The Shovel
OPERATION 3.10 MOVING THE SHOVEL 3.10 MOVING THE SHOVEL 3.10.1 TRAVEL CONTROL WITH FOOT PEDALS NOTICE Travelling directions with cab in normal working and travel position i.e. cab above idler wheel. Counter weight above drive sprockets. Legend for illustration Z 20345 (3L) Left pedal, inside (3R)
Page 232 3.10 MOVING THE SHOVEL OPERATION WARNING Be sure to sound the signal horn before starting to drive to make your intention clear. Regulate travel speed by depressing the pedals more or less. Apply swing circle brake as necessary. On machines with two-speed range travel drive, select normal or fast speed range according to ground conditions.
Page 233 OPERATION 3.10 MOVING THE SHOVEL WARNING Travelling on a grade requires special care. Plan your work so that the Shovel 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.
Page 234: Travelling Instructions
3.10 MOVING THE SHOVEL OPERATION 3.10.2 TRAVELLING INSTRUCTIONS Never travel the Shovel 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 travelling long distances swing the superstructure par- allel to the undercarriage and apply the swing brake.
Page 235: Slewing And Braking The Superstructure
OPERATION 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE 3.11.1 SLEWING THE SUPERSTRUCTURE MACHINES WITH "EURO" CONTROL Legend for illustration Z 21759 ”L” CCW- Lever (1) to the left ”L” ”N” Neutral position ”R” CW- Lever (1) to the right ”R” WARNING Be sure everyone is in the clear before slewing the super- structure.
Page 236 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE OPERATION MACHINES WITH "KMG" CONTROL Legend for illustration Z 21760 ”L” CCW- Lever (2) to the left ”L” ”N” Neutral position ”R” CW- Lever (2) to the right ”R” WARNING Be sure everyone is in the clear before slewing the super- structure.
Page 237 OPERATION 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE Releasing the Parking Brake Move up toggle switch (4) to position ”0”. In this position the switch is automatically pulled down by spring force. NOTICE Be sure to release the parking brake before slewing the superstructure.
Page 238: Working With The Attachment
3.12 WORKING WITH THE ATTACHMENT OPERATION 3.12 WORKING WITH THE ATTACHMENT 3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM NOTICE The illustrations show a typical construction of control stand and working attachment. However, the shown operation - and working movements apply to this machine. BACKHOE LH control lever(1) RH control lever (2)
Page 239: Machines Equipped With "Kmg" Control System
OPERATION 3.12 WORKING WITH THE ATTACHMENT 3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM NOTICE The illustrations show a typical construction of control stand and working attachment. However, the shown operation - and working movements apply to this machine. BACKHOE L.H. control lever (1) R.H.
Page 240: Bottom Dump Bucket
3.12 WORKING WITH THE ATTACHMENT OPERATION 3.12.3 BOTTOM DUMP BUCKET NOTICE The illustration shows a typical construction of control stand and working attachment. However, the shown operation- and working movements apply to this machine. OPERATING THE BUCKET CLAM Closing the bottom dump bucket: Depress LH pedal (4) Opening the bottom dump bucket: Depress RH pedal (5)
Page 241: Drop Ball Operation
OPERATION 3.12 WORKING WITH THE ATTACHMENT 3.12.4 DROP BALL OPERATION SAFETY INSTRUCTIONS WARNING Make sure all safety devices are correctly installed on your machine. Always walk-around and look for hazards before you operate your machine in the work area. Consult the supervisor of the job site for instructions concerning safe operation in the work area.
Page 242 3.12 WORKING WITH THE ATTACHMENT OPERATION SAFETY DEVICES (SPECIAL EQUIPMENT) Legend for illustration Z 20133_1 Front splinter guard for operator’s cab Protection screen for lubrication system, swing gear and working lights (if so equipped) Cylinder piston rod guard Swing ring guard Reinforcement ledges on bucket wall and clam edges NOTICE...
Page 243 OPERATION 3.12 WORKING WITH THE ATTACHMENT Legend for illustration Z 20133_5 Pick-up position of the drop ball A - Greatest circumference of the drop ball Legend for illustration Z 20133_6 Drop height, level with cab roof B - Back wall of the bucket in vertical position WORKING HINTS Place the rock to be crushed on a solid and level ground with the impact surface in a horizontal position.
Page 244: Combined Operation Cycles
3.12 WORKING WITH THE ATTACHMENT OPERATION 3.12.5 COMBINED OPERATION CYCLES With each of the control levers, two operation cycles can be initi- ated simultaneously. In order to obtain efficient operation, always select intermediate control lever positions in relation to work load. NOTICE The illustration shows a typical Shovel.
Page 245 OPERATION 3.12 WORKING WITH THE ATTACHMENT NOTICE The illustration shows a typical Shovel. The movements shown in the illustration are controlled: at KMG control system with R.H. lever at EURO control system with L.H. lever Legend for illustration Z 9711) Neutral position Retracting stick Extending stick (away from machine)
Page 246: Working Instructions
3.13 WORKING INSTRUCTIONS OPERATION 3.13 WORKING INSTRUCTIONS 3.13.1 STABILITY OF THE SHOVEL WARNING Before beginning work prepare a suitable Shovel base, to ensure adequate stability for safe working of the Shovel. The stability of the Shovel is determined according to DIN 24087, and is based on a level ground.
Page 247 OPERATION 3.13 WORKING INSTRUCTIONS CAUTION DO NOT "Sweep" with the loader attachment, illust. (Z 10369), as this may result in severe damage on swing gear components. CAUTION DO NOT use the bucket clam for loosening or removing anchored rocks or other solid objects (illust. Z 19984 and Z 19985), since such operations may result in severe damage to the clam pivot bearings.
Page 248 3.13 WORKING INSTRUCTIONS OPERATION When working with the bucket in the longitudinal direction, the final drives should be in the rear position illust. (Z 0144), for the following reasons: The travel motors and travel gears are protected from fall- ing 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.
