KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL ASSEMBLY MANUAL 08234 & up – PDF DOWNLOAD

Description

KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL ASSEMBLY MANUAL 08234 & up – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL ASSEMBLY MANUAL 08234 & up – PDF DOWNLOAD

SAFETY INFORMATION:

• To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the
  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 PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL ASSEMBLY MANUAL 08234 & up – PDF DOWNLOAD

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 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 ELECTRICAL ENERGY 61
3 1 5 ELECTROMAGNETIC COMPATIBILITY (EMC) 61
3 1 6 MONITORING SYSTEM OF THE MACHINE 61
3 2 ASSEMBLY SITE REQUIREMENTS 62
3 2 1 CONFIGURATION OF COMPONENTS ON ERECTION SITE (EXAMPLE) 62
3 2 2 REQUIRED CRANES 64
3 2 3 MANPOWER / ASSEMBLY TIME 64
3 2 4 TOOLS AND EQUIPMENT FOR ASSEMBLY 65
3 2 5 STANDARD APPLICATION TORQUE CHART 68
3 2 6 PREPARATIONS FOR ASSEMBLY 71
3 2 7 BASIC DIMENSIONS 72
3 3 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES 73
4 ASSEMBLY SEQUENCE 75
4 1 ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES 76
4 1 1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY 77
4 2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES 78
4 2 1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY 79
4 3 ASSEMBLY OF UNDERCARRIAGE 80
4 3 1 ASSEMBLY OF TRACKS 81
4 3 2 ATTACH CARBODY TO SIDE FRAME 82
4 3 3 DETERMINING THE TIGHTENING TORQUE 89
4 3 4 SPECIAL HYDRAULIC TORQUE WRENCH 93
4 3 5 CLOSING THE TRACKS 94
4 3 6 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS 95
4 3 7 MOUNTING OF TRAVEL GEAR PROTECTION 98
4 3 8 MOUNTING OF TRAVEL MOTOR PROTECTION HOOD 100
4 3 9 HYDRAULIC TRACK TENSIONING SYSTEM 102
4 4 MOUNTING OF THE CABLE DRUM 104
4 5 MOUNTING OF THE CABLE GUIDE 106
4 6 MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE 108
4 6 1 CONNECT THE GREASE LINES TO THE ROTARY JOINT 115
4 7 MOUNTING OF THE MACHINERY HOUSE RAILINGS 116
4 8 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM 118
4 9 MOUNTING OF THE HIGH VOLTAGE CABINET 120
4 10 MOUNTING OF BATTERY BOX AND HYDRAULIC ACCESS LADDER 122
4 11 PRE-ASSEMBLY OF FACE SHOVEL BOOM 128
4 11 1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM 132
4 11 2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS 134
4 11 3 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM 136
4 11 4 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME 140
4 12 PRE-ASSEMBLY OF BACKHOE BOOM 142
4 12 1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM 144
4 12 2 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM 146
4 12 3 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME 150
4 13 MOUNTING OF THE COUNTERWEIGHT 152
4 14 HIGH VOLTAGE INTERLOCK SAFETY SWITCHES 154
4 14 1 HIGH VOLTAGE INTERLOCK SAFETY SWITCHES ON CABLE DRUM 155
4 14 2 HIGH VOLTAGE INTERLOCK SAFETY SWITCHES ON CABLE GUIDE 157
4 15 CONNECT HIGH VOLTAGE CABLES AND CONTROL CABLES ON MACHINES WITH CABLE DRUM 158
4 16 CONNECT HIGH VOLTAGE CABLES ON MACHINES WITH CABLE GUIDE 162
4 17 CONNECT THE POWER CABLES INSIDE THE HIGH VOLTAGE SWITCH CABINET 164
4 18 CONNECT THE AIR CONDITIONER HOSES TO THE HIGH VOLTAGE SWITCH CABINET 166
4 19 MOUNTING OF THE CAB BASE 168
4 19 1 ACCOMPLISH ELECTRICAL CABLE CONNECTIONS 170
4 19 2 CONNECT THE FIRE SUPPRESSION SYSTEM PIPING BETWEEN HIGH VOLTAGE CABINET AND CAB BASE 173
4 19 3 ATTACH GROMMET FRAME TO CAB BASE ROOF 174
4 20 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE 176
4 20 1 CONNECTING THE CAB AIR CONDITIONER HOSES 178
4 20 2 INSTALL THE ORBCOMM ANTENNA 180
4 21 CONNECTING THE HIGH PRESSURE LINES OF THE MAIN PUMPS 182
4 22 ATTACHING THE HYDRAULIC OIL RESERVOIR 184
4 23 ATTACHING THE HYDRAULIC OIL COOLER 186
4 23 1 CONNECTING THE HYDRAULIC HOSE LINES OF THE OIL COOLER CIRCUIT 188
4 23 2 CONNECTING THE HOSE LINES OF OIL COOLER FAN MOTORS 190
4 23 3 CONNECTING THE HOSE LINES OF PTO OIL COOLING CIRCUIT 192
4 23 4 CONNECTING THE HOSE LINES FROM RETURN OIL MANIFOLD TO BACK-PRESSURE PIPE 194
4 24 CONNECTING SWING GEAR HYDRAULIC LINES 196
4 24 1 CONNECTING THE RETURN AND LEAKAGE OIL HOSE LINES 197
4 24 2 CONNECTING THE SWING BRAKE PRESSURE HOSES AND PILOT OIL HOSES 198
4 25 CONNECTING THE LEAKAGE AND PRESSURE HOSES FROM VALVE BLOCK 200
4 26 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP 206
4 27 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT 208
