Page 1 15045 and up SERIAL NUMBER This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Germany GmbH. It is our policy to improve our products whenever it is possible and practical to do so. We reserve...
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
Personal SAFETY Operating SAFETY, and READY and EFFICIENT PERFORMANCE of 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 3.3.3 OPERATOR’S CONSOLE ....................81 3.3.4 INTERFACE PANEL FOR DIAGNOSTICS ................. 89 3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER ............91 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS ............92 3.4.1 INTRODUCTION ......................... 93 3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM ..........101 3.4.3 AUTOMATIC DISPLAY OF MESSAGES ................
Page 11 INTRODUCTION 1.6 TABLE OF CONTENTS 3.15 PARKING THE SHOVEL ....................... 263 3.16 STOPPING THE ENGINES ......................264 3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM ............ 267 3.17 OPERATION OF THE LUBRICATION SYSTEM ................268 3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT 3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”...
Page 12 1.6 TABLE OF CONTENTS INTRODUCTION MAINTENANCE ..................307 FOREWORD ..........................308 PRECAUTIONS FOR MAINTENANCE ..................309 FUEL AND LUBRICANTS ......................311 FILLING CAPACITIES ........................313 STANDARD TORQUE LIST ......................314 LUBRICATION AND MAINTENANCE SCHEDULE ..............315 4.6.1 INITIAL SERVICING ......................315 4.6.2 PERIODIC SERVICING INTERVALS ................
Page 13 INTRODUCTION 1.6 TABLE OF CONTENTS 4.10.6 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT ........381 4.10.7 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL ..383 4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL ..........385 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY ..............386 4.11.1 BATTERIES - CHECK FLUID LEVEL ................
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.
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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 REMARK If the operator’s cab is equipped with external metal sun visors, disengage the four catches and push out the sun visor panel. Release lever for hinged railing bar (3) Hinged railing bar Rigidly mounted emergency escape ladder.
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. Z25499 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 25199 NOTICE The Operator’s cab is equipped with an integrated Falling Object Protective Structure (FOPS) that meets the require- ments of ISO 3449. Any modifications on the steel structure of the cab are inadmissible. Repairs on the FOPS must only be carried out by specialists having the authorization for repair work on Falling Object Protective Structures and in accordance with the manufacturer’s repair instructions.
Page 56 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 57 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z25200 Top View of Operator’s Cab Co-driver’s seat, refer to page 62 for more information Windshield washer reservoir, refer to page 59 for more infor- mation. Washbasin with water tap Refrigerator box Portable fire extinguisher located behind the Operator’s seat.
Page 58 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 59 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 60 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 61 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 62 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 63 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL This page left intentionally blank...
Page 64: Engine Oil Management System
3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.7 ENGINE OIL MANAGEMENT SYSTEM...
Page 65 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 66 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 67 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 68 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
Page 69 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 70 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 71 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 72: Operator's Cab - Controls
3.3 OPERATOR’S CAB - CONTROLS OPERATION OPERATOR’S CAB - CONTROLS 3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...
Page 73 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 74 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 75 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 76: Controls With Bottom Dump Bucket Attachment
3.3 OPERATOR’S CAB - CONTROLS OPERATION 3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT...
Page 77 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 78 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 79 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 80 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 81: Operator's Console
OPERATION 3.3 OPERATOR’S CAB - CONTROLS 3.3.3 OPERATOR’S CONSOLE Legend for illustration Z25500 Analog gauges, see page 83 for more information Text display with key board of the Electronic Control and Monitoring System (ECS). Refer to page 92 for more information. Ashtray Switch board, see page 83 for more information Switch for adjustment of left and right cab mirror...
Page 82 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 83 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Control Panel Legend for illust. Z25501 NOTICE The items (A, B, C, D and E) are part of the Elec- tronic Monitoring and Control System, refer to page 92 for more information. The screen (A) displays the condition of the machine, the maintenance status, and messages for the operator and service man.
Page 84 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 85 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Switch Board Legend for illust. Z25501 (18) Switch, cab ventilation blower. Blower runs with low speed, even with switch in -0- position. (Cab pres- surizing prevents ingress of dust). (19) Switch, mirror heating (20) Enable switch for hydraulic service arm operation.
Page 86 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 87 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Switch Board (continued) Legend for illust. Z25501 (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 88 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 89: Interface Panel For Diagnostics
OPERATION 3.3 OPERATOR’S CAB - CONTROLS 3.3.4 INTERFACE PANEL FOR DIAGNOSTICS Legend for illust. Z25502 Interface panel Portable fire extinguisher. Observe the local Fire Prevention Regulations in regard to number, size and location of portable fire extinguishers. Make sure the fire extinguisher is always charged and ready for use.
Page 90 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
Page 91: Control Module For Auxiliary Cab Heater
OPERATION 3.3 OPERATOR’S CAB - CONTROLS 3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER Special Equipment Legend for illust. Z25502 Control module for the engine independent auxiliary cab heater. This module is used for switching ON and OFF the auxiliary cab heater during operation of the shovel with the Diesel engines running, and for pre-selec- tion of heater start times and duration of heating periods.
