Komatsu Hydraulic Mining Shovel PC4000 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Mining Shovel PC4000, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Mining Shovel PC4000 Shop workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 10,501 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SMPC4000-8199 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008152 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008155 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008170 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008172 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
CEAWDPC4000 - Hydraulic Mining Shovel PC4000 General Assembly Procedure Manual (Z21854).pdf
FAMPC4000-05 - Hydraulic Mining Shovel PC4000 General Assembly Procedure.pdf
FAMPC4000-08205 - Hydraulic Mining Shovel PC4000-6 Field Assembly Manual.pdf
GZEAM08189 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
GZEAM08218-0 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OM-PC4000-8224 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008152 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008155 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008170 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008172 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
RRPC4000-6 - Hydraulic Mining Shovel PC4000-6 Remove & Replace Procedures.pdf
MAIN SECTIONS
CEAWDPC4000 - Hydraulic Mining Shovel PC4000 General Assembly Procedure Manual (Z21854)......2
COVER......2
GENERAL CONTENT......4
1. OVERVIEWS......6
1.1 OVERVIEW SUPERSTRUCTURE......6
1.2 OVERVIEW ENGINE HOUSE......8
2. GENERAL......10
2.1 DELIVERY OF THE EXCAVATOR......10
2.2 ASSEMBLING OF THE EXCAVATOR......10
2.3 TRANSPORTATION AND LIFTING......12
2.4 MANPOWER/ASSEMBLY TIME......14
2.5 ASSEMBLY SITE REQUIREMENTS......16
2.6 SPACE AND PLACING REQUIREMENTS......18
2.7 PREPARATION FOR ASSEMBLY......18
2.8 BASIC MEASUREMENTS AND WEIGHTS......20
2.9 TRANSPORT DIMENSIONS AND WEIGHTS......22
3. ASSEMBLY SEQUENCE......24
3.1 ASSEMBLY OF UNDERCARRIAGE......26
3.2 ASSEMBLY OF SUPERSTRUCTURE ONTO THE UNDERCARRIAGE......30
3.3 ASSEMBLY OF ENGINE HOUSE......32
3.4 MOUNTING OF BOOM......34
3.5 MOUNTING OF HYDRAULIC OIL TANK......36
3.6 MOUNTING OF HYDRAULIC OIL COOLER......38
3.7 MOUNTING OF FUEL TANK......40
3.8 MOUNTING OF HYDRAULIC ACCESS LADDER......42
3.9 MOUNTING OF CAB BASE......44
3.10 MOUNTING OF COUNTERWEIGHT......46
3.11 MOUNTING OF HANDRAILS, STEPS AND GRATINGS......48
3.12 MOUNTING OF CAB WITH SUPPORT FRAME......50
3.13 MOUNTING OF BUCKET CYLINDERS......52
3.14 FILLING UP HYDRAULIC TANK AND FUEL TANK......52
3.15 MOUNTING OF STICK......54
3.16 PRE-CHECKS PRIOR TO START-UP......54
3.17 MOUNTING OF STICK CYLINDERS TO THE STICK......56
3.18 ASSEMBLY OF BULLCLAM BUCKET TO THE STICK......58
3.19 MOUNTING OF THE PIN SEALS......62
3.20 CONNECTION OF THE CABLE HARNESSES TO THE TERMINAL RAILS IN THE SWITCH BOX "X2"......64
3.21 PUTTING THE CENTRAL LUBRICATION SYSTEM INTO OPERATION......66
3.22 STANDARD APPLICATION TORQUE CHART......68
FAMPC4000-05 - Hydraulic Mining Shovel PC4000 General Assembly Procedure......72
COVER......72
GENERAL CONTENT......74
1. Overviews......76
1.1 Overview Superstructure (Z22586)......76
1.2 Overview Engine House (Z21446)......78
2. General......80
2.1 Delivery of the Excavator......80
2.2 Assembling of the Excavator......80
2.3 Transportation and Lifting......82
2.4 Manpower / Assembly Time......84
2.5 Assembly Site Requirements......86
2.6 Space and Placing Requirements......90
2.7 Preparation for Assembly......90
2.8 Basic Measurements (Z23038)......92
2.9 Transport Dimensions and Weights (as example)......92
3. Assembly Sequence......94
3.1. Assembly of Undercarriage (Z21859)......94
3.1.1. Mounting of travel gear breather filters (Z21860)......96
3.1.2 Track tensioning system (Z23037)......98
3.2. Assembly of Superstructure onto the Undercarriage (Z23863)......100
3.3 Assembly of engine house (Z21863)......102
3.4 Mounting of Boom (Z21864)......104
3.5. Mounting of Hydraulic Oil Tank (Z23039)......106
3.6. Mounting of Hydraulic Oil Cooler (Z21866)......108
3.7. Mounting of Fuel Tank (Z21867)......110
3.8 Mounting of hydraulic access ladder (Z21871)......112
3.9. Mounting of Cab Base (Z21868)......114
3.10 Mounting of Counterweight (Z21869)......116
3.11 Mounting of Handrails, Steps and Gratings (Z23033)......118
3.12 Mounting of Cable transfer to the Operators Cab (Z22937)......120
3.13 Mounting of Cab with Support Frame (Z22938; Z22939)......124
3.13.1 Mounting of the Cab air cleaner (Cab support to Cab) (Z22940)......126
3.14 Mounting of Bucket Cylinders (Z21873)......128
3.15 Mounting of Stick (Bullclam bucket) (Z21874)......130
3.15.1 Mounting of Stick (Backhoe attachment) (Z23034)......132
3.16 Filling up hydraulic oil tank (Z21585)......134
3.17 Bleed air from all hydraulic pumps and check the Oil Level in all four Main Pump Housings (Z21693; Z22513)......136
3.18 Filling up fuel tank......138
3.19 Pre-checks for initial Start-up......140
3.20 Mounting of stick cylinders to the stick (Z21875)......144
3.21 Assembly of Bullclam Bucket to the Stick (Z21876)......146
3.22 Mounting of the Pin Seals (Z22042)......150
3.22.1 Mounting of the Pin Seals (Backhoe) (Z23035)......152
3.23 Connection of the cable harnesses to the terminal rails in the switch box "X2" (Z21879)......154
3.24 Putting the Central Lubrication System into operation (Z21880)......158
3.25 Metric standard thread......160
FAMPC4000-08205 - Hydraulic Mining Shovel PC4000-6 Field Assembly Manual......166
2 SAFETY......174
2.1 SAFETY INFORMATION......175
2.2 OVERVIEW......176
2.2.1 NORMAL OPERATIONS......176
2.2.2 REGULAR MAINTENANCE......176
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR......176
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR......176
2.3 SOUND PRESSURE LEVEL IN THE OPERATORS CAB......177
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR......178
2.4.1 UNDERSTANDING THE MACHINE......178
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR......178
2.4.3 PREPARATIONS FOR SAFE OPERATION......178
2.4.4 FIRE PREVENTION......180
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE......182
2.4.6 BURN PREVENTION......184
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS......184
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES......185
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)......186
2.4.10 PRECAUTIONS AT JOBSITE......187
2.4.11 STARTING ENGINE......192
2.4.12 OPERATION......193
2.5 PRECAUTION FOR MAINTENANCE......199
2.5.1 GENERAL PRECAUTIONS......199
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE......207