Page 249: Parking The Shovel
OPERATION 3.14 PARKING THE SHOVEL 3.14 PARKING THE SHOVEL Park the machine 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, see "STOPPING THE ENGINES"...
Page 250: Stopping The Engines
3.15 STOPPING THE ENGINES OPERATION 3.15 STOPPING THE ENGINES...
Page 251 OPERATION 3.15 STOPPING THE ENGINES CAUTION Never stop the engines from full load except in case of emer- gency. Before shutting down run the engines at idling speed for approximately 5 minutes. This cooling down period prevents heat accumulation and thermal stress, especially in the tur- bochargers.
Page 252 3.15 STOPPING THE ENGINES OPERATION...
Page 253 OPERATION 3.15 STOPPING THE ENGINES WARNING With the engines at standstill and main switch (1) in ON posi- tion, move all controls for working attachment and crawlers several times through all shift positions to relieve the pres- sure 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.
Page 254: Operation Of The Lubrication System
3.16 OPERATION OF THE LUBRICATION SYSTEM OPERATION 3.16 OPERATION OF THE LUBRICATION SYSTEM 3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS” The central lubrication system works automatically as soon as the engines are running at high idle speed. The ECS System monitors the function of the central lubrication system.
Page 255 OPERATION 3.16 OPERATION OF THE LUBRICATION SYSTEM ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM (For factory installed system only) The following adjustments can be made in the service menu of the ECS system: Level 4: Service Menu / Settings *PAUSE TIME *MONITORING TIME *PRESSURE RELIEF TIME *LUBE CYCLE COUNTER...
Page 256: Swing Circle Pinion Lubrication System "Sls
3.16 OPERATION OF THE LUBRICATION SYSTEM OPERATION 3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” This system works automatically as soon as the engines are run- ning at high idle speed. The ECS System monitors the function of the swing circle lubrica- tion system.
Page 257 OPERATION 3.16 OPERATION OF THE LUBRICATION SYSTEM SWING CIRCLE LUBRICATION SYSTEM ”SLS” Repairs on the swing circle lubrication system with the Engine running or with the Engine OFF and Main Switch Key in ON position If repairs under the above conditions have been carried out it is necessary to reset the control circuit of the lubrication system by actuating the rotary switch (2), illust.
Page 258: Fire Detection And Suppression System
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM (Special Equipment)
Page 259 OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM FIRE DETECTION AND SUPPRESSION SYSTEM WARNING Before operating the Shovel make sure the Fire Detection, Actuation and Suppression system is operative. Carry out inspection and maintenance according to the sepa- rate manuals "Fire Detection and Actuation System" and "Fire Suppression System"...
Page 260 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...
Page 261: High Level Alarm "Fire
OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM 3.17.1 HIGH LEVEL ALARM ”FIRE” The high level alarm (8), illlust. Z 21619 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.
Page 262 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...
Page 263: Indication Of Operational Modes At Control Module, After Automatic Actuation Of The Fire Suppression System
OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM 3.17.4 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"...
Page 264 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...
Page 265: Location Of The Extinguishing Agent Tank Assemblies And Expellant Gas
OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM 3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF REMARK All fourteen extinguishing agent tank assemblies with their expellant gas cartridges are located on the rear railing of the power house roof.
Page 266: Central Refilling System
3.18 CENTRAL REFILLING SYSTEM OPERATION 3.18 CENTRAL REFILLING SYSTEM (Special Equipment)
Page 267: Systems Connected To The Refilling System
OPERATION 3.18 CENTRAL REFILLING SYSTEM 3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM The following systems are connected to the receiver panel (5) of service arm (3), illust. (Z 21764): Fuel Tank Water Tank for Hand Wash Sink in the Operator’s Cab Front and Rear Engine Oil Pan Front and Rear Engine Oil Reserve Tank Front and Rear Engine Coolant Radiator...
Page 268 3.18 CENTRAL REFILLING SYSTEM OPERATION...
Page 269: Operating The Hydraulic Service Arm
OPERATION 3.18 CENTRAL REFILLING SYSTEM 3.18.2 OPERATING THE HYDRAULIC SERVICE ARM A - Diesel Engines OFF The Service Arm can only be lowered. Proceed as follows: 1. Turn main key switch to ON position. 2. Turn enabling switch (1), illust. (Z 21764) to ON position ”1”. 3.
Page 270 3.18 CENTRAL REFILLING SYSTEM OPERATION...
Page 271: Receiver Panel With Monitor Box
OPERATION 3.18 CENTRAL REFILLING SYSTEM 3.18.3 RECEIVER PANEL WITH MONITOR BOX Legend for illustration Z 22469: Service arm, hydraulically operated Monitoring and control box Push button for testing lamps (6, 7, 8, 9, 10 and 11). Push the button, all lamps must light up. If a lamp does not light up, corrective action must be taken.
Page 272 3.18 CENTRAL REFILLING SYSTEM OPERATION...
Page 273 OPERATION 3.18 CENTRAL REFILLING SYSTEM Legend for illustration Z 22469 Engine oil evacuation and filling adapters of the reserve tanks for Front engine (Fr.) and Rear engine (Rr.). Observe the corresponding indicator lamp (9) and (10). (Fr.) Front engine, (Rr.) Rear engine. Radiator coolant draining and filling adapter.
Page 274 3.18 CENTRAL REFILLING SYSTEM OPERATION...
Page 275 OPERATION 3.18 CENTRAL REFILLING SYSTEM RECEIVER PANEL WITH MONITOR BOX Legend for illust. Z 22469 Adapter for filling the water tank in the Operator’s cab. The water tank has a capacity of 50 liters. The filling line of the water tank is equipped with a drain cock. Before filling the water tank, drain the old water by opening this drain cock.
Page 276 3.18 CENTRAL REFILLING SYSTEM OPERATION...
Page 277: Refillable Grease Containers Of The Automatic Lubrication Systems
OPERATION 3.18 CENTRAL REFILLING SYSTEM 3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS Legend for illustration Z22879 Grease filter for swing 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, item no.
