Komatsu PC4000-6 Operation & Maintenance Manual
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Komatsu PC4000-6 Operation & Maintenance Manual

Komatsu PC4000-6 Operation & Maintenance Manual

Hydraulic mining shovel
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Operation & Maintenance
Manual
PC4000-6
HYDRAULIC MINING SHOVEL
SERIAL NUMBERS
This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu Mining Germany GmbH.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
December 2006
PC4000-6
Copyright 2006 Komatsu
Printed in U.S.A.
Komatsu Mining Germany
OMPC40008172
8172

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Summary of Contents for Komatsu PC4000-6

  • Page 1 PC4000-6 SERIAL NUMBERS This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Germany GmbH. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.

  • 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- and Maintenance Manu- als for your KOMATSU Mining Shovel.

  • Page 5: Division Of The Binder

    Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If you have any questions concerning this literature please con- tact Komatsu Mining Germany GmbH Service Information Department 8151.30 P.O. Box 18 03 61 D - 40570 Düsseldorf...

  • Page 6: Designated Use Of The Shovel

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

  • Page 7: Delivery Of The Shovel

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

  • Page 8: Explanation Of Abbreviations

    1.5 EXPLANATION OF ABBREVIATIONS INTRODUCTION EXPLANATION OF ABBREVIATIONS Definition Ampere Alternating Current American Petroleum Institute Centistoke °C Degree Celsius CENSE Engine Monitoring System Central Lubrication System Direct Current German Institute for Standardization Electronic Bucket Levelling System Electronic Control Module (Engine) FGPS Front Guard Protective Structure FOPS...

  • Page 9: Table Of Contents

    INTRODUCTION 1.6 TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION ................... 3 CONTENTS OF THE BINDER ......................4 DIVISION OF THE BINDER ....................... 5 DESIGNATED USE OF THE SHOVEL ....................6 DELIVERY OF THE SHOVEL ......................7 EXPLANATION OF ABBREVIATIONS ..................... 8 TABLE OF CONTENTS ........................
  • Page 10 1.6 TABLE OF CONTENTS INTRODUCTION OPERATOR’S CAB - CONTROLS ....................78 3.3.1 CONTROLS WITH BACKHOE ATTACHMENT ..............78 3.3.2 SAFETY CIRCUIT FOR CONTROLS ................. 79 3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT ......... 82 3.3.4 SAFETY CIRCUIT FOR CONTROLS ................. 83 3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK ..........
  • Page 11 INTRODUCTION 1.6 TABLE OF CONTENTS 3.12 WORKING WITH THE ATTACHMENT ..................178 3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM ......... 178 3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM ..........179 3.12.3 BOTTOM DUMP BUCKET ....................180 3.12.4 DROP BALL OPERATION ....................181 3.12.5 COMBINED OPERATION CYCLES .................
  • Page 12 1.6 TABLE OF CONTENTS INTRODUCTION 3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD ..............230 3.23.4 PREPARING FOR OPERATION ..................231 3.24 TROUBLE SHOOTING ........................232 3.24.1 ENGINE ..........................232 3.24.2 HYDRAULIC SYSTEM ...................... 233 3.24.3 FINAL DRIVES AND SWING MACHINERY ..............234 3.24.4 CRAWLER TRACKS ......................
  • Page 13 INTRODUCTION 1.6 TABLE OF CONTENTS 4.10 EVERY 250 OPERATING HOURS OR MONTHLY ............... 296 4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION ....... 297 4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE ..........299 4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE ............... 299 4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER ....................
  • Page 14 1.6 TABLE OF CONTENTS INTRODUCTION SUPERSTRUCTURE ......................429 4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE ..... 430...

  • 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: Oil, Grease And Other Chemical Substances

    SAFETY 2.1 SAFETY INSTRUCTIONS OIL, GREASE AND OTHER CHEMICAL SUBSTANCES When handling oil, grease and other chemical substances, observe the product-related safety regulations. Be careful when handling hot consumable (risk of burning or scalding). 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.
  • Page 26 2.1 SAFETY INSTRUCTIONS SAFETY FALLING-OBJECT PROTECTIVE STRUCTURE ”FOPS” FOR OPERATOR’S CAB. The Shovel must be equipped with a falling object protective structure ”FOPS” if it is used for applications where there is a risk of falling material. The ”FOPS” structure shall comply with EN 474. FRONT GUARD PROTECTIVE STRUCTURE ”FGPS”...
  • 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 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 Z 22585 Superstructure Undercarriage Bottom dump bucket attachment Backhoe attachment...

  • Page 40: Superstructure

    3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.2 SUPERSTRUCTURE...
  • Page 41 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z25473 Hydraulically operated access ladder, see page 50 for more information. Battery main switches NOTICE After switching OFF the main key switch in the Operator’s cab, wait at least 3 minutes before switching OFF the battery main switches.
  • Page 42 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 43 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z25473 (continued) (16) Counter weight WARNING The chambers of the counterweight are filled with a mixture of concrete, granulated ore and steel pellets. This mixture can create explosive gases which will accumulate in the chambers of the counterweight.
  • Page 44 3.2 CONSTRUCTION OF THE SHOVEL OPERATION Machinery House...
  • Page 45 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z25506 Engine air cleaners Exhaust muffler Expansion tank for radiator Central control and filter carrier Pump distributor gear (PTO) Main hydraulic pumps Auxiliary piggyback hydraulic pumps Eliminator filter Hydraulic pump for radiator fan drive (10) Hydraulic pump for hydraulic oil cooler fan drive (11)
  • Page 46 3.2 CONSTRUCTION OF THE SHOVEL OPERATION Main Hydraulic Oil Reservoir Legend for illust. Z 21467a Breather filter Leakage oil filter Back-pressure valve, temperature controlled Main shut-off slider Drain coupling, main oil reservoir Collector pipe for return oil Return oil filters Drain coupling on collector pipe...
  • Page 47 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Hydraulic Oil Cooler Legend for illust. Z 21472 Cooler frame Lower fan Hydraulic motor for upper fan Fan guard Upper fan (10) Front section of lower cooler Fan guard (11) Rear section of lower cooler Front section of upper cooler (12) Hinged cooler carriers...
  • Page 48 3.2 CONSTRUCTION OF THE SHOVEL OPERATION Fuel Tank Legend for illust. Z 21473 Fuel tank Drain coupling Breather valve Shut-off cock for pressure transducer Fuel shut-off cock Pressure transducer for fuel level...
  • Page 49 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Counterweight Legend for illust. Z 21474a Counter weight, 37000 kg Fastening points for horizontal transport Mounting bolts, Qty 16, size M42, quality Fastening points for vertical transport grade 10.9. Tightening torque 4950 Nm Fastening points for raising up the counter Instruction label weight...

  • Page 50: Hydraulically Operated Access Ladder

    3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...
  • Page 51 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z 23018 Access ladder in lowered position Access ladder in upper position (Working position) Stop bar Manual actuator for fire suppression system (if so equipped) Pull chain for emergency lowering of the access ladder CAUTION Use this chain only in emergency cases, when the Operator does not respond to other communication signals.
  • Page 52 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 53 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Operating the hydraulic Access Ladder, illust. (Z 23018) Raise the ladder Enter the Shovel with ladder in fully lowered position (A). Start the engine. For starting procedure → See "STARTING THE ENGINE" on page 160. Go back to the ladder control switch (S84B) at the radiator door.

  • Page 54: Emergency Escape Ladder

    3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.4 EMERGENCY ESCAPE LADDER...
  • Page 55 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illust. Z24090 Sliding window, serves also for emergency exit REMARK If the operator’s cab is equipped with external metal sun visors, disengage the four catches and push out the sun visor panel. Release lever for hinged railing bar (3) Hinged railing bar Rigidly mounted emergency escape ladder.

  • Page 56: 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 57 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Emergency Engine Shutdown System actuated from Ground Man (special equipment) Legend for illust. Z25443 Actuating chains for emergency shut down of the engine. To stop the engine, pull down one of the chains (1). Actuating chain for hydraulically operated service arm.

