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06253
Komatsu 06253 User Manual
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MAINTENANCE
4.5
STANDARD TORQUE LIST
249
4.5
ST
A
NDARD TORQUE LIST
Bolt
dia.
Wrench
size [mm]
Tight
eni
ng to
rqu
e
Nm
lbs.ft.
Quality grad
es
8.8
10.9
12.9
M 10
17
43
63
73
32
47
54
M 12
19
74
108
127
54.6
80
94
M 14
22
1
18
173
202
87
128
14
9
M 16
24
179
265
310
132
196
22
9
M 18
27
255
360
425
188
265
31
3
M20
30
360
510
60
0
265
376
44
3
M 22
32
4
85
690
810
358
509
59
7
M 24
36
6
20
880
1030
457
649
76
0
M 27
41
9
20
1310
1530
679
966
11
2
8
M 30
46
1
250
1770
2080
922
1305
15
34
M 33
50
1
690
2400
2800
1246
177
0
2065
M 36
55
2
170
3100
3600
1600
228
6
2655
M 39
60
2
800
4000
4700
2065
295
0
3466
Inse
rt all bolts l
ubricate
d with MPG
, KP2
K
248
250
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
9
Safety
15
Safety Instructions
16
Warnings and Symbols
16
Basic Operation and Designated Use of the Hydraulic Shovel
16
Organizational Measures
17
Selection and Qualification of Personnel - Basic Responsibilities
19
Safety Instructions Governing Specific Operational Phases
20
Warning of Special Dangers
23
Transporting and Towing -Recommissioning
25
Special Safety Equipment
25
Safety Harness in Conformity with en 361 (European Standard)
29
Operation
37
Foreword
38
Construction of the Shovel
39
Overall View
39
Undercarriage and Superstructure
40
Hydraulically Operated Access Ladder
46
Emergency Escape Ladder
50
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 System
54
System
54
Operator's Cab with Integrated Falling Object Protective Structure (Fops)
56
Engine Oil Management System
64
Operator's Cab - Controls
72
Controls with Backhoe Attachment
72
Controls with Bottom Dump Bucket
76
Operator's Console
81
Electronic Text Monitoring System Etm
88
Introduction
89
System Components
93
Functions of the Etm System
95
Display the Contents of the Record (Protocol) Memory
99
Several Message Conditions Occur at the same Time
111
Settings of the Text Display Unit
113
Operating the Heater, Ventilation and Air Conditioning
128
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 Arrangement
139
Machinery House
140
Emergency Engine Shutdown Switches
141
Electrical Equipment in Cab Base
142
Switch Box (X2) in Cab Base
147
Components of Electrical Preheating System in Cab Base
151
Preheating Systems
156
For Oil, Coolant and Batteries
156
Heaters for Machinery House (Special Equipment)
162
Checks before Starting the Engine
164
Starting the Engine
170
Starting Procedure
171
Starting Procedure at Ambient Temperature up to -25
173
Moving the Shovel
182
Travel Control with Foot Pedals
182
Travelling Instructions
185
Slewing and Braking the Superstructure
186
Slewing the Superstructure
186
Working with the Attachment
189
Machines Equipped With"Euro" Control System
189
Machines Equipped With"Kmg" Control System
190
Bottom Dump Bucket
191
Drop Ball Operation
192
Combined Operation Cycles
195
Working Instructions
197
Stability of the Shovel
197
Shovel Operation
197
Parking the Shovel
200
Stopping the Engine
202
Relieve Pressure in the Hydraulic System
205
Automatic Lubrication Systems
206
Operation of the Automatic Lubrication Systems
207
Fire Detection and Suppression System
210
High Level Alarm "Fire
213
Engine Shut-Down through Fuel Shut-Off Solenoid Valve
213
Actuation Modes of the Fire Suppression System
213
Indication of Operational Modes at Control Module, after Automatic Actuation of the Fire Suppression System
215
Location of the Extinguishing Agent Tank Assemblies and Expellant Gas Cartridges on Power House Roof
217
Central Refilling System
218
Systems Connected to the Refilling System
219
Operating the Hydraulic Service Arm
221
Receiver Panel with Monitor Box
223
Refillable Grease Containers of the Automatic Lubrication Systems
227
Transfer Pump for Hydraulic Oil
228
Operating the Transfer Pump
229
Functions of the Transfer Pump
229
Work on the Loader Attachment
232
Transportation and Lifting of the Shovel
233