Page 92: Electronic Monitoring And Control System Ecs
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION ELECTRONIC MONITORING AND CONTROL SYSTEM...
Page 93: Introduction
OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 3.4.1 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 Z25237 2. SERVICE FUNCTIONS operated with KEY GROUP (D) and KEY SWITCH (C) TEXT DISPLAY and KEY BOARD 1.1 Text Display (A)
Page 94 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 95 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS SERVICE FUNCTIONS operated with KEY GROUP (D) and KEY SWITCH (C), illustration Z25237, 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 96 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 97 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Legend for illust. Z25237 Display with basic information Key board with 8 keys. For the function of the keys refer to page 99. (C)) Key operated switch for enabling access to the INPUT-OUTPUT levels and input of operational data.
Page 98 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 99 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. MESSAGE Acknowledgement of changed settings.
Page 100 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 101: Operating The Electronic Monitoring System
OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM 1.0 TEXT DISPLAY (A) with integrated KEY BOARD (B) illust. Z25237 After switching on the Shovel’s key operated main switch, the fol- lowing introductory messages will be displayed on screen (A): .
Page 102 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 103 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 104 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 105: Automatic Display Of Messages
OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 3.4.3 AUTOMATIC DISPLAY OF MESSAGES 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” or a present maintenance inter- val message.
Page 106 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 107 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 108 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 109 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 172 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 110 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 111 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 112 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 113 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS TEXT DISPLAY (A), illust. Z25237 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 114 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 115 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 116 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 117 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Display the Contents of Record (PROTOCOL) Memory, illust. Z25237 Press to display Protocol memory. Last entry of the protocol memory will Fault message going be displayed first. Higher numbers indicating older entries. Display: PROTOCOL entry no: 1 status : going message : 716...
Page 118 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 119 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Display the Contents of Statistics Memory, illust. Z25237 Press to display statistics memory. Display: STATISTICS Appeared: 4 = 80.0% Error : 644 Elapsed : 00:02:40 = 100.0% Press to leaf through all recorded messages. DOWN Example: Indication in percent how often the...
Page 120 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 121 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 DATA OUT DOWN Print from the last >...
Page 122 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 123 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 124 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 125 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 126 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 127 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 128 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 129: Menu Control And Service Functions
OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 3.4.4 MENU CONTROL AND SERVICE FUNCTIONS Menu Control operated with Key Switch (C) and Key Group (D), illust. Z25237 The menu controls are structured hierarchically. The highest-level menu is designated ”LEVEL 0” and is accessed by depressing the ”RET”...
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 (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 132 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 133 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 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 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 (Z25242).
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 Manual actuation Mode of the Lubrication Systems with Service Key The manual actuation mode is useful for testing the electrical and hydraulic functions of the lubrication systems. The pause time is reduced to 30 seconds and the holding time to 15 seconds per- mitting rapid sequences of lubrication cycles.
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 Setting of Operational Data, menu item Service *SETTINGS* Example: Changing the hydraulic oil viscosity grade When changing the hydraulic oil, the viscosity grade of the new oil has to be entered in the appropriate ”Service/Settings”...
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 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 142 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 143 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 144 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 145 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 146 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 147 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 148 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 149 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 150 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 151 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 152 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION...
Page 153 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 154 in sequence of their Menu Levels.
Page 154: Menu Control List
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION 3.4.5 MENU CONTROL LIST Level 0: Cockpit - Display # no messages / messages Date M1 *1) 1/min: Time M2 *2) 1/min: - 0 - Gear oil (< °C) M1 : °C - 0 - Gear oil (<...
Page 155 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 156 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 157 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 158 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 4: Service / Settings / CENTRAL LUBRICATION SYSTEM (CLS) - 4 - Settings * CONDITION INDICATION * - 4 - Settings (minutes) * PAUSE TIME : * - 4 - Settings * LUBE CYCLE COUNTER : * Level 5: Service / Settings / CLS / CONDITION INDICATION...
Page 159 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 4: Service / Settings / SWING RING GEAR LUBE SYSTEM (SLS) - 4 - Settings * CONDITION INDICATION * - 4 - Settings (minutes) * PAUSE TIME : * - 4 - Settings * LUBE CYCLE COUNTER : * Level 5: Service / Settings / SLS / CONDITION INDICATION Pressure switch B46 : pump ON Y9 :...
Page 160 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 161 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 162 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 163 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 164 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): S10 (E8.8): S11.1 (E8.7): S11.2 (E13.7): S11.3 (E13.8): (E2.7): S24 (E5.3): (E5.6): S27 (E8.2):...
Page 165 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 3: Inputs - Outputs / DIGITAL-OUTPUTS -3- * K122 RELAY STAB. CURRENT SUPPLY * -3- * K164-1 RELAY ENGINE OIL TANK 1 EMPTY * -3- * K164-2 RELAY ENGINE OIL TANK 2 EMPTY * -3- * K197 LOWER WINDSCREEN WIPER SLOW * -3- * K198 LOWER WINDSCREEN WIPER FAST * -3- * K199 UPPER WINDSCREEN WIPER SLOW *...