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID......208
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS......212
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM......212
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS......212
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR......212
2.7 SPECIAL SAFETY EQUIPMENT......213
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR FOPS FOR OPERATORS CAB......214
2.7.2 OBJECT HANDLING......214
2.7.3 LIGHTING......214
2.7.4 WARNING BEACON......214
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)......214
2.8 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLY......222
2.8.1 WHEN ASSEMBLING THE EXCAVATOR......222
2.8.2 WHEN DISASSEMBLING THE EXCAVATOR......222
2.8.3 WHEN TRANSPORTING THE DISASSEMBLED EXCAVATOR......223
3 GENERAL......224
3.1 GENERAL......225
3.1.1 DELIVERY OF THE EXCAVATOR......225
3.1.2 ASSEMBLING THE EXCAVATOR......225
3.1.3 LIFTING AND TRANSPORTATION......225
3.1.4 PACKING LIST OF A TYPICAL FACE SHOVEL MACHINE......226
3.1.5 PACKING LIST OF A TYPICAL BACKHOE MACHINE......227
3.1.6 ELECTRICAL ENERGY......228
3.1.7 ELECTROMAGNETIC COMPATIBILITY (EMC)......228
3.1.8 MONITORING SYSTEM OF THE MACHINE......228
3.2 ASSEMBLY SITE REQUIREMENTS......229
3.2.1 CONFIGURATION OF COMPONENTS ON ERECTION SITE (EXAMPLE)......229
3.2.2 REQUIRED CRANES......231
3.2.3 MANPOWER / ASSEMBLY TIME......231
3.2.4 TOOLS AND EQUIPMENT FOR ASSEMBLY......232
3.2.5 STANDARD APPLICATION TORQUE CHART......235
3.2.6 PREPARATIONS FOR ASSEMBLY......238
3.2.7 BASIC DIMENSIONS......239
3.3 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES......240
4 ASSEMBLY SEQUENCE......242
4.1 ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES......243
4.1.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINES STABILITY......244
4.2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES......245
4.2.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINES STABILITY......246
4.3 ASSEMBLY OF UNDERCARRIAGE......247
4.3.1 ASSEMBLY OF TRACKS......248
4.3.2 ATTACH CARBODY TO SIDE FRAME......249
4.3.3 DETERMINING THE TIGHTENING TORQUE......256
4.3.4 SPECIAL HYDRAULIC TORQUE WRENCH......260
4.3.5 CLOSING THE TRACKS......261
4.3.6 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS......262
4.3.7 MOUNTING OF TRAVEL GEAR PROTECTION......265
4.3.8 MOUNTING OF TRAVEL MOTOR PROTECTION HOOD......267
4.3.9 HYDRAULIC TRACK TENSIONING SYSTEM......269
4.4 MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE......271
4.5 ASSEMBLY OF MACHINERY HOUSE ROOF......275
4.5.1 MOUNTING OF THE EXHAUST SYSTEM......277
4.5.2 MOUNTING OF THE AIR INTAKE SYSTEM......280
4.6 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM......283
4.7 MOUNTING OF BATTERY BOX AND HYDRAULIC ACCESS LADDER......285
4.8 CONNECTING ENGINE OIL RESERVE SYSTEM......291
4.9 PRE-ASSEMBLY OF FACE SHOVEL BOOM......295
4.9.1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM......299
4.9.2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS......301
4.9.3 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM......303
4.9.4 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME......307
4.10 PRE-ASSEMBLY OF BACKHOE BOOM......309
4.10.1 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM......311
4.10.2 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME......315
4.11 MOUNTING OF COUNTERWEIGHT......317
4.12 MOUNTING OF THE FUEL TANK......319
4.12.1 CONNECTING FUEL SYSTEM HOSE LINES......321
4.13 ATTACHING THE CAB BASE......325
4.13.1 MAKING OF ELECTRICAL CABLE CONNECTIONS......327
4.13.2 CONNECT CAB HEATER HOSES TO CAB BASE......329
4.14 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE......331
4.14.1 CONNECTING THE AIR CONDITIONER HOSES OF THE CAB......333
4.14.2 INSTALL ORBCOMM ANTENNA......335
4.15 CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE AND SUPERSTRUCTURE......337
4.15.1 CONNECTING HIGH PRESSURE LINES OF THE MAIN PUMPS......339
4.16 ATTACHING THE HYDRAULIC OIL RESERVOIR......341
4.17 ATTACHING THE HYDRAULIC OIL COOLER......343
4.17.1 CONNECTING THE HYDRAULIC HOSE LINES OF THE OIL COOLER CIRCUIT......345
4.17.2 CONNECTING THE HOSE LINES OF OIL COOLER FAN MOTORS......347
4.17.3 CONNECTING THE HOSE LINES OF PTO OIL COOLING CIRCUIT......349
4.17.4 CONNECTING THE RETURN OIL HOSE LINE OF RADIATOR FAN MOTOR......351
4.17.5 CONNECTING THE HOSE LINES FROM RETURN OIL MANIFOLD TO BACK-PRESSURE PIPE......353
4.18 CONNECTING SWING GEAR HYDRAULIC LINES......355
4.18.1 CONNECTING THE RETURN AND LEAKAGE OIL HOSE LINES......356
4.18.2 CONNECTING THE SWING BRAKE PRESSURE HOSES AND PILOT OIL HOSES......357
4.19 CONNECTING THE RETURN AND PRESSURE OIL HOSES FROM VALVE BLOCK......359
4.20 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP......365
4.21 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT......367
4.21.1 CONNECTING THE PILOT OIL LINE, RETURN OIL LINE AND LEAKAGE OIL LINE TO THE ROTARY JOINT......369
4.22 ATTACHING THE HANDRAILS, CATWALKS AND STEPS......371
4.23 MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES......373
4.24 CENTRAL REFILLING SYSTEM......377
4.24.1 CONNECTING THE REFILLING LINES......378
4.25 CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS......383
4.26 MOUNTING THE CAN-NODE BOXES ONTO THE MACHINERY HOUSE ROOF......385
4.26.1 CONNECTING THE CABLES TO THE CAN-NODES......386
4.27 PRE-CHECKS PRIOR TO INITIAL START UP......387
4.28 FILLING AND BLEEDING THE HYDRAULIC SYSTEM......389
4.28.1 FILLING THE HYDRAULIC SYSTEM......390
4.28.2 BLEEDING THE HYDRAULIC SYSTEM......391
4.28.3 BLEEDING THE GEAR PUMP FOR PTO GEAR LUBRICATION......394
4.29 ASSEMBLY FACE SHOVEL ATTACHMENT......395
4.29.1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM......396
4.29.2 ATTACHING THE STICK TO THE BOOM......398
4.29.3 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM......399
4.29.4 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS......399
4.29.5 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS......402
4.29.6 CONNECTING HOSE LINES FROM STICK TO BUCKET CYLINDERS......404
4.29.7 CONNECTING STICK CYLINDERS TO THE STICK......405
4.30 BLEEDING HYDRAULIC CIRCUITS......407
4.30.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT......408
4.30.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT......408
4.30.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT......410
4.30.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER......411
4.30.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS......411
4.30.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS......412
4.31 ATTACHING FACE SHOVEL TO THE STICK......413
