KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL FIELD ASSEMBLY MANUAL – PDF Download

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KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL FIELD ASSEMBLY MANUAL

KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL FIELD ASSEMBLY MANUAL – PDF DOWNLOAD:

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KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL FIELD ASSEMBLY MANUAL

precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed. The safety information in this manual does not replace any safety rules or laws in your area. To identify important safety messages in the manual and on the machine labels, the following signal words are used. The “Safety Alert Symbol” identifies important safety messages on machines, in manuals, and elsewhere. When you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message

TABLE OF CONTENTS:

KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL FIELD ASSEMBLY MANUAL

2 SAFETY.........................................................................................................  9
	2.1 SAFETY INFORMATION....................................................................................... 10
	2.2 OVERVIEW................................................................................................. 11
		2.2.1 NORMAL OPERATIONS.................................................................................. 11
		2.2.2 REGULAR MAINTENANCE................................................................................ 11
		2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR............................................................ 11
		2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR.... 11
	2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB............................................................... 12
	2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR................................................. 13
		2.4.1 UNDERSTANDING THE MACHINE.......................................................................... 13
		2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR............................................. 13
		2.4.3 PREPARATIONS FOR SAFE OPERATION.................................................................... 13
		2.4.4 FIRE PREVENTION.................................................................................... 15
		2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE..................................................... 17
		2.4.6 BURN PREVENTION.................................................................................... 19
		2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS................................................................ 19
		2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....................................................... 20
		2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)................................................................ 21
		2.4.10 PRECAUTIONS AT JOBSITE............................................................................ 22
		2.4.11 STARTING ENGINE................................................................................... 27
		2.4.12 OPERATION......................................................................................... 28
	2.5 PRECAUTION FOR MAINTENANCE............................................................................... 34
		2.5.1 GENERAL PRECAUTIONS................................................................................ 34
		2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE......................................................... 42
		2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 43
	2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS........................................ 47
		2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM................................................................. 47
		2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS.................................... 47
		2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR..................................................... 47
	2.7 SPECIAL SAFETY EQUIPMENT................................................................................. 48
		2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB.......................................... 49
		2.7.2 OBJECT HANDLING.................................................................................... 49
		2.7.3 LIGHTING........................................................................................... 49
		2.7.4 WARNING BEACON..................................................................................... 49
		2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)....................................... 49
	2.8 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLY............................................................... 57
		2.8.1 WHEN ASSEMBLING THE EXCAVATOR...................................................................... 57
		2.8.2 WHEN DISASSEMBLING THE EXCAVATOR................................................................... 57
		2.8.3 WHEN TRANSPORTING THE DISASSEMBLED EXCAVATOR....................................................... 58
3 GENERAL........................................................................................................ 59
	3.1 GENERAL.................................................................................................. 60
		3.1.1 DELIVERY OF THE EXCAVATOR.......................................................................... 60
		3.1.2 ASSEMBLING THE EXCAVATOR........................................................................... 60
		3.1.3 LIFTING AND TRANSPORTATION......................................................................... 60
		3.1.4 PACKING LIST OF A TYPICAL FACE SHOVEL MACHINE...................................................... 61
		3.1.5 PACKING LIST OF A TYPICAL BACKHOE MACHINE.......................................................... 62
		3.1.6 ELECTRICAL ENERGY.................................................................................. 63
		3.1.7 ELECTROMAGNETIC COMPATIBILITY (EMC)................................................................ 63
		3.1.8 MONITORING SYSTEM OF THE MACHINE................................................................... 63
	3.2 ASSEMBLY SITE REQUIREMENTS............................................................................... 64
		3.2.1 CONFIGURATION OF COMPONENTS ON ERECTION SITE (EXAMPLE)............................................. 64
		3.2.2 REQUIRED CRANES.................................................................................... 66
		3.2.3 MANPOWER / ASSEMBLY TIME........................................................................... 66
		3.2.4 TOOLS AND EQUIPMENT FOR ASSEMBLY................................................................... 67
		3.2.5 STANDARD APPLICATION TORQUE CHART.................................................................. 70
		3.2.6 PREPARATIONS FOR ASSEMBLY.......................................................................... 73