Page 166 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 167 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / K50 RELAY BUCKET CUT-OFF -4- Output signals OPERATE KEY SWITCH -4- Relay bucket cut-off | 0 | 1 | K50 (A1.5): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / K93-1 RELAY SHUTDOWN 1 -4- Output signals OPERATE KEY SWITCH...
Page 168 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / K164-2 RELAY ENGINE OIL TANK 2 EMPTY -4- Output signals OPERATE KEY SWITCH -4- Relay engine oil tank 2 empty | 0 | 1 | K164-2 (A7.8): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / K197 RELAY LOWER WINDSCREEN WIPER SLOW...
Page 169 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y6a-1 VALVE FAN DRIVE 1 OIL COOLER (minimum speed) -4- Output signals OPERATE KEY SWITCH -4- Valve fan drive 1 oil cooler | 0 | 1 | Y6a-1 (A3.1): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y6a-2 VALVE FAN DRIVE 2 OIL COOLER...
Page 170 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y14a-1 VALVE FAN DRIVE 1 RADIATOR (minimum speed) -4- Output signals OPERATE KEY SWITCH -4- Valve fan drive 1 radiator | 0 | 1 | Y14a-1 (A3.5): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y14a-2 VALVE FAN DRIVE 2 RADIATOR...
Page 171 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y53-1 Y53-2 GEAR OIL COOLER 1 / 2 BACK - PRESSURE -4- Output signals OPERATE KEY SWITCH -4- Cooler 1 Y53-1 (A13.3): | 0 | 1 | Cooler 2 Y53-2 (A13.4): Level 4: Inputs - Outputs / DIGITAL-OUTPUTS / Y101 VALVE OIL COOLER BACK-PRESSURE -4- Output signals...
Page 172: Fault And Information Message List
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION 3.4.6 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 173 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS Fault and Information Message List GROUP 1Fault Message Texts of message pages No. 500 - 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 174 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 175 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 176 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 177 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 178 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 179 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS GROUP 2Fault 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 180 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 181 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 182 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 183 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 184 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 185 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 186 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 187 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 188 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 189 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 190 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 191 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 192 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION GROUP 3 Information Message Texts of message pages No. 1310 - 1319 will be stored Information No. 1310: (1311) ? 250 h Maintenance performed Information No. 1312: (1313) ? 500 h Maintenance performed Information No.
Page 193 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS GROUP 4 Information Message Texts of message pages No. 1320 - 1535 will not be stored Information No. 1320: # Hydraulic oil not at operating temp. ! (1321) Operate with reduced power ! Information No.
Page 194 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Information No. 1344: # Messages switched OFF (1345) Information No. 1346: (1347) Information No. 1348: # Trucks : @ C05 (1349) # Pilot control switched OFF. Information No. 1350: Safety lever in locked position or ladder end (1352) switch closed or service arm switch closed.
Page 195 OPERATION 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS # Central lube system grease container on Information No. 1382: reserve. (1384) Replace or fill grease container. # Hydraulic oil below operating temperature! Information No. 1386: Pre-heat hydraulic oil or warm up at low idle (1388) speed and reduced power.
Page 196 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS OPERATION Information No. 1426: # SERVICE: Central lubrication system. (1428) Information No. 1434: # SERVICE: Swing ring gear lubrication system. (1436)
Page 197 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 198: Operating The Heater, Ventilation And Air Conditioning
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING OPERATION OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING Digital Display Air Flow Control For defrosting the windshield close the slide in the seat base. The whole air flow is now directed to the windshield. To direct the air flow to your feet, open the slide in the seat base.
Page 199 OPERATION 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...
Page 200 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING OPERATION...
Page 201: Auxiliary Heater For Operator's Cab
OPERATION 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 3.5.1 AUXILIARY HEATER FOR OPERATOR’S CAB Special Equipment REMARK The auxiliary cab heater is located in the compartment below the stair to the operator’s cab. View A-A shows the arrangement of components and the flow of water, fuel and air. Legend for illustration Z25357 Fuel tank Stair to operator’s cab...
Page 202: Machinery House
3.6 MACHINERY HOUSE OPERATION MACHINERY HOUSE...
Page 203: Emergency Engine Shutdown Switches
OPERATION 3.6 MACHINERY HOUSE 3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES Legend for illustration Z25238 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 204 3.6 MACHINERY HOUSE OPERATION...
Page 205: Safety Switch For Maintenance
OPERATION 3.6 MACHINERY HOUSE 3.6.2 SAFETY SWITCH FOR MAINTENANCE Legend for illustration Z25238 Maintenance safety switch for start prevention of the engines CAUTION Before beginning any maintenance operations set the safety switch (6) to "0" position to prevent starting of the engines during maintenance.
Page 206 3.6 MACHINERY HOUSE OPERATION...