4.31.1 ATTACHING BUCKET BACK WALL TO THE STICK......414
4.31.2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM CYLINDERS......416
4.31.3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL......418
4.31.4 CONNECTING GREASE LINES OF THE FACE SHOVEL ATTACHMENT......420
4.31.5 CONNECTING GREASE LINES ON THE BUCKET......422
4.31.6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS......422
4.32 ASSEMBLY BACKHOE ATTACHMENT......423
4.32.1 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM......424
4.32.2 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS......425
4.32.3 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS......426
4.32.4 ATTACHING THE STICK TO THE BOOM......428
4.32.5 CONNECTING HOSE LINES FROM BOOM TO BUCKET CYLINDERS......432
4.33 BLEEDING HYDRAULIC CIRCUITS......433
4.33.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT......434
4.33.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT......434
4.33.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT......436
4.33.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER......437
4.33.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS......437
4.33.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS......438
4.34 ATTACHING BACKHOE BUCKET TO THE STICK......439
4.34.1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT......444
4.35 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS......445
5 FINAL CHECKS AND ADJUSTMENTS......446
5.0.1 COMMISSIONING CHECK LIST......448
5.0.2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS......448
5.0.3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE......450
5.0.4 PRESSURE COMPENSATION OF SEALED COMPONENTS......450
5.0.5 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE......451
5.0.6 COMMISSIONING OF THE AIR CONDITIONING......469
5.1 PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC MANUAL......473
5.1.1 VISUAL INSPECTION......474
5.1.2 TRAVELLING INSTRUCTIONS......474
5.2 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING......475
6 DISASSEMBLY OF THE MACHINE......476
6.0.1 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES......477
6.0.2 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE......478
6.0.3 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES......479
6.0.4 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE......480
6.0.5 DISPOSAL OF WASTE MATERIAL......481
GZEAM08189 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual......501
COVER......501
1. INTRODUCTION......503
1.1 CONTENTS OF THE BINDER......504
1.2 DIVISION OF THE BINDER......505
1.3 DESIGNATED USE OF THE SHOVEL......506
1.4 DELIVERY OF THE SHOVEL......507
1.5 EXPLANATION OF ABBREVIATIONS......508
1.6 TABLE OF CONTENTS......509
2. SAFETY......515
2.1 SAFETY INSTRUCTIONS......516
2.1.1 WARNINGS AND SYMBOLS......516
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC MINING SHOVEL......516
2.1.3 ORGANIZATIONAL MEASURES......517
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES......519
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES......520
2.1.6 WARNING OF SPECIAL DANGERS......523
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING......525
2.1.8 SPECIAL SAFETY EQUIPMENT......525
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)......529
3. OPERATION......537
3.1 FOREWORD......538
3.2 CONSTRUCTION OF THE SHOVEL......539
3.2.1 OVERALL VIEW......539
3.2.2 SUPERSTRUCTURE......540
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER......550
3.2.4 EMERGENCY ESCAPE LADDER......554
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM......556
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)......558
3.2.7 UNDERCARRIAGE......569
3.2.8 WORKING ATTACHMENT......570
3.2.9 DIESEL ENGINE TYPE SDA 16V160......572
3.2.10 ENGINE OIL MANAGEMENT SYSTEM......574
3.3 OPERATORS CAB - CONTROLS......578
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT......578
3.3.2 SAFETY CIRCUIT FOR CONTROLS......579
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT......582
3.3.4 SAFETY CIRCUIT FOR CONTROLS......583
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK......585
3.3.6 OPERATORS CONSOLE......587
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS......595
3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER......597
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS HEALTH MONITOR......598
3.4.1 SEQUENCE OF DISPLAYS......599
3.4.2 OPENING SCREEN......599
3.4.3 MAIN GAUGE SCREENS 1 TO 3......600
3.4.4 FUEL CONSUMPTION SCREEN......607
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR......608
3.4.6 MAIN SCREEN - CHANGE >TIME >SMR >DATE......608
3.4.7 MAINTENANCE MONITOR......609
3.4.8 SETTINGS FOR OPERATOR......610
3.4.9 AUTOMATIC MESSAGES......615
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM......619
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES......629
3.5 CAMERA SYSTEM WITH MONITORS......632
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS......633
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING......640
3.6.1 AUXILIARY HEATER FOR OPERATORS CAB......645
3.7 POWER HOUSE......646
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES......647
3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES......649
3.7.3 CENTRAL CONTROL AND FILTER PANEL......651
3.8 ELECTRICAL EQUIPMENT IN CAB BASE......654
3.8.1 STANDARD COMPONENTS IN CAB BASE......655
3.8.2 SWITCH BOARD (X2) IN CAB BASE......657
3.8.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE......667
3.9 CHECKS BEFORE STARTING THE ENGINE......674
3.10 STARTING THE ENGINE......680
3.10.1 STARTING PROCEDURE......683
3.10.2 ENGINE WARM-UP......691
3.10.3 HYDRAULIC OIL WARM-UP......691
3.11 MOVING THE SHOVEL......693
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS......693
3.11.2 TRAVELLING INSTRUCTIONS......696
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE......697
3.12.1 SLEWING THE SUPERSTRUCTURE......697
3.12.2 BRAKING THE SUPERSTRUCTURE......699
3.12.3 SLEW PARKING BRAKE......700
3.13 WORKING WITH THE ATTACHMENT......702
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM......702
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM......703
3.13.3 BOTTOM DUMP BUCKET......704
3.13.4 DROP BALL OPERATION......705
3.13.5 COMBINED OPERATION CYCLES......708
3.14 WORKING INSTRUCTIONS......710
3.14.1 STABILITY OF THE SHOVEL......710
3.14.2 SHOVEL OPERATION......710
3.15 PARKING THE SHOVEL......713
3.16 STOPPING THE ENGINE......714
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM......717
3.17 OPERATION OF THE LUBRICATION SYSTEM......718
3.17.1 CENTRAL LUBRICATION SYSTEM CLS......718
