Komatsu PC3000-6 Operation & Maintenance Manual
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Komatsu PC3000-6 Operation & Maintenance Manual

Komatsu PC3000-6 Operation & Maintenance Manual

Hydraulic mining shovel
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Operation & Maintenance
Manual

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  • Page 1 Operation & Maintenance Manual HYDRAULIC MINING SHOVEL  DQG XS 6(5,$/ 180%(5 7KLV PDWHULDO LV SURSULHWDU\ WR .RPDWVX 0LQLQJ *HUPDQ\ *PE+ DQG LV QRW WR EH UHSURGXFHG XVHG RU GLVFORVHG H[FHSW LQ DFFRUGDQFH ZLWK ZULWWHQ DXWKRUL]DWLRQ IURP .RPDWVX 0LQLQJ *HUPDQ\ *PE+ ,W LV RXU SROLF\ WR LPSURYH RXU SURGXFWV ZKHQHYHU LW LV SRVVLEOH DQG SUDFWLFDO WR GR VR :H UHVHUYH WKH ULJKW WR PDNH FKDQJHV RU DGG LPSURYHPHQWV DW DQ\ WLPH ZLWKRXW LQFXUULQJ DQ\ REOLJDWLRQ WR LQVWD VXFK FKDQJHV RQ SURGXFWV VROG SUHYLRXVO\...

  • Page 3: Introduction

    1. INTRODUCTION...

  • Page 4: Contents Of The Binder

    1.1 CONTENTS OF THE BINDER INTRODUCTION CONTENTS OF THE BINDER Assembled in this file are the Operation-, Lubrication- and Mainte- nance Manuals for your KOMATSU Hydraulic Mining Shovel.

  • Page 5: Division Of The Binder

    READY EFFICIENT PERFORMANCE your KOMATSU Hydraulic Mining Shovel. Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses.

  • Page 6: Designated Use Of The Shovel

    1.3 DESIGNATED USE OF THE SHOVEL INTRODUCTION DESIGNATED USE OF THE SHOVEL This machine has been manufactured in accordance with advanced and up-to-date technology standards including recog- nized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property.

  • Page 7: Delivery Of The Shovel

    In order to keep your Shovel in first-class operating condition use only genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee. SERVICE For all questions related to your Shovel please contact your local Service Center.

  • Page 8: Explanation Of Abbrevations

    1.5 EXPLANATION OF ABBREVATIONS INTRODUCTION EXPLANATION OF ABBREVATIONS 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 Text Monitoring System FGPS Front Guard Protective Structure FOPS Falling-Object Protective Structure Gear Lubricant...

  • 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 ABBREVATIONS ....................8 TABLE OF CONTENTS ........................
  • Page 10 1.6 TABLE OF CONTENTS INTRODUCTION 3.3.3 OPERATOR’S CONSOLE ....................79 ELECTRONIC TEXT MONITORING SYSTEM ETM ............... 86 3.4.1 INTRODUCTION ......................... 87 3.4.2 SYSTEM COMPONENTS ....................91 3.4.3 FUNCTIONS OF THE ETM SYSTEM ................. 93 3.4.4 DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY ......97 3.4.5 SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME .......
  • Page 11 INTRODUCTION 1.6 TABLE OF CONTENTS 3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM ........... 183 3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF ..............185 3.18 CENTRAL REFILLING SYSTEM ....................
  • Page 12 1.6 TABLE OF CONTENTS INTRODUCTION 4.6.2 PERIODIC SERVICING INTERVALS ................217 4.6.3 PERIODIC SERVICING SCHEDULE ................218 4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM ..........................225 4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL ........227 4.6.6 MAINTENANCE OF THE ENGINE ...................
  • Page 13 INTRODUCTION 1.6 TABLE OF CONTENTS 4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE ..............335 4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR AND TRAVEL GEARS - OIL SAMPLE ANALYSIS ......................... 349 4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE .......... 351 4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS ..4.12.6 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES ....
  • Page 14 1.6 TABLE OF CONTENTS INTRODUCTION...

  • Page 15: Safety

    2. SAFETY...

  • Page 16: Safety Instructions

    2.1 SAFETY INSTRUCTIONS SAFETY SAFETY INSTRUCTIONS 2.1.1 WARNINGS AND SYMBOLS The following signs and designations are used in the manual to designate in-structions of particular importance. WARNING Refers to orders and prohibitions designed to prevent injury or extensive damage. CAUTION Refers to special information and/or orders and prohibitions directed towards preventing damage.

  • Page 17: Organizational Measures

    SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.3 ORGANIZATIONAL MEASURES The Operation,- Lubrication and Maintenance Manual must always be at hand at the place of use of the machine, e. g. by stowing them in the box provided for such purpose. In addition to the Operation,- Lubrication and Maintenance Manual, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.
  • Page 18 2.1 SAFETY INSTRUCTIONS SAFETY Replace hydraulic hoses within stipulated and appropriate intervals even if no safety-relevant defects have been detected. Adhere to prescribed intervals or those specified in the Oper- ation,- Lubrication and Maintenance Manual for routine checks and inspections. For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indis- pensable.

  • Page 19: Selection And Qualification Of Personnel - Basic Responsibilities

    SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES Any work on and with the machine must be executed by reli- able personnel only. Statutory minimum age limits must be observed. Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set- up, maintenance and repair.

  • Page 20: Safety Instructions Governing Specific Operational Phases

    2.1 SAFETY INSTRUCTIONS SAFETY 2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES STANDARD OPERATION Avoid any operational mode that might be prejudicial to safety. Before beginning work, familiarize yourself with the surround- ings and circumstances of the site, such as obstacles in the working and travelling area, the soil bearing capacity and any barriers separating the construction site from public roads.
  • Page 21 SAFETY 2.1 SAFETY INSTRUCTIONS Always keep at a distance from the edges of building pits and slopes. Avoid any operation that might be a risk to machine stability. Never travel across slopes; always keep the working equip- ment and the load close to the ground, especially when trav- elling downhill.
  • Page 22 2.1 SAFETY INSTRUCTIONS SAFETY The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The mar- shaller giving the instructions must be within sight or sound of the operator. For carrying out overhead assembly work always use spe- cially designed or otherwise safety-oriented ladders and working platforms.

  • Page 23: Warning Of Special Dangers

    SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.6 WARNING OF SPECIAL DANGERS ELECTRIC ENERGY Use only original fuses and circuit breakers with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system. When working with the machine , maintain a safe distance from overhead electric lines.
  • Page 24 2.1 SAFETY INSTRUCTIONS SAFETY GAS, DUST, STEAM AND SMOKE Operate internal combustion engines and fuel operated heat- ing systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation. Observe the regulations in force at the respective site. Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

  • Page 25: Transporting And Towing -Recommissioning

    SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING The machine must be towed, loaded and transported only in accordance with the Operation,- Lubrication and Maintenance Manual. For towing the machine observe the prescribed transport position, admissible speed and itinerary. Use only appropriate means of transport and lifting gear of adequate capacity.
  • Page 26 2.1 SAFETY INSTRUCTIONS SAFETY LIGHTING The Shovel must only be operated when the operator has suffi- cient visibility in relation to the work area. Disturbing shady areas or dazzling effects must be avoided. If necessary, the Shovel must be retrofitted with lighting equip- ment (working lights) in order to ensure sufficient visibility condi- tions.
  • Page 27 SAFETY 2.1 SAFETY INSTRUCTIONS This page left intentionally blank...
  • Page 28 2.1 SAFETY INSTRUCTIONS SAFETY...

  • Page 29: Safety Harness In Conformity With En 361 (European Standard)

    SAFETY 2.1 SAFETY INSTRUCTIONS 2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) WARNING Always use the Safety Harness (1) in conjunction with strap type Fall Absorber (2), illust. (Z 20885) before mounting onto the loader attachment or other unsecured places of the Shovel.
  • Page 30 2.1 SAFETY INSTRUCTIONS SAFETY...
  • Page 31 SAFETY 2.1 SAFETY INSTRUCTIONS INSTRUCTIONS FOR USE Open the lock, lift the harness by the catch hook (C), the blue straps (leg straps J) are below. The harness is being put on just like a jacket. Pull the belly strap (E) through the lock, as shown on the illustration, and secure it.
  • Page 32 2.1 SAFETY INSTRUCTIONS SAFETY...
  • Page 33 SAFETY 2.1 SAFETY INSTRUCTIONS PRIOR TO USING THE HARNESS (1), THE WEARER SHALL Carry out a visual check of the system or component; correct functioning and perfect working order have to be assured. Make sure that the recommendations for use with other com- ponents of the system be observed in conformity with the instructions for use.
  • Page 34 2.1 SAFETY INSTRUCTIONS SAFETY...
  • Page 35 SAFETY 2.1 SAFETY INSTRUCTIONS INSTRUCTIONS FOR USE Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD) Within a fall-arrest system, the strap-type fall absorber (2) has to be used in conjunction with a safety harness (1) acc. to DIN EN 361.
  • Page 36 2.1 SAFETY INSTRUCTIONS SAFETY...