  • Page 58: 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 59 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illust. Z 25199 NOTICE The Operator’s cab is equipped with an integrated Falling Object Protective Structure (FOPS) that meets the require- ments of ISO 3449. Any modifications on the steel structure of the cab are inadmissible. Repairs on the FOPS must only be carried out by specialists having the authorization for repair work on Falling Object Protective Structures and in accordance with the manufacturer’s repair instructions.
  • Page 60 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 61 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Legend for illustration Z25444 Top View of Operator’s Cab Co-driver’s seat, refer to page 68 for more information Windshield washer reservoir, refer to page 63 for more infor- mation. Washbasin with water tap Refrigerator box Portable fire extinguisher located behind the Operator’s seat.
  • Page 62 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 63 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Operator’s Cab - Hand Wash Sink and Refrigerator Legend for illust. Z 22462 Hand wash sink Water-tap WARNING No drinking water. Use for hand washing only Water tank for hand wash sink. The capacity of the water tank is 50 liters.
  • Page 64 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 65 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Sound Pressure Level in the Operator’s Cab The sound pressure level in the operator’s cab is 73 dB(A), mea- sured according to ISO6396 (Dynamic test method). The sound pressure value is also shown on the decal affixed in the operator’s cab, see illustration Z25214.
  • Page 66 3.2 CONSTRUCTION OF THE SHOVEL OPERATION...
  • Page 67 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 68 3.2 CONSTRUCTION OF THE SHOVEL OPERATION Co-driver’s Seat Legend for illust. Z 21421 Seat suspension frame Back rest Folding seat Adjust Seat Position A - Fold down seat to sitting position. The seat will automatically move up when released. B - To swing the seat out, towards the front, first lift seat suspen- sion frame (1) and then swing seat to the front;...

  • Page 69: Undercarriage

    OPERATION 3.2 CONSTRUCTION OF THE SHOVEL 3.2.7 UNDERCARRIAGE Legend for illustration Z 21481 Center frame Travel motor Crawler carrier, RH Parking brake Crawler carrier, LH (10) Travel gear Connecting pins, crawler carrier to center (11) Drive sprocket frame Crawler track (12) Track roller Swivel joint...

  • Page 70: Working Attachment

    3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.8 WORKING ATTACHMENT Loader attachment with bottom dump bucket Legend for illustration Z 21483 Boom Bucket wall Boom cylinders Bucket cylinders Stick Bucket bowl Stick cylinders Bowl opening - closing cylinders...
  • Page 71 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Loader attachment with backhoe bucket Legend for illustration Z 21482 Boom Backhoe bucket Boom cylinders Bucket cylinders Stick Link Stick cylinders...

  • Page 72: Diesel Engine Type Sda 16V160

    3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.9 DIESEL ENGINE TYPE SDA 16V160 Legend for illustration Z 21537, engine left side view LTA water outlet connection (11) Fuel filter head Rocker lever cover (12) Fuel pump Turbocharger (13) Air compressor (Not used) Air crossover connection (14) Accessory drive...
  • Page 73 Oil cleaning centrifuge *) (12) Engine bearing rear *) These units are part of the Komatsu engine oil management system which combines the automatic engine oil supply system "Reserve" and the oil burning system "Centinel" in connection with the "Eliminator" oil filtration system.

  • Page 74: Engine Oil Management System

    3.2 CONSTRUCTION OF THE SHOVEL OPERATION 3.2.10 ENGINE OIL MANAGEMENT SYSTEM...
  • Page 75 OPERATION 3.2 CONSTRUCTION OF THE SHOVEL Engine Oil Management System 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, illustration Z25458 Reserve oil tank, usable contents 457 liters.
  • Page 76 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 Oil filter (11) System malfunction indicator Pump unit (12) Oil level gauge Suction oil to reserve tank (13)
  • Page 77 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 78: Operator's Cab - Controls

    3.3 OPERATOR’S CAB - CONTROLS OPERATION OPERATOR’S CAB - CONTROLS 3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...

  • Page 79: Hydraulic Control System

    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 80 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
  • Page 81 OPERATION 3.3 OPERATOR’S CAB - CONTROLS EURO Control Pattern Legend for illustration Z25460 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 number 1 (TR1) For counting loaded trucks press this button.

  • Page 82: Controls With Bottom Dump Bucket Attachment

    3.3 OPERATOR’S CAB - CONTROLS OPERATION 3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT...

  • Page 83: Safety Circuit For Controls

    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 84 3.3 OPERATOR’S CAB - CONTROLS OPERATION...

  • Page 85: Automatic Float Position For Boom And Stick

    OPERATION 3.3 OPERATOR’S CAB - CONTROLS EURO Control Pattern Legend for illustration Z21542.3 Control lever for stick and swing machinery Control lever for boom and bucket Push button for deactivation of boom float position Push button for deactivation of stick float position Toggle switch for engine speed selection Low idle –...
  • Page 86 3.3 OPERATOR’S CAB - CONTROLS OPERATION...

  • Page 87: Operator's Console

    OPERATION 3.3 OPERATOR’S CAB - CONTROLS 3.3.6 OPERATOR’S CONSOLE Legend for illustration Z25445 Monitor of the Vehicle Health Monitoring System >VHMS< The monitor (1) displays the condition of the machine, the maintenance status, and messages for the opera- tor and service man, and is also used to input the nec- essary data.
  • Page 88 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
  • Page 89 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Switch Board Legend for illustration Z25446 Key operated main switch CAUTION After switching OFF main switch (1), wait at least 3 minutes before switching OFF the battery main switches. VHMS needs this period for saving data.
  • Page 90 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
  • Page 91 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Switch Board (continued) Legend for illustration Z25446 (10) Switch for main working lights (11) Toggle switch, swing parking brake 0 - Parking brake released - UP 1 - Parking brake applied - DOWN. CAUTION The parking brake should only be applied with superstructure at complete standstill, except in case of emergency.
  • Page 92 3.3 OPERATOR’S CAB - CONTROLS OPERATION...

  • Page 93: Interface Panel For Diagnostics And Controls For Heating And Air Conditioning

    OPERATION 3.3 OPERATOR’S CAB - CONTROLS 3.3.7 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING Legend for illust. (Z25447) Interface panel on rear operator’s console (X27A) Data link connector for download of VHMS memory data (S49) Reset button for VHMS monitor (X13) Data link connector for Electronic Tool connection to the electronic pump control system MC7...
  • Page 94 3.3 OPERATOR’S CAB - CONTROLS OPERATION...
  • Page 95 OPERATION 3.3 OPERATOR’S CAB - CONTROLS Interface Panel for Diagnostics and Controls for Heating and Air Conditioning (continued) Legend for illust. Z25447 Control module for the engine independent auxiliary cab heater (if so equipped). This module is used for switching ON and OFF the auxiliary cab heater dur- ing operation of the shovel with the Diesel engine running, and for pre-selection of heater start times and duration of heating periods.

  • Page 96: Vehicle Health Monitoring System Vhms - Health Monitor

    3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR 3.4.1 INITIALIZATION SCREEN NO. 0.0 The Monitor of the Vehicle Health Monitoring System ”VHMS” illust. (Z 21569) displays the condition of the machine, the mainte- nance status, and messages for the operator and service man, and is also used to input the necessary data.

  • Page 97: Standard Monitor 1 (No. 1.2)

    OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR 3.4.3 STANDARD MONITOR 1 (NO. 1.2) See illust. (Z 21571) Displayed items: LH column Date Time °C = Ambient temperature h = Operating hours (SMR) TR1 = Truck counter 1 TR2 = Truck counter 2 1/min = Engine speed (RPM) Monitor No.
  • Page 98 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION Touch Switches ”Brightness” This button switches to Brightness and Contrast setting screen, for details see picture No. 1.2.1. ”Fuel Consumption” This button switches to Fuel consumption screen, for details see picture No. 1.2.2.
  • Page 99 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR Expansion Monitor 3 (No. 1.4) See illust. (Z 21573) Displayed items: LH column Same as Standard Monitor 1 Gauges: HYDRAULIC OIL LEVEL ENGINE OIL LEVEL GREASE LEVEL CENTRAL LUBRICATION SYSTEM (CLS) GREASE LEVEL SWING RING GEAR LUBRICATION SYS- TEM (SLS) Touch Switches...
  • Page 100 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION Brightness and Contrast Setting Screen (No. 1.2.1) See illust. (Z 21574) When the brightness button is pressed, the screen No. 1.2.1 is displayed. If this screen is not touched within 5 seconds, it will dis- appear and the original screen will be displayed.
  • Page 101 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR Fuel Consumption Screen (No. 1.2.2) See illust. (Z 21575) When the fuel consumption button (2) is pressed, the screen No. 1.2.2 is displayed. The last data are displayed in each field on the screen.
  • Page 102 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION Settings for Operator, Screen (No. 1.2.3), see illust. (Z 21576) When the button -Settings for Operator is pressed, the screen No. 1.2.3 is displayed. Entry of the Operator identification number (USER ID button): In the selection menu for settings (1.2.3) appears on the right side of the button ”USER ID”...
  • Page 103 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR Maintenance Monitor 1.2.4 The Maintenance Monitor can be selected from the Standard monitor 1 and from the expansion monitors 2 and 3 by pressing the Maintenance button (4). The color of this button changes to yellow when maintenance is due.
  • Page 104 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION Maintenance Monitor 1.2.4 (continued) Illust. Z 21579D: 3050 Operating hours The 250 h, 500 h, 1000 h and 3000 h maintenance has not been carried out within the yellow time period so the background color has changed to red, indicating that the limit for these maintenance items is exceeded by 50 h WARNING...
  • Page 105 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR Maintenance confirmation through Service Personnel Maintenance indicated with yellow or red background color should be confirmed through Service Personnel in the Service Menu subsequent to the execution of the maintenance. With the confirmation the actual value maintenance number is increased by 1.
  • Page 106 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION 1.2.5 Failure Message (for Operator) Failure history for Operator The Failure Message history screen illustration (Z 21580) can be selected from the Standard monitor 1 and from the expansion monitors 2 and 3 by pressing the ”Message” button. The color of this button changes to yellow when a current message is avail- able in the failure message history for the operator.
  • Page 107 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR Automatic Messages If a failure or an information condition occurs during operation, the present display is automatically replaced by a message in text. If there are several messages at the same time, the system starts rolling up of all present messages and the present display.
  • Page 108 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION Automatic Messages Example of a message with red background color of the top mes- sage, see illust. (Z 21581). Legend for illust. (Z 21581) and (Z 21582) Top message: Type of failure Instruction message: Follow the displayed instruc- tions Message number (Error code): G = Shovel gener-...
  • Page 109 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR Automatic Messages Legend for illust. (Z 21581) and (Z 21582) continued Restart button (red): This button restarts automatic roll up of current messages. Jump button: This button switches to the last dis- played menu, normally the Standard Monitor 1.
  • Page 110 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION Automatic Messages Example of an information message with green background color of the top message, see illust. (Z 21583). Legend for illust. (Z 21583) Top message: Type of information Explanation of condition Message number (Error code): G = Shovel generated message C = engine 1 generated message Order of occurrence of message now being displayed...