Page 278: Service Crane
3.19 SERVICE CRANE OPERATION 3.19 SERVICE CRANE...
Page 279: Operating The Crane
OPERATION 3.19 SERVICE CRANE 3.19.1 OPERATING THE CRANE WARNING Before operating the crane, check condition and fasten- ing of the crane structure and base. Read the separate Instruction Manual ”CRANE TYPE HMK 60 Ta1” before operating the Crane. The Crane Instruction Manual is filed in volume 2 Binder.
Page 280 3.19 SERVICE CRANE OPERATION...
Page 281 OPERATION 3.19 SERVICE CRANE Operating the Service Crane (continued) WARNING Make sure everyone is in the clear before lifting or lower- ing a load with the crane. Never swing or position a load over personnel. DO NOT exceed the maximum permissible lifting load of 1000 kg.
Page 282: Work On The Loader Attachment
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. OBSERVE THE FOLLOWING INSTRUCTIONS Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this necessary.
Page 283: Transportation And Lifting Of The Shovel
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL WARNING Before Disassembling, Lifting or Transporting this Shovel contact your local Komatsu Service Station for all the neces- sary instructions for safe and economic disassembling, lift- ing and transportation procedures of your Shovel. 3.21.1 DISASSEMBLING OF THE SHOVEL The Shovel is being transported disassembled into its main com- ponents.
Page 284: Retrieval Procedure
Check whether fuel or oil has flown out. Observe the local fire prevention- and safety regulations. CAUTION Contact your local Komatsu service station for all the neces- sary instructions for safe and economic retrieval procedures of your Shovel NOTICE Select the sequence of retrieval steps with regard to the sta- bility of the Shovel.
Page 285: Shovel Storage
OPERATION 3.23 SHOVEL STORAGE 3.23 SHOVEL STORAGE GENERAL Storage periods up to 30 days require no special preservation when the unit is stored in a protected place. When the Shovel is placed in storage for 30 days or more follow the procedure below. NOTICE The description below includes special equipment which may not be installed in your machine.
Page 286: One Month Repetitive Service Period
3.23 SHOVEL STORAGE OPERATION 3.23.2 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.
Page 287: Preparing For Operation
OPERATION 3.23 SHOVEL STORAGE 3.23.4 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 cool- ant level.
Page 288: Trouble Shooting
3.24 TROUBLE SHOOTING OPERATION 3.24 TROUBLE SHOOTING GENERAL The following charts list a number of the most common problems encountered in operation. Some of the faults may be due to care- less handling or operation, improper maintenance or the use of lubricating oils other than specified.
Page 289: Hydraulic System
OPERATION 3.24 TROUBLE SHOOTING 3.24.2 HYDRAULIC SYSTEM Problem Probable cause 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 Poor hydraulic system perfor- defective.
Page 290: Final Drives And Swing Gear
3.24 TROUBLE SHOOTING OPERATION 3.24.3 FINAL DRIVES AND SWING GEAR Incorrect lubricant or oil level too low Bearings scored or damaged. Noisy operation Sun gear teeth excessively worn or damaged Bearings of planetary pinions worn 3.24.4 CRAWLER TRACKS Wrong track tension Track roller loose or out of alignment Excessive track wear Track shoes loose...
Page 291: Maintenance
4. MAINTENANCE...
Page 292: Foreword
4.1 FOREWORD MAINTENANCE FOREWORD This section contains instructions for the correct care and mainte- nance of your machine. NOTICE Since this section covers also special equipment and acces- sories, you may find illustrations and descriptions which do not apply to your machine. DEFINITIONS Service point Unit or system where the prescribed maintenance work has to be...
Page 293: Precautions For Maintenance
MAINTENANCE 4.2 PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 16. Park the Excavator at a safe place on level ground. Proceed according to the instructions on page 253 ”Parking the Excavator”.
Page 294 4.2 PRECAUTIONS FOR MAINTENANCE MAINTENANCE After servicing, remove oily cloth, inflammable material and all tools from the machine. Clean the Excavator with a steam jet, especially after servic- ing fuel system, engine and hydraulic system. NOTICE For cleaning the Excavator and its components use only fresh water with a salt content of less than 0.05%.
Page 295: Fuel And Lubricants
MAINTENANCE 4.3 FUEL AND LUBRICANTS FUEL AND LUBRICANTS Ambient Point of Viscosity Quality Grades Lubricant Temperature Lubrication Grades DIN/API °C Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for Engines Specifications of Engine Oil, Coolant and Fuel. - 20 to + 11 Hydraulic oil -14 to + 21 “HLP or...
Page 296 4.3 FUEL AND LUBRICANTS MAINTENANCE Ambient Quality Grades Point of Viscosity Lubricant Temperature Lubrication Grades °C DIN/API Grease Fittings Refer to the Lubricant Chart in volume 2 binder for the recommended (manual lubrication) Multi-Purpose Multi-Purpose Greases. The part numbers of recommended Multi- Grease ”MPG”...
Page 297: Filling Capacities
MAINTENANCE 4.4 FILLING CAPACITIES FILLING CAPACITIES Liter Liter Unit or System Unit or System (approx.) (approx.) Cooling System Swing Gears made by L&S, each: 42.0 Front Engine 360.0 Motor Adapter Housings Swing Gears made by Sieben- Rear Engine 360.0 haar, each: 60.0 Engine Oil Motor Adapter Housings...
Page 298: Standard Torque List
4.5 STANDARD TORQUE LIST MAINTENANCE STANDARD TORQUE LIST Tightening torque Bolt Wrench lbs.ft. dia. size [mm] Quality grades 10.9 12.9 M 10 M 12 54.6 M 14 M 16 M 18 M 22 M 24 1030 M 27 1310 1530 1128 M 30 1250...
Page 299: Lubrication And Maintenance Schedule
MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE LUBRICATION AND MAINTENANCE SCHEDULE 4.6.1 INITIAL SERVICING AFTER THE FIRST 250 OPERATING HOURS Change oil in Swing gears, Travel gears and PTO’s (pump distrib- utor gears). Thereafter every 3000 hours, but at least once a year. An oil sample analysis should be made every 1000 operating hours.