  • Page 37: Operation

    3. OPERATION...

  • Page 38: Foreword

    3.1 FOREWORD OPERATION FOREWORD This Operation Manual contains the instructions for correct opera- tion of your KOMATSU Mining Shovel. It should always be ready for use in the Operator’s cab. WARNING The information in this manual does not replace any safety rules or laws used in your area.

  • Page 39: Construction Of The Shovel

    OPERATION 3.2 CONSTRUCTION OF THE SHOVEL CONSTRUCTION OF THE SHOVEL 3.2.1 OVERALL VIEW Legend for illustration Z23073 Undercarriage (5A) Bottom dump bucket Superstructure Boom cylinders Boom Stick cylinders Stick Bucket cylinders Backhoe bucket Bucket opening cylinders...

  • 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 Z23074 Final drive, hub type travel gear Crawler carrier Track roller Carrier roller Guide wheel Travel motors Center frame Swing circle guard Hydraulically operated access ladder, see page 46 for more information (10) Light switch for access area lighting (11)
  • Page 42 3.2 CONSTRUCTION OF THE SHOVEL OPERATION SUPERSTRUCTURE - TOP VIEW...
  • Page 43 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z23075 Hydraulically operated access ladder, see page 46 for more information Stair to operator’s cab Operator’s cab door, see page 54 for more informa- tion Operator’s cab, see page 54 for more information Machinery house door, main access, see page 128 for more information Coolant radiator...
  • Page 44 3.2 CONSTRUCTION OF THE SHOVEL OPERATION MACHINERY HOUSE...
  • Page 45 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z23076 Side view from main control blocks (front) Top view Main hydraulic pumps (three tandem swash plate type pumps) Hydraulic oil cooler fan drive pump PTO lubrication pump Suction oil reservoir Control oil pump (pilot oil circuit) PTO (pump distributor gear) Elastic mounts...

  • 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 Z23077 Access ladder in lowered position Access ladder in upper position (Working position) Access ladder Light switch for access area lighting Pull chain for emergency lowering of the access ladder WARNING 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. (Z23077) Raise the ladder Enter the Shovel with ladder in fully lowered position (A). Start the engine. For starting procedure → See "STARTING THE ENGINE" on page 142. Go back to the ladder control switch (4B).

  • 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. Z 22461 Sliding window, serves for emergency exit Rigidly mounted emergency escape ladder Rope ladder. The upper end of the rope ladder is fixed onto the lower rung of the rigid escape ladder (2) by means of the fasteners (4), see detail (X).

  • Page 52: Emergency Engine Shutdown From Ground Man Or Operator Warning System

    3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...
  • Page 53 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Emergency Engine Shutdown System actuated from Ground Man (Special Equipment) Legend for illust. Z23078 Actuating chains for emergency shut down of the engine. To stop the engine, pull down one of the chains (1). Pull chain for emergency lowering of the access ladder 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 23080 Left View of Operator’s Cab Control switch for hydraulically operated access ladder Door fastener, engages into the door latch when the cab door is fully opened. Access door to the air filter of the operator’s cab Release lever inside the cab for door fastener (2) Portable fire extinguisher.
  • Page 56 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 57 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Operator’s Cab (continued) Legend for illust. Z 23018 Top View of Operator’s Cab Control switch for hydraulically operated access ladder Door fastener, engages into the door latch when the cab door is fully opened. Release lever inside the cab for door fastener (2) Operator’s console Safety lock lever...
  • Page 58 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 59 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Operator’s Seat Adjustment Before operating the Shovel adjust the seat and mirrors for Oper- ators maximum comfort, visibility, and complete control of the Shovel. Legend for illust. (Z 21420): Seat suspension adjustment (firm to soft ride) Height adjustment Seat depth adjustment Seat cushion tilt adjustment...
  • Page 60 3.2 CONSTRUCTION OF THE SHOVEL OPERATION Co-driver’s Seat Legend for illust. Z 24027 Co-driver’s seat Portable fire extinguisher Seat belt Cabinet door WARNING Use seat belt in accordance with the local safety regula- tions and laws. Check condition and fastening of the seat belt. Replace any worn or damaged part of the seat belt system.
  • Page 61 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL This page left intentionally blank...

  • Page 62: Engine Oil Management System

    3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.7 ENGINE OIL MANAGEMENT SYSTEM...
  • Page 63 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Engine Oil Management System (Special Equipment) The engine oil management system combines the automatic engine oil supply system “Reserve” and the oil burning system “Centinel” in connection with the “Eliminator” oil filtration sys- tem. Reserve System Oil Flow Schematic, illust.
  • Page 64 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 65 ON position. Turn starter switch and release. Once the correct fault code is identified, refer to the Master Repair Manual CENTINEL filed in volume 2 binder for fault code explanation, and inform your Komatsu Service Organization about the trouble con- dition.
  • Page 66 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 67 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Clearing Active Faults and Reset the Centinel System to Operational Condition Legend for illust. (Z 23085) The illustration shows the terminal configuration on the (X2) switch board in the cab base Calibration Plug for Engine Oil Quality Bridge wire for resetting the Centinel system to oper- ational condition Resetting of the Centinel system is necessary:...
  • Page 68 3.2 CONSTRUCTION OF THE SHOVEL OPERATION Oil Burning System “Centinel” combined with Oil Supply System “Reserve” Legend for illust. Z 21473 (schematic illustration) Engine oil reserve tank (10) Fuel/lube oil blend return to fuel tank Oil filters (11) System function indicator LED’s Pump unit (12) Oil level gauge...
  • Page 69 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Eliminator Engine Oil Filtration System Legend for illust. Z 21541 (schematic illustration) Oil inlet from engine (100%) Oil flow to engine oil pan (5%) Stainless steel filter removes particles as Oil outlet to engine (95%) small as 20 µm Centrifugal separator removes particles up to Backflush oil (5%) for cleaning the filter...

  • Page 70: Operator's Cab - Controls

    3.3 OPERATOR’S CAB - CONTROLS OPERATION OPERATOR’S CAB - CONTROLS 3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...
  • Page 71 Hydraulic Control System There are two control patterns of levers (1 and 2) available: ”EURO” control pattern and ”KMG” (Komatsu Mining Germany) control pattern Your Shovel is equipped with the EURO control pattern for levers (1 and 2). For more information → See "WORKING WITH THE ATTACHMENT"...
  • Page 72 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
  • Page 73 OPERATION 3.3 OPERATOR’S CAB - CONTROLS EURO Control Pattern Legend for illustration (Z 23086) Control lever for stick and swing machinery Control lever for boom and bucket Toggle switch for engine speed selection Low idle – High idle Push button for Truck counter. For counting loaded trucks press this button.

  • Page 74: Controls With Bottom Dump Bucket

    3.3 OPERATOR’S CAB - CONTROLS OPERATION 3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET...
  • Page 75 Hydraulic Control System There are two control patterns of levers (1 and 2) available: ”EURO” control pattern and ”KMG” (Komatsu Mining Germany) control pattern Your Shovel is equipped with the EURO control pattern for levers (1 and 2). For more information → See "WORKING WITH THE ATTACHMENT"...
  • Page 76 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
  • Page 77 OPERATION 3.3 OPERATOR’S CAB - CONTROLS EURO Control Pattern Legend for illustration (Z 22363) Control lever for stick and swing gear Control lever for boom and bucket Push button for deactivation of boom float position Push button for deactivation of stick float position Toggle switch for engine speed selection Low idle –...
  • Page 78 3.3 OPERATOR’S CAB - CONTROLS OPERATION...

  • Page 79: Operator's Console

    OPERATION 3.3 OPERATOR’S CAB - CONTROLS 3.3.3 OPERATOR’S CONSOLE Legend for illust. Z25073 Analogous gauges, see page 81 for more informa- tion Text display with key board of the Electronic Text Monitoring System “ETM”. Refer to page 86 for more information.
  • Page 80 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
  • Page 81 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Control Panel Legend for illust. Z 23088 Hydraulic oil temperature gauge Operating hour meter Fuel level gauge Ammeter Voltmeter Engine oil pressure gauge Engine coolant temperature gauge Text display of the Electronic Text Monitoring system ETM, refer to page 86 for operating instructions.
  • Page 82 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
  • Page 83 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Control Panel (continued) Legend for illust. Z 23088 (20) Enable switch for hydraulic service arm operation. Set this switch to ON position”1” before lowering the service arm. With this switch in ON position, the pilot control system is made inoperative and the hydraulic swing brake is applied.
  • Page 84 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
  • Page 85 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Rear Panel Controls Legend for illust. Z25074 Control unit for air conditioning and heating, see page 126 for more information. A - Plus key B - Minus key C - Digital display D - Selector keys and LED indication Radio Plug socket (X27) for download of ETM data from pro- tocol and statistics memory...

  • Page 86: Electronic Text Monitoring System Etm

    3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION ELECTRONIC TEXT MONITORING SYSTEM ETM...