  • Page 111: Table Of All Top Messages Provided By The System

    OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR 3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM NOTICE The Instruction Messages belonging to the TOP Messages are listed in a separate Table. The number shown in the Instruction Message column indicates the applying Instruc- tion Message for the TOP Message.
  • Page 112 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION TOP Message Instruction ErrorCode Color code of with colored background Message (Message TOP Message: Number. REMARK number) 0 = RED Refer to Messages w/o color code are not displayed. G = Shovel 1 = YELLOW separate These messages are stored in the history memory...
  • Page 113 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR TOP Message Instruction ErrorCode Color code of with colored background Message (Message TOP Message: Number. REMARK number) 0 = RED Refer to Messages w/o color code are not displayed. G = Shovel 1 = YELLOW separate These messages are stored in the history memory...
  • Page 114 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION TOP Message Instruction ErrorCode Color code of with colored background Message (Message TOP Message: Number. REMARK number) 0 = RED Refer to Messages w/o color code are not displayed. G = Shovel 1 = YELLOW separate These messages are stored in the history memory...
  • Page 115 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR TOP Message Instruction ErrorCode Color code of with colored background Message (Message TOP Message: Number. REMARK number) 0 = RED Refer to Messages w/o color code are not displayed. G = Shovel 1 = YELLOW separate These messages are stored in the history memory...
  • Page 116 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION TOP Message Instruction ErrorCode Color code of with colored background Message (Message TOP Message: Number. REMARK number) 0 = RED Refer to Messages w/o color code are not displayed. G = Shovel 1 = YELLOW separate These messages are stored in the history memory...
  • Page 117 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR TOP Message Instruction ErrorCode Color code of with colored background Message (Message TOP Message: Number. REMARK number) 0 = RED Refer to Messages w/o color code are not displayed. G = Shovel 1 = YELLOW separate These messages are stored in the history memory...
  • Page 118 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION TOP Message Instruction ErrorCode Color code of with colored background Message (Message TOP Message: Number. REMARK number) 0 = RED Refer to Messages w/o color code are not displayed. G = Shovel 1 = YELLOW separate These messages are stored in the history memory...
  • Page 119 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR TOP Message Instruction ErrorCode Color code of with colored background Message (Message TOP Message: Number. REMARK number) 0 = RED Refer to Messages w/o color code are not displayed. G = Shovel 1 = YELLOW separate These messages are stored in the history memory...

  • Page 120: Table Of Available Instruction Messages

    3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR OPERATION 3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES NOTICE TOP Messages and applying Instruction Messages are always displayed together. Message Instruction Message Engine stopped because of main Shut-Off (gate) valve. - Open the Shut-Off (gate) valve. - If failure exist further, inform service.
  • Page 121 OPERATION 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR Message Instruction Message Swing gear house brake OFF - Inform service till end of shift and then press cancel button. Travel gear house brake OFF - Inform service till end of shift and then press cancel button. Inform service and then press cancel button.

  • Page 122: Operating The Heater, Ventilation And Air Conditioning

    3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING OPERATION OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING Legend for illustration Z25448 Switch, cab ventilation blower. Heater and air conditioning control panel Cab heating control Cab heating blower control Control module for the engine independent auxiliary cab heater (if so equipped).

  • Page 123: A - Heating

    OPERATION 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 3.5.1 A - HEATING 1. Set temperature control (3) to desired stage. 2. Set blower control (4) to desired stage. 3.5.2 B - COOLING 1. Set blower switch (16) to high stage. 2.
  • Page 124 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING OPERATION...

  • Page 125: Auxiliary Heater For Operator's Cab

    OPERATION 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 3.5.4 AUXILIARY HEATER FOR OPERATOR’S CAB Special Equipment REMARK The auxiliary cab heater is located in the compartment below the stair to the operator’s cab. View A-A shows the arrangement of components and the flow of water, fuel and air. Legend for illustration Z25452 Fuel tank Stair to operator’s cab...

  • Page 126: Power House

    3.6 POWER HOUSE OPERATION POWER HOUSE...

  • Page 127: Emergency Engine Shutdown Switches

    OPERATION 3.6 POWER HOUSE 3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES Legend for illustration Z25359 Battery main switch keys NOTICE After switching OFF the main key switch in the Operator’s cab, wait at least 3 minutes before switching OFF the battery main switches. The Vehicle Health Monitoring System (VHMS) needs this period for saving data.
  • Page 128 3.6 POWER HOUSE OPERATION...

  • Page 129: Maintenance Safety Switch And Battery Main Switches

    OPERATION 3.6 POWER HOUSE 3.6.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES Legend for illustration Z25359 Maintenance safety switch (S58) for start prevention of the Diesel engine. This switch is located inside the power house, next to the front door. WARNING Before beginning any maintenance operations set the safety switch (6) to -0- position to prevent...
  • Page 130 3.6 POWER HOUSE OPERATION...

  • Page 131: Central Control And Filter Panel

    OPERATION 3.6 POWER HOUSE 3.6.3 CENTRAL CONTROL AND FILTER PANEL Legend for illustration Z 23021 Central control and filter panel Valve bank (2.1) Valve block, pump load limiting circuit (2.2) Valve block, fixed pump 1and 3 for swing (2.3) Valve block, pilot oil circuit (2.4) Valve block, pump control circuit (2.5)
  • Page 132 3.6 POWER HOUSE OPERATION...
  • Page 133 OPERATION 3.6 POWER HOUSE Legend for illustration Z 23021 (continued) Solenoid Valves (Y5)) Swing parking brake operating pressure (Y6a) Oil cooler fan RPM control minimum speed (Y6b) Oil cooler fan RPM control medium speed (Y16) Travel parking brake operating pressure (Y17) Pump idle time control system (Y17a)

  • Page 134: Electrical Equipment In Cab Base

    3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION ELECTRICAL EQUIPMENT IN CAB BASE...

  • Page 135: Standard Components In Cab Base

    OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE 3.7.1 STANDARD COMPONENTS IN CAB BASE REMARK On shovels with electrical pre-heating systems there are addi- tional components in the cab base. Refer to page 147 for more information. WARNING The cab base contains batteries which are located in a com- partment below the floor plate.
  • Page 136 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...

