Komatsu PC7000E-6 Hydraulic Mining Shovel Operation & Maintenance Manual 35003-xE-GB-3 – PDF DOWNLOAD

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Komatsu PC7000E-6 Hydraulic Mining Shovel Operation & Maintenance Manual 35003-xE-GB-3 – PDF DOWNLOAD

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Komatsu PC7000E-6 Hydraulic Mining Shovel Operation & Maintenance Manual 35003-xE-GB-3 – PDF DOWNLOAD

SERIAL NUMBER 35003

BEFORE READING THIS MANUAL:

• This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
• Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death.
• Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you or others engage in prohibited uses or actions described in this manual. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death.
  If you sell the machine, be sure to give this manual to the new owner together with the machine.
• This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ).
• The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.

TABLE OF CONTENTS:

Komatsu PC7000E-6 Hydraulic Mining Shovel Operation & Maintenance Manual 35003-xE-GB-3 – PDF DOWNLOAD

1 FOREWORD 1-1
1 1BEFORE READING THIS MANUAL 1-2
1 2EC DECLARATION OF CONFORMITY 1-3
1 3DIRECTIONS OF THE MACHINE 1-4
1 4SPECIFICATION AND SERIAL PLATE 1-5
1 4 1 PRODUCT IDENTIFICATION NUMBER 1-5
1 5DIVISION OF THE BINDER 1-6
1 6DESIGNATED USE OF THE SHOVEL 1-7
1 7DELIVERY OF THE SHOVEL 1-8
1 7 1 SPARE PARTS 1-8
1 7 2 SERVICE 1-8
1 8EXPLANATION OF ABBREVIATIONS 1-9
2 SAFETY 2-1
2 1SAFETY INFORMATION 2-2
2 2OVERVIEW 2-3
2 2 1 NORMAL OPERATIONS 2-3
2 2 2 REGULAR MAINTENANCE 2-3
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 2-3
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 2-3
2 3SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 2-4
2 3 1 SOUND 2-4
2 3 2 VIBRATION 2-4
2 4GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 2-5
2 4 1 UNDERSTANDING THE MACHINE 2-5
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 2-5
2 4 3 PREPARATIONS FOR SAFE OPERATION 2-5
2 4 4 FIRE PREVENTION 2-7
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 2-10
2 4 6 BURN PREVENTION 2-11
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 2-12
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-12
2 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 2-13
2 4 10 PRECAUTIONS AT JOBSITE 2-14
2 4 11 STARTING MOTOR 2-19
2 4 12 OPERATION 2-20
2 5PRECAUTION FOR MAINTENANCE 2-26
2 5 1 GENERAL PRECAUTIONS 2-26
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-34
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 2-35
2 6ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 2-39
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 2-39
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 2-39
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 2-39
2 7SPECIAL SAFETY EQUIPMENT 2-40
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 2-41
2 7 2 OBJECT HANDLING 2-41
PC7000
2 7 3 LIGHTING 2-41
2 7 4 WARNING BEACON 2-41
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 2-41
2 8SAFETY WARNING SIGNS 2-49
2 8 1 LOCATION AND DESCRIPTION OF THE SIGNS 2-50
2 9HIGH VOLTAGE SAFETY INSTRUCTIONS FOR MACHINES WITH ELECTRIC MOTOR 2-67
2 9 1 QUALIFICATION OF PERSONNEL 2-67
2 9 2 ELECTRICAL TOOLS 2-67
2 9 3 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT 2-68
2 9 4 CONNECTION OF PILOT LINE (GROUND CHECK WIRE) 2-68
2 9 5 PREPARATION BEFORE WORKING ON THE CABLE DRUM 2-68