Page 300: Periodic Servicing Schedule
4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE 4.6.3 PERIODIC SERVICING SCHEDULE Service Intervals Service Point Service Engine Air Cleaners Maintenance page 315 Immediately apply grease if bare Swing circle toothing page 319 spots are visible Fill grease containers When necessary Automatic lubrication systems page 321 Clean or replace filter elements Track rollers...
Page 301 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Service Intervals Service Point Service Refrigerant compressor Check drive belt tension page 359 Signal horn compressor Lubricate page 361 Oil cooler fan bearings and Check for leakages and clean page 361 Radiator fan bearing breather filters Clean in-line grease screens Automatic lube systems...
Page 302 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE Service Intervals Service Point Service Check for correct tightening High strength bolt connections page 381 torque and security - Replace return and pressure filter elements - Clean or replace high pressure Hydraulic system filter elements page 439 - Replace breather filter ele- ments...
Page 303 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Service Intervals Service Point Service - Change oil (*) Hydraulic system - Replace suction strainers (*) page 465 - Replace pulsation damper Every 2000 operating hours or yearly. Emergency escape ladder Inspect page 477 Fire detection and actuation sys- Maintenance Swing gears and Motor adapter...
Page 304 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE Lubrication Chart...
Page 305 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE REPLACEMENT OF HYDRAULIC HOSE LINES Hydraulic Hose lines are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years. CAUTION The maximum permissible storage time of hydraulic hose lines is 2 years. This storage period is part of the usable life- time and must be considered when a new hose line is being installed.
Page 306 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...
Page 307: Extended Service Intervals For Engines With Engine Oil Management System
MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE 4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM REMARK The engine oil management system of each engine combines the automatic engine oil supply system "Reserve" and the oil burning system "Centinel" in connection with the "Eliminator" oil filtration system.
Page 308 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...
Page 309 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Extended Service Intervals for Engines with Engine Oil Management System Every 500 operating hours The contents of each engine oil reserve tank is sufficient for approximately 500 hours of operation. The oil level in the reserve tanks is also monitored by the ECS system.
Page 310 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...
Page 311 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Extended Service Intervals for Engines with Engine Oil Management System Reserve System Oil Flow Schematic, illust. Z 22452A. Front engine -2- shown. Rear engine -1- is connected to the reserve tank in the LH side member of the main frame Oil filters for the engine oil reserve system Suction line from reserve tank Suction line to pumping unit...
Page 312 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...
Page 313 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE 4.6.7 ENGINE FUEL FILTER LOCATIONS REMARK The fuel filters for engine 1 and 2 are relocated as shown in illustration Z22880 for better accessibility. Legend for illustration Z 22880 Rear engine 1 Front engine 2 Fuel filters for rear engine 1 mounted on rear machinery house post Fuel filters for front engine 2 mounted on center radiator post Fuel tank...
Page 314 4.7 WHEN NECESSARY MAINTENANCE WHEN NECESSARY...
Page 315 MAINTENANCE 4.7 WHEN NECESSARY 4.7.1 ENGINE AIR CLEANER MAINTENANCE NOTICE Before servicing the filter elements clean dust cups of the pre-cleaners. Servicing the main filter elements, illust. Z 20716: CAUTION Never service air cleaner while engine is running. Clean main filter elements as soon as the fault message "Air cleaner element restricted"...
Page 316 4.7 WHEN NECESSARY MAINTENANCE...
Page 317 MAINTENANCE 4.7 WHEN NECESSARY Air Cleaner Maintenance, illustration Z 20716 NOTICE If the fault message "Air cleaner element restricted" is again displayed on the ECS 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 ser- vicing the main filter element also the safety filter ele- ment has to be replaced.
Page 318 4.7 WHEN NECESSARY MAINTENANCE...
Page 319 MAINTENANCE 4.7 WHEN NECESSARY 4.7.2 SWING CIRCLE TOOTHING LUBRICATION See illustration Z 20850 All teeth of the ring gear (3) must be completely covered with grease. If teeth are not completely covered with grease, they have to be lubricated immediately with special adhesive spray grease, illust. (Z 0148) or spread type adhesive grease as specified in the Parts Catalog.
Page 320 4.7 WHEN NECESSARY MAINTENANCE...
Page 321 MAINTENANCE 4.7 WHEN NECESSARY 4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS Fill the grease containers of the Central Lubrication System and Swing circle pinion Lubrication System when the corresponding message "grease container on reserve" is displayed on the ECS screen. Make sure the grease filters in the filling lines are not obstructed.
Page 322 4.7 WHEN NECESSARY MAINTENANCE...
Page 323 MAINTENANCE 4.7 WHEN NECESSARY Service the Grease Filters for Refillable Grease Containers of the Central Lubrication System and Swing circle pinion Lubrication System, illustration Z 20718 1. Screw off filter case. 2. Remove element assy. (02) and clean. Take care not to con- taminate the ”Clean”...
Page 324 4.7 WHEN NECESSARY MAINTENANCE...
Page 325 MAINTENANCE 4.7 WHEN NECESSARY 4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS Legend for illustration Z 21768 Guide wheel, if leakage occurs. replace floating seal. Refer to repair manual for replacement procedure. Carrier roller, if leakage occurs. replace floating seal. Refer to repair manual for replacement procedure.
Page 326 4.7 WHEN NECESSARY MAINTENANCE...
Page 327 MAINTENANCE 4.7 WHEN NECESSARY 4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER Legend for illustration Z 23060 Air cleaner for rear engine 1 Air cleaner for front engine 2 Cold starting aid mounted on the air cleaner carrier Electrically operated valve Mounting clamp Cold start fluid cylinder WARNING...
Page 328 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE EVERY 10 OPERATING HOURS OR DAILY...
Page 329 In case the bucket base is already weakened, reconditioning measures will be necessary. Contact your Komatsu dealer for support. Check guide wheels for leakage. Check carrier rollers for leakage.