  • Page 137: Switch Board (X2) In Cab Base

    OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE 3.7.2 SWITCH BOARD (X2) IN CAB BASE Legend for illustration Z25468 Switches Emergency By-pass switch for the shutdown f unction of the PLC (E6). If an automatic (S27) shutdown is initiated by Shovel systems , with a dangerous situation for man or machine, which needs the Shovel to be operable to over-come the dangerous situation, actuate this switch to override the shutdown function of the system and to enable a restart of the Diesel engine.
  • Page 138 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
  • Page 139 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Legend for illustration Z25468 Service Indicator Lights (H94.1) Engine STOP lamp red. This lamp flashes out fault codes of the QUAN- TUM electronic engine control system. See heading -Checking active diagnostic fault codes- for more information. (H95.1) Engine WARNING lamp yellow.
  • Page 140 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
  • Page 141 3 second delay before the fault code flashout begins again. CAUTION Active faults MUST be corrected as soon as possible. Contact your Komatsu dealer for repair. REMARK For more information, refer to the separate Engine Operation and Maintenance Manual filed in volume 2 binder.
  • Page 142 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
  • Page 143 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Emergency Indication of Operating Conditions The VHMS system is equipped with an emergency indication via LED’s on the Programmable Logic Controller ”PLC” (E6), illust. (Z 22588). In case of a malfunction of the health monitor in the operator’s cab, the LED’s in the fourth column (A7/A12 and A8/E12) of the ”PLC”...
  • Page 144 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
  • Page 145 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE High Pressure Filter "HPF" Identification Codes of LED H31 The LED ”H31”, illust. (Z 22588), monitors all four high pressure filters of the four main pumps. If a failure condition of a high pres- sure filter occurs, the LED ”H31”...
  • Page 146 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...

  • Page 147: Components Of Electrical Pre-Heating System Located In The Cab Base

    OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE 3.7.3 COMPONENTS OF ELECTRICAL PRE-HEATING SYSTEM LOCATED IN THE CAB BASE WARNING The cab base contains high tension electrical appliances. Access to the cab base for authorized service staff only. General The preheating system is a special equipment and can be installed in the factory or locally at site.
  • Page 148 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
  • Page 149 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Components of Electrical Preheating System in Cab Base (continued) Operating the Preheating System Use the preheating system during stand-still periods e.g. over night and low ambient temperatures. The heating system should be energized as soon as the engine is shut down.
  • Page 150 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
  • Page 151 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Pre-heating System (continued) Engine Coolant and Engine Oil Heatings REMARK Use the heating system during stand-still periods e.g. over night and low ambient temperatures. The heating system should be energized as soon as the engine is stopped.
  • Page 152 3.7 ELECTRICAL EQUIPMENT IN CAB BASE OPERATION...
  • Page 153 OPERATION 3.7 ELECTRICAL EQUIPMENT IN CAB BASE Pre-heating System (continued) Heaters for Hydraulic Oil Reservoirs, PTO Housing, Engine Oil Reserve Tank and Batteries, illustration Z 22893 Junction box for hydraulic oil heating Switch, hydraulic oil heating ON / OFF. Warning light red, heating system failure, Indicator light green, hydraulic oil heating ON.

  • Page 154: Checks Before Starting The Engine

    3.8 CHECKS BEFORE STARTING THE ENGINE OPERATION CHECKS BEFORE STARTING THE ENGINE...
  • Page 155 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 Z 21613 Engine oil reserve tank of the RESERVE system Sight gauge reserve tank oil level Eliminator engine oil filtration system Centrifugal separator for engine oil...
  • Page 156 3.8 CHECKS BEFORE STARTING THE ENGINE OPERATION...
  • Page 157 OPERATION 3.8 CHECKS BEFORE STARTING THE ENGINE 3. Coolant level WARNING DO NOT remove the radiator pressure cap (9), illust. Z21613 from a hot engine. Wait until the temperature is below 50°C before removing the pressure cap (9). Failure to do so can result in personal injury from heated coolant spray or steam.
  • Page 158 3.8 CHECKS BEFORE STARTING THE ENGINE OPERATION...
  • Page 159 OPERATION 3.8 CHECKS BEFORE STARTING THE ENGINE 4. 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 Z 21585 Main hydraulic oil reservoir Hydraulic oil level sight gauge...

  • Page 160: Starting The Engine

    3.9 STARTING THE ENGINE OPERATION STARTING THE ENGINE...
  • Page 161 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 connected before starting the engine. Loose or missing ground cables can cause fire, serious injury or death.
  • Page 162 3.9 STARTING THE ENGINE OPERATION...

  • Page 163: Starting Procedure

    OPERATION 3.9 STARTING THE ENGINE 3.9.1 STARTING PROCEDURE 1. Insert battery main switch keys and turn to operating position, refer to section 3.6 for the location of the battery main switches. REMARK Start the engine with the safety lock lever (9) illust. Z25449 in the fully rear LOCKED position.
  • Page 164 3.9 STARTING THE ENGINE OPERATION...
  • Page 165 OPERATION 3.9 STARTING THE ENGINE After starting observe the following The VHMS System monitors the Shovel’s functions and pro- vides information about the appropriate operational data. If a FAULT message is displayed on screen (3), the acoustic warning signal (2) will sound simultaneously for approxi- mately 1 second.
  • Page 166 3.9 STARTING THE ENGINE OPERATION...

  • Page 167: Engine Warm-Up

    OPERATION 3.9 STARTING THE ENGINE 3.9.2 ENGINE WARM-UP After starting let the engine run for a warm-up period before increasing the engine speed. This is necessary to avoid piston and bearing seizure. Refer to the engine operation and maintenance manual for more information.
  • Page 168 3.9 STARTING THE ENGINE OPERATION HYDRAULIC OIL VISCOSITY AND TEMPERATURE CHART Starting Operating Ratedviscosity temperature range at 40° C of (max. 1000 cSt) (100 - 10 cSt) hydraulic oil grade: ISO VG °C °C HLP 22 8 - 55 HLP 32 16 - 70 HLP 46 25 - 80...

  • Page 169: 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 170 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 171 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 172: 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 173: 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 Z25450 ”L” CCW- Lever (1) to the left ”L” ”N” Neutral position ”R” CW- Lever (1) to the right ”R” REMARK The slew speed can be increased by activating the slew speed switch (2).
  • Page 174 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE OPERATION MACHINES WITH "KMG" CONTROL Legend for illustration Z25451 ”L” CCW- Lever (2) to the left ”L” ”N” Neutral position ”R” CW- Lever (2) to the right ”R” REMARK The slew speed can be increased by activating the slew speed switch (5).

  • Page 175: Braking The Superstructure

    OPERATION 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE 3.11.2 BRAKING THE SUPERSTRUCTURE Braking of the superstructure from a slewing movement is carried out first by returning the control lever (1) or (2) to the neutral posi- tion (N). This procedure can be shortened by depressing pedal (3).

  • Page 176: Slew Parking Brake

    If the parking brake has been used for emergency stop- ping, it is necessary to shut down the Excavator and to have the parking brake of each swing gear inspected and repaired if necessary. Contact your Komatsu dealer for support. SWITCH POSITIONS ”0”...
  • Page 177 OPERATION 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System The hydraulic slew brake will be applied automatically when the access ladder and/or the service arm of the central refilling sys- tem is not in its completely lifted position.

  • Page 178: 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 179: 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 180: 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 181: 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 182 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, slew gear and working lights (if so equipped) Cylinder piston rod guard Slew ring guard Reinforcement ledges on bucket wall and clam edges NOTICE...
  • Page 183 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 184: 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 185 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 186: 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 187 OPERATION 3.13 WORKING INSTRUCTIONS CAUTION DO NOT "Sweep" with the loader attachment, illust. (Z 10369), as this may result in severe damage on slew gear components. CAUTION DO NOT use the bucket clam for loosening or removing anchored rocks or other solid objects (illust. Z 19984 and Z 19985), since such operations may result in severe damage to the clam pivot bearings.
  • Page 188 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 189: 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 in a position as shown on the oil level plate at the hydraulic oil reservoir. Stop the engine and relieve the pressure in the hydraulic sys- tem, see "STOPPING THE ENGINE"...

  • Page 190: Stopping The Engine

    3.15 STOPPING THE ENGINE OPERATION 3.15 STOPPING THE ENGINE...
  • Page 191 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 192 3.15 STOPPING THE ENGINE OPERATION...

  • Page 193: Relieve Pressure In The Hydraulic System

    OPERATION 3.15 STOPPING THE ENGINE 3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 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.

  • Page 194: Operation Of The Lubrication System

    3.16 OPERATION OF THE LUBRICATION SYSTEM OPERATION 3.16 OPERATION OF THE LUBRICATION SYSTEM 3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS” The central lubrication system works automatically as soon as the engine is running at high idle speed. The VHMS System monitors the function of the central lubrication system.
  • Page 195 OPERATION 3.16 OPERATION OF THE LUBRICATION SYSTEM ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM The following adjustments can be made in the service menu of the VHMS system, under menu point 4.8.1: Level 4: Service Menu / Settings 4.8.1 *PAUSE TIME *MONITORING TIME *PRESSURE RELIEF TIME *LUBE CYCLE COUNTER...