		3.2.7 BASIC DIMENSIONS................................................................................... 74
	3.3 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES................................................. 75
4 ASSEMBLY SEQUENCE.............................................................................................. 77
	4.1 ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES................................................................ 78
		4.1.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY................................... 79
	4.2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES.................................................................... 80
		4.2.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY................................... 81
	4.3 ASSEMBLY OF UNDERCARRIAGE................................................................................ 82
		4.3.1 ASSEMBLY OF TRACKS................................................................................. 83
		4.3.2 ATTACH CARBODY TO SIDE FRAME....................................................................... 84
		4.3.3 DETERMINING THE TIGHTENING TORQUE.................................................................. 91
		4.3.4 SPECIAL HYDRAULIC TORQUE WRENCH.................................................................... 95
		4.3.5 CLOSING THE TRACKS................................................................................. 96
		4.3.6 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS....................................................... 97
		4.3.7 MOUNTING OF TRAVEL GEAR PROTECTION.................................................................100
		4.3.8 MOUNTING OF TRAVEL MOTOR PROTECTION HOOD...........................................................102
		4.3.9 HYDRAULIC TRACK TENSIONING SYSTEM..................................................................104
	4.4 MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE......................................................106
	4.5 ASSEMBLY OF MACHINERY HOUSE ROOF.........................................................................110
		4.5.1 MOUNTING OF THE EXHAUST SYSTEM.....................................................................112
		4.5.2 MOUNTING OF THE AIR INTAKE SYSTEM..................................................................115
	4.6 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM................................................118
	4.7 MOUNTING OF BATTERY BOX AND HYDRAULIC ACCESS LADDER......................................................120
	4.8 CONNECTING ENGINE OIL RESERVE SYSTEM.....................................................................126
	4.9 PRE-ASSEMBLY OF FACE SHOVEL BOOM.........................................................................130
		4.9.1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM.......................................................134
		4.9.2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS..............................................136
		4.9.3 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM..............................................138
		4.9.4 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME...............................................................142
	4.10 PRE-ASSEMBLY OF BACKHOE BOOM............................................................................144
		4.10.1 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM.............................................146
		4.10.2 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME..............................................................150
	4.11 MOUNTING OF COUNTERWEIGHT...............................................................................152
	4.12 MOUNTING OF THE FUEL TANK...............................................................................154
		4.12.1 CONNECTING FUEL SYSTEM HOSE LINES.................................................................156
	4.13 ATTACHING THE CAB BASE..................................................................................160
		4.13.1 MAKING OF ELECTRICAL CABLE CONNECTIONS............................................................162
		4.13.2 CONNECT CAB HEATER HOSES TO CAB BASE..............................................................164
	4.14 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE....................................................166
		4.14.1 CONNECTING THE AIR CONDITIONER HOSES OF THE CAB...................................................168
		4.14.2 INSTALL ORBCOMM ANTENNA...........................................................................170
	4.15 CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE AND SUPERSTRUCTURE...................................172
		4.15.1 CONNECTING HIGH PRESSURE LINES OF THE MAIN PUMPS..................................................174
	4.16 ATTACHING THE HYDRAULIC OIL RESERVOIR...................................................................176
	4.17 ATTACHING THE HYDRAULIC OIL COOLER......................................................................178
		4.17.1 CONNECTING THE HYDRAULIC HOSE LINES OF THE OIL COOLER CIRCUIT.....................................180
		4.17.2 CONNECTING THE HOSE LINES OF OIL COOLER FAN MOTORS................................................182
		4.17.3 CONNECTING THE HOSE LINES OF PTO OIL COOLING CIRCUIT..............................................184
		4.17.4 CONNECTING THE RETURN OIL HOSE LINE OF RADIATOR FAN MOTOR.........................................186
		4.17.5 CONNECTING THE HOSE LINES FROM RETURN OIL MANIFOLD TO BACK-PRESSURE PIPE..........................188
	4.18 CONNECTING SWING GEAR HYDRAULIC LINES...................................................................190
		4.18.1 CONNECTING THE RETURN AND LEAKAGE OIL HOSE LINES..................................................191
		4.18.2 CONNECTING THE SWING BRAKE PRESSURE HOSES AND PILOT OIL HOSES.....................................192
	4.19 CONNECTING THE RETURN AND PRESSURE OIL HOSES FROM VALVE BLOCK...........................................194
	4.20 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP..........................................................200
	4.21 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT..........................................................202
		4.21.1 CONNECTING THE PILOT OIL LINE, RETURN OIL LINE AND LEAKAGE OIL LINE TO THE ROTARY JOINT...........204
	4.22 ATTACHING THE HANDRAILS, CATWALKS AND STEPS.............................................................206
	4.23 MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES......................................................208
	4.24 CENTRAL REFILLING SYSTEM................................................................................212
		4.24.1 CONNECTING THE REFILLING LINES....................................................................213
	4.25 CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS........................................218