Page 330 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 331 MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY WORKING ATTACHMENT - CHECK GREASE INJECTORS FOR PROPER OPERATION NOTICE There are two types of grease injectors installed “SL1” and “SL11” injectors, see illust. (Z 19721). Legend for illustration Z 19721 Injectors on bucket Injectors on stick Injectors on boom Indicator stem for visual indication of injector opera-...
Page 332 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 333 MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY CHECK GREASE INJECTORS Legend for illustration Z 19511 Injectors on slewing connection Indicator stem for visual indication of injector opera- tion Output adjusting screw Protection cap Grease fitting Check operation of all grease injectors (D) by visually watching the cycle indicator stem (1) while operating the central lubrication system manually.
Page 334 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 335 MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY SWING CIRCLE - CHECK GREASE INJECTORS Legend for illustration Z 19191 Injectors for swing circle teeth lubrication Indicator stem for visual indication of injector operar- tion Output adjusting screw Slew gear ring Slew gear ring Slew gear ring guard (if so equipped) (10)
Page 336 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 337 MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY 4.8.2 AIR CLEANER - CLEAN PRE-CLEANER Clean dust cups of pre-cleaners Legend for illust. Z 21770: Roof mounted air cleaner units Air intake screen Clamps Dust cups Jet tubes 1. Provide suitable container for collecting the dust before open- ing the dust cups (4).
Page 338 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 339 MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY 4.8.3 RADIATORS - CHECK COOLANT LEVEL Legend for illustration Z 21770 Coolant expansion tank of front and rear engine radi- ators Coolant level sight gauge on front and rear coolant expansion tanks Cover plates on power house roof above front and rear radiator pressure caps Radiator pressure caps...
Page 340 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE EVERY 50 OPERATING HOURS OR WEEKLY...
Page 341 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS REMARK The machine can be equipped either with a swing gear of manufacturer "L&S" or of manufacturer "Siebenhaar". Refer to the data plate on each swing gear housing to find out the manufac- turer of the swing gear.
Page 342 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 343 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY Swing gear manufactured by "Siebenhaar" Legend for illustration Z 21656 Position of oil level gauge for checking the oil levels Swing gear Brake housing Compensator oil tank for swing gear Oil level gauge for swing gear Oil drain plug for motor adapter housing Oil level gauge for motor adapter housing Breather filter for brake housing...
Page 344 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 345 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS Legend for illustration Z25244 - A - View of the RH Final drive. The configuration of the LH Final drive is the same. Travel gear Oil level gauge Oil filler plug...
Page 346 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 347 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY TRAVEL GEAR BOX - CHECK OIL LEVEL Illustration Z25244: Remove oil level gauge (2) and wipe it clean. Screw in the gauge and remove again. Oil level should be at the upper mark of gauge (2).
Page 348 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 349 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES - CHECK BREATHER FILTERS Legend for illustration Z25243 (11) Connector on travel gear box for breather filter (18) (16) Connectors on motor adapter housing for breather filter (19) (18) Breather filters for travel gears...
Page 350 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 351 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL Legend for illustration Z 20696 Oil level gauge Oil filler plug Breather filter Oil drain plug Oil collector reservoir for adapter housings of hydraulic pumps for fan drives Breather filter with oil level gauge Adapter housings for main hydraulic pumps...
Page 352 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 353 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY OIL COLLECTOR RESERVOIR - CHECK OIL LEVEL. 1. Unscrew level gauge (8), illustration Z 20696 and wipe it clean. 2. Insert gauge (8), but DO NOT screw in, see detail (A). 3. Remove level gauge and read the oil level. The oil level should be between the "MIN"...
Page 354 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 355 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR Legend for illustration Z 23018 Access ladder in lowered position Access ladder in upper position (Working position) Stop bar Manual actuator for fire suppression system (if so equipped) Pull chain for emergency lowering of the access ladder CAUTION Use this chain only in emergency cases, when the Operator...
Page 356 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 357 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY See illustration Z 20369 WARNING 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 car- rier frames.
Page 358 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY...
Page 359 MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION WARNING Be sure to set the maintenance safety switch to 0 position before to start the checking procedure. Refer to page 199 for the location of the maintenance safety switch.
Page 360 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
Page 361 MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.2 SIGNAL HORN COMPRESSOR - LUBRICATE See illustration Z 10689 The compressor (2) is located in the cab base. Fill several 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°...
Page 362 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
Page 363 MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.5 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER Legend for illustration Z 22726 Grease container of swing circle pinion lubrication system Grease container of central lubrication system Breather filters Components of In-Line-Grease-Filter: (12)
Page 364 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
Page 365 MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.6 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT Legend for illustration Z 21468 Air cleaner housing located on cab base Filter element Cab base wall Seal ring Cab blower Blower housing Air hose to base roof Air hose to cab bottom Clean and inspect filter element (2) as follows:...
Page 366 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
Page 367 MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.7 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL Legend for illustration Z 22591 Air conditioner door with filter mat Air conditioner unit Sight glass for checking refrigerant filling Shut-off valve on dryer cartridge Dryer cartridge Refrigerant collector reservoir Condenser...
Page 368 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY...
Page 369 MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY 4.11.1 BATTERIES - CHECK FLUID LEVEL See illustration Z 21773 WARNING Batteries give off highly inflammable 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.
Page 370 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 371 MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY 4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL See illustration Z 20703 NOTICE The Engines must be out of operation for approximately 30 minutes before checking the oil level. This period is nec- essary for settling of the oil in the lower part of the coupling housing.
Page 372 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 373 MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY 4.11.3 FUEL TANK - DRAIN CONDENSATION Legend for illustration Z 20702 Fuel tank Cover Filler cap Seal ring Fuel tank breather valve on machines with refilling system Main fuel shut-off cock Protection cap for drain coupling (8) Drain coupling Seal ring (10)
Page 374 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 375 MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY 4.11.4 CRAWLER TRACK - INSPECTION CHECK ADJUSTING RANGE OF GUIDE WHEELS (Track retensioning range) GENERAL The hydraulic track tensioning system, illust. Z 20371 maintains automatically the correct track tension. The pilot pressure oil of the travel brake release circuit is used, to pressurize the four adjusting cylinders (10) and (11).
