Komatsu PC8000-6 Hydraulic Mining Shovel Operation & Maintenance Manual SN 12066 and up – DOWNLOAD

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Komatsu PC8000-6 Hydraulic Mining Shovel Operation & Maintenance Manual

FILE DETAILS:

Komatsu PC8000-6 Hydraulic Mining Shovel Operation & Maintenance Manual

Size : 4.84 MB
Format : PDF
Language : English
Brand: Komatsu
Type of machine: Hydraulic Mining Shovel
Type of document: Operation & Maintenance Manual
Model: PC8000-6
Serial: 12066
Number of Pages : 522 Pages

KOMATSU PC8000-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL SN 12066 AND UP – DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC8000-6 Hydraulic Mining Shovel Operation & Maintenance Manual

Read the Manuals before You Start the Engines.

Before operating the machine, familiarize yourself with its instruments and controls.

Observe the instructions in these manuals for:

• your Personal SAFETY
•  Operating SAFETY, and
• READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts wfll prevent failures and avoid expenses.

 DESIGNATED USE OF THE SHOVEL:

• This machine has been manufactured in accordance with advanced and up-to-date technology standards inclucfing recog- nized safety rules. Nevertheless, its use may constitute a risk to life and limb ofthe user or of third parties, or cause damage to the machine and to other material property. The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual.
• Only trained safety-conscious operators who are fully aware of the risks involved should operate the machine. Any functional disorders, especially those afiecting the safety of the machine, should, therefore, w rectified immediately. The hydraulic Shovel is designed exclusively for excavating, i.e. excavation of bulk material and natural soil structure (e.g. earth, clay, sand and stones ashore and off-shore). Observe local and national safety regulations.
• Special conditions at the worksite require additional safe working precautions, follow your com- paan safety instructions. Short travefing cfistances for changing the working site are considered as part of the designated use of the Shovel.
• Using the Shovel for purposes other than those mentioned above (such as object handling and use as a transport vehicle) is consid- ered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user.

TABLE OF CONTENTS:

Komatsu PC8000-6 Hydraulic Mining Shovel Operation & Maintenance Manual

1. INTRODUCTION................................................................................................  3
	1.1 CONTENTS OF THE BINDER..................................................................................  4
	1.2 DIVISION OF THE BINDER..................................................................................  5
	1.3 DESIGNATED USE OF THE SHOVEL............................................................................  6
	1.4 DELIVERY OF THE SHOVEL..................................................................................  7
	1.5 EXPLANATION OF ABBREVIATIONS............................................................................  8
	1.6 TABLE OF CONTENTS.......................................................................................  9
2. SAFETY...................................................................................................... 15
	2.1 SAFETY INSTRUCTIONS..................................................................................... 16
		2.1.1 WARNINGS AND SYMBOLS.............................................................................. 16
		2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL........................................ 16
		2.1.3 ORGANIZATIONAL MEASURES........................................................................... 17
		2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASICRESPONSIBILITIES................................. 19
		2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES......................................... 20
		2.1.6 WARNING OF SPECIAL DANGERS........................................................................ 23
		2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING.......................................................... 25
		2.1.8 SPECIAL SAFETY EQUIPMENT.......................................................................... 25
		2.1.9 ELECTROMAGNETIC COMPATIBILITY (EMC)............................................................... 27
		2.1.10 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE........................... 27
		2.1.11 VISIBILITY FROM OPERATOR’S SEAT.................................................................. 29
		2.1.12 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEANSTANDARD)..................................... 31
3. OPERATION................................................................................................... 39
	3.1 FOREWORD................................................................................................ 40
	3.2 CONSTRUCTION OF THE SHOVEL.............................................................................. 41
		3.2.1 OVERALL VIEW WITH BACKHOE ATTACHMENT.............................................................. 41
		3.2.2 OVERALL VIEW WITH BOTTOM DUMP BUCKET ATTACHMENT................................................... 42
		3.2.3 SUPERSTRUCTURE.................................................................................... 44
		3.2.4 UNDERCARRIAGE..................................................................................... 52
		3.2.5 HYDRAULICALLY OPERATED ACCESS LADDER.............................................................. 54
		3.2.6 EMERGENCY ESCAPE LADDER AT THE OPERATOR’S CAB PLATFORM............................................ 58
		3.2.7 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR......................... 60
		3.2.8 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE................................... 62
		3.2.9 FOLDING LADDER INSIDE OF CARBODY.................................................................. 64
		3.2.10 BOOM ACCESS LADDER AND WALKWAY................................................................... 66
		3.2.11 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.............................. 68
		3.2.12 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)........................ 70
	3.3 OPERATOR’S CAB - CONTROLS............................................................................... 80
		3.3.1 HYDRAULIC CONTROL SYSTEM.......................................................................... 81
		3.3.2 SAFETY CIRCUIT FOR CONTROLS....................................................................... 81
		3.3.3 OPERATOR’S CONSOLE................................................................................ 85
		3.3.4 INTERFACE PANEL FOR DIAGNOSTICS................................................................... 93
	3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS............................................................ 94
		3.4.1 INTRODUCTION...................................................................................... 95
		3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM........................................................103
		3.4.3 AUTOMATIC DISPLAY OF MESSAGES.....................................................................107
		3.4.4 MENU CONTROL AND SERVICE FUNCTIONS................................................................131
		3.4.5 MENU CONTROL LIST.................................................................................158
		3.4.6 FAULT AND INFORMATION MESSAGE LIST................................................................176
	3.5 CAMERA SYSTEM WITH MONITORS (SPECIAL EQUIPMENT).........................................................202
		3.5.1 LOCATION OF MONITORS AND CONTROL UNITS............................................................203
	3.6 OPERATING THE HEATERS, VENTILATION AND AIRCONDITIONING.................................................210
		3.6.1 AIR CONDITIONING AND HEATING......................................................................211
		3.6.2 A - HEATING.......................................................................................211
		3.6.3 B - COOLING.......................................................................................211
		3.6.4 COMBINED OPERATION OF AIR CONDITIONING AND HEATING................................................213
	3.7 MACHINERY HOUSE.........................................................................................214
		3.7.1 EMERGENCY MOTOR SHUTDOWN SWITCHES.................................................................215
		3.7.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE...........................................217
		3.7.3 CENTRAL CONTROL AND FILTER PANEL..................................................................219
		3.7.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO...................................................221
	3.8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE...............................................................222
		3.8.1 COMPONENTS IN THE MEDIUM VOLTAGE SWITCH CABINET...................................................225
		3.8.2 SWITCH BOARD (X2) IN CAB BASE.....................................................................227
		3.8.3 MONITOR AND CONTROL PANEL IN CAB BASE.............................................................235
	3.9 HIGH VOLTAGE SWITCH CABINET.............................................................................238
	3.10 CHECKS BEFORE STARTING THE MOTORS......................................................................240
	3.11 STARTING THE MAIN DRIVE MOTORS.........................................................................242
	3.12 MOVING THE SHOVEL......................................................................................249
		3.12.1 TRAVEL CONTROL WITH FOOT PEDALS..................................................................249
		3.12.2 TRAVELLING INSTRUCTIONS..........................................................................252
	3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE.................................................................253
		3.13.1 SLEWING THE SUPERSTRUCTURE.......................................................................253
	3.14 WORKING WITH THE ATTACHMENT............................................................................256
		3.14.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM.....................................................256
		3.14.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM......................................................257
		3.14.3 BOTTOM DUMP BUCKET...............................................................................258
		3.14.4 DROP BALL OPERATION..............................................................................259
		3.14.5 COMBINED OPERATION CYCLES........................................................................262
	3.15 WORKING INSTRUCTIONS...................................................................................264
		3.15.1 STABILITY OF THE SHOVEL..........................................................................264
		3.15.2 SHOVEL OPERATION.................................................................................264
	3.16 PARKING THE SHOVEL.....................................................................................267
	3.17 STOPPING THE MAIN DRIVE MOTORS.........................................................................268