  • Page 87: Introduction

    OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM 3.4.1 INTRODUCTION The ETM system with plaintext display provides continuous moni- toring of all Excavator functions and operating conditions. The ETM has the capability to cover a total amount of 60 different messages, the text messages can be selected in English or Ger- man language.
  • Page 88 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...
  • Page 89 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Function of the keys (1 to 8) of Keyboard (B): Text display of that page, which was selected from the Text store, Record memory or Statistics memory. Shifting to the mode -leaf through- of current messages. ME S S AGE Calls up the next text lines (shift between English and German) or the next pages (in the text mode)
  • Page 90 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...

  • Page 91: System Components

    OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM 3.4.2 SYSTEM COMPONENTS see illust. Z 23090 (A) Text Display Unit Plaintext messages Multi-lingual text display Text store for all available texts Record memory capacity for max. 1300 mes- sages Statistics memory for frequency and total time period of the messages (B) Key board with 8 keys Function of the keys, refer to page 89...
  • Page 92 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...

  • Page 93: Functions Of The Etm System

    OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Message Classification The 60 possible messages are classified as follows: Fault messages are stored in the record memory and also kept in the statistics memory. When these messages are dis- played, an acoustic signal is heard. Information messages are identified by the sign (#) in the upper LH corner of screen (A).
  • Page 94 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...
  • Page 95 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM NOTICE The steps for operating the ETM keyboard are indicated by the key symbols. Call up the Basic Display from any message If a fault condition occurs (e.g. message 21) it is possible to call up the basic display for information of current time or engine speed.
  • Page 96 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...

  • Page 97: Display The Contents Of The Record (Protocol) Memory

    OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM 3.4.4 DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY Press to display Protocol memory. PR O Last entry of the proto- col memory will be dis- Fault mes- played first. Higher sage going numbers indicating older entries.
  • Page 98 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...
  • Page 99 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Display the Contents of Record Memory Press to return to the last message text. PAGE NO ME S S AGE Display: PROTOCOL entry no: status: coming message: 2 date 14.06.05 at 16:20:00 Press to return to the basic display. S YS T E M Display the Contents of Statistics Memory Press to display statistics memory.
  • Page 100 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...
  • Page 101 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Print out Contents of Statistics Memory: 15.06.05 14: 36: 39 h: 1351:20 1/min: 1800 The complete statistics are now being printed out. S T A DAT A OU T Display: *******STATISTICS PRINTOUT****** Printing statistics table, please wait..NOTICE it is recommended to erase all entries in the statistics mem- ory with key switch (C) after each main service period in...
  • Page 102 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...
  • Page 103 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM STA START: Date STA PRINT: Date Operating hours:...h Good: Err.:...
  • Page 104 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...
  • Page 105 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Print out the last Entries of the Record (PROTOCOL) Memory 1st. Possibility - The last X Entries under consideration of all Messages X = desired number of the last entries e.g. 10 (the last 10 entries of 39 total entries) Press until the desired nos.
  • Page 106 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...
  • Page 107 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Change - over from English to German Language Six text lines are provided for each message. Use key 3 for changing the message text. DOWN Example Line 1: English $h: 1350:40 Gear lubrication out of Line 2: English function...
  • Page 108 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...

  • Page 109: Several Message Conditions Occur At The Same Time

    OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM 3.4.5 SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME The last message received will be displayed with regard to the pri- ority (importance) of the condition. The displayed message can be switched-over (English / German). All other current messages are kept in the background.
  • Page 110 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...

  • Page 111: Settings Of The Text Display Unit

    OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM 3.4.6 SETTINGS OF THE TEXT DISPLAY UNIT Setting: DATE (Message page 27) Set enable key switch “Adjustments” (E) to ON position Set Selector switch “Adjustments” (D) to position “1” The cursor flashes in the enter zone. Use key 4 (PAGE NO) to shift the cursor to the input place.
  • Page 112 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION...
  • Page 113 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Settings of the Text Display Unit (continued) Erase: RECORD (PROTOCOL) AND STATISTICS memory (page 30) Set key switch “Service” (C) to ON position. The contents of both memories will be erased. Display: protocol cancelled statistics cancelled **** No protocol entry recorded **** Call up and reset the lubrication cycle counter of automatic...
  • Page 114 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION TABLE OF MESSAGES Basic Display (message page no. 0): DATE. TIME OF DAY: OPERATING HOURS (h): ENGINE RPM (1/min): TRUCK COUNTER: Message Pages Number 1 to 7. (Page No.) Gear Lubrication out of function Getriebeschmierung ausgefallen Engine air filter restricted Motor-Luftfilter verschmutzt...
  • Page 115 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Message Pages Number 8 to 15. (Page No.) Not used Low idle speed: coolant temperature too high Niedriger Leerlauf Kühlwassertemperatur zu hoch Engine shutdown: engine oil pressure too low Motorabschaltung: Motoroeldruck zu niedrig Low idle speed: High pressure filter #1 restricted Niedriger Leerlauf: Hochdruckfilter 1 verschmutzt...
  • Page 116 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION Message Pages Number 16 to 24. (Page No.) # Caution, travel gear house brake ON Achtung, Fahrwerkbremse geschlossen # No clearance for starting: shift engine to low idle Keine Startfreigabe: Motor auf niedrigen Leerlauf schalten Central lubrication system fault Zentralschmieranlage gestoert Slew ring gear lubrication system fault...
  • Page 117 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Message Pages Number 25 to 34. (Page No.) Not used Not used # date: new date # time: new time # operating hours h: new operating hours # protocol cancelled statistics cancelled Not used PTO gear lubrication filter restricted Oelfilter für Getriebeschmierung verschmutzt Cooler fan drive filter restricted...
  • Page 118 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION Message Pages Number 35 to 43. (Page No.) Not used Oil filter for clamshell rotation restricted Oelfilter für Greifer drehen verschmutzt Not used Not used Engine shutdown: main shut-off (gate) valve closed Motorabschaltung: Absperrklappe Oelbehälter Engine shutdwon: overspeed Motorabschaltung: Überdrehzahl Not used...
  • Page 119 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Message Pages Number 44 to 51. (Page No.) Engine shutdown: Safety maintenance switch actuated Motorabschaltung: Sicherheitsschalter betätigt Not used Warning signal from engine control module Warnsignal vom Motorrechner Engine shutdown by engine control module Motorabschaltung durch Motorrechner Too high PTO-gear oil temperature Temperatur Getriebeoel zu hoch...
  • Page 120 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION Message Pages Number 52 to 60. (Page No. Load limiting for bucket clam defective Druckabschneidung für Schaufelklappe defekt # Pressure switch of the central lubrication system actuated Druckwächter der Zentralschmieranlage betätigt # Pressure switch of the slew ring gear lubrication system actuated Druckwächter der Drehkranzschmieran- lage betätigt...
  • Page 121 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Message Pages Number 61 to 64. (Page No. Program Identification Number: XXXXXX Central Lubrication System "CLS" cycle counter resetting Counter reading: “CLS” cycle counter Slew ring gear lubrication System “SLS” cycle counter resetting Counter reading: “SLS”...
  • Page 122 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION Grouping of the Messages according to their Priority The messages are divided into four priority groups. A Message of a higher priority group remains on the display, even if further mes- sages of a lower priority group occur. These messages are regis- tered and statistically analyzed, although the are not displayed.
  • Page 123 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Priority Group: Page number: Gear lubrication out of function *1) Engine air filter restricted *2) Oil filter for control oil restricted *2) Oil tank breather filter restricted *2) Return oil filter restricted *2) Leak oil filter restricted *2) Hydraulic oil temperature too high (Bucket motion cutout, operate without load until the oil temperature is within the operating range) *2)
  • Page 124 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM OPERATION # Caution, pull switch from ground man actuated # Pressure switch for central lubrication system actuated # Pressure switch for slew ring lubrication system actuated # Engine reserve oil tank empty # Central lubrication system, refill grease barrel # Slew ring gear lubrication system, refill grease barrel Explanation of the statistics print-out You receive for example the following print-out:...
  • Page 125 OPERATION 3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM Time Diagram of Statistics Print The diagram below shows an example, how the time without faults (Good) and the time faults (Err) could be distributed within the total operating time of the ETM. Total operation time of the ETM T1/T2/T3/T4: Total time of a message...

  • Page 126: 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 127 OPERATION 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...

  • Page 128: Machinery House

    3.6 MACHINERY HOUSE OPERATION MACHINERY HOUSE...

  • Page 129: Emergency Engine Shutdown Switches

    OPERATION 3.6 MACHINERY HOUSE 3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES Legend for illustration Z25076 Handle of machinery house door Door fastener, secure the machinery house door in open position by inserting fastener (2) into the sleeve on the door Light switch Emergency engine shutdown switch Maintenance safety switch for start prevention of the engine Fire wall between engine room and pump compartment viewed from counterweight side...