Page 376 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 377 MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY CHECK ADJUSTING RANGE FOR GUIDE WHEELS Legend for illustration Z 20015 Guide wheel Slide block 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).
Page 378 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 379 MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY CHECK ADJUSTING RANGE FOR GUIDE WHEELS NOTICE The cocks (9), illust. Z 20371 must always be in OPEN posi- tion. Close only in such cases, when the adjusting cylinders (10 and 11) must remain under pressure while servicing other components of the system.
Page 380 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...
Page 381 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD Check high-strength bolt connections and securing elements for damage and looseness. If any damages, failures or wrong condi- tion are found, corrective action must be taken. NOTICE If the torque load is not stated otherwise refer to standard torque chart for torque data.
Page 382 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 383 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of railings (A, B, C, D and E), illust. Z 21670 Bolt size SW * Tightening torque Reference No.: Grade * SW = Wrench size NOTICE Detail (C) shows the bracket for attaching the emergency escape ladder (storage position).
Page 384 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 385 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of cab base, illust. Z 21671 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 3100 * SW = Wrench size* Re-tighten mounting bolts to their correct torque and replace missing or damaged bolts.
Page 386 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 387 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check mounting of Operator’s cab, illust. Z 22663 Check tightening torque of mounting bolts as indicated in the illustration. Check condition and fastening of chains (1). Check the silicone oil filled viscous mounts (2) for leakage and signs of fatigue.
Page 388 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 389 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of fuel tank, illust. Z 21672 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 1770 10.9 1770 * SW = Wrench size* SW = Wrench size Re-tighten mounting bolts to their correct torque and replace missing or damaged bolts.
Page 390 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 391 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of hydraulic oil cooler, illust. Z 21673 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 1770 10.9 1770 * SW = Wrench size Re-tighten mounting bolts to their correct torque and replace missing or damaged bolts.
Page 392 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 393 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of hydraulic oil tank, illust. Z 21674 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 1770 10.9 1770 * SW = Wrench size Re-tighten mounting bolts to their correct torque and replace missing or damaged bolts.
Page 394 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 395 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening of power house frame (01) to superstructure main frame, illust. Z 20705 Bolt size SW * Tightening torque Reference No.: Grade Qty. (02) 10.9 1770 (03) Washer...
Page 396 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 397 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of the eight power house posts (75) and transverse carrier (82), illust. Z 20706 Bolt size SW * Tightening torque Reference No.: Grade Qty.
Page 398 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 399 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Power House Doors, illust. Z 20707 Check fastening and condition of power house doors (24 - 25) and door hinges (26). Check fastening and condition of safety rods (41). Check upper pump compartment door locks (35 - 36) for cor- rect mounting.
Page 400 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 401 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH Power house Roof, illust. Z 20708 Check fastening and condition of power house roof segments (02 - 05). Check sealing elements (08) between roof segments for cor- rect seat and good condition. Check sealing elements (11 - 16) between roof segments and roof frame (01) for correct seat and good condition.
Page 402 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 403 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check mounting and security of Diesel engines and pump distributor gears, illust. Z 21776 Legend for illustration Z 21776: Bolt size SW * Tightening Qty. both Reference No.: Grade torque Nm...
Page 404 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 405 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check mounting and security of each Diesel engine and pump distributor gear, illust. Z 21776 Check all flexible bearings (1) for engine and pump distributor gear. Check the flexible bearings for damage and signs of fatigue.
Page 406 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 407 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of main hydraulic pumps (1-6), illust. Z 20710. Mounting bolt size: M20, Grade 8.8, tightening torque 360 Nm. Check fastening and condition of auxiliary pumps (8.1 - 8.6) and secondary hydraulic pumps (10.1 - 10.4).
Page 408 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 409 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of control valve carrier, main control valves (I, II and III) and swing control valve (5), illust. Z 21777 Bolt size SW * Tightening Reference No.: Grade...
Page 410 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 411 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of both swing gears (01) and swing motors (02), illust. Z 22514 Bolt size SW * Tightening torque Reference No.: Grade Qty. M 16 10.9 (25)
Page 412 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 413 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check tightening torque of the counterweight mounting bolts, illust. Z 21778 Bolt size SW * Tightening torque Reference No.: Grade Qty. (1) Counterweight (2) Lifting eyes (3) Mounting bolts 10.9 7500...
Page 414 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 415 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Swing circle, illust. Z 20614 Check tightening torque of inner and outer mounting bolts (02 and 04) according to PARTS & SERVICE NEWS, No. AH00511. NOTICE Checking/retightening of swing circle mounting bolts is only necessary after the first 1000 operating hours.
Page 416 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 417 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of swivel joint (A), illust. Z 20865 Bolt size SW * Tightening torque Reference No.: Grade Qty. M 16 10.9 M 16 10.9 * SW = Wrench size Re-tighten mounting bolts to their correct torque and replace...
Page 418 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 419 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Excavators with Electric Prime Mover Check condition and fastening of slip ring unit (01), illust. Z 20616 Bolt size SW * Tightening torque Reference No.: Grade Qty.
Page 420 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 421 NOTICE If the outer bolts (9) have been found loose, it is necessary to check also the inner bolts (10) for looseness. For this purpose the travel gear assy has to be removed. Contact your Komatsu Dealer for support.
Page 422 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 423 Necessary equipment for the retightening procedure: Measuring device (1 - 6) delivered with the new machine, see table below. Special hydraulic torque wrench, see illustration Z24072 on page 427. This tool will be provided by your Komatsu dealer. Measuring Device PN 92847640 Position Part name Part No.