Page 207: Control And Filter Panel Of Rear- And Front Power Unit
OPERATION 3.6 MACHINERY HOUSE 3.6.3 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 208: Electrical Equipment In Cab Base
3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION ELECTRICAL EQUIPMENT IN CAB BASE...
Page 209: Standard Components In Cab Base
OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE 3.7.1 STANDARD COMPONENTS IN CAB BASE REMARK On shovels equipped with electrical pre-heating systems there are additional components in the cab base. Refer to page 219 for more information. WARNING The cab base may contain high tension electrical appli- ances.
Page 210 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 211: Switch Board (X2) In Cab Base
OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE 3.7.2 SWITCH BOARD (X2) IN CAB BASE Legend for illustration Z25505 Emergency By-pass switch for the shutdown func- (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 212 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 213 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 Z25505 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 214 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 215 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 216 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 217 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 218 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 219: Components Of Electrical Preheating System In Cab Base
OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE 3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE WARNING The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff only. General The preheating system is a special equipment and can be installed in the factory or locally at site.
Page 220 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
Page 221 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Components of Electrical Preheating System in Cab Base (continued) WARNING Be sure to switch off main switch (2), illust. Z25358 and to shut down the generator set or to disconnect the power sup- ply cable from external power source before working on any part of the heating system.
Page 222: Preheating Systems For Oil, Coolant And Batteries
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES OPERATION PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES...
Page 223 OPERATION 3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES Engine Coolant and Engine Oil Reserve Tank Heatings Legend for illustration Z 22553 Coolant heating for engine, vertically mounted on inside of counter-weight. Control box for coolant heating Switch, coolant heater ON/OFF. Indicator light, coolant heating ON, Water pump with motor Coolant heating element and tank...
Page 224 3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES OPERATION...
Page 225 OPERATION 3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES 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. Indicator light, coolant heating ON, (16) Coolant hoses, preheated coolant to the engine.
Page 226 3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES OPERATION...
Page 227 OPERATION 3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES Hydraulic Oil and PTO Gear Oil Heatings 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 228: Checks Before Starting The Engines
3.9 CHECKS BEFORE STARTING THE ENGINES OPERATION CHECKS BEFORE STARTING THE ENGINES...
Page 229 OPERATION 3.9 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 230 3.9 CHECKS BEFORE STARTING THE ENGINES OPERATION...
Page 231 OPERATION 3.9 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 232 3.9 CHECKS BEFORE STARTING THE ENGINES OPERATION...
Page 233 OPERATION 3.9 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 234: Starting The Engines
3.10 STARTING THE ENGINES OPERATION 3.10 STARTING THE ENGINES...
Page 235 OPERATION 3.10 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 236 3.10 STARTING THE ENGINES OPERATION...
Page 237: Starting Procedure
OPERATION 3.10 STARTING THE ENGINES 3.10.1 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. REMARK Start the engines with the safety lock lever (13), illustration Z25492 in the fully rear LOCKED position.
Page 238 3.10 STARTING THE ENGINES OPERATION...
Page 239 OPERATION 3.10 STARTING THE ENGINES REMARK Never operate the starter longer than 30 seconds at a time in order to avoid damage. If the engine does not start within the first 30 seconds, wait 2 minutes before cranking again. 8. As soon as the engines are running, check display (3) for messages.
Page 240 3.10 STARTING THE ENGINES OPERATION...
Page 241 OPERATION 3.10 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 242 3.10 STARTING THE ENGINES OPERATION...
Page 243 OPERATION 3.10 STARTING THE ENGINES Messages displayed with hydraulic oil too cold: Hydraulic oil far below operating temp. Fault 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 244 3.10 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 SL 0851 *1) - 32 10 - 85 SL 0851 *2) - 34...
Page 245: Moving The Shovel
OPERATION 3.11 MOVING THE SHOVEL 3.11 MOVING THE SHOVEL 3.11.1 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 246 3.11 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 247 OPERATION 3.11 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 248: Travelling Instructions
3.11 MOVING THE SHOVEL OPERATION 3.11.2 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 249: Slewing And Braking The Superstructure
OPERATION 3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE 3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE 3.12.1 SLEWING THE SUPERSTRUCTURE MACHINES WITH "EURO" CONTROL Legend for illustration Z25222 ”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 250 If the parking brake has been used for emergency stop- ping, it is necessary to shut down the Excavator and to have the parking brake of each swing gear inspected and repaired if necessary. Contact your Komatsu dealer for support.
Page 251 OPERATION 3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE Switch Positions, illustration Z25223 ”0” Parking brake OFF ”1” Parking brake ON Applying the Parking Brake Pull out toggle switch (4) against spring force and move down to position ”1”. Releasing the Parking Brake Move up toggle switch (4) to position ”0”.