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS......720
3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS......722
3.18.1 HIGH LEVEL ALARM FIRE......727
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE......727
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS......727
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S.......729
3.18.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER.......731
3.19 TRANSFER PUMP FOR HYDRAULIC OIL......732
3.19.1 OPERATING THE TRANSFER PUMP......733
3.19.2 FUNCTIONS OF THE TRANSFER PUMP......735
3.20 CENTRAL REFILLING SYSTEM......738
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM......739
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM......741
3.20.3 RECEIVER PANEL WITH MONITOR BOX......743
3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB.......749
3.21 WORK ON THE LOADER ATTACHMENT......752
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL......753
3.22.1 DISASSEMBLING OF THE SHOVEL......753
3.22.2 TRANSPORTATION AND LIFTING......753
3.23 RETRIEVAL PROCEDURE......754
3.24 SHOVEL STORAGE......755
3.24.1 PREPARING FOR STORAGE......755
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD......756
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD......756
3.24.4 PREPARING FOR OPERATION......757
3.25 TROUBLE SHOOTING......758
3.25.1 ENGINE......758
3.25.2 HYDRAULIC SYSTEM......759
3.25.3 FINAL DRIVES AND SWING MACHINERY......760
3.25.4 CRAWLER TRACKS......760
4. MAINTENANCE......761
4.1 FOREWORD......762
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE......763
4.3 FLUIDS AND LUBRICANTS......765
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES......765
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES......766
4.4 FILLING CAPACITIES......768
4.5 STANDARD TORQUE LIST......769
4.6 LUBRICATION AND MAINTENANCE SCHEDULE......770
4.6.1 INITIAL SERVICING......770
4.6.2 PERIODIC SERVICING INTERVALS......770
4.6.3 PERIODIC SERVICING SCHEDULE......771
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES......776
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......777
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM......781
4.6.7 MAINTENANCE OF THE ENGINE......783
4.7 WHEN NECESSARY......784
4.7.1 ENGINE AIR CLEANER SERVICE......785
4.7.2 SWING CIRCLE TOOTHING LUBRICATION......789
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS......791
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS......795
4.8 EVERY 10 OPERATING HOURS OR DAILY......796
4.8.1 WALK-AROUND INSPECTION......797
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER......807
4.8.3 RADIATOR - CHECK COOLANT LEVEL......809
4.8.4 TRACK GROUPS - CLEAN......809
4.8.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER......811
4.9 EVERY 50 OPERATING HOURS OR WEEKLY......812
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS......813
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S" - CHECK OIL L.......817
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL......819
4.9.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN" - CHECK OIL LEVELS......821
4.9.5 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL......823
4.9.6 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL......825
4.9.7 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR......827
4.9.8 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY......829
4.10 EVERY 250 OPERATING HOURS OR MONTHLY......830
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION......831
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE......833
4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE......833
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER......833
4.10.5 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER......833
4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER......835
4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT......839
4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL......843
4.10.9 AIR CONDITIONING FOR OPERATORS CAB - CHECK REFRIGERANT LEVEL......845
4.11 EVERY 500 OPERATING HOURS OR MONTHLY......846
4.11.1 BATTERIES - CHECK FLUID LEVEL......847
4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL......849
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL......851
4.11.4 FUEL TANK - DRAIN CONDENSATION......853
4.11.5 CRAWLER TRACK - INSPECTION......855
4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION......861
4.11.7 GROUND CABLE OF OPERATORS CAB - CHECK FOR CORRECT CONNECTION......863
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH......864
4.12.1 HIGH STRENGTH BOLT CONNECTIONS......865
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE......913
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS......927
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE......929
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS......931
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE......933
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES......935
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES......937
4.13 EVERY 2000 OPERATING HOURS OR YEARLY......938
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER......939
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION......951
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR......952
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL......953
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S"- CHANGE OIL......961
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL......965
4.14.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN"- CHANGE OIL......967
4.14.5 FINAL DRIVE HOUSINGS - CHANGE OIL......971
4.14.6 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL......973
4.15 FIRE PREVENTION......974
4.16 WELD REPAIRS......976
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE......979
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT......981
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE......983
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE......984
GZEAM08218-0 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual......991
1 FOREWORD......993
1.1 BEFORE READING THIS MANUAL......994
1.2 DIRECTIONS OF THE MACHINE......995
1.3 SPECIFICATION AND SERIAL PLATE......996
1.3.1 PRODUCT IDENTIFICATION NUMBER......996
1.4 DIVISION OF THE BINDER......997
1.5 DESIGNATED USE OF THE SHOVEL......998
1.6 DELIVERY OF THE SHOVEL......999
1.6.1 SPARE PARTS......999
1.6.2 SERVICE......999
1.7 EXPLANATION OF ABBREVIATIONS......1000
1.8 CONTENTS......1001
2 SAFETY......1007
2.1 SAFETY INFORMATION......1008
2.2 OVERVIEW......1009
2.2.1 NORMAL OPERATIONS......1009