  • Page 130: Electrical Equipment In Cab Base

    3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION ELECTRICAL EQUIPMENT IN CAB BASE...
  • Page 131 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE WARNING The cab base may contain high voltage electrical appli- ances. Access to the cab base for authorized service staff only. All cables of the 24V board net system are of blue color. All other cable colors indicate a higher voltage.
  • Page 132 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
  • Page 133 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Access Cover for the Head Lights mounted on Cab Base Legend for illustration Z 23094 View from inside the cab base Head lights (Xenon) on cab base Access cover to the headlights from inside the cab base Head light mounting bracket Voltage amplifier for the headlights...
  • Page 134 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...

  • Page 135: Switch Box (X2) In Cab Base

    OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE 3.7.1 SWITCH BOX (X2) IN CAB BASE Legend for illustration Z 23095 Main switch board (X2) Cover Cover fastener Plug socket 24V (E34) Master input signal module for the ETM (E39) Slave input signal module for the ETM (E62) Multi monitor for diagnostic of the electronic pump control system CR700 (S57)

  • Page 136: Checks Before Starting The Engine

    3.8 CHECKS BEFORE STARTING THE ENGINE OPERATION CHECKS BEFORE STARTING THE ENGINE...
  • Page 137 OPERATION 3.8 CHECKS BEFORE STARTING THE ENGINE CAUTION Before starting the Engine, make sure that no one will be endangered when starting the Engine. CHECK THE FOLLOWING ITEMS Legend for illustration Z23098 Engine oil pan dipstick oil level gauge Oil filler tube for engine oil pan Coolant expansion tank of engine radiator Coolant level sight gauge on coolant expansion tank Cover plate on power house roof above the radiator pressure cap...
  • Page 138 3.8 CHECKS BEFORE STARTING THE ENGINE OPERATION...
  • Page 139 OPERATION 3.8 CHECKS BEFORE STARTING THE ENGINE Coolant Level WARNING DO NOT remove the radiator pressure cap (6), illust. Z23098 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 140 3.8 CHECKS BEFORE STARTING THE ENGINE OPERATION...
  • Page 141 OPERATION 3.8 CHECKS BEFORE STARTING THE ENGINE 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 Z23099 Main hydraulic oil reservoir Hydraulic oil level sight gauge...

  • Page 142: Starting The Engine

    3.9 STARTING THE ENGINE OPERATION STARTING THE ENGINE...
  • Page 143 OPERATION 3.9 STARTING THE ENGINE NOTICE Before starting read the Engine Operation Manual. Observe the instructions for starting the Engine. WARNING After repairs on the Diesel Engine or starter motors, make sure that the ground cables are correctly con- nected before starting the engine. Loose or missing ground cables can cause fire, serious injury or death.
  • Page 144 3.9 STARTING THE ENGINE OPERATION...

  • Page 145: Starting Procedure

    OPERATION 3.9 STARTING THE ENGINE 3.9.1 STARTING PROCEDURE 1. Insert battery main switch keys and turn to operating position. 2. Insert key into the switch (1), illustration Z24000 and turn to operating position. The warning buzzer (2) must give an acoustic test signal.
  • Page 146 3.9 STARTING THE ENGINE OPERATION...
  • Page 147 OPERATION 3.9 STARTING THE ENGINE After starting observe the following: The ETM System monitors the Shovel’s functions and provides information about the appropriate operational data. If a FAULT message is displayed on screen (3), the acoustic warning signal (2) will sound simultaneously for approximately 1 second.
  • Page 148 3.9 STARTING THE ENGINE OPERATION...
  • Page 149 OPERATION 3.9 STARTING THE ENGINE Hydraulic oil warm-up On machines without hydraulic oil pre-heating system: DO NOT start the engine if the ambient temperature (oil temperature) is below the starting temperature shown in column “1” of the hydraulic oil viscosity chart on page page 150 in this section.
  • Page 150 3.9 STARTING THE ENGINE OPERATION Hydraulic Oil Viscosity and Temperature Chart Rated Starting Operating range viscosity temperature (100 - 10 cSt) at 40° C of (max. 1000 cSt) hydraulic oil grade: ISO VG °C °C HLP 22 8 - 55 HLP 32 16 - 70 HLP 46...

  • Page 151: Moving The Shovel

    OPERATION 3.10 MOVING THE SHOVEL 3.10 MOVING THE SHOVEL 3.10.1 TRAVEL CONTROL WITH FOOT PEDALS NOTICE Travelling directions with cab in normal working and travel position i.e. cab above idler wheel. Counter weight above drive sprockets. Legend for illustration Z 20345 (3L) Left pedal, inside (3R)
  • Page 152 3.10 MOVING THE SHOVEL OPERATION WARNING Be sure to sound the signal horn before starting to drive to make your intention clear. Regulate travel speed by depressing the pedals more or less. Apply swing circle brake as necessary. On machines with two-speed range travel drive, select normal or fast speed range according to ground conditions.
  • Page 153 OPERATION 3.10 MOVING THE SHOVEL WARNING Travelling on a grade requires special care. Plan your work so that the Shovel travels up- and downhill parallel to the grade. The superstructure must be parallel with the undercarriage and the working attachment must face to the front in travel direction.

  • Page 154: Travelling Instructions

    3.10 MOVING THE SHOVEL OPERATION 3.10.2 TRAVELLING INSTRUCTIONS Never travel the Shovel without first making certain that no one will be endangered. Be sure to sound the signal horn before starting to drive to make your intention clear. Before travelling long distances swing the superstructure par- allel to the undercarriage and apply the swing brake.

  • Page 155: Slewing And Braking The Superstructure

    OPERATION 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE 3.11.1 SLEWING THE SUPERSTRUCTURE MACHINES WITH “EURO” CONTROL Legend for illustration Z24001 ”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 156 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE OPERATION MACHINES WITH “KMG” CONTROL Legend for illustration Z24002 CCW- Lever (2) to the left ”L” ”L” ”N” Neutral position ”R” CW- Lever (2) to the right ”R” WARNING Be sure everyone is in the clear before slewing the super- structure.
  • Page 157 OPERATION 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE Releasing the Parking Brake Move up toggle switch (4) to position ”0”. In this position the switch is automatically pulled down by spring force. NOTICE Be sure to release the parking brake before slewing the superstructure.

  • Page 158: Working With The Attachment

    3.12 WORKING WITH THE ATTACHMENT OPERATION 3.12 WORKING WITH THE ATTACHMENT 3.12.1 MACHINES EQUIPPED WITH”EURO” CONTROL SYSTEM NOTICE The illustrations show a typical construction of control stand and working attachment. However, the shown operation - and working movements apply to this machine. BACKHOE LH control lever(1) RH control lever (2)

  • Page 159: Machines Equipped With"Kmg" Control System

    OPERATION 3.12 WORKING WITH THE ATTACHMENT 3.12.2 MACHINES EQUIPPED WITH”KMG” CONTROL SYSTEM NOTICE The illustrations show a typical construction of control stand and working attachment. However, the shown operation - and working movements apply to this machine. BACKHOE L.H. control lever (1) R.H.

  • Page 160: Bottom Dump Bucket

    3.12 WORKING WITH THE ATTACHMENT OPERATION 3.12.3 BOTTOM DUMP BUCKET NOTICE The illustration shows a typical construction of control stand and working attachment. However, the shown operation- and working movements apply to this machine. OPERATING THE BUCKET CLAM Closing the bottom dump bucket: Depress LH pedal (4) Opening the bottom dump bucket: Depress RH pedal (5)

  • Page 161: Drop Ball Operation

    OPERATION 3.12 WORKING WITH THE ATTACHMENT 3.12.4 DROP BALL OPERATION SAFETY INSTRUCTIONS WARNING Make sure all safety devices are correctly installed on your machine. Always walk-around and look for hazards before you operate your machine in the work area. Consult the supervisor of the job site for instructions concerning safe operation in the work area.
  • Page 162 3.12 WORKING WITH THE ATTACHMENT OPERATION SAFETY DEVICES (SPECIAL EQUIPMENT) Legend for illustration Z 20133_1 Front splinter guard for operator’s cab Protection screen for lubrication system, swing gear and working lights (if so equipped) Cylinder piston rod guard Swing ring guard Reinforcement ledges on bucket wall and clam edges NOTICE...
  • Page 163 OPERATION 3.12 WORKING WITH THE ATTACHMENT Legend for illustration Z 20133_5 Pick-up position of the drop ball A - Greatest circumference of the drop ball Legend for illustration Z 20133_6 Drop height, level with cab roof B - Back wall of the bucket in vertical position WORKING HINTS Place the rock to be crushed on a solid and level ground with the impact surface in a horizontal position.