Page 424 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 425 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Procedure for determination of the tightening torque for the crawler carrier mounting bolts after the first 1000 operating hours, see illustration Z25246 1. Loosen the two measuring bolts (7) at the left crawler carrier and the two measuring bolts at the right crawler carrier.
Page 426 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 427 Special wrench socket with supporting bar (P/N 793 376 73) Hydraulic wrench (P/N 793 374 73) Electro-hydraulic pump set (P/N 793 375 73) The equipment shown in illustration Z24072 will be provided by your Komatsu dealer. Location of the four measuring bolts (7), illustration Z25247...
Page 428 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 429 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Crawler Carrier Check condition and fastening of guide wheels (01), stop plates (03) and rollers (06 and 09), illust. Z 20618. Legend for illust. Z 20618: (01) Guide wheel (02)
Page 430 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 431 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength 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. Legend for illust. Z 20619 Mounting assembly for steps (03) to steel pipe, ver- sion I Mounting assembly for railing posts to steps (03)
Page 432 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 433 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Cable Drum for Excavators with Electric Prime Mover Check condition anf fastening of parts (01 - 06) and (10, 30 and 40), illust. Z 20620 Legend for illust. Z 20620 (01) Junction box (02)
Page 434 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 435 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Roof-mounted service crane Check condition and fastening of crane base and crane Legend for illust. Z 22635 Crane base Slew crane Outrigger Electric chain hoist or hydraulic rope winch Safety hook Electric -.hydraulic power unit Bolt size...
Page 436 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 437 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Roof-mounted crane for grease barrel replacement Check condition and fastening of the crane Legend for illustration Z 23054 Crane post Outrigger Ropes for securing the outrigger (2) in home position Ring for fastening the wire ropes (7).
Page 438 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 439 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE Legend for illust. Z 20373 Return of filter location Leakage oil filter location Mounting bolt Filter cover retainer Filter cover assy Return- and leakage filter unit Oil filler plug Back-pressure valve Breather filter...
Page 440 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 441 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE Replace return oil filter elements Replace leakage oil filter element Check filter screens Follow the steps shown in illust. Z 19336: Loosen bolt (1). Turn retainer (2). Remove cover assy (3). Inspect O-ring (4) and replace if necessary.
Page 442 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 443 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE Replace breather filter element Drain water and sediments from hydraulic oil tank Legend for illust. Z 21503 Hand wheel of main shut-off valve located between suction oil reservoir and main oil reservoir To OPEN the valve, turn hand wheel (6) CCW to the stop To CLOSE the valve, turn hand wheel CW to the...
Page 444 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 445 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE High Pressure Filters "HPF", illustration Z 21780 NOTICE The filter reference numbers (1 - 6) correspond to the numbering of the main pumps. If, for example, the fault message "High pressure filter #5 restricted"...
Page 446 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 447 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE High Pressure Filters "HPF", illustration Z 21780 NOTICE Carefully inspect elements for damage. Always install new elements if ruptures or other damages are found. 5. Remove element (10) and clean. Take care not to contami- nate the "Clean"...
Page 448 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 449 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE Replace filter elements of the hydraulic oil pressure filters NOTICE When a fault message "Pressure Filter restricted" is dis- played, stop work and replace element of the corresponding pressure filter.
Page 450 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 451 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE Replace pressure filter elements, illust. Z 22515, as follows: 1. Place working equipment on the ground and shut-off the engines. Relieve pressure in the hydraulic system according to page 254 in the operation section.
Page 452 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 453 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS The oil sample analysis gives information about the grade of con- tamination and aging of the gear oils. Refer to the tables below for limits of contamination.
Page 454 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 455 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE See illustration Z 9543 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.
Page 456 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 457 For checking the charging pressure a special testing and fill- ing device must be used. This device can be ordered from your Komatsu Dealer. The testing and filling procedure of the pressure accumula- tors has to be carried out in accordance with Service Bulletin No.
Page 458 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 459 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE Legend for illust. Z22991 Location of filler neck for water tank (5) Location of water filter (2), pump (3) and pressure compensation tank (4). Access cover for water filter compartment Water filter Water pump...
Page 460 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 461 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES WARNING Provide adequate working platform for safe access to the hydraulic oil cooler. Check all door hinges (2) for good condition and proper fastening to their carrier frames.
Page 462 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 463 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES WARNING Provide adequate working platform for safe access to the rear machinery house doors (2). Check all door hinges (3) for good condition and proper fastening to their carrier frames.
Page 464 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY...
Page 465 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY 4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER NOTICE The hydraulic oil change intervals can be extended for a fur- ther time period, when an oil sample analysis shows a posi- tive result.
Page 466 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 467 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Legend for illust. Z 21785 Return oil collector manifold Drain coupling Pulsation damper Return oil collector pipe Main control valves Swing control valve NOTICE Attach drain hose (part of tool set) to coupling (2) and drain oil from return oil collector manifold (1).
Page 468 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 469 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Legend for illust. Z 21787 Hand wheel of main shut off valve between main oil reservoir and suction oil reservoir To open the valve, turn hand wheel (6) CCW to the stop To close the valve, turn hand wheel (6) CW to the stop...
Page 470 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 471 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Legend for illust. Z 21171 (I-VI) Main Hydraulic pumps Location of the suction strainers for the six main pumps (05-06) Main pump suction lines Secondary hydraulic pumps on PTO gear 1 Secondary hydraulic pumps on PTO gear 2 (10)
Page 472 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 473 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER FILLING THE HYDRAULIC SYSTEM 1. Make sure main shut-off valve is in open position and all con- nections are securely tightened. REMARK Select hydraulic oil viscosity grade according to ambient tem- peratures.
Page 474 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 475 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Vent Hydraulic pumps 1. Open vent plug (13), illust. Z 22513 on the pump suction port of all six main pumps. 2.
Page 476 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 477 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY 4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION Legend for illust. Z24090 Sliding window, serves also for emergency exit Release lever for hinged railing bar (3) Hinged railing bar Rigidly mounted emergency escape ladder Rope ladder.
Page 478 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...