2.2.2 REGULAR MAINTENANCE......1009
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR......1009
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR......1009
2.3 SOUND PRESSURE LEVEL IN THE OPERATORS CAB......1010
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR......1011
2.4.1 UNDERSTANDING THE MACHINE......1011
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR......1011
2.4.2.1 ENSURING SAFE OPERATION......1011
2.4.3 PREPARATIONS FOR SAFE OPERATION......1011
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT......1011
2.4.3.2 INSPECTING THE MACHINE......1011
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT......1012
2.4.3.4 KEEP MACHINE CLEAN......1012
2.4.3.5 PRECAUTIONS INSIDE OPERATORS COMPARTMENT......1012
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT......1013
2.4.3.7 IF A PROBLEM IS FOUND......1013
2.4.4 FIRE PREVENTION......1013
2.4.4.1 PRECAUTIONS TO PREVENT FIRE......1013
2.4.4.2 ACTION IF FIRE OCCURS......1014
2.4.4.3 EMERGENCY EXIT FROM OPERATORS CAB......1015
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE......1015
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE......1015
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE......1015
2.4.5.3 NO PEOPLE ON THE ATTACHMENT......1015
2.4.5.4 WORKING IN HIGH PLACES......1015
2.4.5.5 LEAVING OPERATORS SEAT WITH LOCK......1016
2.4.5.6 LEAVING THE MACHINE......1016
2.4.6 BURN PREVENTION......1017
2.4.6.1 Hot coolant......1017
2.4.6.2 Hot oil......1017
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS......1017
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES......1018
2.4.8.1 UNAUTHORIZED MODIFICATION......1018
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS......1018
2.4.9 PRECAUTIONS AT JOBSITE......1020
2.4.9.1 VISIBILITY FROM OPERATORS SEAT......1021
2.4.9.2 CAMERA SYSTEM WITH MONITORS......1021
2.4.9.3 ENSURE GOOD VISIBILITY......1021
2.4.9.4 CHECKING SIGNS AND SIGNALMANS SIGNALS......1021
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS......1022
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES......1022
2.4.9.7 WORKING ON LOOSE GROUND......1023
2.4.9.8 GAS, DUST, STEAM AND SMOKE......1023
2.4.9.9 VENTILATION OF ENCLOSED AREAS......1024
2.4.10 STARTING ENGINE......1025
2.4.10.1 WARNING TAG......1025
2.4.10.2 CHECKS BEFORE STARTING ENGINE......1025
2.4.10.3 PRECAUTION WHEN STARTING ENGINE......1025
2.4.10.4 PRECAUTION IN COLD AREAS......1026
2.4.11 OPERATION......1026
2.4.11.1 CHECKS BEFORE OPERATION......1026
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE......1027
2.4.11.3 PRECAUTIONS WHEN travelling......1028
2.4.11.4 TRAVELLING ON SLOPES......1029
2.4.11.5 OPERATIONS ON SLOPES......1030
2.4.11.6 PROHIBITED OPERATIONS......1030
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES......1031
2.4.11.8 PARKING THE MACHINE......1031
2.4.11.9 TRANSPORTATION......1031
2.5 PRECAUTION FOR MAINTENANCE......1032
2.5.1 GENERAL PRECAUTIONS......1032
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES......1033
2.5.1.2 STOP ENGINE FOR MAINTENANCE......1034
2.5.1.3 WARNING TAG......1035
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY......1036
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS......1036
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING......1037
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS......1037
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT......1038
2.5.1.9 NOISE......1038
2.5.1.10 WHEN USING A HAMMER......1038
2.5.1.11 PROPER TOOLS......1039
2.5.1.12 ACCUMULATOR......1039
2.5.1.13 PERSONNEL......1039
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE......1040
2.5.2.1 PRECAUTION WHEN WELDING......1040
2.5.2.2 BATTERY HANDLING......1040
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID......1041
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE......1041
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES......1042
2.5.3.3 REPLACEMENT OF HOSE LINES......1042
2.5.3.4 INSPECTION OF HOSE LINES......1042
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......1043
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE......1043
2.5.3.7 AIR CONDITIONING MAINTENANCE......1043
2.5.3.8 COMPRESSED AIR......1044
2.5.3.9 WASTE MATERIALS......1044
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS......1045
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM......1045
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS......1045
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR......1045
2.7 SPECIAL SAFETY EQUIPMENT......1046
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR FOPS FOR OPERATORS CAB......1047
2.7.2 OBJECT HANDLING......1047
2.7.3 LIGHTING......1047
2.7.4 WARNING BEACON......1047
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)......1047
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)......1047
2.7.5.2 INSTRUCTIONS FOR USE......1049
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL......1051
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),......1051
2.7.5.5 INSTRUCTIONS FOR USE......1053
2.8 SAFETY WARNING SIGNS......1055
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS......1056
3 OPERATION......1069
3.1 FOREWORD......1070
3.2 CONSTRUCTION OF THE SHOVEL......1071
3.2.1 OVERALL VIEW......1071
3.2.2 SUPERSTRUCTURE......1072
3.2.2.1 Machinery House......1076
3.2.2.2 Main Hydraulic Oil Reservoir......1078
3.2.2.3 Hydraulic Oil Cooler......1079
3.2.2.4 Fuel Tank......1080
3.2.2.5 Counterweight......1081
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER......1082
3.2.3.1 Operating the hydraulic Access Ladder......1083
3.2.4 EMERGENCY ESCAPE LADDER......1086
3.2.5 BOOM ACCESS LADDER AND WALKWAY......1088
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM......1090
3.2.6.1 Emergency Engine Shutdown System actuated from Ground Man (special equipment)......1091
3.2.6.2 Operator Warning System (special equipment)......1091
3.2.7 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)......1092
3.2.7.1 Operators Cab - Emergency Escape Hammer and Storage Box for Operation Manual......1097
3.2.7.2 Operators Seat Adjustment......1099
3.2.7.3 Co-drivers Seat and Refrigerator Box......1100
3.2.8 UNDERCARRIAGE......1101
3.2.9 WORKING ATTACHMENT......1102
3.2.9.1 Loader attachment with bottom dump bucket......1102
3.2.9.2 Loader attachment with backhoe bucket......1103
3.2.10 DIESEL ENGINE TYPE SDA 16V160E-2......1104
3.2.11 ENGINE OIL MANAGEMENT SYSTEM......1106
3.2.11.1 Oil Burning System "Centinel" combined with Oil Supply System "Reserve"......1108
3.2.11.2 Eliminator Engine Oil Filtration System......1109
3.3 OPERATORS CAB - CONTROLS......1110
