Komatsu PC4000E-6 Mining Shovel Assembly Manual AM08233ECSup-EN-5 PDF

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Komatsu PC4000E-6 Hydraulic Mining Shovel Assembly Manual AM08233ECSup-EN-5 – PDF DOWNLOAD

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Komatsu PC4000E-6 Hydraulic Mining Shovel Assembly Manual AM08233ECSup-EN-5 – PDF DOWNLOAD

Language : English
Pages : 395
Downloadable : Yes
File Type : PDF
Size: 19.2 MB

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TABLE OF CONTENTS:

Komatsu PC4000E-6 Hydraulic Mining Shovel Assembly Manual AM08233ECSup-EN-5 – 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 15 1 OVERVIEW OF THE CABLE DRUM 159
4 15 2 MAIN SWITCH BOX ON CABLE DRUM 161
4 15 3 CONNECT HIGH VOLTAGE CABLES AND CONTROL CABLES 162
4 16 CONNECT HIGH VOLTAGE CABLES ON MACHINES WITH CABLE GUIDE 166
4 16 1 OVERVIEW OF THE CABLE GUIDE 167
4 16 2 MAIN SWITCH BOX ON CABLE GUIDE 169
4 16 3 CONNECT HIGH VOLTAGE CABLE FROM MACHINE TO CABLE GUIDE 172
4 17 CONNECT THE POWER CABLES INSIDE THE HIGH VOLTAGE SWITCH CABINET 174
4 18 CONNECT THE AIR CONDITIONER HOSES TO THE HIGH VOLTAGE SWITCH CABINET 176
4 19 MOUNTING OF THE CAB BASE 178
4 19 1 ACCOMPLISH ELECTRICAL CABLE CONNECTIONS 180
4 19 2 CONNECT THE FIRE SUPPRESSION SYSTEM PIPING BETWEEN HIGH VOLTAGE CABINET AND CAB BASE 183
4 19 3 ATTACH GROMMET FRAME TO CAB BASE ROOF 184
4 20 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE 186
4 20 1 CONNECTING THE CAB AIR CONDITIONER HOSES 188
4 20 2 INSTALL THE ORBCOMM ANTENNA 190
4 21 CONNECTING THE HIGH PRESSURE LINES OF THE MAIN PUMPS 192
4 22 ATTACHING THE HYDRAULIC OIL RESERVOIR 194
4 23 ATTACHING THE HYDRAULIC OIL COOLER 196
4 23 1 CONNECTING THE HYDRAULIC HOSE LINES OF THE OIL COOLER CIRCUIT 198
4 23 2 CONNECTING THE HOSE LINES OF OIL COOLER FAN MOTORS 200
4 23 3 CONNECTING THE HOSE LINES OF PTO OIL COOLING CIRCUIT 202
4 23 4 CONNECTING THE HOSE LINES FROM RETURN OIL MANIFOLD TO BACK-PRESSURE PIPE 204
4 24 CONNECTING SWING GEAR HYDRAULIC LINES 206
4 24 1 CONNECTING THE RETURN AND LEAKAGE OIL HOSE LINES 207
4 24 2 CONNECTING THE SWING BRAKE PRESSURE HOSES AND PILOT OIL HOSES 208
4 25 CONNECTING THE LEAKAGE AND PRESSURE HOSES FROM VALVE BLOCK 210
4 26 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP 216
4 27 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT 218
4 27 1 CONNECTING THE PILOT OIL LINE, RETURN OIL LINE AND LEAKAGE OIL LINE TO THE ROTARY JOINT 220
4 28 ATTACHING THE HANDRAILS, CATWALKS AND STEPS 222
4 29 CENTRAL REFILLING SYSTEM 224
4 29 1 CONNECTING THE REFILLING LINES 225
4 30 CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS 226
4 31 PRE-CHECKS PRIOR TO INITIAL START UP 228
4 32 HIGH VOLTAGE INTERLOCK SYSTEM 230
4 32 1 APPLYING HIGH VOLTAGE CURRENT ON MACHINES WITH CABLE DRUM 231
4 32 2 APPLYING HIGH VOLTAGE CURRENT ON MACHINES WITH CABLE GUIDE 234
4 33 CHECKING DIRECTION OF MOTOR ROTATION 238
4 34 CHECK AND ADJUST ALIGNMENT OF MAIN MOTOR 240
4 34 1 ALIGNMENT TOLERANCES 247
4 34 2 SHIM SETS 247
4 34 3 RECOMMENDED TOOLS FOR MOTOR ALIGNMENT 249
4 35 FILLING AND BLEEDING THE HYDRAULIC SYSTEM 250
4 35 1 FILLING THE HYDRAULIC SYSTEM 251
4 35 2 BLEEDING THE HYDRAULIC SYSTEM 252
4 35 3 BLEEDING THE GEAR PUMP FOR PTO GEAR LUBRICATION 255
4 36 ASSEMBLY FACE SHOVEL ATTACHMENT 256
4 36 1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM 257
4 36 2 ATTACHING THE STICK TO THE BOOM 259
4 36 3 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM 260
4 36 4 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS 260
4 36 5 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS 263
