Komatsu 06253 - Page 2

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Introduction3
Contents of the Binder4
Division of the Binder5
Designated Use of the Shovel6
Delivery of the Shovel7
Explanation of Abbreviations8
Table of Contents9
Safety15
Safety Instructions16
Warnings and Symbols16
Basic Operation and Designated Use of the Hydraulic Shovel16
Organizational Measures17
Selection and Qualification of Personnel - Basic Responsibilities19
Safety Instructions Governing Specific Operational Phases20
Warning of Special Dangers23
Transporting and Towing -Recommissioning25
Special Safety Equipment25
Safety Harness in Conformity with en 361 (European Standard)29
Operation37
Foreword38
Construction of the Shovel39
Overall View39
Undercarriage and Superstructure40
Hydraulically Operated Access Ladder46
Emergency Escape Ladder50
Emergency Escape Ladder and Escape Hatch in the Machinery House (Special Equipment)52
(Special Equipment)52
Emergency Engine Shutdown from Ground man or Operator Warning System54
System54
Operator's Cab with Integrated Falling Object Protective Structure (Fops)56
Engine Oil Management System64
Operator's Cab - Controls72
Controls with Backhoe Attachment72
Controls with Bottom Dump Bucket76
Operator's Console81
Electronic Text Monitoring System Etm88
Introduction89
System Components93
Functions of the Etm System95
Display the Contents of the Record (Protocol) Memory99
Several Message Conditions Occur at the same Time111
Settings of the Text Display Unit113
Operating the Heater, Ventilation and Air Conditioning128
Control Module for Auxiliary Cab Heater (if so Equipped)133
Auxiliary Heater for Operators Cab (if so Equipped)135
Auxilliary Heater for Operators Cab (if so Equipped)137
Fuel Pump Arrangement139
Machinery House140
Emergency Engine Shutdown Switches141
Electrical Equipment in Cab Base142
Switch Box (X2) in Cab Base147
Components of Electrical Preheating System in Cab Base151
Preheating Systems156
For Oil, Coolant and Batteries156
Heaters for Machinery House (Special Equipment)162
Checks before Starting the Engine164
Starting the Engine170
Starting Procedure171
Starting Procedure at Ambient Temperature up to -25173
Moving the Shovel182
Travel Control with Foot Pedals182
Travelling Instructions185
Slewing and Braking the Superstructure186
Slewing the Superstructure186
Working with the Attachment189
Machines Equipped With"Euro" Control System189
Machines Equipped With"Kmg" Control System190
Bottom Dump Bucket191
Drop Ball Operation192
Combined Operation Cycles195
Working Instructions197
Stability of the Shovel197
Shovel Operation197
Parking the Shovel200
Stopping the Engine202
Relieve Pressure in the Hydraulic System205
Automatic Lubrication Systems206
Operation of the Automatic Lubrication Systems207
Fire Detection and Suppression System210
High Level Alarm "Fire213
Engine Shut-Down through Fuel Shut-Off Solenoid Valve213
Actuation Modes of the Fire Suppression System213
Indication of Operational Modes at Control Module, after Automatic Actuation of the Fire Suppression System215
Location of the Extinguishing Agent Tank Assemblies and Expellant Gas Cartridges on Power House Roof217
Central Refilling System218
Systems Connected to the Refilling System219
Operating the Hydraulic Service Arm221
Receiver Panel with Monitor Box223
Refillable Grease Containers of the Automatic Lubrication Systems227
Transfer Pump for Hydraulic Oil228
Operating the Transfer Pump229
Functions of the Transfer Pump229
Work on the Loader Attachment232
Transportation and Lifting of the Shovel233
Disassembling of the Shovel233
Transportation and Lifting233
Retrieval Procedure234
Shovel Storage235
Preparing for Storage235
One Month Repetitive Service Period236
Six Month Repetitive Service Period236
Preparing for Operation237
Trouble Shooting238
Engine238
Hydraulic System239
Final Drives and Swing Gear240
Crawler Tracks240
Maintenance241
Foreword242
Precautions for Maintenance243
Fluids and Lubricants245
Lubricants for Operation in Cold and Arctic Climates245
Fluids and Lubricants for Moderate and Hot Climates246
Filling Capacities248
Standard Torque List249
Lubrication and Maintenance Schedule250
Initial Servicing250
Periodic Servicing Intervals250
Periodic Servicing Schedule251
Periodic Replacement of Safety Critical Parts257
Extended Service Intervals for Engines with Engine Oil Management System261
Resetting the Engine Oil Burning System Centinel263
Maintenance of the Engine267
When Necessary268
Engine Air Cleaner Maintenance269
Swing Circle Toothing Lubrication273
Automatic Lubrication Systems Fill Grease Containers275
Track Rollers and Guide Wheels - Replace Floating Seals279
Cold Starting Aid, Replace Fluid Cylinder281
Every 10 Operating Hours or Daily282
Walk - Around Inspection283
Air Cleaner - Clean Pre-Cleaner295
Radiator - Check Coolant Level297
Track Groups - Clean297
Fuel System Water Separator - Drain Water299
Every 50 Operating Hours or Weekly300
Swing Gear and Motor Adapter Housing - Check Oil Level301
Travel Gears, Brake Housings and Motor Adapter Housings - Check Oil Levels305
Pto (Pump Distributor Gear) - Check Oil Level309
Hydraulic Access Ladder - Check Safety Sensor311
Hydraulic Oil Coolers - Inspect and Clean if Necessary313
Every 250 Operating Hours or Monthly314
Air Conditioning Compressor - Check Drive Belt Tension315
Radiator Fan Belt and Automatic Belt Tensioner - Maintenance Check317
Radiator Fan Belt and Automatic Belt Tensioner - Maintenance Check319
Generator - Check Belt Tension321
Signal Horn Compressor - Lubricate323
Hydraulic Oil Cooler Fan - Check Condition and Fastening323
Automatic Lubrication Systems - Clean In-Line Grease Filter and Check Breather Filter325
Cab Air Cleaner - Clean or Replace Filter Element329
Windshield Washer Reservoir - Check Fluid Level331
Air Conditioning for Operator's Cab - Check Refrigerant Level331
Every 500 Operating Hours or Monthly332
Batteries - Check Fluid Level333
Flexible Drive Coupling - Check Oil Level335
Fuel Tank - Drain Condensation337
Crawler Track - Inspection339
Every 1000 Operating Hours or Every 6 Month344
High Strength Bolt Connections - Check Torque Load345
Hydraulic System - Filter Service377
Pto (Pump Distributor Gear), Swing Gear and Travel Gears - Oil Sample Analysis391
Signal Horn Compressor - Clean and Lubricate393
Hydraulic Track Tensioning System - Check Pressure Accumulators395
Hydraulic Oil Cooler - Inspect and Lubricate Door Hinges397
Machinery House Doors - Inspect and Lubricate Door Hinges397
Every 2000 Operating Hours or Yearly398
Hydraulic System - Change Oil, Replace Suction Strainers and Pulsation Damper399
Emergency Escape Ladder - Inspection413
Every 3000 Operating Hours However at Least Once a Year414
Swing Gear and Motor Adapter Housing - Change Oil415
Travel Gears, Brake and Motor Adapter Housings - Change Oil423
Pto (Pump Distributor Gear) - Change Oil427
Fire Prevention430
Weld Repairs432
Protective Measures before Starting Weld Repairs on the Undercarriage435
Protective Measures before Starting Weld Repairs on the Loader Attachment437
Protective Measures before Starting Weld Repairs on the Superstructure439
After Finishing the Repair Weldings on the Superstructure441

Komatsu 06253 - Page 2

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