Page 252: Working With The Attachment
3.13 WORKING WITH THE ATTACHMENT OPERATION 3.13 WORKING WITH THE ATTACHMENT 3.13.1 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 253: Machines Equipped With "Kmg" Control System
OPERATION 3.13 WORKING WITH THE ATTACHMENT 3.13.2 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 254: Bottom Dump Bucket
3.13 WORKING WITH THE ATTACHMENT OPERATION 3.13.3 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 255: Drop Ball Operation
OPERATION 3.13 WORKING WITH THE ATTACHMENT 3.13.4 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 256 3.13 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 257 OPERATION 3.13 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 258: Combined Operation Cycles
3.13 WORKING WITH THE ATTACHMENT OPERATION 3.13.5 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 259 OPERATION 3.13 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 260: Working Instructions
3.14 WORKING INSTRUCTIONS OPERATION 3.14 WORKING INSTRUCTIONS 3.14.1 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 261 OPERATION 3.14 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 262 3.14 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 263: Parking The Shovel
OPERATION 3.15 PARKING THE SHOVEL 3.15 PARKING THE SHOVEL Park the machine at a safe place on level and solid ground. Lower the working attachment onto the ground in a position as shown on the oil level plate at the hydraulic oil reservoir. Stop the engines and relieve the pressure in the hydraulic system, see page 267 for more information.
Page 264: Stopping The Engines
3.16 STOPPING THE ENGINES OPERATION 3.16 STOPPING THE ENGINES...
Page 265 OPERATION 3.16 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 266 3.16 STOPPING THE ENGINES OPERATION...
Page 267: Relieve Pressure In The Hydraulic System
OPERATION 3.16 STOPPING THE ENGINES 3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 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.
Page 268: Operation Of The Lubrication System
3.17 OPERATION OF THE LUBRICATION SYSTEM OPERATION 3.17 OPERATION OF THE LUBRICATION SYSTEM 3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT The central lubrication system works automatically as soon as the engine is running. The ECS System monitors the function of the central lubrication system.
Page 269 OPERATION 3.17 OPERATION OF THE LUBRICATION SYSTEM ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM Manual actuation Mode of the Lubrication System with Service Key The manual actuation in the Service mode is useful for testing the electrical and hydraulic functions of the of the lubrication system. The pause time is reduced to 30 seconds and the holding time to 15 seconds permitting rapid sequences of lubrication cycles.
Page 270: Swing Circle Pinion Lubrication System "Sls
3.17 OPERATION OF THE LUBRICATION SYSTEM OPERATION 3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” This system works automatically as soon as the engine is run- ning. The ECS System monitors the function of the swing circle lubrication system. Trouble conditions of the lubrication system are indicated through fault messages on ECS display (A).
Page 271 OPERATION 3.17 OPERATION OF THE LUBRICATION SYSTEM SWING CIRCLE LUBRICATION SYSTEM ”SLS” Manual actuation Mode of the Lubrication System with Ser- vice Key The manual actuation in the Service mode is useful for testing the electrical and hydraulic functions of the lubrication system. The pause time is reduced to 30 seconds and the holding time to 15 seconds permitting rapid sequences of lubrication cycles.
Page 272: Fire Detection And Suppression System
3.18 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION 3.18 FIRE DETECTION AND SUPPRESSION SYSTEM (Special Equipment)
Page 273 OPERATION 3.18 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 274 3.18 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...
Page 275: High Level Alarm "Fire
OPERATION 3.18 FIRE DETECTION AND SUPPRESSION SYSTEM 3.18.1 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 276 3.18 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...
Page 277: Indication Of Operational Modes At Control Module, After Automatic Actuation Of The Fire Suppression System
OPERATION 3.18 FIRE DETECTION AND SUPPRESSION SYSTEM 3.18.4 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 278 3.18 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...
Page 279: Location Of The Extinguishing Agent Tank Assemblies And Expellant Gas Cartridges On Power House Roof
OPERATION 3.18 FIRE DETECTION AND SUPPRESSION SYSTEM 3.18.5 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 280: Transfer Pump For Hydraulic Oil
3.19 TRANSFER PUMP FOR HYDRAULIC OIL OPERATION 3.19 TRANSFER PUMP FOR HYDRAULIC OIL (SPECIAL EQUIPMENT)
Page 281: Operating The Transfer Pump
OPERATION 3.19 TRANSFER PUMP FOR HYDRAULIC OIL 3.19.1 OPERATING THE TRANSFER PUMP Legend for illust. Z25265 REMARK The illustration shows the transfer pump arrangement viewed from center of the platform. Cock for suction oil reservoir (12) Cock for return oil collector pipe (13) Cock for back-pressure valve pipe (15) C - Closed O - Open...
Page 282 3.19 TRANSFER PUMP FOR HYDRAULIC OIL OPERATION...
Page 283: Functions Of The Transfer Pump
OPERATION 3.19 TRANSFER PUMP FOR HYDRAULIC OIL 3.19.2 FUNCTIONS OF THE TRANSFER PUMP A - Transfusing oil from the suction oil reservoir (12), illustra- tion Z25265 into the main oil reservoir. Necessary for evacua- tion of the suction oil reservoir, when changing the hydraulic oil (main oil reservoir will be evacuated via service arm con- nector, see page 286 for details).
Page 284 3.19 TRANSFER PUMP FOR HYDRAULIC OIL OPERATION...