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT......1110
3.3.1.1 HYDRAULIC CONTROL SYSTEM......1111
3.3.2 SAFETY CIRCUIT FOR CONTROLS......1111
3.3.2.1 EURO Control Pattern......1113
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT......1114
3.3.3.1 HYDRAULIC CONTROL SYSTEM......1115
3.3.4 SAFETY CIRCUIT FOR CONTROLS......1115
3.3.4.1 EURO Control Pattern......1117
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK......1117
3.3.6 OPERATORS CONSOLE......1119
3.3.6.1 Switch Board......1121
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS......1127
3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER......1129
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS HEALTH MONITOR (KOMTRAX PLUS)......1130
3.4.1 SEQUENCE OF DISPLAYS......1131
3.4.2 OPENING SCREEN......1131
3.4.3 MAIN GAUGE SCREENS 1 TO 3......1132
3.4.3.1 Main Gauge Screen 1......1133
3.4.3.2 Main Gauge Screen 2......1135
3.4.3.3 Main Gauge Screen 3......1135
3.4.3.4 Color Definition......1137
3.4.3.5 Automatic Shutdown of the Machine......1137
3.4.4 FUEL CONSUMPTION SCREEN......1139
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR......1140
3.4.6 MAIN SCREEN - CHANGE >TIME >SMR >DATE......1140
3.4.7 MAINTENANCE MONITOR......1141
3.4.7.1 Maintenance confirmation through Service Personnel......1141
3.4.8 SETTINGS FOR OPERATOR......1142
3.4.8.1 Settings for Operator......1143
3.4.8.2 User ID Screen......1143
3.4.8.3 Reset Truck Counter 1......1143
3.4.8.4 Screen Adjustment......1144
3.4.8.5 Date Adjustment Screen......1146
3.4.8.6 Clock Adjustment Screen......1146
3.4.8.7 Language Selection Screen......1146
3.4.9 AUTOMATIC MESSAGES......1147
3.4.9.1 Automatic Messages......1148
3.4.9.2 Automatic Messages......1149
3.4.9.3 Automatic Messages......1150
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM......1151
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES......1163
3.5 CAMERA SYSTEM WITH MONITORS......1166
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS......1167
3.5.1.1 Operating the Monitors......1169
3.5.1.2 Ajustments of the Monitor......1169
3.5.1.3 Arrangement of the Cameras......1173
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING......1174
3.6.1 Digital Display......1174
3.6.2 AUXILIARY HEATER FOR OPERATORS CAB......1179
3.7 POWER HOUSE......1180
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES......1181
3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES......1183
3.7.3 CENTRAL CONTROL AND FILTER PANEL......1185
3.8 ELECTRICAL EQUIPMENT IN CAB BASE......1186
3.8.1 STANDARD COMPONENTS IN CAB BASE......1187
3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE......1191
3.8.2.1 Checking diagnostic fault codes of the engine electronic controlled fuel system QUANTUM and of the engine monitoring system CENSE......1193
3.8.3 MASTER TURBO CONTROLLER MTC - LED INDICATIONS......1195
3.8.4 BINARY FAULT CODE LIST......1202
3.8.4.1 Combination Message 308 Trouble Can-Bus or Can Hardware......1204
3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS......1204
3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE......1207
3.9 CHECKS BEFORE STARTING THE ENGINE......1214
3.9.0.1 Coolant Level......1217
3.9.0.2 Machinery House Doors......1219
3.9.0.3 Operators Seat Adjustment......1219
3.10 STARTING THE ENGINE......1220
3.10.1 STARTING PROCEDURE......1223
3.10.2 ENGINE WARM-UP......1231
3.10.3 HYDRAULIC OIL WARM-UP......1231
3.10.4 JUMP START WITH BOOSTER BATTERIES......1231
3.11 MOVING THE SHOVEL......1233
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS......1233
3.11.1.1 TRAVEL ALARM / BACK-UP ALARM......1235
3.11.2 TRAVELLING INSTRUCTIONS......1235
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE......1236
3.12.1 SLEWING THE SUPERSTRUCTURE......1236
3.12.1.1 MACHINES WITH "EURO" CONTROL......1236
3.12.1.2 MACHINES WITH "KMG" CONTROL......1237
3.12.2 BRAKING THE SUPERSTRUCTURE......1237
3.12.3 SLEW PARKING BRAKE......1238
3.12.3.1 Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System......1239
3.12.3.2 IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE......1239
3.13 WORKING WITH THE ATTACHMENT......1240
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM......1240
3.13.1.1 Backhoe......1240
3.13.1.2 FACE SHOVEL......1240
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM......1241
3.13.2.1 Backhoe......1241
3.13.2.2 FACE SHOVEL......1241
3.13.3 BOTTOM DUMP BUCKET......1242
3.13.3.1 Operating the bucket clam......1242
3.13.3.2 OPERATING THE BUCKET CLAM......1242
3.13.4 DROP BALL OPERATION......1243
3.13.4.1 SAFETY INSTRUCTIONS......1243
3.13.4.2 SAFETY DEVICES (SPECIAL EQUIPMENT)......1245
3.13.4.3 WORKING HINTS......1245
3.13.5 COMBINED OPERATION CYCLES......1246
3.14 WORKING INSTRUCTIONS......1248
3.14.1 STABILITY OF THE SHOVEL......1248
3.14.2 SHOVEL OPERATION......1248
3.15 PARKING THE SHOVEL......1251
3.15.0.1 CLEANING THE TRACK GROUPS......1251
3.16 STOPPING THE ENGINE......1252
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM......1255
3.17 OPERATION OF THE LUBRICATION SYSTEM......1256
3.17.1 CENTRAL LUBRICATION SYSTEM CLS......1256
3.17.1.1 Manual actuation of the central lubrication system......1256
3.17.1.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM......1257
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS......1257
3.17.2.1 Manual actuation of the swing circle lubrication system......1258
3.17.2.2 SWING CIRCLE LUBRICATION SYSTEM SLS......1259
3.17.2.3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM......1259
3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS......1260
3.18.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS......1261
3.18.1 HIGH LEVEL ALARM FIRE......1265
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE......1265
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS......1265
3.18.3.1 MANUAL ACTUATION......1265
3.18.3.2 AUTOMATIC ACTUATION......1265
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS......1267
3.18.5 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF......1269
3.19 TRANSFER PUMP FOR HYDRAULIC OIL......1270
3.19.1 OPERATING THE TRANSFER PUMP......1271
3.19.2 FUNCTIONS OF THE TRANSFER PUMP......1273
3.20 CENTRAL REFILLING SYSTEM......1276
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM......1277
3.20.1.1 Operation of the hydraulic Service Arm......1277
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM......1279
3.20.3 RECEIVER PANEL WITH MONITOR BOX......1281
3.20.3.1 Refilling Procedure......1283
3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM......1285
3.20.4.1 Refilling the Grease Containers of the Automatic Lubrication Systems......1287