Disassembling of the Shovel
233
Transportation and Lifting
233
Retrieval Procedure
234
Shovel Storage
235
Preparing for Storage
235
One Month Repetitive Service Period
236
Six Month Repetitive Service Period
236
Preparing for Operation
237
Trouble Shooting
238
Engine
238
Hydraulic System
239
Final Drives and Swing Gear
240
Crawler Tracks
240
Maintenance
241
Foreword
242
Precautions for Maintenance
243
Fluids and Lubricants
245
Lubricants for Operation in Cold and Arctic Climates
245
Fluids and Lubricants for Moderate and Hot Climates
246
Filling Capacities
248
Standard Torque List
249
Lubrication and Maintenance Schedule
250
Initial Servicing
250
Periodic Servicing Intervals
250
Periodic Servicing Schedule
251
Periodic Replacement of Safety Critical Parts
257
Extended Service Intervals for Engines with Engine Oil Management System
261
Resetting the Engine Oil Burning System Centinel
263
Maintenance of the Engine
267
When Necessary
268
Engine Air Cleaner Maintenance
269
Swing Circle Toothing Lubrication
273
Automatic Lubrication Systems Fill Grease Containers
275
Track Rollers and Guide Wheels - Replace Floating Seals
279
Cold Starting Aid, Replace Fluid Cylinder
281
Every 10 Operating Hours or Daily
282
Walk - Around Inspection
283
Air Cleaner - Clean Pre-Cleaner
295
Radiator - Check Coolant Level
297
Track Groups - Clean
297
Fuel System Water Separator - Drain Water
299
Every 50 Operating Hours or Weekly
300
Swing Gear and Motor Adapter Housing - Check Oil Level
301
Travel Gears, Brake Housings and Motor Adapter Housings - Check Oil Levels
305
Pto (Pump Distributor Gear) - Check Oil Level
309
Hydraulic Access Ladder - Check Safety Sensor
311
Hydraulic Oil Coolers - Inspect and Clean if Necessary
313
Every 250 Operating Hours or Monthly
314
Air Conditioning Compressor - Check Drive Belt Tension
315
Radiator Fan Belt and Automatic Belt Tensioner - Maintenance Check
317
Radiator Fan Belt and Automatic Belt Tensioner - Maintenance Check
319
Generator - Check Belt Tension
321
Signal Horn Compressor - Lubricate
323
Hydraulic Oil Cooler Fan - Check Condition and Fastening
323
Automatic Lubrication Systems - Clean In-Line Grease Filter and Check Breather Filter
325
Cab Air Cleaner - Clean or Replace Filter Element
329
Windshield Washer Reservoir - Check Fluid Level
331
Air Conditioning for Operator's Cab - Check Refrigerant Level
331
Every 500 Operating Hours or Monthly
332
Batteries - Check Fluid Level
333
Flexible Drive Coupling - Check Oil Level
335
Fuel Tank - Drain Condensation
337
Crawler Track - Inspection
339
Every 1000 Operating Hours or Every 6 Month
344
High Strength Bolt Connections - Check Torque Load
345
Hydraulic System - Filter Service
377
Pto (Pump Distributor Gear), Swing Gear and Travel Gears - Oil Sample Analysis
391
Signal Horn Compressor - Clean and Lubricate
393
Hydraulic Track Tensioning System - Check Pressure Accumulators
395
Hydraulic Oil Cooler - Inspect and Lubricate Door Hinges
397
Machinery House Doors - Inspect and Lubricate Door Hinges
397
Every 2000 Operating Hours or Yearly
398
Hydraulic System - Change Oil, Replace Suction Strainers and Pulsation Damper
399
Emergency Escape Ladder - Inspection
413
Every 3000 Operating Hours However at Least Once a Year
414
Swing Gear and Motor Adapter Housing - Change Oil
415
Travel Gears, Brake and Motor Adapter Housings - Change Oil
423
Pto (Pump Distributor Gear) - Change Oil
427
Fire Prevention
430
Weld Repairs
432
Protective Measures before Starting Weld Repairs on the Undercarriage
435
Protective Measures before Starting Weld Repairs on the Loader Attachment
437
Protective Measures before Starting Weld Repairs on the Superstructure
439
After Finishing the Repair Weldings on the Superstructure
441
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Assembly Procedure
76 pages
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Komatsu 06253 Specifications
General
Brand
Komatsu
Model
06253
Category
Construction Equipment
Language
English
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