Page 285 OPERATION 3.19 TRANSFER PUMP FOR HYDRAULIC OIL A - Pumping the oil from the Suction Oil Reservoir (12) into the Main Oil Reservoir (continued) 7. The suction oil reservoir and the suction hoses are filled, when bubble free oil flows out at the vent plug openings on each main pump.
Page 286: Central Refilling System
3.20 CENTRAL REFILLING SYSTEM OPERATION 3.20 CENTRAL REFILLING SYSTEM...
Page 287: Systems Connected To The Refilling System
OPERATION 3.20 CENTRAL REFILLING SYSTEM 3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM The following systems are connected to the receiver panel (5) of service arm (3), illust. (Z25495): 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 288 3.20 CENTRAL REFILLING SYSTEM OPERATION...
Page 289: Operating The Hydraulic Service Arm
OPERATION 3.20 CENTRAL REFILLING SYSTEM 3.20.2 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. (Z25495) to ON position ”1”. 3.
Page 290 3.20 CENTRAL REFILLING SYSTEM OPERATION...
Page 291: Receiver Panel With Monitor Box
OPERATION 3.20 CENTRAL REFILLING SYSTEM 3.20.3 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 292 3.20 CENTRAL REFILLING SYSTEM OPERATION...
Page 293 OPERATION 3.20 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 294 3.20 CENTRAL REFILLING SYSTEM OPERATION...
Page 295 OPERATION 3.20 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 296 3.20 CENTRAL REFILLING SYSTEM OPERATION...
Page 297: Refillable Grease Containers Of The Automatic Lubrication Systems
OPERATION 3.20 CENTRAL REFILLING SYSTEM 3.20.4 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 298: 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 299: Transportation And Lifting Of The Shovel
3.22 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. 3.22.1 DISASSEMBLING OF THE SHOVEL The Shovel is being transported disassembled into its main com- ponents.
Page 300: 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 301: Shovel Storage
OPERATION 3.24 SHOVEL STORAGE 3.24 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 302: One Month Repetitive Service Period
3.24 SHOVEL STORAGE OPERATION 3.24.2 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 303: Preparing For Operation
OPERATION 3.24 SHOVEL STORAGE 3.24.4 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 304: Trouble Shooting
3.25 TROUBLE SHOOTING OPERATION 3.25 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 305: Hydraulic System
OPERATION 3.25 TROUBLE SHOOTING 3.25.2 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 306: Final Drives And Swing Gear
3.25 TROUBLE SHOOTING OPERATION 3.25.3 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 3.25.4 CRAWLER TRACKS Wrong track tension Track roller loose or out of alignment Excessive track wear Track shoes loose...
Page 307: Maintenance
4. MAINTENANCE...
Page 308: 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 309: 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 15. Park the Excavator at a safe place on level ground. Proceed according to the instructions on page 263 ”Parking the Excavator”.
Page 310 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 311: Fluids And Lubricants
MAINTENANCE 4.3 FLUIDS AND LUBRICANTS FLUIDS AND LUBRICANTS 4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES Ambient Temperature Lubrication Point Lubricant ° Hydraulic System (pre-heated) Shell Tellus Arctic Oil 32 NG - 50 to + 35 Travel Gears Shell Omala HD 220 All seasons Final Drives Shell Omala HD 220...
Page 312: Fluids And Lubricants For Moderate And Hot Climates
4.3 FLUIDS AND LUBRICANTS MAINTENANCE 4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES Ambient Point of Viscosity Quality Grades Lubricant Temperature Lubrication Grades DIN/API °C Refer to page 312 and to the motor maintenance manual for Motors specifications. - 20 to + 11 Hydraulic oil -14 to + 21 “HLP or...
Page 313 MAINTENANCE 4.3 FLUIDS AND LUBRICANTS 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 314 4.3 FLUIDS AND LUBRICANTS MAINTENANCE...
Page 315 MAINTENANCE 4.3 FLUIDS AND LUBRICANTS...
Page 316: Filling Capacities
4.4 FILLING CAPACITIES MAINTENANCE 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 317: Standard Torque List
MAINTENANCE 4.5 STANDARD TORQUE LIST 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 318: Lubrication And Maintenance Schedule
4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE 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 319: Periodic Servicing Schedule
MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE 4.6.3 PERIODIC SERVICING SCHEDULE Service Intervals Service Point Service Engine Air Cleaners Maintenance page 335 Immediately apply grease if bare Swing circle toothing page 339 spots are visible Fill grease containers When necessary Automatic lubrication systems page 341 Clean or replace filter elements Track rollers...
Page 320 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE Service Intervals Service Point Service Refrigerant compressor Check drive belt tension page 379 Signal horn compressor Lubricate page 381 Oil cooler fan bearings and Check for leakages and clean page 381 Radiator fan bearing breather filters Clean in-line grease screens Automatic lube systems...
Page 321 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Service Intervals Service Point Service Check for correct tightening High strength bolt connections page 407 torque and security - Replace return and pressure filter elements - Clean or replace high pressure Hydraulic system filter elements page 465 - Replace breather filter ele- ments...