2 9 6 PREPARATION BEFORE WORKING ON THE CABLE GUIDE 2-69
2 9 7 MODIFICATION OF THE ELECTRICAL SYSTEM 2-69
2 9 8 FIRE 2-69
2 9 9 GENERAL INSTRUCTIONS 2-70
2 9 10 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM 2-70
3 OPERATION 3-1
3 1FOREWORD 3-2
3 2CONSTRUCTION OF THE SHOVEL 3-3
3 2 1 OVERALL VIEW 3-3
3 2 2 UNDERCARRIAGE AND SUPERSTRUCTURE 3-4
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 3-10
3 2 4 EMERGENCY ESCAPE LADDERS 3-14
3 2 5 BOOM ACCESS LADDER AND WALKWAY 3-22
3 2 6 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING
SYSTEM 3-24
3 2 7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE
STRUCTURE (FOPS) 3-26
3 3OPERATOR’S CAB – CONTROLS 3-36
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 3-36
3 3 2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 3-40
3 3 3 OPERATOR’S CONSOLE 3-45
3 3 4 AUXILIARY HEATERS FOR OPERATOR’S CAB 3-51
3 3 5 CONTROL MODULE FOR AUXILIARY CAB HEATER 3-53
3 3 6 INTERFACE PANEL FOR DIAGNOSTICS 3-55
3 4VEHICLE HEALTH MONITORING SYSTEM KOMTRAX PLUS – HEALTH MONITOR 3-56
3 4 1 SEQUENCE OF DISPLAYS 3-57
3 4 2 OPENING SCREEN 3-57
3 4 3 MAIN GAUGE SCREENS 1 TO 3 3-58
3 4 4 ENERGY CONSUMPTION SCREEN 3-63
3 4 5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR 3-63
3 4 6 MAIN SCREEN – CHANGE >TIME >SMR >DATE 3-64
3 4 7 MAINTENANCE MONITOR 3-64
3 4 8 SETTINGS FOR OPERATOR 3-65
3 4 9 SERVICE MENU 3-69
3 4 10 AUTOMATIC MESSAGES 3-69
3 5OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 3-74
PC7000
3 5 1 DIGITAL DISPLAY 3-74
3 5 2 LUMINOUS INDICATION 3-76
3 6CAMERA SYSTEM WITH MONITORS 3-78
3 6 1 LOCATION OF MONITORS AND CONTROL UNITS 3-79
3 7MACHINERY HOUSE 3-86
3 7 1 MOTOR SHUTDOWN SWITCHES 3-87
3 7 2 SAFETY SWITCH FOR MAINTENANCE 3-89
3 7 3 MOTOR LOAD CUT-OFF SWITCH BOX 3-91
3 7 4 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT 3-93
3 8ELECTRICAL EQUIPMENT IN CAB BASE 3-94
3 8 1 COMPONENTS IN CAB BASE 3-95
3 8 2 MASTER TURBO CONTROLLER MTC – LED INDICATIONS 3-103
3 8 3 BINARY FAULT CODE LIST 3-110
3 8 4 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS 3-112
3 9PREHEATING SYSTEM 3-114
3 9 1 HYDRAULIC OIL AND PTO GEAR OIL HEATINGS 3-115
3 10CHECKS BEFORE STARTING THE MOTORS 3-118
3 10 1 WALK AROUND INSPECTION 3-119
3 10 2 TURNING ON THE POWER SUPPLY 3-119
3 11STARTING THE MAIN DRIVE MOTORS 3-122
3 11 1 STARTING PROCEDURE 3-125
3 12MOVING THE SHOVEL 3-129
3 12 1 TRAVEL CONTROL WITH FOOT PEDALS 3-129
3 12 2 TRAVELLING INSTRUCTIONS 3-131
3 13SLEWING AND BRAKING THE SUPERSTRUCTURE 3-134
3 13 1 SLEWING THE SUPERSTRUCTURE 3-134
3 14WORKING WITH THE ATTACHMENT 3-137
3 14 1 COMBINED OPERATION CYCLES 3-139
3 15WORKING INSTRUCTIONS 3-142
3 15 1 STABILITY OF THE SHOVEL 3-142
3 15 2 FURTHER OPERATING PRACTICES 3-144
3 15 3 LOADING TRUCKS 3-148
3 16PARKING THE SHOVEL 3-149
3 17STOPPING THE MAIN DRIVE MOTORS 3-150
3 17 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 3-153
3 18OPERATION OF THE LUBRICATION SYSTEM 3-154
3 18 1 CENTRAL LUBRICATION SYSTEM ”CLS” 3-154
3 18 2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 3-155
3 19FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM 3-158
3 19 1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION
SYSTEMS 3-159
3 19 2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB 3-163
3 19 3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM: 3-163
3 19 4 IN THE CASE OF A FIRE 3-165
3 20TRANSFER PUMP FOR HYDRAULIC OIL 3-166
3 20 1 OPERATING THE TRANSFER PUMP 3-167