4 27 1 CONNECTING THE PILOT OIL LINE, RETURN OIL LINE AND LEAKAGE OIL LINE TO THE ROTARY JOINT 210
4 28 ATTACHING THE HANDRAILS, CATWALKS AND STEPS 212
4 29 CENTRAL REFILLING SYSTEM 214
4 29 1 CONNECTING THE REFILLING LINES 215
4 30 CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS 216
4 31 PRE-CHECKS PRIOR TO INITIAL START UP 218
4 32 HIGH VOLTAGE INTERLOCK SYSTEM 220
4 32 1 APPLYING HIGH VOLTAGE CURRENT ON MACHINES WITH CABLE DRUM 221
4 32 2 APPLYING HIGH VOLTAGE CURRENT ON MACHINES WITH CABLE GUIDE 224
4 33 CHECKING DIRECTION OF MOTOR ROTATION 228
4 34 CHECK AND ADJUST ALIGNMENT OF MAIN MOTOR 230
4 34 1 ALIGNMENT TOLERANCES 237
4 34 2 SHIM SETS 237
4 34 3 RECOMMENDED TOOLS FOR MOTOR ALIGNMENT 239
4 35 FILLING AND BLEEDING THE HYDRAULIC SYSTEM 240
4 35 1 FILLING THE HYDRAULIC SYSTEM 241
4 35 2 BLEEDING THE HYDRAULIC SYSTEM 242
4 35 3 BLEEDING THE GEAR PUMP FOR PTO GEAR LUBRICATION 245
4 36 ASSEMBLY FACE SHOVEL ATTACHMENT 246
4 36 1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM 247
4 36 2 ATTACHING THE STICK TO THE BOOM 249
4 36 3 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM 250
4 36 4 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS 250
4 36 5 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS 253
4 36 6 CONNECTING HOSE LINES FROM STICK TO BUCKET CYLINDERS 255
4 36 7 CONNECTING STICK CYLINDERS TO THE STICK 256
4 37 BLEEDING HYDRAULIC CIRCUITS 258
4 37 1 BLEEDING THE SWING PARKING BRAKE CIRCUIT 259
4 37 2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT 259
4 37 3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT 261
4 37 4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER 262
4 37 5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS 262
4 37 6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS 263
4 38 ATTACHING FACE SHOVEL TO THE STICK 264
4 38 1 ATTACHING BUCKET BACK WALL TO THE STICK 265
4 38 2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM CYLINDERS 267
4 38 3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL 269
4 38 4 CONNECTING GREASE LINES OF THE FACE SHOVEL ATTACHMENT 271
4 38 5 CONNECTING GREASE LINES ON THE BUCKET 273
4 38 6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS 273
4 39 ASSEMBLY BACKHOE ATTACHMENT 274
4 39 1 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM 275
4 39 2 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS 276
4 39 3 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS 277
4 39 4 ATTACHING THE STICK TO THE BOOM 279
4 39 5 CONNECTING HOSE LINES FROM BOOM TO BUCKET CYLINDERS 283
4 40 BLEEDING HYDRAULIC CIRCUITS 284
4 40 1 BLEEDING THE SWING PARKING BRAKE CIRCUIT 285
4 40 2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT 285
4 40 3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT 287
4 40 4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER 288
4 40 5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS 288
4 40 6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS 289
4 41 ATTACHING BACKHOE BUCKET TO THE STICK 290
4 41 1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT 295
4 42 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS 296
5 FINAL CHECKS AND ADJUSTMENTS 297
5 0 1 COMMISSIONING CHECK LIST 299
5 0 2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS 299
5 0 3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE 301
5 0 4 PRESSURE COMPENSATION OF SEALED COMPONENTS 301
5 0 5 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE 302
5 1 COMMISSIONING OF THE AIR CONDITIONING 326
5 1 1 AIR CONDITIONING FOR OPERATOR’S CAB 329
5 1 2 AIR CONDITIONING FOR MEDIUM AND HIGH VOLTAGE SWITCH CABINETS 331
5 2 PERFORM THE PM-CLINIC ACCORDING TO THE PM-CLINIC PROCEDURE MANUAL 337
5 2 1 VISUAL INSPECTION 338
5 2 2 TRAVELLING INSTRUCTIONS 338
5 3 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING 339
6 ORBCOMM INITIALIZATION 341
6 1 ORBCOMM TERMINAL ACTIVATION 342
6 1 1 APPLICATION FORM FOR TERMINAL ACTIVATION 343
6 2 WEBCARE BASIC INFORMATION FOR MACHINE REGISTRATION 344
7 DISASSEMBLY OF THE MACHINE 347
7 1 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE 349
7 2 GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM ON MACHINES WITH CABLE DRUM 351
7 3 GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM ON MACHINES WITH CABLE GUIDE 356
7 4 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES 362
7 5 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES 364
7 6 DISPOSAL OF WASTE MATERIAL 366

Questions? Email us: [email protected]

https://vimeo.com/742523758

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com

I.G