3.21 WORK ON THE LOADER ATTACHMENT......1288
3.21.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS......1288
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL......1289
3.22.1 DISASSEMBLING OF THE SHOVEL......1289
3.22.2 TRANSPORTATION AND LIFTING......1289
3.23 RETRIEVAL PROCEDURE......1290
3.24 SHOVEL STORAGE......1291
3.24.0.1 GENERAL......1291
3.24.1 PREPARING FOR STORAGE......1291
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD......1291
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD......1291
3.24.4 PREPARING FOR OPERATION......1292
3.25 TROUBLE SHOOTING......1293
3.25.0.1 GENERAL......1293
3.25.1 ENGINE......1293
3.25.2 HYDRAULIC SYSTEM......1294
3.25.3 FINAL DRIVES AND SWING MACHINERY......1295
3.25.4 CRAWLER TRACKS......1295
4 MAINTENANCE......1297
4.1 FOREWORD......1298
4.1.0.1 DEFINITIONS......1298
4.1.0.2 GENERAL RECOMMENDATIONS......1298
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE......1299
4.3 FLUIDS AND LUBRICANTS......1300
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES......1300
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES......1301
4.4 FILLING CAPACITIES......1303
4.5 STANDARD TORQUE LIST......1304
4.6 LUBRICATION AND MAINTENANCE SCHEDULE......1305
4.6.1 INITIAL SERVICING......1305
4.6.1.1 AFTER THE FIRST 250 OPERATING HOURS......1305
4.6.1.2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS......1305
4.6.2 PERIODIC SERVICING INTERVALS......1305
4.6.3 PERIODIC SERVICING SCHEDULE......1306
4.6.3.1 Lubrication Chart......1310
4.7 SAFETY CRITICAL PARTS......1312
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES......1312
4.7.2 INSPECTION OF HOSE LINES......1312
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS......1312
4.8 EXTENDED SERVICE INTERVALS......1315
4.8.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM......1315
4.8.1.1 Servicing Intervals......1319
4.8.2 MAINTENANCE OF THE ENGINE......1319
4.9 ENGINE FUEL FILTER LOCATION......1320
4.9.1 fuel line connections on the engine......1321
4.10 WHEN NECESSARY......1322
4.10.1 ENGINE AIR CLEANER SERVICE......1323
4.10.1.1 General Service Tips......1325
4.10.2 SWING CIRCLE TOOTHING LUBRICATION......1327
4.10.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS......1329
4.10.3.1 CLEAN OR REPLACE FILTER ELEMENTS......1331
4.10.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS......1333
4.11 EVERY 10 OPERATING HOURS OR DAILY......1334
4.11.1 WALK-AROUND INSPECTION......1335
4.11.1.1 WORKING ATTACHMENT - INITIAL CHECKS FOR PROPER LUBRICATION......1339
4.11.1.2 CHECK GREASE INJECTORS......1341
4.11.1.3 CORRECTIVE ACTIONS......1341
4.11.1.4 CHECK GREASE INJECTORS......1343
4.11.2 AIR CLEANER - CLEAN PRE-CLEANER......1345
4.11.2.1 Clean dust cups of pre-cleaners......1345
4.11.3 RADIATOR - CHECK COOLANT LEVEL......1347
4.11.4 TRACK GROUPS - CLEAN......1347
4.11.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER......1349
4.11.6 BOOM - CHECK LADDER AND WALKWAY......1351
4.12 EVERY 50 OPERATING HOURS OR WEEKLY......1352
4.12.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS......1353
4.12.1.1 Swing gears manufactured by "L&S"......1353
4.12.1.2 Swing gears manufactured by SIEBENHAAR......1355
4.12.1.3 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S" - CHECK OIL LEVELS......1357
4.12.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN" - CHECK OIL LEVELS......1361
4.12.2 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL......1365
4.12.2.1 CHECK OIL LEVEL OF PTO GEAR......1365
4.12.2.2 CHECK OIL LEVEL OF OIL COLLECTOR RESERVOIR (4)......1365
4.12.3 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR......1367
4.12.4 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY......1369
4.13 EVERY 250 OPERATING HOURS OR MONTHLY......1370
4.13.1 AIR CONDITIONING......1371
4.13.2 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION......1371
4.13.3 AIR CONDITIONING FOR OPERATORS CAB - CHECK REFRIGERANT LEVEL......1375
4.13.4 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE......1377
4.13.5 SIGNAL HORN COMPRESSOR - LUBRICATE......1377
4.13.6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER......1377
4.13.7 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER......1377
4.13.8 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER......1379
4.13.9 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT......1383
4.13.9.1 Clean and inspect filter element (2) as follows:......1383
4.13.9.2 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT (Heavy duty version, special equipment)......1385
4.13.9.3 Clean pre-cleaner dust bowl......1385
4.13.9.4 Clean and inspect main filter element......1385
4.13.10 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL......1387
4.14 EVERY 500 OPERATING HOURS OR MONTHLY......1388
4.14.1 BATTERIES - CHECK FLUID LEVEL......1389
4.14.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL......1391
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL......1393
4.14.3.1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS......1393
4.14.4 FUEL TANK - DRAIN CONDENSATION......1395
4.14.4.1 DRAIN CONDENSATION AS FOLLOWS......1395
4.14.5 CRAWLER TRACK - INSPECTION......1397
4.14.5.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS......1397
4.14.5.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS......1399
4.14.5.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS......1401
4.14.5.4 Bleeding the System......1401
4.14.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION......1403
4.14.7 GROUND CABLE OF OPERATORS CAB - CHECK FOR CORRECT CONNECTION......1405
4.15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH......1406
4.15.1 HIGH STRENGTH BOLT CONNECTIONS......1407
4.15.2 HYDRAULIC SYSTEM - FILTER SERVICE......1457
4.15.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS......1471
4.15.3.1 Oil drain plugs, illustration......1471
4.15.3.2 PTO (PUMP DISTRIBUTOR GEAR)......1471
4.15.3.3 SWING GEARS AND TRAVEL GEARS......1471
4.15.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE......1473
4.15.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS......1475
4.15.6 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES......1477
4.15.7 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES......1479
4.16 EVERY 2000 OPERATING HOURS OR YEARLY......1480
4.16.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER......1481
4.16.2 FILLING THE HYDRAULIC SYSTEM......1491
4.16.3 BLEEDING THE HYDRAULIC SYSTEM......1493
4.16.4 GEAR PUMP FOR PTO GEAR LUBRICATION......1495
4.16.5 EMERGENCY ESCAPE LADDER - INSPECTION......1497
4.17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR......1498