4 36 6 CONNECTING HOSE LINES FROM STICK TO BUCKET CYLINDERS 265
4 36 7 CONNECTING STICK CYLINDERS TO THE STICK 266
4 37 BLEEDING HYDRAULIC CIRCUITS 268
4 37 1 BLEEDING THE SWING PARKING BRAKE CIRCUIT 269
4 37 2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT 269
4 37 3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT 271
4 37 4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER 272
4 37 5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS 272
4 37 6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS 273
4 38 ATTACHING FACE SHOVEL TO THE STICK 274
4 38 1 ATTACHING BUCKET BACK WALL TO THE STICK 275
4 38 2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM CYLINDERS 277
4 38 3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL 279
4 38 4 CONNECTING GREASE LINES OF THE FACE SHOVEL ATTACHMENT 281
4 38 5 CONNECTING GREASE LINES ON THE BUCKET 283
4 38 6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS 283
4 39 ASSEMBLY BACKHOE ATTACHMENT 284
4 39 1 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM 285
4 39 2 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS 286
4 39 3 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS 287
4 39 4 ATTACHING THE STICK TO THE BOOM 289
4 39 5 CONNECTING HOSE LINES FROM BOOM TO BUCKET CYLINDERS 293
4 40 BLEEDING HYDRAULIC CIRCUITS 294
4 40 1 BLEEDING THE SWING PARKING BRAKE CIRCUIT 295
4 40 2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT 295
4 40 3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT 297
4 40 4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER 298
4 40 5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS 298
4 40 6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS 299
4 41 ATTACHING BACKHOE BUCKET TO THE STICK 300
4 41 1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT 305
4 42 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS 306
5 FINAL CHECKS AND ADJUSTMENTS 307
5 0 1 COMMISSIONING CHECK LIST 309
5 0 2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS 309
5 0 3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE 311
5 0 4 PRESSURE COMPENSATION OF SEALED COMPONENTS 311
5 1 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE 312
5 1 1 Connecting the Fire Suppression System Hose to the Carbon Dioxide Cylinder 317
5 1 2 Electric Fire Detection and Actuation System 319
5 1 3 Testing the CHECKFIRE Release Circuit 323
5 1 4 Install the Protracting Actuation Device (PAD) in the Manual/Automatic Actuator 333
5 1 5 CONTROL MODULE – LED INDICATIONS 334
5 1 6 MAINTENANCE SCHEDULE OF THE CO2 SYSTEM 335
5 2 COMMISSIONING OF THE AIR CONDITIONING 336
5 2 1 AIR CONDITIONING FOR OPERATOR’S CAB 339
5 2 2 AIR CONDITIONING FOR MEDIUM AND HIGH VOLTAGE SWITCH CABINETS 341
5 3 PERFORM THE PM-CLINIC ACCORDING TO THE PM-CLINIC PROCEDURE MANUAL 347
5 3 1 VISUAL INSPECTION 348
5 3 2 TRAVELLING INSTRUCTIONS 348
5 4 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING 349
6 ORBCOMM INITIALIZATION 351
6 1 ORBCOMM TERMINAL ACTIVATION 352
6 1 1 APPLICATION FORM FOR TERMINAL ACTIVATION 353
6 2 WEBCARE BASIC INFORMATION FOR MACHINE REGISTRATION 354
7 DISASSEMBLY OF THE MACHINE 357
7 1 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE 359
7 2 GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM ON MACHINES WITH CABLE DRUM 361
7 3 GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM ON MACHINES WITH CABLE GUIDE 366
7 4 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES 372
7 5 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES 374
7 6 DISPOSAL OF WASTE MATERIAL 376

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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