Page 479 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL REMARK The machine can be equipped either with a swing gear of manufacturer "L&S" or of manufacturer "Siebenhaar". Refer to the data plate on each swing gear housing to find out the manufac- turer of the swing gear.
Page 480 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 481 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR Motor Adapter Housing, Change Oil: 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.
Page 482 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 483 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR SWING GEAR MANUFACTURED BY "SIEBENHAAR" Legend for illustration Z24091 Position of oil level gauge for checking the oil levels Swing gear (RH and LH) Brake housing Compensator oil tank for swing gear Oil level gauge for swing gear Oil drain plug for motor adapter housing Oil level gauge for motor adapter housing...
Page 484 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 485 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR Brake Housing - Change Oil (Siebenhaar) 1. Remove level gauge (8), illustration Z24091, drain plug (9) and breather filter (7). Drain the oil into a receptacle of approx. 5 liter capacity. 2.
Page 486 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 487 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL Legend for illustration Z25244 - A - View of the RH Final drive. The configuration of the LH Final drive is the same.
Page 488 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 489 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR TRAVEL GEARS - CHANGE OIL Illustration Z25244: REMARK The breather filters for the travel gears are mounted inside the center frame and connected with extension hoses. 1. Remove drain plugs (4), filler plug (3) and oil level gauge (2). Check breather filter, mounted inside center frame, and clean as necessary.
Page 490 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 491 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL Legend for illustration Z 20696 Oil level gauge Oil filler plug Breather filter Oil drain plug Oil collector reservoir for adapter housings of hydraulic pumps for fan drives of radiator and hydraulic oil coolers Breather filter with oil level gauge...
Page 492 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 493 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR Change the Oil 1. Remove drain plug (4). 2. Remove gauge (1) and filler plug (2). 3. Remove breather filter (3), blow out with compressed air from inside to outside and re-install. 4.
Page 494 4.15 FIRE PREVENTION MAINTENANCE 4.15 FIRE PREVENTION...
Page 495 MAINTENANCE 4.15 FIRE PREVENTION PRECAUTIONS See illustration Z 19360 In order to prevent risks of possible fire break out observe the fol- lowing items: 1. Keep the excavator clean, especially from inflammable mate- rials. Clean the excavator after servicing the hydraulic system, engine and fuel system by means of a steam jet.
Page 496 4.16 WELD REPAIRS MAINTENANCE 4.16 WELD REPAIRS CAUTION Before carry out weld repairs, contact our Service Depart- ment EXCAVATORS in order to avoid improper welding pro- cedures. 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 Ser- vice Department as soon as possible.
Page 497 MAINTENANCE 4.16 WELD REPAIRS GENERAL INFORMATION Welding operations can cause damage to electronic components. (Computers, Control Units, Sensors etc.), in case the welding cur- rent goes through these units. Therefore protective measures are necessary before any weld repair is started. GENERAL PROTECTIVE MEASURES Observe the prevailing safety and fire prevention regulations.
Page 498 4.16 WELD REPAIRS MAINTENANCE...
Page 499 MAINTENANCE 4.16 WELD REPAIRS 4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE See illustration Z 20674 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.
Page 500 4.16 WELD REPAIRS MAINTENANCE...
Page 501 MAINTENANCE 4.16 WELD REPAIRS 4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT Legend for illustration Z 20675 Electrical cable connector of the end-line pressure switch for the central lubrication system Plug socket Protection cap for (2) Protection cap for (1) Switch box of the electronic bucket levelling system ”EBL”, (Special Equipment) Bucket position detector box for the ”EBL”...
Page 502 4.16 WELD REPAIRS MAINTENANCE...
Page 503 MAINTENANCE 4.16 WELD REPAIRS 4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE Legend for illustration Z 21788 Battery main switch keys Battery box cover underneath the cat walk Battery current sensor (auxiliary resistor) Cables for transmitting the battery charging current to the DC converter (E7) Location of battery current sensor (auxiliary resistor) (3)
Page 504 4.16 WELD REPAIRS MAINTENANCE...
Page 505 MAINTENANCE 4.16 WELD REPAIRS Electrical Units in Cab Base, illustration Z 22480 1. Switch off all circuit breakers on switch board "X2". 2. Disconnect all plugs on the programmable logic controller (2). 3. Remove the wiring harness connector from electronic pump control module (6).
Page 506 4.16 WELD REPAIRS MAINTENANCE...
Page 507 INTRODUCTION ................... 3 CONTENTS OF THE BINDER ......................4 DIVISION OF THE BINDER ....................... 5 DESIGNATED USE OF THE SHOVEL ....................6 DELIVERY OF THE SHOVEL ......................7 EXPLANATION OF ABBREVIATIONS ..................... 8 TABLE OF CONTENTS ........................9 SAFETY ...................... 15 SAFETY INSTRUCTIONS ........................
Page 508 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS ............88 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING ........192 3.5.1 A - HEATING ........................192 3.5.2 B - COOLING ........................193 3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING ....... 193 POWER HOUSE ..........................194 3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES ............
Page 509 CARTRIDGES ON POWER HOUSE ROOF ..............265 3.18 CENTRAL REFILLING SYSTEM ....................266 3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM ..........267 3.18.2 OPERATING THE HYDRAULIC SERVICE ARM ............. 269 3.18.3 RECEIVER PANEL WITH MONITOR BOX ..............271 3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS ... 3.19 SERVICE CRANE ..........................
Page 510 4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL ........309 4.6.6 MAINTENANCE OF THE ENGINES ................. 311 4.6.7 ENGINE FUEL FILTER LOCATIONS ................313 WHEN NECESSARY ........................314 4.7.1 ENGINE AIR CLEANER MAINTENANCE ................. 315 4.7.2 SWING CIRCLE TOOTHING LUBRICATION ..............319 4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS ......
Page 511 4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE ............459 4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES ....461 4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES ....463 4.13 EVERY 2000 OPERATING HOURS OR YEARLY ................ 464 4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER ......................

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