3 20 2 TRANSFUSION PROCEDURE 3-169
PC7000
3 21CENTRAL REFILLING SYSTEM 3-172
3 21 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 3-173
3 21 2 OPERATING THE HYDRAULIC SERVICE ARM 3-175
3 21 3 RECEIVER PANEL AND MONITOR BOX 3-177
3 21 4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS
MOUNTED ON THE POWER HOUSE ROOF 3-179
3 22CABLE DRUM (SPECIAL EQUIPMENT) 3-180
3 22 1 DESCRIPTION OF MAIN COMPONENTS 3-181
3 22 2 OPERATION OF THE CABLE DRUM 3-183
3 23CABLE GUIDE (IF SO EQUIPPED) 3-187
3 23 1 LIFTING DEVICE FOR THE POWER CABLE 3-187
3 24SERVICE CRANE (SPECIAL EQUIPMENT) 3-188
3 24 1 OPERATING THE CRANE 3-189
3 25WORK ON THE LOADER ATTACHMENT 3-192
3 26TRANSPORTATION AND LIFTING OF THE SHOVEL 3-193
3 26 1 DISASSEMBLING OF THE SHOVEL 3-193
3 26 2 TRANSPORTATION AND LIFTING 3-193
3 27RETRIEVAL PROCEDURE 3-194
3 27 1 GENERAL 3-194
3 28SHOVEL STORAGE 3-195
3 28 1 GENERAL 3-195
3 28 2 PREPARING FOR STORAGE 3-195
3 28 3 ONE MONTH REPETITIVE SERVICE PERIOD 3-195
3 28 4 SIX MONTH REPETITIVE SERVICE PERIOD 3-195
3 28 5 PREPARING FOR OPERATION 3-196
3 29TROUBLE SHOOTING 3-197
3 29 1 GENERAL 3-197
3 29 2 ENGINE 3-197
3 29 3 HYDRAULIC SYSTEM 3-198
3 29 4 FINAL DRIVES AND SWING GEAR 3-199
3 29 5 CRAWLER TRACKS 3-199
4 MAINTENANCE 4-1
4 1FOREWORD 4-2
4 1 1 DEFINITIONS 4-2
4 1 2 GENERAL RECOMMENDATIONS 4-2
4 2PRECAUTIONS FOR MAINTENANCE 4-3
4 2 1 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM 4-4
4 3FLUIDS AND LUBRICANTS 4-5
4 3 1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 4-5
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 4-6
4 4FILLING CAPACITIES 4-10
4 5STANDARD TORQUE LIST 4-11
4 5 1 TORQUE FOR FLANGE JOINTS 4-12
4 5 2 TORQUES FOR SPECIAL COMPONENTS 4-13
4 6LUBRICATION AND MAINTENANCE SCHEDULE 4-15
4 6 1 INITIAL AND FIRST SERVICING 4-15
PC7000
4 6 2 SERVICING THE CRITICAL BOLT CONNECTIONS 4-16
4 6 3 PERIODIC SERVICING INTERVALS 4-16
4 6 4 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS 4-21
4 6 5 MAINTENANCE OF THE MAIN DRIVE MOTORS 4-22
4 7SAFETY CRITICAL PARTS 4-23
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 4-23
4 7 2 INSPECTION OF HOSE LINES 4-24
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 4-24
4 8FIRST SERVICING 4-25
4 8 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 4-25
4 8 2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS 4-26
4 8 3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND
GREASE CONNECTIONS 4-27
4 8 4 SWING CIRCLE PINION – CHECK GREASE INJECTORS AND GREASE
CONNECTIONS 4-28
4 8 5 SWING CIRCLE – CHECK TORQUE OF BOLT CONNECTIONS 4-29
4 8 6 RETIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS 4-30
4 9WHEN NECESSARY 4-33
4 9 1 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 4-34
4 9 2 SWING CIRCLE TOOTHING LUBRICATION 4-36
4 9 3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 4-38
4 9 4 GUIDE WHEELS – REPLACE FLOATING SEALS 4-40
4 10EVERY 10 OPERATING HOURS OR DAILY 4-41
4 10 1 WALK – AROUND INSPECTION 4-42
4 10 2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL CHECK 4-46
4 10 3 TRACK GROUPS – CLEAN 4-46
4 10 4 CAMERA SYSTEM 4-50
4 10 5 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 4-52
4 11EVERY 50 OPERATING HOURS OR WEEKLY 4-53
4 11 1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL
LEVELS 4-56
4 11 2 PTOS (PUMP DISTRIBUTOR GEARS) – CHECK OIL LEVEL 4-62
4 11 3 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 4-66