Page 322 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE Service Intervals Service Point Service - Change oil (*) Hydraulic system - Replace suction strainers (*) page 491 - Replace pulsation damper Every 2000 operating hours or yearly. Emergency escape ladder Inspect page 503 Fire detection and actuation sys- Maintenance Swing gears and Motor adapter...
Page 323 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Lubrication Chart...
Page 324 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE 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 325 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE...
Page 326: Extended Service Intervals For Engines With Engine Oil Management System
4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE 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 327 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE...
Page 328: Extended Service Intervals For Engines With Engine Oil Management System
4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE 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 329 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE...
Page 330 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE 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 331: Maintenance Of The Engines
MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE 4.6.6 MAINTENANCE OF THE ENGINES All maintenance has to be carried out in accordance with the sep- arate Engine Operation and Maintenance Manual. REMARK Service the Eliminator Oil Filter according to the separate Service Bulletin "Eliminator Filter" filed in volume 2 Binder.
Page 332 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...
Page 333: Engine Fuel Filter Locations
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 334: When Necessary
4.7 WHEN NECESSARY MAINTENANCE WHEN NECESSARY...
Page 335: Engine Air Cleaner Maintenance
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 336 4.7 WHEN NECESSARY MAINTENANCE...
Page 337 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 338 4.7 WHEN NECESSARY MAINTENANCE...
Page 339: Swing Circle Toothing Lubrication
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 340 4.7 WHEN NECESSARY MAINTENANCE...
Page 341: Automatic Lubrication Systems Fill Grease Containers
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 342 4.7 WHEN NECESSARY MAINTENANCE...
Page 343 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 344 4.7 WHEN NECESSARY MAINTENANCE...
Page 345: Track Rollers And Guide Wheels - Replace Floating Seals
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 346 4.7 WHEN NECESSARY MAINTENANCE...
Page 347: Cold Starting Aid, Replace Fluid Cylinder
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 348: Every 10 Operating Hours Or Daily
4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE EVERY 10 OPERATING HOURS OR DAILY...
Page 349: Walk - Around Inspection
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 350 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 351 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 352 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 353 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 354 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 355 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 356 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 357: Air Cleaner - Clean Pre-Cleaner
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 358 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
Page 359: Radiators - Check Coolant Level
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 360: Every 50 Operating Hours Or Weekly
4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE EVERY 50 OPERATING HOURS OR WEEKLY...
Page 361: Swing Gears And Motor Adapter Housings - Check Oil Levels
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 362 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 363 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 364 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 365: Travel Gears, Motor Adapter Housings And Final Drives Check Oil Levels
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 366 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 367 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 368 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 369 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 370 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 371: Pto's (Pump Distributor Gears) And Oil Reservoir - Check Oil Level
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 372 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 373 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 374 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 375: Hydraulic Access Ladder - Check Safety Sensor
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 376 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
Page 377: Hydraulic Oil Coolers - Inspect And Clean If Necessary
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 378: Every 250 Operating Hours Or Monthly
4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY...
Page 379: Air Conditioning Compressor - Check Drive Belt Tension
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 205 for the location of the maintenance safety switch.
Page 380 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
Page 381: Signal Horn Compressor - Lubricate
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 382 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
Page 383: Automatic Lubrication Systems - Clean In-Line Grease Filter And Check Breather Filter
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 384 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
Page 385: Cab Air Cleaner - Clean Or Replace Filter Element
MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.6 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT Legend for illustration Z25455 Pre-cleaner Air cleaner housing located on cab base Air cleaner mounting bolts Clean pre-cleaner dust bowl 1. Check the dust level in bowl (1), if the level is near the Max. marking remove and clean the dust bowl.
Page 386 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
Page 387: Air Conditioning For Operator's Cab - Check Refrigerant Level
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 388 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
Page 389: Windshield Washer System - Check Fluid Level
MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL Legend for illustration Z 25422 Water reservoir for windshield washer Filler cap with suction line Water pump for windshield washer Upper washer nozzle for windshield Water pump for windshield washer Lower washer nozzle for windshield Wiper motor for lower windshield wiper...
Page 390: Every 500 Operating Hours Or Quarterly
4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY...
Page 391: Batteries - Check Fluid Level
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 392 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 393: Flexible Drive Couplings - Check Oil Level
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 394 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 395: Fuel Tank - Drain Condensation
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 396 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 397: Crawler Track - Inspection
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 398 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 399 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 400 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 401 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 402 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 403: Ground Cables Of Engine And Alternator - Check For Correct Connection
MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY 4.11.5 GROUND CABLES OF ENGINE AND ALTERNATOR - CHECK FOR CORRECT CONNECTION Legend for illustration Z25498 Alternator seen from below RH member of engine carrier frame Ground strap from engine to the ground terminal of alternator (A) Ground cable from alternator (A) to RH member of engine carrier frame (B)
Page 404 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY MAINTENANCE...