  • Page 196: Swing Circle Pinion Lubrication System "Sls

    3.16 OPERATION OF THE LUBRICATION SYSTEM OPERATION 3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” This system works automatically as soon as the engine is running at high idle speed. The VHMS System monitors the function of the swing circle lubri- cation system.
  • Page 197 OPERATION 3.16 OPERATION OF THE LUBRICATION SYSTEM SWING CIRCLE LUBRICATION SYSTEM ”SLS” Repairs on the swing circle lubrication system with the Engine running or with the Engine OFF and Main Switch Key in ON position If repairs under the above conditions have been carried out it is necessary to reset the control circuit of the lubrication system by actuating the rotary switch (2), illust.

  • Page 198: Fire Detection And Suppression System

    3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM (Special Equipment)
  • Page 199 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 200 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...

  • Page 201: 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 202 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...

  • Page 203: 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 204 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM OPERATION...

  • Page 205: 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 Legend for illustration Z 21620 Rear mounting bracket for the Extinguishing agent tank assemblies and Expellant gas cartridges Front mounting bracket for the Extinguishing agent tank assemblies and Expellant gas cartridges Expellant gas cartridges...

  • Page 206: Transfer Pump For Hydraulic Oil

    3.18 TRANSFER PUMP FOR HYDRAULIC OIL OPERATION 3.18 TRANSFER PUMP FOR HYDRAULIC OIL (SPECIAL EQUIPMENT)

  • Page 207: Operating The Transfer Pump

    OPERATION 3.18 TRANSFER PUMP FOR HYDRAULIC OIL 3.18.1 OPERATING THE TRANSFER PUMP Legend for illust. Z25471 REMARK The illustration shows the transfer pump arrangement viewed from center of the platform. Cock for suction oil reservoir (11) Cock for return oil collector pipe (12) Cock for back-pressure valve pipe (13) C - Closed O - Open...
  • Page 208 3.18 TRANSFER PUMP FOR HYDRAULIC OIL OPERATION...

  • Page 209: Functions Of The Transfer Pump

    OPERATION 3.18 TRANSFER PUMP FOR HYDRAULIC OIL 3.18.2 FUNCTIONS OF THE TRANSFER PUMP A - Transfusing oil from the suction oil reservoir (11), illustra- tion Z25471 into the main oil reservoir. Necessary for evacua- tion of the suction oil reservoir, when changing the hydraulic oil (main oil reservoir will be evacuated via service arm con- nector, see page 212 for details).
  • Page 210 3.18 TRANSFER PUMP FOR HYDRAULIC OIL OPERATION...
  • Page 211 OPERATION 3.18 TRANSFER PUMP FOR HYDRAULIC OIL A - Pumping the oil from the Suction Oil Reservoir (11) into the Main Oil Reservoir (continued) 6. The suction oil reservoir and the suction hoses are filled, when bubble free oil flows out at the vent plug openings on each main pump.

  • Page 212: Central Refilling System

    3.19 CENTRAL REFILLING SYSTEM OPERATION 3.19 CENTRAL REFILLING SYSTEM (Special Equipment)

  • Page 213: Systems Connected To The Refilling System

    OPERATION 3.19 CENTRAL REFILLING SYSTEM 3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM The following systems are connected to the receiver panel (5) of service arm (3), illust. (Z25457): Fuel Tank Water Tank for Hand Wash Sink in the Operator’s Cab Engine oil reserve Tank of the RESERVE System Engine Oil Pan Engine Coolant Radiator...
  • Page 214 3.19 CENTRAL REFILLING SYSTEM OPERATION...

  • Page 215: Operating The Hydraulic Service Arm

    OPERATION 3.19 CENTRAL REFILLING SYSTEM 3.19.2 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. (Z25457) to ON position ”1”. 3.
  • Page 216 3.19 CENTRAL REFILLING SYSTEM OPERATION...

  • Page 217: Receiver Panel With Monitor Box

    OPERATION 3.19 CENTRAL REFILLING SYSTEM 3.19.3 RECEIVER PANEL WITH MONITOR BOX Legend for illustration Z 21623: Service arm, hydraulically operated Monitoring and control box Receiver panel Fuel filling adapter REMARK The fuel nozzle cut-out pressure should be adjusted to 0,38 bar. If this pressure is too low for filling the fuel tank up to the correct level, gradually increase the cut- out pressure until the pressure is sufficient for filling up to the correct level...
  • Page 218 3.19 CENTRAL REFILLING SYSTEM OPERATION...
  • Page 219 OPERATION 3.19 CENTRAL REFILLING SYSTEM Legend for illustration Z 21623 Adapter for evacuation and filling of the main hydraulic oil reservoir. After the oil is completely evacuated, drain the oil from suction oil reservoir, collector pipe and back- pressure valve pipe. Refer to maintenance section, item hydraulic oil change for draining procedure.
  • Page 220 3.19 CENTRAL REFILLING SYSTEM OPERATION...
  • Page 221 OPERATION 3.19 CENTRAL REFILLING SYSTEM RECEIVER PANEL WITH MONITOR BOX Legend for illust. Z 21623 Adapter for filling the water tank in the Operator’s cab. The water tank has a capacity of 50 liters. The filling line of the water tank is equipped with a drain cock. Before filling the water tank, drain the old water by opening this drain cock.
  • Page 222 3.19 CENTRAL REFILLING SYSTEM OPERATION...

  • Page 223: Refillable Grease Containers Of The Central Lubrication System And Swing Circle Pinion Lubrication System

    OPERATION 3.19 CENTRAL REFILLING SYSTEM 3.19.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM Legend for illustration Z 23030 Grease supply line to the injectors for lubrication of the loader attachment, swing circle bearing and swing machinery pinion bearing Grease supply line to the injectors for lubrication of the swing circle tooth- Pressure oil supply from pilot oil circuit to hydraulically driven grease pumps (5 and 12)
  • Page 224 3.19 CENTRAL REFILLING SYSTEM OPERATION...
  • Page 225 OPERATION 3.19 CENTRAL REFILLING SYSTEM Refilling the Grease Containers of the Automatic Lubrication Systems Refill the respective grease container, when the Fault message ”Central lube system grease container empty” ”Swing circle lube system grease container empty” is being displayed on the VHMS monitor. CAUTION The central lubrication system and the swing circle pinion lubrication system have to be filled with different types of...

  • Page 226: 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 227: 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 228: Retrieval Procedure

    Check for fuel or oil spillage. 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 229: 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 230: 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 231: 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 232: 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 233: 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 234: Final Drives And Swing Machinery

    3.24 TROUBLE SHOOTING OPERATION 3.24.3 FINAL DRIVES AND SWING MACHINERY 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 235: Maintenance

    4. MAINTENANCE...

  • Page 236: 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 237: 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 Shovel at a safe place on level ground. Proceed according to the instructions on page 189 ”Parking the Shovel”.
  • Page 238 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 239: Fuel And Lubricants

    MAINTENANCE 4.3 FUEL AND LUBRICANTS FUEL AND LUBRICANTS Ambient Lubrication Viscosity Quality Grades Lubricant Temperature Point Grades DIN/API °C Engine Oil Refer to ”Engine Operation and Coolant Maintenance Manual" for Specifications. Fuel DIN-51524 - 25 to + 15 T.2 - HLP Hydraulic oil “HLP or -15 to + 25...
  • Page 240 4.3 FUEL AND LUBRICANTS MAINTENANCE Ambient Quality Grades Lubrication Viscosity Lubricant Temperature Point Grades °C DIN/API Grease Fittings Refer to the Lubricant Chart in Part 3 of Volume 2 Binder for the rec- (manual lubrication) Multi-Purpose ommended Multi-Purpose Greases. The part numbers of recom- Grease ”MPG”...

  • Page 241: Filling Capacities

    MAINTENANCE 4.4 FILLING CAPACITIES FILLING CAPACITIES Unit or System Liter (approx.) Engine cooling system 475.0 Engine oil pan 290.0 Engine oil reserve tank 580.0 (457.0 Refill) Fuel tank 6400.0 Hydraulic oil reservoir 3900,0 Hydraulic system 5900.0 Flexible coupling between engine and PTO PTO (Pump distributor gear) 150.0 Swing machinery (Manufacturer L&S), each...

  • Page 242: 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 243: 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 machinery, travel gears and PTO (pump dis- tributor gear). Thereafter every 3000 hours, but at least once a year.