4.17.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL......1499
4.17.1.1 Swing gears manufactured by "L&S"......1499
4.17.1.2 "SWING GEARS MANUFACTURED BY SIEBENHAAR......1503
4.17.1.3 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S"- CHANGE OIL......1507
4.17.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN"- CHANGE OIL......1513
4.17.2 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL......1519
4.18 FIRE PREVENTION......1520
4.18.1 PRECAUTIONS......1521
4.19 WELD REPAIRS......1522
4.19.1 GENERAL PROTECTIVE MEASURES......1523
4.19.1.1 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL......1523
4.19.1.2 COUNTERWEIGHT......1523
4.19.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE......1525
4.19.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT......1527
4.19.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE......1529
4.19.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE......1531
OM-PC4000-8224 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual......1539
1 FOREWORD......1541
1.1 BEFORE READING THIS MANUAL......1542
1.2 DIRECTIONS OF THE MACHINE......1543
1.3 SPECIFICATION AND SERIAL PLATE......1544
1.3.1 PRODUCT IDENTIFICATION NUMBER......1544
1.4 DIVISION OF THE BINDER......1545
1.5 DESIGNATED USE OF THE SHOVEL......1546
1.6 DELIVERY OF THE SHOVEL......1547
1.6.1 SPARE PARTS......1547
1.6.2 SERVICE......1547
1.7 EXPLANATION OF ABBREVIATIONS......1548
1.8 CONTENTS......1549
2 SAFETY......1555
2.1 SAFETY INFORMATION......1556
2.2 OVERVIEW......1557
2.2.1 NORMAL OPERATIONS......1557
2.2.2 REGULAR MAINTENANCE......1557
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR......1557
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR......1557
2.3 SOUND PRESSURE LEVEL IN THE OPERATORS CAB......1558
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR......1559
2.4.1 UNDERSTANDING THE MACHINE......1559
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR......1559
2.4.2.1 ENSURING SAFE OPERATION......1559
2.4.3 PREPARATIONS FOR SAFE OPERATION......1559
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT......1559
2.4.3.2 INSPECTING THE MACHINE......1559
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT......1560
2.4.3.4 KEEP MACHINE CLEAN......1560
2.4.3.5 PRECAUTIONS INSIDE OPERATORS COMPARTMENT......1560
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT......1561
2.4.3.7 IF A PROBLEM IS FOUND......1561
2.4.4 FIRE PREVENTION......1561
2.4.4.1 PRECAUTIONS TO PREVENT FIRE......1561
2.4.4.2 ACTION IF FIRE OCCURS......1562
2.4.4.3 EMERGENCY EXIT FROM OPERATORS CAB......1563
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE......1563
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE......1563
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE......1563
2.4.5.3 NO PEOPLE ON THE ATTACHMENT......1563
2.4.5.4 WORKING IN HIGH PLACES......1563
2.4.5.5 LEAVING OPERATORS SEAT WITH LOCK......1564
2.4.5.6 LEAVING THE MACHINE......1564
2.4.6 BURN PREVENTION......1565
2.4.6.1 Hot coolant......1565
2.4.6.2 Hot oil......1565
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS......1565
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES......1566
2.4.8.1 UNAUTHORIZED MODIFICATION......1566
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS......1566
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)......1567
2.4.10 PRECAUTIONS AT JOBSITE......1568
2.4.10.1 VISIBILITY FROM OPERATORS SEAT......1569
2.4.10.2 CAMERA SYSTEM WITH MONITORS......1569
2.4.10.3 ENSURE GOOD VISIBILITY......1569
2.4.10.4 CHECKING SIGNS AND SIGNALMANS SIGNALS......1569
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS......1570
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES......1570
2.4.10.7 WORKING ON LOOSE GROUND......1571
2.4.10.8 GAS, DUST, STEAM AND SMOKE......1571
2.4.10.9 VENTILATION OF ENCLOSED AREAS......1572
2.4.11 STARTING ENGINE......1573
2.4.11.1 WARNING TAG......1573
2.4.11.2 CHECKS BEFORE STARTING ENGINE......1573
2.4.11.3 PRECAUTION WHEN STARTING ENGINE......1573
2.4.11.4 PRECAUTION IN COLD AREAS......1574
2.4.12 OPERATION......1574
2.4.12.1 CHECKS BEFORE OPERATION......1574
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE......1575
2.4.12.3 PRECAUTIONS WHEN travelling......1576
2.4.12.4 TRAVELLING ON SLOPES......1577
2.4.12.5 OPERATIONS ON SLOPES......1578
2.4.12.6 PROHIBITED OPERATIONS......1578
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES......1579
2.4.12.8 PARKING THE MACHINE......1579
2.4.12.9 TRANSPORTATION......1579
2.5 PRECAUTION FOR MAINTENANCE......1580
2.5.1 GENERAL PRECAUTIONS......1580
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES......1581
2.5.1.2 STOP ENGINE FOR MAINTENANCE......1582
2.5.1.3 WARNING TAG......1583
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY......1584
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS......1584
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING......1585
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS......1585
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT......1586
2.5.1.9 NOISE......1586
2.5.1.10 WHEN USING A HAMMER......1586
2.5.1.11 PROPER TOOLS......1587
2.5.1.12 ACCUMULATOR......1587
2.5.1.13 PERSONNEL......1587
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE......1588
2.5.2.1 PRECAUTION WHEN WELDING......1588
2.5.2.2 BATTERY HANDLING......1588
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID......1589
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE......1589
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES......1590
2.5.3.3 REPLACEMENT OF HOSE LINES......1590
2.5.3.4 INSPECTION OF HOSE LINES......1590
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......1591
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE......1591
2.5.3.7 AIR CONDITIONING MAINTENANCE......1591
2.5.3.8 COMPRESSED AIR......1592
2.5.3.9 WASTE MATERIALS......1592
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS......1593
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM......1593
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS......1593
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR......1593
2.7 SPECIAL SAFETY EQUIPMENT......1594
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR FOPS FOR OPERATORS CAB......1595
2.7.2 OBJECT HANDLING......1595
2.7.3 LIGHTING......1595
2.7.4 WARNING BEACON......1595
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)......1595
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)......1595
2.7.5.2 INSTRUCTIONS FOR USE......1597
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL......1599
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),......1599