Page 405: Ground Cable Of Operator's Cab - Check For Correct Connection
MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY 4.11.6 GROUND CABLE OF OPERATOR’S CAB - CHECK FOR CORRECT CONNECTION Legend for illustration Z25520 Ground cable fixing point inside the operator’s con- sole Ground cable fixing point in the cab base on the lower left mounting bolt of the (X2) switch board Ground cable from operator’s console to the lower left mounting bolt of the (X2) switch board...
Page 406: Every 1000 Operating Hours Or Every 6 Month
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...
Page 407: High Strength Bolt Connections - Check Torque Load
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 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 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 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 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 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 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 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) 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 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 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 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) 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 420 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 421 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 422 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 423 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 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) 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 426 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 427 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 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) 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 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 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 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) 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 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) 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 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) 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 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 High-Strength Bolt Connections (continued) Check tightening torque of the counterweight mounting bolts, illustration Z 21778A Bolt size SW * Tightening torque Reference No.: Grade Qty. (3) Mounting bolts 10.9 7500 * SW = Wrench size Re-tighten mounting bolts to their correct torque and replace missing or damaged bolts.
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 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 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 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 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 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 446 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 447 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 448 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 449 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 453. This tool will be provided by your Komatsu dealer. Measuring Device PN 92847640 Position Part name Part No.
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 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 452 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 453 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 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 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 456 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 457 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 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 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 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 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 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 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 464 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 465: Hydraulic System - Filter Service
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 466 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 467 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 468 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 469 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 470 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 471 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 472 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 473 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 474 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 475 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 476 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 477 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 264 in the operation section.
Page 478 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 479: Pto's (Pump Distributor Gears), Swing Gears And Travel Gears - Oil Sample Analysis
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 480 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 481: Signal Horn Compressor - Clean And Lubricate
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 482 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 483: Hydraulic Track Tensioning System - Check Pressure Accumulators
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 484 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 485: Water Filter - Replace Filter Cartridge
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 486 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 487: Hydraulic Oil Cooler - Inspect And Lubricate Door Hinges
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 488 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
Page 489: Machinery House Doors - Inspect And Lubricate Door Hinges
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 490: Every 2000 Operating Hours Or Yearly
4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY...
Page 491: Hydraulic System - Change Oil, Replace Suction Strainers And Pulsation Damper
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 492 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 493: Hydraulic System - Change Oil, Replace Suction Strainers And Pulsation Damper
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 494 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 495 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 496 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 497 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 498 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 499 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 500 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 501 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 502 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
Page 503: Emergency Escape Ladder - Inspection
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 504: Every 3000 Operating Hours However At Least Once A Year
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 505: Swing Gears And Motor Adapter Housing - Change Oil
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 506 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 507 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 508 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 509 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 510 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 511 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 512 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 513: Travel Gears, Motor Adapter Housings And Final Drives Change Oil
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 514 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 515 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 516 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 517: Pto (Pump Distributor Gear) - Change Oil
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 518 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
Page 519 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 520: Fire Prevention
4.15 FIRE PREVENTION MAINTENANCE 4.15 FIRE PREVENTION...
Page 521 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 522: Weld Repairs
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 523 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 524 4.16 WELD REPAIRS MAINTENANCE...
Page 525: Protective Measures Before Starting Weld Repairs On The Undercarriage
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 526 4.16 WELD REPAIRS MAINTENANCE...
Page 527: Protective Measures Before Starting Weld Repairs On The Loader Attachment
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 528 4.16 WELD REPAIRS MAINTENANCE...
Page 529: Protective Measures Before Starting Weld Repairs On The Superstructure
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 530 4.16 WELD REPAIRS MAINTENANCE...
Page 531: After Finishing The Repair Weldings On The Superstructure
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 532 4.16 WELD REPAIRS MAINTENANCE...
Page 533 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 534 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS ............92 3.4.1 INTRODUCTION ......................... 93 3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM ..........101 3.4.3 AUTOMATIC DISPLAY OF MESSAGES ................105 3.4.4 MENU CONTROL AND SERVICE FUNCTIONS .............. 129 3.4.5 MENU CONTROL LIST ..................... 154 3.4.6 FAULT AND INFORMATION MESSAGE LIST ..............
Page 535 3.17 OPERATION OF THE LUBRICATION SYSTEM ................268 3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT 3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” ..........270 3.18 FIRE DETECTION AND SUPPRESSION SYSTEM ..............272 3.18.1 HIGH LEVEL ALARM ”FIRE” .................... 275 3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE .....
Page 536 FOREWORD ..........................308 PRECAUTIONS FOR MAINTENANCE ..................309 FLUIDS AND LUBRICANTS ......................311 4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES ......311 4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES ......312 FILLING CAPACITIES ........................316 STANDARD TORQUE LIST ......................317 LUBRICATION AND MAINTENANCE SCHEDULE ..............
Page 537 BREATHER FILTER ......................383 4.10.6 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT ........385 4.10.7 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL ..387 4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL ..........389 4.11 EVERY 500 OPERATING HOURS OR QUARTERLY ..............390 4.11.1 BATTERIES - CHECK FLUID LEVEL ................

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Komatsu 15045 Operation & Maintenance Manual

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