  • Page 244: 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 255 Immediately apply grease if bare Swing circle toothing page 259 spots are visible Replace or fill grease containers When necessary Automatic lubrication systems page 261 Clean or replace filter elements...
  • Page 245 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Service Intervals Service Point Service Refrigerant compressor Check drive belt tension page 297 Undercarriage pin connections Lubricate page 299 Signal horn compressor Lubricate page 299 Oil cooler fan bearing housings Check for leakages and clean page 299 and Radiator fan bearing housing breather filters...
  • Page 246 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE Service Intervals Service Point Service Check for correct tightening High strength bolt connections page 325 torque and security Replace return and pressure fil- ter elements Clean or replace high pressure Hydraulic system page 367 filter elements Replace breather filter elements Drain sediments...
  • Page 247 MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Service Intervals Service Point Service Change oil (*) Hydraulic system Replace suction strainers (*) page 391 Replace pulsation damper Every 2000 operating hours or yearly. Emergency escape ladder Inspect page 403 Fire detection and actuation sys- Maintenance Swing machinery and Motor Change oil...
  • Page 248 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE Lubrication Chart...
  • Page 249 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 250 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...

  • Page 251: Extended Service Intervals For Engines Equipped With Engine Oil Management System

    MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE 4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED 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 252 4.6 LUBRICATION AND MAINTENANCE SCHEDULE MAINTENANCE...

  • Page 253: Maintenance Of The Engine

    MAINTENANCE 4.6 LUBRICATION AND MAINTENANCE SCHEDULE Extended Service Intervals for Engines equipped with Engine Oil Management System Every 400 to 500 operating hours The reserve tank contents of engine oil is sufficient for 400 to 500 hours of operation depending on operating condi- tions and environmental factors.

  • Page 254: When Necessary

    4.7 WHEN NECESSARY MAINTENANCE WHEN NECESSARY...

  • Page 255: Engine Air Cleaner Service

    MAINTENANCE 4.7 WHEN NECESSARY 4.7.1 ENGINE AIR CLEANER SERVICE Servicing the Engine Air Cleaners NOTICE Before servicing the filter elements clean dust cups of the pre-cleaners. Servicing the main filter elements, illust. Z 21653: CAUTION Never service air cleaner while engine is running. Clean main filter elements as soon as the fault message "Air cleaner element restricted"...
  • Page 256 4.7 WHEN NECESSARY MAINTENANCE...
  • Page 257 MAINTENANCE 4.7 WHEN NECESSARY NOTICE Before installing main elements (4) check service indicator (6) of safety element (7). If a red signal is shown, replace safety element (7). Clean indicator (6) then suck on the outer side of the indica- tor to reset signal to green indication.
  • Page 258 4.7 WHEN NECESSARY MAINTENANCE...

  • Page 259: 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 260 4.7 WHEN NECESSARY MAINTENANCE...

  • Page 261: Automatic Lubrication Systems Fill Grease Barrels

    MAINTENANCE 4.7 WHEN NECESSARY 4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS Fill the grease barrels of the Central Lubrication System and Swing circle pinion Lubrication System when the corresponding message "grease barrel empty" is displayed on the health moni- tor. Make sure the grease filters in the filling line are not obstructed.
  • Page 262 4.7 WHEN NECESSARY MAINTENANCE...
  • Page 263 MAINTENANCE 4.7 WHEN NECESSARY Service the Grease Filters for Refillable Grease Containers of the Central Lubrication System and Swing circle pinion Lubrication System, illust. Z 20718 1. Screw off filter case. 2. Remove element assy. (02) and clean. Take care not to con- taminate the ”Clean”...
  • Page 264 4.7 WHEN NECESSARY MAINTENANCE...

  • Page 265: 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 21654 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 266: Every 10 Operating Hours Or Daily

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

  • Page 267: Walk-Around Inspection

    In case the bucket base is already weakened, reconditioning measures will be necessary. Contact your Komatsu dealer for support. Hydraulic cylinders. Check cylinders, hydraulic lines and connections for leakage and damage.
  • Page 268 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
  • Page 269 MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY Legend for illustration Z25475 (18) Check automatic lubrication systems for leakage, damaged hoses and connections. (19) Check housing of oil cooler fan bearing for leakage. Check fan guards and coverings for correct installation, good condition and security. (20) Check hydraulic oil cooler for plugged cores.
  • Page 270 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
  • Page 271 MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY 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 bottom dump bucket Injectors on stick Injectors on boom Indicator stem for visual indication of injector opera-...
  • Page 272 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
  • Page 273 MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY CHECK GREASE INJECTORS Legend for illustration Z 19191 Injectors for swing circle teeth lubrication Indicator stem for visual indication of injector operation Output adjusting screw Swing circle Swing machinery drive pinion Swing circle guard (10) Inspection cover for swing circle teeth Check operation of injectors “E”...
  • Page 274 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...
  • Page 275 MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY CHECK GREASE INJECTORS Legend for illustration Z 21651 Injectors for lubrication of swing circle bearing, boom cylinder foot bearings and swing machinery pinion bearings Grease supply line to injectors (A) Grease supply lines to swing circle bearing lube con- nectors Grease supply line to LH boom cylinder foot bearing Grease supply line to RH boom cylinder foot bearing...
  • Page 276 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...

  • Page 277: Air Cleaner - Clean Pre-Cleaner

    MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY 4.8.2 AIR CLEANER - CLEAN PRE-CLEANER Clean dust cups of pre-cleaners Legend for illust. Z 21652: 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 278 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...

  • Page 279: Radiator - Check Coolant Level

    MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY 4.8.3 RADIATOR - CHECK COOLANT LEVEL Legend for illustration Z 21652 Radiator Coolant level sight gauge Radiator pressure cap WARNING DO NOT remove the radiator pressure cap (8) from a hot engine. Wait until the temperature is below 50°C before removing the pressure cap (8).
  • Page 280 4.8 EVERY 10 OPERATING HOURS OR DAILY MAINTENANCE...

  • Page 281: Fuel System Water Separator - Drain Water

    MAINTENANCE 4.8 EVERY 10 OPERATING HOURS OR DAILY 4.8.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER Legend for illustration Z 23062 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 282: Every 50 Operating Hours Or Weekly

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

  • Page 283: Swing Machinery And Motor Adapter Housings - Check Oil Levels

    MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS REMARK The machine can be equipped either with a swing machinery of manufacturer "L&S" or of manufacturer "Siebenhaar". Refer to the data plate on each swing machinery housing to find out the manufacturer of the swing machinery.
  • Page 284 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE " & "...
  • Page 285 MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY Swing Machinery manufactured by "Siebenhaar" Legend for illustration Z 21656 Position of oil level gauge for checking the oil levels Swing machinery Brake housing Compensator oil tank for swing machinery Oil level gauge for swing machinery Oil drain plug for motor adapter housing Oil level gauge for motor adapter housing Breather filter for brake housing...
  • Page 286 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...

  • Page 287: 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 Legend for illustration Z 20434 Travel Gears Oil level gauge Oil filler plug Breather filter REMARK The breather filters for the travel gears are mounted inside the center frame and connected with extension hoses.
  • Page 288 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...

  • Page 289: Final Drive Housings - Check Oil Level

    MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL (Drive Shaft Housings) Legend for illustration Z 19087 Oil level gauge Oil filler plug Breather filter REMARK The breather filters for the final drives are mounted inside the center frame and connected with extension hoses.
  • Page 290 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...

  • Page 291: Pto (Pump Distributor Gear) And Oil Reservoir - Check Oil Level

    MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL Legend for illustration Z 21657 Oil level gauge Oil filler plug Breather filter Oil collector reservoir for secondary oil pump drive shaft housings Breather filter with oil level gauge Main pump drive shaft housings...
  • Page 292 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...

  • Page 293: Hydraulic Access Ladder - Check Safety Sensor

    MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR Legend for illustration Z 23018 Access ladder in lowered position Access ladder in upper position (Working position) Stop bar Manual actuator for fire suppression system (if so equipped) Pull chain for emergency lowering of the access ladder CAUTION Use this chain only in emergency cases, when the Operator...
  • Page 294 4.9 EVERY 50 OPERATING HOURS OR WEEKLY MAINTENANCE...

  • Page 295: Hydraulic Oil Coolers - Inspect And Clean If Necessary

    MAINTENANCE 4.9 EVERY 50 OPERATING HOURS OR WEEKLY 4.9.6 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY See illustration Z 20369 WARNING Provide adequate working platform for safe access to the hydraulic oil coolers. Before removing mounting bolts (1) of the hydraulic oil cooler door (2) check to make sure that all door hinges are in good condition and properly fastened on their car- rier frames.