4 11 4 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 4-68
4 12EVERY 250 OPERATING HOURS OR MONTHLY 4-69
4 12 1 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 4-70
4 12 2 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN
BREATHER FILTER 4-70
4 12 3 SIGNAL HORN COMPRESSOR – LUBRICATE 4-70
4 12 4 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP
STATION 4-72
4 12 5 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 4-74
4 12 6 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 4-76
4 12 7 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 4-78
4 12 8 SLIP RING UNIT – VISUAL CHECK 4-79
4 13EVERY 500 OPERATING HOURS OR QUARTERLY 4-81
4 13 1 BATTERIES – CHECK FLUID LEVEL 4-82
4 13 2 CYLINDER ROD PROTECTION (IF EQUIPPED), INSPECT 4-86
PC7000
4 13 3 HIGH VOLTAGE SWITCH CABINET – VISUAL CHECK 4-88
4 13 4 CRAWLER TRACK – INSPECTION 4-90
4 13 5 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 4-96
4 13 6 EMERGENCY ESCAPE LADDERS 4-98
4 13 7 EMERGENCY LOWERING OF ACCESS LADDER – TEST FUNCTIONALITY 4-100
4 14EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4-101
4 14 1 CRITICAL BOLT CONNECTIONS 4-102
4 14 2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 4-108
4 14 3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST
FUNCTIONALITY 4-110
4 14 4 ELECTRICAL EQUIPMENT – MAINTENANCE 4-112
4 14 5 HYDRAULIC SYSTEM – FILTER SERVICE 4-114
4 14 6 BLEEDING AIR FROM THE RETURN OIL CHAMBERS 4-118
4 14 7 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL
SAMPLE ANALYSIS 4-130
4 14 8 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 4-132
4 14 9 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 4-134
4 14 10 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 4-136
4 14 11 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 4-138
4 15EVERY 2000 OPERATING HOURS OR YEARLY 4-139
4 15 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND
PULSATION DAMPER 4-140
4 15 2 FILLING THE HYDRAULIC SYSTEM 4-150
4 15 3 BLEEDING THE HYDRAULIC SYSTEM 4-152
4 15 4 EMERGENCY ESCAPE LADDERS – INSPECTION 4-156
4 15 5 HYDRAULIC HOSES – CHECK CONDITION 4-158
4 15 6 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 4-160
4 15 7 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 4-162
4 15 8 SLIP RING UNIT – MAINTENANCE 4-163
4 16EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4-167
4 16 1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL 4-172
4 16 2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 4-176
4 16 3 FLEXIBLE COUPLING – VISUAL CHECK 4-178
4 17CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS 4-179
4 17 1 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD 4-180
4 18EVERY 6000 HOURS HOWEVER AT LEAST ONCE A YEAR 4-221
4 18 1 AUTOMATIC LUBRICATION SYSTEMS – REPLACE PUMP OUTLET GREASE
FILTERS 4-222
4 18 2 HYDRAULIC OIL TANK – CHECK LEAKAGE OIL SCREEN FILTER 4-224
4 18 3 CHANGING THE HIGH PRESSURE FILTERS 4-226
4 19FIRE PREVENTION 4-227
4 19 1 PRECAUTIONS 4-228
4 20WELD REPAIRS 4-229
4 20 1 GENERAL INFORMATION 4-229
4 20 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 4-230
4 20 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
UNDERCARRIAGE 4-232
4 20 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER
PC7000
ATTACHMENT 4-234
4 20 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
SUPERSTRUCTURE 4-236
4 20 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 4-238

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