  • Page 164: Combined Operation Cycles

    3.12 WORKING WITH THE ATTACHMENT OPERATION 3.12.5 COMBINED OPERATION CYCLES With each of the control levers, two operation cycles can be initi- ated simultaneously. In order to obtain efficient operation, always select intermediate control lever positions in relation to work load. NOTICE The illustration shows a typical Shovel.
  • Page 165 OPERATION 3.12 WORKING WITH THE ATTACHMENT NOTICE The illustration shows a typical Shovel. The movements shown in the illustration are controlled: at KMG control system with R.H. lever at EURO control system with L.H. lever Legend for illustration Z 9711) Neutral position Retracting stick Extending stick (away from machine)

  • Page 166: Working Instructions

    3.13 WORKING INSTRUCTIONS OPERATION 3.13 WORKING INSTRUCTIONS 3.13.1 STABILITY OF THE SHOVEL WARNING Before beginning work prepare a suitable Shovel base, to ensure adequate stability for safe working of the Shovel. The stability of the Shovel is determined according to DIN 24087, and is based on a level ground.
  • Page 167 OPERATION 3.13 WORKING INSTRUCTIONS CAUTION DO NOT “Sweep” with the loader attachment, illust. (Z10369), as this may result in severe damage on swing gear compo- nents. 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 168 3.13 WORKING INSTRUCTIONS OPERATION When working with the bucket in the longitudinal direction, the final drives should be in the rear position illust. (Z 0144), for the following reasons: The travel motors and travel gears are protected from fall- ing rocks etc. When the Shovel is operated on muddy ground and the tracks are covered with mud, the sprocket runs on a clean track when backing up.

  • Page 169: Parking The Shovel

    OPERATION 3.14 PARKING THE SHOVEL 3.14 PARKING THE SHOVEL Park the machine at a safe place on level and solid ground. Lower the working attachment onto the ground. Stop the engine and relieve the pressure in the hydraulic system, see "STOPPING THE ENGINE"...

  • Page 170: Stopping The Engine

    3.15 STOPPING THE ENGINE OPERATION 3.15 STOPPING THE ENGINE...
  • Page 171 OPERATION 3.15 STOPPING THE ENGINE CAUTION Never stop the engine from full load except in case of emer- gency. Before shutting down run the engine at idling speed for approximately 5 minutes. This cooling down period prevents heat accumulation and thermal stress, especially in the tur- bochargers.
  • Page 172 3.15 STOPPING THE ENGINE OPERATION...
  • Page 173 OPERATION 3.15 STOPPING THE ENGINE WARNING With the engine at standstill and main switch (1) in ON posi- tion, move all controls for working attachment and crawlers several times through all shift positions to relieve the pres- sure in the hydraulic system. The necessary oil pressure for shifting the spools of the main control valves is provided by a pressure accumulator in the pilot oil circuit.

  • Page 174: Automatic Lubrication Systems

    3.16 AUTOMATIC LUBRICATION SYSTEMS OPERATION 3.16 AUTOMATIC LUBRICATION SYSTEMS...

  • Page 175: Operation Of The Automatic Lubrication Systems

    OPERATION 3.16 AUTOMATIC LUBRICATION SYSTEMS 3.16.1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS The shovel is equipped with two automatic lubrication systems: 1. Central Lubrication System (CLS) for lubrication of the attach- ment bearings, the slewing connection bearing and the slew gear bearing.
  • Page 176 3.16 AUTOMATIC LUBRICATION SYSTEMS OPERATION...
  • Page 177 OPERATION 3.16 AUTOMATIC LUBRICATION SYSTEMS Operation of the automatic Lubrication Systems (continued) CAUTION If one of the automatic lubrication systems fails to work for a period longer than 4.2 hours automatic bucket motion cut off will happen. Repair the system as soon as possible. NOTICE For more information regarding inspection, trouble shooting and maintenance of the lubrication systems, refer to the sep-...

  • Page 178: Fire Detection And Suppression System

    3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM (Special Equipment)
  • Page 179 OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM FIRE DETECTION AND SUPPRESSION SYSTEM WARNING Before operating the Shovel make sure the Fire Detection, Actuation and Suppression system is operative. Carry out inspection and maintenance according to the sepa- rate manuals “Fire Detection and Actuation System” and “Fire Suppression System”...
  • Page 180 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...

  • Page 181: High Level Alarm "Fire

    OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM 3.17.1 HIGH LEVEL ALARM ”FIRE” The high level alarm (8), illlust. Z 21619 will sound approximately 15 seconds before discharge of the fire suppression system in case of automatic actuation of the system. Act according to the circumstances and the applying safety regulations.
  • Page 182 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...

  • Page 183: Indication Of Operational Modes At Control Module, After Automatic Actuation Of The Fire Suppression System

    OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM 3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM Alarm to Shutdown Period - The RED alarm LED and the audio alarm will pulse at a rate of 2 times per second. Shutdown to Discharge Period - The RED alarm LED and the audio alarm pulses "on"...
  • Page 184 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...

  • Page 185: Location Of The Extinguishing Agent Tank Assemblies And Expellant Gas Cartridges On Power House Roof

    OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM 3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF REMARK All extinguishing agent tank assemblies with their expellant gas cartridges are located on the rear railing of the power house roof.

  • Page 186: Central Refilling System

    3.18 CENTRAL REFILLING SYSTEM OPERATION 3.18 CENTRAL REFILLING SYSTEM...

  • Page 187: Systems Connected To The Refilling System

    OPERATION 3.18 CENTRAL REFILLING SYSTEM 3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM The following systems are connected to the receiver panel (5) of service arm (3), illust. (Z24005): Fuel Tank Engine Oil Pan Engine Oil Reserve Tank (if so equipped) Engine Coolant Radiator Main Hydraulic Oil Reservoir Central Lubrication System (CLS)
  • Page 188 3.18 CENTRAL REFILLING SYSTEM OPERATION...

  • Page 189: Operating The Hydraulic Service Arm

    OPERATION 3.18 CENTRAL REFILLING SYSTEM 3.18.2 OPERATING THE HYDRAULIC SERVICE ARM A - Diesel Engine OFF The Service Arm can only be lowered. Proceed as follows: 1. Turn main key switch to ON position. 2. Turn enabling switch (1), illust. (Z24005) to ON position ”1”. 3.
  • Page 190 3.18 CENTRAL REFILLING SYSTEM OPERATION...

  • Page 191: Receiver Panel With Monitor Box

    OPERATION 3.18 CENTRAL REFILLING SYSTEM 3.18.3 RECEIVER PANEL WITH MONITOR BOX Legend for illustration Z25112: Service arm, hydraulically operated Monitoring and control box Push button for testing lamps (6, 7, 8 and 9). Push the button, all lamps must light up. If a lamp does not light up, corrective action must be taken.
  • Page 192 3.18 CENTRAL REFILLING SYSTEM OPERATION...
  • Page 193 OPERATION 3.18 CENTRAL REFILLING SYSTEM Legend for illustration Z25112 Radiator coolant draining and filling adapter. Monitor coolant level at radiator filler neck. NOTICE The two-loop type cooling system of the engine is equipped with two radiators. One radiator for the engine crankcase and cylinder heads and one radia- tor for the low temperature aftercooler (LTA) system.
  • Page 194 3.18 CENTRAL REFILLING SYSTEM OPERATION...

  • Page 195: Refillable Grease Containers Of The Automatic Lubrication Systems

    OPERATION 3.18 CENTRAL REFILLING SYSTEM 3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS Legend for illustration Z21666A Grease level gauges for manual checking of the grease level Grease filter for central lubrication system. Before filling the grease container make sure the filter is not obstructed.

  • Page 196: Transfer Pump For Hydraulic Oil

    3.19 TRANSFER PUMP FOR HYDRAULIC OIL OPERATION 3.19 TRANSFER PUMP FOR HYDRAULIC OIL Special Equipment...

  • Page 197: Operating The Transfer Pump

    OPERATION 3.19 TRANSFER PUMP FOR HYDRAULIC OIL 3.19.1 OPERATING THE TRANSFER PUMP Legend for illust. Z25100 REMARK The illustration shows the transfer pump arrangement viewed from center of the platform. Transfer pump with electric motor Cock for suction oil reservoir Cock for return oil collector pipe C - Closed O - Open...
  • Page 198 3.19 TRANSFER PUMP FOR HYDRAULIC OIL OPERATION...
  • Page 199 OPERATION 3.19 TRANSFER PUMP FOR HYDRAULIC OIL A - Pumping the oil from the Suction Oil Reservoir into the Main Oil Reservoir 1. Close main valve (8), illustration Z25100. 2. Open cock (2), position (O). REMARK In order to prevent build-up of a vacuum in the suction sys- tem, open the vent valves on each main hydraulic pump, see page 369 for more information.

  • Page 200: 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 201: Transportation And Lifting Of The Shovel

    3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL WARNING Before Disassembling, Lifting or Transporting this Shovel contact your local Komatsu Service Station for all the neces- sary instructions for safe and economic disassembling, lift- ing and transportation procedures of your Shovel. 3.21.1 DISASSEMBLING OF THE SHOVEL The Shovel is being transported disassembled into its main com- ponents.