  • Page 296: Every 250 Operating Hours Or Monthly

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

  • Page 297: 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 298 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 299: Undercarriage Pin Connections - Lubricate

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE See illustration Z 10972 Lubricate the pin connections via grease fittings (1) at center sec- tion (16 fittings; front, rear and from inside). 4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE See illustration Z 10689 The compressor (2) is located in the cab base.
  • Page 300 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 301: Automatic Lubrication Systems - Clean In-Line Grease Filter

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE 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 barrel)
  • Page 302 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...
  • Page 303 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 304 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 305: 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 Z25455( Pre.cleaner Air cleaner housing located on cab base Air cleaner mounting bolts Clean pre-cleaner dust bowl 1. Check the dust level in bowl (1), if the level is near the Max. marking remove and clean the dust bowl.
  • Page 306 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 307: Windshield Washer System - Check Fluid Level

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL Legend for illustration Z 25422 Water reservoir for windshield washer Filler cap with suction line Water pump for windshield washer Upper washer nozzle for windshield Water pump for windshield washer Lower washer nozzle for windshield Wiper motor for lower windshield wiper...
  • Page 308 4.10 EVERY 250 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 309: Air Conditioning For Operator's Cab - Check Refrigerant Level

    MAINTENANCE 4.10 EVERY 250 OPERATING HOURS OR MONTHLY 4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL Legend for illustration Z 22591 Air conditioner door with filter mat Air conditioner unit Sight glass for checking refrigerant filling Shut-off valve on dryer cartridge Dryer cartridge Refrigerant collector reservoir Condenser...

  • Page 310: Every 500 Operating Hours Or Monthly

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

  • Page 311: Batteries - Check Fluid Level

    MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 4.11.1 BATTERIES - CHECK FLUID LEVEL See illustration Z25474 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 312 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 313: 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 neces- sary for settling of the oil in the lower part of the coupling housing.
  • Page 314 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 315: Pto (Pump Distributor Gear) Main Pump Drive Shaft Housings - Check Oil Level

    MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL Legend for illustration Z 21657 Oil level gauge Oil filler plug Breather filter Oil collector reservoir for secondary oil pump drive shaft housings Breather filter with oil level gauge Main pump drive shaft housings...
  • Page 316 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 317: Fuel Tank - Drain Condensation

    MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 4.11.4 FUEL TANK - DRAIN CONDENSATION Legend for illust. Z 21668 Fuel tank breather valve on machines with central refilling system Fuel filler caps on machines without central refilling system Main fuel shut-off cock on machines without auto- matic fire suppression system Shut-off cock for fuel pressure transducer (5).
  • Page 318 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...

  • Page 319: Crawler Track - Inspection

    MAINTENANCE 4.11 EVERY 500 OPERATING HOURS OR MONTHLY 4.11.5 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 320 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...
  • Page 321 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 322 4.11 EVERY 500 OPERATING HOURS OR MONTHLY MAINTENANCE...
  • Page 323 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 324: 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 325: High Strength Bolt Connections

    MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.1 HIGH STRENGTH BOLT CONNECTIONS Check high-strength bolt connections for correct tightening torque. Check securing elements for damage and looseness. If any damages, failures or wrong conditions are found, corrective action must be taken.
  • Page 326 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 327 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of railings (A, B, C, D, F and G), illust. Z 23028 Bolt size SW * Tightening torque Reference No.: Grade Qty. * SW = Wrench size REMARK Detail (C) shows the bracket for attaching the emergency...
  • 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) Check fastening and condition of cab base, illust. Z 21671 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 3100 * SW = Wrench size...
  • Page 330 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 331 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check mounting of Operator’s cab, illust. Z 21683 Check tightening torque of mounting bolts as indicated in the illustration. Re-tighten loose mounting bolts and replace missing or dam- aged bolts.
  • 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 fastening and condition of fuel tank, illust. Z 21672 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 1770 10.9 1770 * SW = Wrench size...
  • Page 334 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 335 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check fastening and condition of hydraulic oil cooler, illust. Z 21673 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 1770 10.9 1770 * SW = Wrench size...
  • 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 High-Strength Bolt Connections (continued) Check fastening and condition of hydraulic oil tank, illust. Z 21674 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 1770 10.9 1770 * SW = Wrench size...
  • 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 High-Strength Bolt Connections (continued) Check mounting of power frame, illust. Z 21675 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 1770 10.9 1770 * SW = Wrench size...
  • 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 High-Strength Bolt Connections (continued) Machinery house, check mounting of posts and cross mem- ber. Check roof frame and roof elements for proper mounting and good condition, illust. Z 21676 Bolt size SW * Tightening torque Reference No.:...
  • 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 High-Strength Bolt Connections (continued) Check mounting and security of central control and filter panel and of the suction oil tank, illustration Z 23029 Legend for illustration (Z 23029): Bolt size SW * Tightening Reference No.:...
  • 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 High-Strength Bolt Connections (continued) Check mounting and security of Diesel engine and pump dis- tributor gear, illust. Z 21601 Check all flexible bearings (1) for engine and pump distributor gear. Check the flexible bearings for damage and signs of fatigue.
  • 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 High-Strength Bolt Connections (continued) Check mounting and security of Diesel engine and pump dis- tributor gear, illust. Z 21601 Legend for illustration (Z 21601): Bolt size SW * Tightening Reference No.: Grade Qty.
  • Page 348 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 349 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of the hydraulic pumps, illust. Z 21680 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 10.9 Guard for flex- ible coupling * SW = Wrench size...
  • Page 350 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 351 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of main control valves and high pressure filters, illust. Z 21681 Bolt size SW * Tightening torque Reference No.: Grade Qty. 10.9 10.9 10.9 10.9...
  • Page 352 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 353 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check tightening torque of the counterweight mounting bolts (2), illustration Z 21474a Bolt size SW * Tightening torque Reference No.: Grade Qty. (1) Counter weight (2) Mounting bolts 10.9 4950 (3) Instruction label...
  • Page 354 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 355 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of both swing gears (01) and swing motors (02), illust. Z 22514 Bolt size SW * Tightening torque Qty. Reference No.: Grade M 16 10.9 (25)
  • Page 356 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 357 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Swing circle, illust. Z 20864 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 358 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 359 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of swivel joint (A), illust. Z 20865 Bolt size SW * Tightening torque Reference No.: Grade Qty. M 16 M 16 10.9 * SW = Wrench size...
  • Page 360 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 361 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of travel gear and sprocket, illust. Z 21679 Bolt size SW * Tightening torque Reference No.: Grade Qty. (1) see NOTICE below M 30 1250 M 30...
  • Page 362 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 363 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Check condition and fastening of track rollers and carrier rollers, illust. Z 21677 Bolt size SW * Tightening torque Reference No.: Grade Qty. M 30 10.9 1770 M 30 10.9...
  • Page 364 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 365 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH High-Strength Bolt Connections (continued) Loader attachment, check condition and fastening of pin retainer plates and bolts, illust. Z 20868 Bolt size SW * Tightening torque Reference No.: Grade Qty. Retainer bolts M 16 * SW = Wrench size...
  • Page 366 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 367: Hydraulic System - Filter Service

    MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE Legend for illust. Z 20373 Return of filter location Leakage oil filter location Mounting bolt Filter cover retainer Filter cover assy Return- and leakage filter unit, see next page for details Oil filler plug Back-pressure valve...
  • Page 368 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 369 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 370 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 371 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE Replace breather filter element Drain water and sediments from hydraulic oil tank Legend for illust. Z 21503 Hand wheel of main shut-off valve located between suction oil tank and main oil tank To open the valve, turn hand wheel (6) CCW to the stop To close the valve, turn hand wheel CW to the...
  • Page 372 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 373 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE High Pressure Filters "HPF", illustration Z 21684 NOTICE The filter reference numbers correspond to the number- ing of main pumps and control valves. If a fault message "Trouble HPF .." is displayed on the VHMS monitor, the engine will be shifted automatically to low idle speed.
  • Page 374 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 375 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE High Pressure Filters "HPF", illustration Z 21684 NOTICE Carefully inspect elements for damage. Always install new elements if ruptures or other damages are found. 6. Inspect O-rings (7 and 9) and back-up ring (10). Replace if necessary.
  • Page 376 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...
  • Page 377 MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH FILTER SERVICE Replace Pressure Oil Filter Elements, illust. Z 23026 NOTICE If a fault message "Trouble oil filter.." is displayed, stop the engine and replace element of the respective pressure filter. Legend for illust.
  • Page 378 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 379: Pto (Pump Distributor Gear), Swing Machinery 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 MACHINERY 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 380 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 381: 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). If the fins of the collector are very strongly blackened or coated with verdigris, clean them with emery cloth. Unscrew ball bearing cover and fill it half way up with grease.
  • Page 382 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 383: Hydraulic Track Tensioning System - Check 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 Parts & Service News No.
  • Page 384 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 385: Water Filter - Replace Filter Cartridge

    MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE Legend for illust. Z22991 Location of filler neck for water tank (5) Location of water filter (2), pump (3) and pressure compensation tank (4). Access cover for water filter compartment Water filter Water pump...
  • Page 386 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 387: Hydraulic Oil Cooler - Inspect And Lubricate Door Hinges

    MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES WARNING Provide adequate working platform for safe access to the hydraulic oil coolers. Check all door hinges (2) for good condition and proper fastening to their carrier frames.
  • Page 388 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH MAINTENANCE...