	4.26 MOUNTING THE CAN-NODE BOXES ONTO THE MACHINERY HOUSE ROOF...............................................220
		4.26.1 CONNECTING THE CABLES TO THE CAN-NODES............................................................221
	4.27 PRE-CHECKS PRIOR TO INITIAL START UP....................................................................222
	4.28 FILLING AND BLEEDING THE HYDRAULIC SYSTEM...............................................................224
		4.28.1 FILLING THE HYDRAULIC SYSTEM......................................................................225
		4.28.2 BLEEDING THE HYDRAULIC SYSTEM.....................................................................226
		4.28.3 BLEEDING THE GEAR PUMP FOR PTO GEAR LUBRICATION...................................................229
	4.29 ASSEMBLY FACE SHOVEL ATTACHMENT.........................................................................230
		4.29.1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM........................................................231
		4.29.2 ATTACHING THE STICK TO THE BOOM...................................................................233
		4.29.3 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM...........................................234
		4.29.4 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS.................................................234
		4.29.5 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS................................................237
		4.29.6 CONNECTING HOSE LINES FROM STICK TO BUCKET CYLINDERS..............................................239
		4.29.7 CONNECTING STICK CYLINDERS TO THE STICK...........................................................240
	4.30 BLEEDING HYDRAULIC CIRCUITS.............................................................................242
		4.30.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT..........................................................243
		4.30.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT.........................................................243
		4.30.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT...................................................245
		4.30.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER.......................................................246
		4.30.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS................................................246
		4.30.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS........................................................247
	4.31 ATTACHING FACE SHOVEL TO THE STICK......................................................................248
		4.31.1 ATTACHING BUCKET BACK WALL TO THE STICK...........................................................249
		4.31.2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM CYLINDERS.........................................251
		4.31.3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL......................................................253
		4.31.4 CONNECTING GREASE LINES OF THE FACE SHOVEL ATTACHMENT.............................................255
		4.31.5 CONNECTING GREASE LINES ON THE BUCKET.............................................................257
		4.31.6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS...............................................257
	4.32 ASSEMBLY BACKHOE ATTACHMENT.............................................................................258
		4.32.1 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM...........................................259
		4.32.2 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS.................................................260
		4.32.3 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS................................................261
		4.32.4 ATTACHING THE STICK TO THE BOOM...................................................................263
		4.32.5 CONNECTING HOSE LINES FROM BOOM TO BUCKET CYLINDERS...............................................267
	4.33 BLEEDING HYDRAULIC CIRCUITS.............................................................................268
		4.33.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT..........................................................269
		4.33.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT.........................................................269
		4.33.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT...................................................271
		4.33.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER.......................................................272
		4.33.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS................................................272
		4.33.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS........................................................273
	4.34 ATTACHING BACKHOE BUCKET TO THE STICK...................................................................274
		4.34.1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT.................................................279
	4.35 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS........................................................280
5 FINAL CHECKS AND ADJUSTMENTS...................................................................................281
	5.0.1 COMMISSIONING CHECK LIST...............................................................................283
	5.0.2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS............................................................283
	5.0.3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE..........................................285
	5.0.4 PRESSURE COMPENSATION OF SEALED COMPONENTS.............................................................285
	5.0.5 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE...........................................286
	5.0.6 COMMISSIONING OF THE AIR CONDITIONING..................................................................304
	5.1 PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC MANUAL........................................308
		5.1.1 VISUAL INSPECTION..................................................................................309
		5.1.2 TRAVELLING INSTRUCTIONS............................................................................309
	5.2 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING...............................................310
6 DISASSEMBLY OF THE MACHINE.....................................................................................311
	6.0.1 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES...........................................................312
	6.0.2 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE.......................................................313
	6.0.3 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES...............................................................314
	6.0.4 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE.......................................................315
	6.0.5 DISPOSAL OF WASTE MATERIAL.............................................................................316

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