  • Page 202: 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 203: Shovel Storage

    OPERATION 3.23 SHOVEL STORAGE 3.23 SHOVEL STORAGE GENERAL Storage periods up to 30 days require no special preservation when the unit is stored in a protected place. When the Shovel is placed in storage for 30 days or more follow the procedure below. NOTICE The description below includes special equipment which may not be installed in your machine.

  • Page 204: One Month Repetitive Service Period

    3.23 SHOVEL STORAGE OPERATION 3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD 1. Service the engine according to the engine manual. 2. Check coolant level and cooling systems for leakage. 3. Check all oil levels according to the lubrication chart. 4. Drain condensation from fuel tank and hydraulic oil reservoir. 5.

  • Page 205: Preparing For Operation

    OPERATION 3.23 SHOVEL STORAGE 3.23.4 PREPARING FOR OPERATION 1. Remove grease from all machined unpainted surfaces (piston rods). 2. Install fully charged batteries. 3. Remove all coverings. 4. Fill up fuel tank with an approved Diesel fuel. 5. Check cooling system for leaks, loose connections and cool- ant level.

  • Page 206: Trouble Shooting

    3.24 TROUBLE SHOOTING OPERATION 3.24 TROUBLE SHOOTING GENERAL The following charts list a number of the most common problems encountered in operation. Some of the faults may be due to care- less handling or operation, improper maintenance or the use of lubricating oils other than specified.

  • Page 207: Hydraulic System

    OPERATION 3.24 TROUBLE SHOOTING 3.24.2 HYDRAULIC SYSTEM Problem Probable cause Hydraulic oil not at operating temperature. Engine speed too low. Reservoir low on oil Restrictions in lines Cooling circuit, pump control system and/or pilot control circuit Poor hydraulic system perfor- defective.

  • Page 208: Final Drives And Swing Gear

    3.24 TROUBLE SHOOTING OPERATION 3.24.3 FINAL DRIVES AND SWING GEAR Incorrect lubricant or oil level too low Bearings scored or damaged. Noisy operation Sun gear teeth excessively worn or damaged Bearings of planetary pinions worn 3.24.4 CRAWLER TRACKS Wrong track tension Track roller loose or out of alignment Excessive track wear Track shoes loose...

  • Page 209: Maintenance

    4. MAINTENANCE...

  • Page 210: 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 211: Precautions For Maintenance

    MAINTENANCE 4.2 PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 16. Park the Excavator at a safe place on level ground. Proceed according to the instructions on page 169. ”Parking the Excavator”.
  • Page 212 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 213: Fuel And Lubricants

    MAINTENANCE 4.3 FUEL AND LUBRICANTS FUEL AND LUBRICANTS Ambient Point of Viscosity Quality Grades Lubricant Temperature Lubrication Grades DIN/API °C Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for Engine Specifications of Engine Oil, Coolant and Fuel. - 20 to + 11 Hydraulic oil -14 to + 21 “HLP or...
  • Page 214 4.3 FUEL AND LUBRICANTS MAINTENANCE Ambient Quality Grades Point of Viscosity Lubricant Temperature Lubrication Grades °C DIN/API Grease Fittings Refer to the Lubricant Chart in volume 2 binder for the recommended (manual lubrication) Multi-Purpose Multi-Purpose Greases. The part numbers of recommended Multi- Grease ”MPG”...

  • Page 215: Filling Capacities

    MAINTENANCE 4.4 FILLING CAPACITIES FILLING CAPACITIES Unit or System Liter (approx.) Engine cooling system 360.0 Engine oil pan 190.0 Engine oil reserve tank 510.0 (424.0 Refill) Fuel tank 4500.0 Hydraulic oil reservoir 2900,0 Hydraulic system 4400.0 Flexible coupling between engine and PTO 1.45 PTO (Pump distributor gear) 87.0...

  • Page 216: Standard Torque List

    4.5 STANDARD TORQUE LIST MAINTENANCE STANDARD TORQUE LIST Tightening torque Bolt Wrench lbs.ft. dia. size [mm] Quality grades 10.9 12.9 M 10 M 12 54.6 M 14 M 16 M 18 M 22 M 24 1030 M 27 1310 1530 1128 M 30 1250...

  • Page 217: Lubrication And Maintenance Schedule

    MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE LUBRICATION AND MAINTENANCE SCHEDULE 4.6.1 INITIAL SERVICING AFTER THE FIRST 250 OPERATING HOURS Change oil in Swing gear, Travel gears and PTO (pump distributor gear). Thereafter every 3000 hours, but at least once a year. An oil sample analysis should be made every 1000 operating hours.

  • Page 218: Periodic Servicing Schedule

    4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE 4.6.3 PERIODIC SERVICING SCHEDULE Service Intervals Service Point Service Engine Air Cleaners Maintenance page 231 Immediately apply grease if bare Swing circle toothing page 235 spots are visible Fill grease containers Automatic lubrication systems page 237 When necessary Clean or replace filter elements...
  • Page 219 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Service Intervals Service Point Service Refrigerant compressor Check drive belt tension page 273 Radiator fan belt and automatic Maintenance check page 275 belt tensioner Generator Check drive belt tension page 279 Signal horn compressor Lubricate page 281 Oil cooler fans...
  • Page 220 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE Service Intervals Service Point Service Check for correct tightening High strength bolt connections page 303 torque and security Replace return and pressure fil- ter elements Clean or replace high pressure Hydraulic system page 335 filter elements Replace breather filter elements Drain sediments...
  • Page 221 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Service Intervals Service Point Service Change oil (*) Hydraulic system Replace suction strainers (*) page 357 Replace pulsation damper Every 2000 operating Emergency escape ladder Inspect page 371 hours or yearly. Fire detection and actuation sys- Maintenance Swing gear and Motor adapter Change oil...
  • Page 222 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE Lubrication Chart...
  • Page 223 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE REPLACEMENT OF HYDRAULIC HOSE LINES Hydraulic Hose lines are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years. CAUTION The maximum permissible storage time of hydraulic hose lines is 2 years. This storage period is part of the usable life- time and must be considered when a new hose line is being installed.
  • Page 224 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...

  • Page 225: Extended Service Intervals For Engines With Engine Oil Management System

    MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE 4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM REMARK The engine oil management system of the engine combines the automatic engine oil supply system "Reserve" and the oil burning system "Centinel" in connection with the "Eliminator" oil filtration system.
  • Page 226 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...

  • Page 227: Resetting The Engine Oil Burning System Centinel

    MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Extended Service Intervals for Engines with Engine Oil Management System Every 500 operating hours The contents of the engine oil reserve tank is sufficient for approximately 500 hours of operation. The oil level in the reserve tank is also monitored by the ETM system.
  • Page 228 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...

  • Page 229: Maintenance Of The Engine

    MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Extended Service Intervals for Engines with Engine Oil Management System Reserve System Oil Flow Schematic, illust. Z23083 Oil filters for the engine oil reserve system Suction line from reserve tank Suction line to pumping unit Supply line from pumping unit to crankcase Withdrawal oil line from engine oil pan to pump Ventilation line for reserve tank...

  • Page 230: When Necessary

    4.7 WHEN NECESSARY MAINTENANCE WHEN NECESSARY...

  • Page 231: 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. Z24050: CAUTION Never service air cleaner while engine is running. Clean main filter elements when the fault message "Air cleaner element restricted"...
  • Page 232 4.7 WHEN NECESSARY MAINTENANCE...
  • Page 233 MAINTENANCE 4.7 WHEN NECESSARY Air Cleaner Maintenance, illustration Z24050 NOTICE If the fault message "Air cleaner element restricted" is again displayed on the ETM 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 234 4.7 WHEN NECESSARY MAINTENANCE...

  • Page 235: Swing Circle Toothing Lubrication

    MAINTENANCE 4.7 WHEN NECESSARY 4.7.2 SWING CIRCLE TOOTHING LUBRICATION See illustration Z 20850 All teeth of the gear ring (3) must be completely covered with grease. NOTICE If the machine is equipped with gear ring guard (6), remove covers (7) for swing circle teeth inspection. If the automatic lubrication system of the swing circle toothing fails to function for more than four operating hours, bucket motion cut-off will occur.
  • Page 236 4.7 WHEN NECESSARY MAINTENANCE...

  • Page 237: 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 empty" is displayed on the ETM screen. Make sure the grease filters in the filling lines are not obstructed.
  • Page 238 4.7 WHEN NECESSARY MAINTENANCE...
  • Page 239 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 240 4.7 WHEN NECESSARY MAINTENANCE...

  • Page 241: 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 242 4.7 WHEN NECESSARY MAINTENANCE...

  • Page 243: Cold Starting Aid, Replace Fluid Cylinder

    MAINTENANCE 4.7 WHEN NECESSARY 4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER Legend for illustration Z 24051 Rear exhaust muffler Engine air cleaner Cold starting aid mounted on the air cleaner frame Electrically operated valve Mounting clamp Cold start fluid cylinder WARNING Starting fluid is poisonous and flammable Do not store replacement cylinders in living areas...

  • Page 244: Every 10 Operating Hours Or Daily

    4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE EVERY 10 OPERATING HOURS OR DAILY...