  • Page 389: Machinery House Doors - Inspect And Lubricate Door Hinges

    MAINTENANCE 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES WARNING Provide adequate working platform for safe access to the rear machinery house door (2). Check all door hinges (3) for good condition and proper fastening to their carrier frames.

  • Page 390: Every 2000 Operating Hours Or Yearly

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

  • Page 391: Hydraulic System - Change Oil, Replace Suction Strainers And Pulsation Damper

    MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY 4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER NOTICE The hydraulic oil change intervals can be extended for a fur- ther time period, when an oil sample analysis shows a posi- tive result.
  • Page 392 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...

  • Page 393: Hydraulic System - Change Oil, Replace Suction Strainers And Pulsation Damper

    MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Legend for illust. Z 21690 Distributor manifold Return oil collector manifold Drain coupling Pulsation damper Attach drain hose (part of tool set) to coupling (3) and drain oil from return oil collector manifold (2).
  • Page 394 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
  • Page 395 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Legend for illust. Z 21691A Suction oil reservoir Drain coupling Suction oil strainer Bolts Intermediate pipe REMARK On the bottom of the intermediate pipe there is a cover for inspection of strainer (3), see detail (A).
  • Page 396 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
  • Page 397 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Legend for illust. Z 21692 Location of main pump suction strainers Bolts Suction hose flange Suction screen Gaskets Replace suction oil strainers of the four main pumps 1.
  • Page 398 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
  • Page 399 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER FILLING THE HYDRAULIC SYSTEM 1. Make sure main shut-off valve is in open position and all con- nections are securely tightened. REMARK Select hydraulic oil viscosity grade according to ambient tem- peratures.
  • Page 400 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...
  • Page 401 MAINTENANCE 4.13 EVERY 2000 OPERATING HOURS OR YEARLY HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER Bleed air from all Hydraulic Pumps and check the Oil Level in the four Main Pump Housings Legend for illust. Z 21693 I - IV Main hydraulic pumps (swash plate type) Axial piston pump for hydraulic oil cooler fan drive...
  • Page 402 4.13 EVERY 2000 OPERATING HOURS OR YEARLY MAINTENANCE...

  • Page 403: 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 404: 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 405: Swing Machinery And Motor Adapter Housing - Change Oil

    MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4.14.1 SWING MACHINERY AND MOTOR ADAPTER HOUSING - CHANGE REMARK The machine can be equipped either with a swing machinery of manufacturer "L&S" or of manufacturer "Siebenhaar". Refer to the data plate on each swing machinery housing to find out the manufacturer of the swing machinery.
  • Page 406 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
  • Page 407 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 408 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE " "...
  • Page 409 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR SWING MACHINERY MANUFACTURED BY "SIEBENHAAR" Legend for illustration Z 21694 Position of oil level gauge for checking the oil levels Swing machinery (RH and LH) Brake housing Compensator oil tank for swing machinery Oil level gauge for swing machinery Oil drain plug for motor adapter housing Oil level gauge for motor adapter housing...
  • Page 410 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
  • Page 411 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 412 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...

  • Page 413: 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 Legend for illustration Z 20436 Oil level gauge for travel gear Oil filler plug Adapter for breather filter hose line Drain plugs Breather filter for motor adapter housing.
  • Page 414 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...
  • Page 415 MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR BRAKE HOUSINGS - CHANGE OIL See illustration Z 20436 CAUTION The brakes must be released for changing the oil. 1. Place wedges at front and rear side of both crawlers. 2.
  • Page 416 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...

  • Page 417: Final Drive Housings - Change Oil

    MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL See illustration Z 19117 1. Remove drain plug (4), filler plug (2) and oil level gauge (1) and drain the lubricating oil. 2.
  • Page 418 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR MAINTENANCE...

  • Page 419: Pto (Pump Distributor Gear) - Change Oil

    MAINTENANCE 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL Legend for illustration Z 21657 Oil level gauge Oil filler plug Breather filter Oil collector reservoir for secondary oil pump drive shaft housings Breather filter with oil level gauge Main pump drive shaft housings...

  • Page 420: Fire Prevention

    4.15 FIRE PREVENTION MAINTENANCE 4.15 FIRE PREVENTION...
  • Page 421 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 Shovel clean, especially from inflammable materi- als. Clean the Shovel after servicing the hydraulic system, engine and fuel system by means of a steam jet.

  • Page 422: Weld Repairs

    4.16 WELD REPAIRS MAINTENANCE 4.16 WELD REPAIRS CAUTION Before carry out weld repairs, contact our Service Depart- ment 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 con- struction of your Shovel, please inform our Service Depart- ment as soon as possible.
  • Page 423 MAINTENANCE 4.16 WELD REPAIRS GENERAL INFORMATION Welding operations can cause damage to electronic components. (Computers, Control Units, Sensors etc.), in case the welding cur- rent goes through these units. Therefore protective measures are necessary before any weld repair is started. GENERAL PROTECTIVE MEASURES Observe the prevailing safety and fire prevention regulations.
  • Page 424 4.16 WELD REPAIRS MAINTENANCE...

  • Page 425: Protective Measures Before Starting Weld Repairs On The Undercarriage

    MAINTENANCE 4.16 WELD REPAIRS 4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE On standard Shovels there are no special protective measures necessary. However, the general protective measures (A and B) must be observed. On Shovels with a power unit (generator set) mounted to the undercarriage, all electrical connections between the Shovel and the power unit have to be disconnected.
  • Page 426 4.16 WELD REPAIRS MAINTENANCE...

  • Page 427: Protective Measures Before Starting Weld Repairs On The Loader Attachment

    MAINTENANCE 4.16 WELD REPAIRS 4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT Legend for illustration Z 20675 Electrical cable connector of the end-line pressure switch for the central lubrication system Plug socket Protection cap for (2) Protection cap for (1) Switch box of the electronic bucket levelling system ”EBL”, (Special Equipment) Bucket position detector box for the ”EBL”...
  • Page 428 4.16 WELD REPAIRS MAINTENANCE...

  • Page 429: Protective Measures Before Starting Weld Repairs On The Superstructure

    DO NOT carry out weld repairs on engine (3), on the cen- tral control and filter panel (4) and on the cab base (6). Contact your local Komatsu dealer if such repairs are necessary. Be sure to isolate Electronic Components of Special Equipment e.g.

  • Page 430: After Finishing The Weld Repairs On The Superstructure

    4.16 WELD REPAIRS MAINTENANCE 4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE After finishing the weld repairs connect all cable connectors which have been disconnected and switch on all circuit breakers. When all electrical connections are established insert the battery main switch keys.
  • Page 431 INTRODUCTION ................... 3 CONTENTS OF THE BINDER ......................4 DIVISION OF THE BINDER ....................... 5 DESIGNATED USE OF THE SHOVEL ....................6 DELIVERY OF THE SHOVEL ......................7 EXPLANATION OF ABBREVIATIONS ..................... 8 TABLE OF CONTENTS ........................9 SAFETY ...................... 15 SAFETY INSTRUCTIONS ........................
  • Page 432 3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT ......... 82 3.3.4 SAFETY CIRCUIT FOR CONTROLS ................. 83 3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK ..........85 3.3.6 OPERATOR’S CONSOLE ....................87 3.3.7 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING ........................
  • Page 433 3.12.4 DROP BALL OPERATION ....................181 3.12.5 COMBINED OPERATION CYCLES ................. 184 3.13 WORKING INSTRUCTIONS ......................186 3.13.1 STABILITY OF THE SHOVEL ................... 186 3.13.2 SHOVEL OPERATION ...................... 186 3.14 PARKING THE SHOVEL ....................... 189 3.15 STOPPING THE ENGINE ......................190 3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM ............
  • Page 434 3.24 TROUBLE SHOOTING ........................232 3.24.1 ENGINE ..........................232 3.24.2 HYDRAULIC SYSTEM ...................... 233 3.24.3 FINAL DRIVES AND SWING MACHINERY ..............234 3.24.4 CRAWLER TRACKS ......................234 MAINTENANCE ..................235 FOREWORD ..........................236 PRECAUTIONS FOR MAINTENANCE ..................237 FUEL AND LUBRICANTS ......................239 FILLING CAPACITIES ........................

  • Page 435: Protective Measures Before Starting Weld Repairs On The

    4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE ..........299 4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE ............... 299 4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER .................... 299 4.10.5 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER ..........................

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