  • Page 245: 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 246 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
  • Page 247 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 20840). Legend for illustration Z 20840 Injectors on bucket Injectors on stick Injectors on boom Indicator stem for visual indication of injector opera-...
  • Page 248 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
  • Page 249 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 250 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
  • Page 251 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 252 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...

  • Page 253: 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. Z24053: 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 254 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...

  • Page 255: Radiator - Check Coolant Level

    MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY 4.8.3 RADIATOR - CHECK COOLANT LEVEL Legend for illustration Z24053 Coolant expansion tank of the engine radiator Coolant level sight gauge on coolant expansion tank Cover plate on power house roof above the radiator pressure cap Radiator pressure cap WARNING...
  • Page 256 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...

  • Page 257: Fuel System Water Separator - Drain Water

    MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY 4.8.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER Special Equipment Legend for illustration Z25113 Front view of the engine Top view of engine compartment Fuel tank Fuel shut-off solenoid valve. This solenoid valve cuts- off fuel supply to the engine when the stop switch on the instrument panel is actuated.

  • Page 258: Every 50 Operating Hours Or Weekly

    4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE EVERY 50 OPERATING HOURS OR WEEKLY...

  • Page 259: Swing Gear And Motor Adapter Housing - Check Oil Level

    MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.1 SWING GEAR AND MOTOR ADAPTER HOUSING - CHECK OIL LEVEL 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 the swing gear housing to find out the manufacturer of the swing gear.
  • Page 260 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
  • Page 261 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 262 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...

  • Page 263: Travel Gears, Brake Housings And Motor Adapter Housings - Check Oil Levels

    MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS Planetary Gear Box Spur Gear Box Brake Housing Motor Adapter Housing Legend for illustration Z20836 Planetary gear box: Oil level plug Oil filler plug Drain plug (13)
  • Page 264 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...
  • Page 265 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY SPUR GEAR BOX - CHECK OIL LEVEL Check oil level by removing oil level plug (4). Oil level should be at lower edge of opening (4), if necessary add oil through filler opening (5). Install level and filler plug (4 and 5). Check breather filter (13) for restriction.
  • Page 266 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...

  • Page 267: Pto (Pump Distributor Gear) - Check Oil Level

    MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.3 PTO (PUMP DISTRIBUTOR GEAR) - CHECK OIL LEVEL Legend for illustration Z24055 Oil level gauge Oil filler plug Breather filter Oil drain plug Adapter housings for main hydraulic pumps Adapter housing for pilot oil pump Oil level plug Oil filler plug with breather pipe Oil drain plug...
  • Page 268 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...

  • Page 269: 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 Z23077 Access ladder in lowered position Access ladder in upper position (Working position) Access ladder Light switch for access area lighting Pull chain for emergency lowering of the access ladder WARNING Use this chain only in emergency cases, when the Operator...
  • Page 270 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...

  • Page 271: 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 Z24056 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 272: Every 250 Operating Hours Or Monthly

    4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY...

  • Page 273: 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 129 for the location of the maintenance safety switch.
  • Page 274 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 275: Radiator Fan Belt And Automatic Belt Tensioner - Maintenance Check

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER - MAINTENANCE CHECK WARNING Before starting the maintenance check, set the maintenance safety switch to 0 position. Refer to page 129 for location of the maintenance safety switch.
  • Page 276 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 277: Radiator Fan Belt And Automatic Belt Tensioner - Maintenance Check

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER - MAINTENANCE CHECK (continued) Automatic Belt Tensioner Inspection Check belt tensioner pulley, spring assembly (6) and control rod (7) illustration (Z25102) for good condition and alignment. If a pul- ley is worn or damaged, it should be replaced.
  • Page 278 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 279: Generator - Check Belt Tension

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.3 GENERATOR - CHECK BELT TENSION REMARK For the correct belt tension and belt tension gauge refer to the Drive Belt Tension Chart in the Engine Operation and Mainte- nance Manual, Section V, page 19. The engine can be equipped with one of the two versions of belt tensioning systems.
  • Page 280 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 281: Signal Horn Compressor - Lubricate

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.4 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 282 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 283: Automatic Lubrication Systems - Clean In-Line Grease Filter And Check Breather Filter

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER Legend for illustration Z 21465 Grease pump drive (Hydraulic cylinder) Solenoid valve (Oil pressure supply) Flow control valve Pressure reducing valve Hydraulic oil supply line (Pilot pressure) Hydraulic oil return line Vent valve (Solenoid valve, de-energized open to...
  • Page 284 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
  • Page 285 MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY Service the in-line grease filter as follows: 1. Unscrew plug (18), illustration Z 21465, using 36 mm width wrench and remove packing ring (19). 2. Take out spring (21), spring guide (22) and element (12). 3.
  • Page 286 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 287: Cab Air Cleaner - Clean Or Replace Filter Element

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT Legend for illustration Z24059 Access door to cab air cleaner Air cleaner housing Filter element Carrier Seal ring Cab blower Blower housing Air conditioning condenser Access door to the water tank of the windshield washer system and to the dryer cartridge of the air...
  • Page 288 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 289: Windshield Washer Reservoir - Check Fluid Level

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.8 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL Legend for illustration Z24060 Access door to the water reservoir of the windshield washer system and to the dryer cartridge of the air conditioning Water reservoir for windshield washer Cab air filter Cab blower...

  • Page 290: Every 500 Operating Hours Or Monthly

    4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY...

  • Page 291: Batteries - Check Fluid Level

    MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 4.11.1 BATTERIES - CHECK FLUID LEVEL See illustration Z24061 A - Top view of access area WARNING Batteries give off highly inflammable gas! Never allow sparks or open flame near the batteries! Avoid spilling any electrolyte on hands or clothing.
  • Page 292 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 293: Flexible Drive Coupling - Check Oil Level

    MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL See illustration Z 20703 NOTICE The Engine 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 294 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 295: Fuel Tank - Drain Condensation

    MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 4.11.3 FUEL TANK - DRAIN CONDENSATION Legend for illustration Z24014 Rear view of fuel tank Left view Top view Fuel tank Fuel return port (engine fuel pump return line) Drain coupling Fuel outlet port for auxiliary user (Generator set) Fuel outlet port to engine fuel pump Stair to cab Pressure transducer for level indication...
  • Page 296 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 297: Crawler Track - Inspection

    MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 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 298 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...
  • Page 299 MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 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 300 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...
  • Page 301 MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 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 302: 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 303: 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 304 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 305 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of Cab base (1) Fuel tank (2) Hydraulic oil cooler carrier (3) and Main hydraulic oil reservoir (4) see illustration Z24064 Bolt size SW * Tightening torque Reference No.:...
  • Page 306 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 307 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check mounting of Operator’s cab Legend for illustration Z24065 Cab brackets Cab carrier plates Viscous mounts, filled with silicon oil Support bars with inner thread on cab base Cab base Mounting bolts carrier plates (2) to support bars (4) Resilient sleeves...
  • Page 308 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 309 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check mounting and security of the Diesel engine and pump distributor gear, illustration Z24069 Check all flexible bearings (1) for engine and pump distributor gear. Check the flexible bearings for damage and signs of fatigue.
  • Page 310 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 311 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of main hydraulic pumps (1-3), illustration Z24070. Check fastening and condition of auxiliary pumps (4 - 6). Legend for illustration Z24070 (1-3) Main hydraulic pumps, swash plate type for all work- ing and travelling motions.
  • Page 312 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 313 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of control valve carrier (01), main control valves (04 - 06) and hose support (02), illustration Z20861 Reference Bolt size SW * Tightening Grade Qty.
  • Page 314 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 315 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of the swing gear (01) and swing motor (02), illustration Z22642 Bolt size SW * Tightening torque Reference No.: Grade Qty. M 16 10.9 (25) Socket head M 24...
  • Page 316 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 317 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check tightening torque of the mounting bolts (2) for coun- terweight (1), illustration Z22911 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 4950 * SW = Wrench size Check all mounting bolts (2) for correct tightening torque.
  • Page 318 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 319 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Swing circle (01), illustration Z20864 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 320 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 321 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Center frame (1), check condition and fastening of swivel joint (2), illustration Z24071 Bolt size SW * Tightening torque Reference No.: Grade Qty. M 16 10.9 M 16 10.9 * SW = Wrench size...
  • Page 322 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 323 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 324 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 325 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of travel gears, sprockets and travel motors Legend for illustration Z20866: Crawler carrier Travel gear Sprocket Travel motor Mounting bolts for sprocket to travel gear Mounting bolts for travel gear to crawler carrier Mounting bolts for travel motors Bolt size...
  • Page 326 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 327 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 331. This tool will be provided by your Komatsu dealer. Measuring Device PN 92847640 Position Part name Part No.
  • Page 328 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 329 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 Z24073 1. Loosen the two measuring bolts (7) at the left crawler carrier and the two measuring bolts at the right crawler carrier.
  • Page 330 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 331 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 Z24074...
  • Page 332 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 333 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. WARNING Always use the safety harness in conjunction with the strap type fall absorber when mounting onto the loader attach- ment.
  • Page 334 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 335: 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. Z20872 Return of filter location Leakage oil filter location Mounting bolt Filter cover retainer Filter cover assy Return- and leakage filter unit Oil filler plug O-ring Breather filter...
  • Page 336 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 337 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 338 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 339 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. Z24075 Hand wheel of main shut-off valve located between suction oil reservoir and main oil reservoir To OPEN the valve, turn hand wheel (1) CCW to the stop To CLOSE the valve, turn hand wheel CW to the...
  • Page 340 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 341 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE High Pressure Filters "HPF", illustration Z24076 NOTICE The filter reference numbers (1 - 3) correspond to the numbering of the main pumps. If, for example, the fault message "High pressure filter #3 restricted"...
  • Page 342 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 343 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE High Pressure Filters "HPF", illustration Z24076 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 344 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 345 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 346 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 347 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE Replace pressure filter elements, illust. Z24077, as follows: 1. Place working equipment on the ground and shut-off the engine. Relieve pressure in the hydraulic system according to page 170 in the operation section. 2.
  • Page 348 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 349: Pto (Pump Distributor Gear), Swing Gear And Travel Gears - Oil Sample Analysis

    MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR 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 350 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 351: 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 352 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 353: 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 354 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 355: Hydraulic Oil Cooler - Inspect And Lubricate Door Hinges

    MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.6 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES WARNING Provide adequate working platform for safe access to the hydraulic oil cooler (1). Check all door hinges (4) for good condition and proper fastening to their carrier frames.

  • Page 356: Every 2000 Operating Hours Or Yearly

    4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY...

  • Page 357: 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 further time period, when an oil sample analysis shows a positive result.
  • Page 358 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...

  • Page 359: 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. Z25002 Main hydraulic oil reservoir Back-pressure valve Swing gear location Return oil collector manifold Drain coupling of the return oil collector manifold Branch pipe Strainer of the oil cooler circuit Intermediate pipe...
  • Page 360 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
  • Page 361 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Legend for illustration Z25012 Main hydraulic pump -1- Main hydraulic pump -2- Location of main hydraulic pump -3- (shown on next page) Hydraulic oil cooler fan drive pump Flexible hoses Flange...
  • Page 362 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
  • Page 363 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Legend for illustration Z25013 Main hydraulic pump -3- Flexible hoses Flange O-rings Suction strainer Control oil pump (pilot oil circuit) (10) PTO gear lubrication pump (11) Suction oil reservoir...
  • Page 364 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
  • Page 365 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 (2), see illustration Z25010 on page 356, is in open position. 2.
  • Page 366 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
  • Page 367 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY Hydraulic oil viscosity and adjustment of tempera- ture switch units If the new hydraulic oil has a different viscosity grade compared with the drained oil it is necessary to adjust the temperature limit values at switch units (K26, K39 and K100), illustration Z24089 in accordance with the viscosity grade of the new hydraulic oil.
  • Page 368 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
  • Page 369 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Vent Suction Oil Reservoir and Hydraulic Pumps, illustration Z25014 1. Loosen vent plug (A) of suction oil reservoir (1). Retighten vent plug (A) when the outflowing oil is free of air bubbles. 2.
  • Page 370 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...

  • Page 371: Emergency Escape Ladder - Inspection

    MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY 4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION See illustration Z 22461 Sliding window, serves also for emergency exit Rigidly mounted emergency escape ladder Rope ladder. The upper end of the rope ladder is fixed onto the lower rung of the rigid escape ladder (2) by means of the fasteners (4), see detail (X).

  • Page 372: 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 373: Swing Gear And Motor Adapter Housing - Change Oil

    MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4.14.1 SWING GEAR 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 the swing gear housing to find out the manufacturer of the swing gear.
  • Page 374 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
  • Page 375 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR Motor Adapter Housing, Change Oil (L&S) 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 376 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
  • Page 377 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR SWING GEAR MANUFACTURED BY "SIEBENHAAR" Legend for illustration Z 21694 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...
  • Page 378 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
  • Page 379 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR Brake Housing - Change Oil (Siebenhaar) 1. Remove level gauge (8), illustration Z 21694, drain plug (9) and breather filter (7). Drain the oil into a receptacle of approx.
  • Page 380 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...

  • Page 381: Travel Gears, Brake And Motor Adapter Housings - Change Oil

    MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL Planetary Gear Box Spur Gear Box Brake Housing Motor Adapter Housing Legend for illustration Z20836 Planetary gear box Oil level plug Oil filler plug Drain plug...
  • Page 382 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
  • Page 383 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR TRAVEL GEARS - CHANGE OIL Illustration Z20836 1. Move the Excavator so, that the drain plug (3) is in the lowest and filler plug (3) is in the uppermost position. The oil level plug (1) is then correctly positioned.
  • Page 384 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...

  • Page 385: 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 Z24055 Oil level gauge Oil filler plug Breather filter Oil drain plug Adapter housings for main hydraulic pumps Adapter housing for pilot oil pump Oil level plug Oil filler plug with breather pipe...
  • Page 386 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
  • Page 387 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR PTO gear oil viscosity and adjustment of tempera- ture switch units If the new gear oil has a different viscosity grade compared with the drained oil it is necessary to adjust the temperature limit val- ues at switch units (K43 and K182), illustration Z24089 in accor- dance with the viscosity grade of the new gear oil.

  • Page 388: Fire Prevention

    4.15 FIRE PREVENTION MAINTENANCE 4.15 FIRE PREVENTION...
  • Page 389 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 390: Repair Weldings

    4.16 REPAIR WELDINGS MAINTENANCE 4.16 REPAIR WELDINGS...
  • Page 391 MAINTENANCE 4.16 REPAIR WELDINGS CAUTION Before carry out weld repairs, contact our Service Depart- ment ”EXCAVATORS” in order to avoid improper welding procedures. Weld repairs can cause severe damage to an entire structure if performed incorrectly. If cracks are found in the steel construction of your excavator, please inform our Service Department as soon as possible.
  • Page 392 4.16 REPAIR WELDINGS MAINTENANCE...

  • Page 393: Protective Measures Before Starting Weld Repairs On The Undercarriage

    MAINTENANCE 4.16 REPAIR WELDINGS 4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE See illustration Z24083 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 394 4.16 REPAIR WELDINGS MAINTENANCE...

  • Page 395: Protective Measures Before Starting Weld Repairs On The Loader Attachment

    MAINTENANCE 4.16 REPAIR WELDINGS 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 396 4.16 REPAIR WELDINGS MAINTENANCE...

  • Page 397: Protective Measures Before Starting Weld Repairs On The Superstructure

    MAINTENANCE 4.16 REPAIR WELDINGS 4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE Legend for illustration Z24061 Top view of access area Battery main switch keys Battery box cover underneath the cat walk Batteries Fluid level Remove keys (1) of the two battery main switches. WARNING Batteries give off highly inflammable gas! Never allow sparks or open flame near the batteries! Avoid spilling any electro-...
  • Page 398 4.16 REPAIR WELDINGS MAINTENANCE...

  • Page 399: After Finishing The Repair Weldings On The Superstructure

    MAINTENANCE 4.16 REPAIR WELDINGS Electrical Units in Cab Base, illustration Z23095 1. Switch off all circuit breakers in the switch box "X2". 2. Disconnect all plugs on both input signal modules (E34 and E39). 3. Disconnect all plugs on the multi monitor (E62) 4.
  • Page 400 4.16 REPAIR WELDINGS MAINTENANCE...
  • Page 401 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 ABBREVATIONS ....................8 TABLE OF CONTENTS ........................9 SAFETY ...................... 15 SAFETY INSTRUCTIONS ........................
  • Page 402 3.4.2 SYSTEM COMPONENTS ....................91 3.4.3 FUNCTIONS OF THE ETM SYSTEM ................. 93 3.4.4 DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY ......97 3.4.5 SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME ....... 109 3.4.6 SETTINGS OF THE TEXT DISPLAY UNIT ............... 111 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING ........
  • Page 403 3.18 CENTRAL REFILLING SYSTEM ....................186 3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM ..........187 3.18.2 OPERATING THE HYDRAULIC SERVICE ARM ............. 189 3.18.3 RECEIVER PANEL WITH MONITOR BOX ..............191 3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS ... 3.19 TRANSFER PUMP FOR HYDRAULIC OIL ...................
  • Page 404 4.6.6 MAINTENANCE OF THE ENGINE ................... 229 WHEN NECESSARY ........................230 4.7.1 ENGINE AIR CLEANER MAINTENANCE ................. 231 4.7.2 SWING CIRCLE TOOTHING LUBRICATION ..............235 4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS ......237 4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS ....241 4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER .............
  • Page 405 4.12.6 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES ....355 4.12.7 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES ....355 4.13 EVERY 2000 OPERATING HOURS OR YEARLY ................ 356 4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER ......................

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