		3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.........................................................271
	3.18 OPERATION OF THE LUBRICATION SYSTEM....................................................................272
		3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT...............................272
		3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”.....................................................274
	3.19 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM (SPECIAL EQUIPMENT)...................................276
		3.19.1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS..........................277
		3.19.2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB................................................281
		3.19.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM:..................................................281
		3.19.4 IN CASE OF FIRE..................................................................................283
	3.20 TRANSFER PUMP FOR HYDRAULIC OIL........................................................................284
		3.20.1 OPERATING THE TRANSFER PUMP......................................................................285
		3.20.2 TRANSFUSION PROCEDURE............................................................................287
	3.21 CENTRAL REFILLING SYSTEM...............................................................................290
		3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM........................................................291
		3.21.2 RECEIVER PANEL AND MONITOR BOX...................................................................291
		3.21.3 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOU.......295
	3.22 FOLDING PEDESTAL ON THE OPERATOR’S CAB.................................................................296
	3.23 SERVICE CRANE (SPECIAL EQUIPMENT)......................................................................300
		3.23.1 OPERATING THE CRANE..............................................................................301
	3.24 CABLE DRUM (SPECIAL EQUIPMENT).........................................................................304
		3.24.1 OPERATION OF THE CABLE DRUM......................................................................305
		3.24.2 TRAVELLING INSTRUCTIONS..........................................................................309
	3.25 WORK ON THE LOADER ATTACHMENT..........................................................................312
	3.26 TRANSPORTATION AND LIFTING OF THE SHOVEL...............................................................313
		3.26.1 DISASSEMBLING OF THE SHOVEL......................................................................313
		3.26.2 TRANSPORTATION AND LIFTING.......................................................................313
	3.27 RETRIEVAL PROCEDURE....................................................................................314
	3.28 SHOVEL STORAGE.........................................................................................315
		3.28.1 PREPARING FOR STORAGE............................................................................315
		3.28.2 ONE MONTH REPETITIVE SERVICE PERIOD..............................................................315
		3.28.3 SIX MONTH REPETITIVE SERVICE PERIOD..............................................................316
		3.28.4 PREPARING FOR OPERATION..........................................................................316
	3.29 TROUBLE SHOOTING.......................................................................................317
		3.29.1 MAIN DRIVE ELECTRIC MOTOR........................................................................317
		3.29.2 HYDRAULIC SYSTEM.................................................................................318
		3.29.3 FINAL DRIVES AND SWING GEAR......................................................................319
		3.29.4 CRAWLER TRACKS...................................................................................319
4. MAINTENANCE.................................................................................................321
	4.1 FOREWORD................................................................................................322
	4.2 SAFETY PRECAUTIONS FOR MAINTENANCE......................................................................323
	4.3 FLUIDS AND LUBRICANTS...................................................................................325
		4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES..............................................325
		4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...............................................326
		4.3.3 MAIN DRIVE ELECTRIC MOTORS – BEARING LUBRICATION..................................................327
	4.4 FILLING CAPACITIES......................................................................................328
	4.5 STANDARD TORQUE LIST....................................................................................329
	4.6 LUBRICATION AND MAINTENANCE SCHEDULE....................................................................330
		4.6.1 INITIAL SERVICING.................................................................................330
		4.6.2 PERIODIC SERVICING INTERVALS......................................................................330
		4.6.3 PERIODIC SERVICING SCHEDULE.......................................................................331
		4.6.4 MAINTENANCE OF THE MAIN DRIVE ELECTRIC MOTORS.....................................................335
		4.6.5 REPLACEMENT OF HYDRAULIC HOSE LINES...............................................................337
		4.6.6 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....................................................338
	4.7 WHEN NECESSARY..........................................................................................340
		4.7.1 SWING CIRCLE TOOTHING LUBRICATION.................................................................341
		4.7.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS..............................................343
		4.7.3 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...........................................347
	4.8 EVERY 10 OPERATING HOURS OR DAILY.......................................................................348
		4.8.1 WALK - AROUND INSPECTION..........................................................................349
		4.8.2 CLEANING THE TRACK GROUPS.........................................................................357
	4.9 EVERY 50 OPERATING HOURS OR WEEKLY......................................................................358
		4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVEL..........................................359
		4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS........................363
		4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL............................................................365
		4.9.4 PUMP DISTRIBUTOR GEARS - CHECK OIL LEVEL..........................................................367
		4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....................................................369
		4.9.6 MAIN HYDRAULIC OIL COOLER - INSPECT AND CLEAN IF NECESSARY........................................371
		4.9.7 PTO GEAR OIL COOLERS - INSPECT AND CLEAN IF NECESSARY.............................................375
	4.10 EVERY 250 OPERATING HOURS OR MONTHLY...................................................................376
		4.10.1 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE........................................................377
		4.10.2 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER..................377
		4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE...............................................................377
		4.10.4 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER............379
		4.10.5 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT................................................381
		4.10.6 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL..................................................383
		4.10.7 AIR CONDITIONING FOR OPERATOR’S CAB - VERSION "KYSOR"............................................385
		4.10.8 AIR CONDITIONING FOR ELECTRICAL SWITCH CABINETS - CHECK REFRIGERANT LEVEL........................387
	4.11 EVERY 500 OPERATING HOURS OR MONTHLY...................................................................390
		4.11.1 BATTERIES - CHECK FLUID LEVEL....................................................................391
		4.11.2 DRIVE SHAFT HOUSINGS ON PTO GEARS - CHECK OIL LEVEL..............................................393
		4.11.3 CRAWLER TRACK - INSPECTION.......................................................................395
		4.11.4 GROUND CABLE OF OPERATOR’S CAB - CHECK FOR CORRECT CONNECTION....................................401
	4.12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH............................................................402
		4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...............................................403
		4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE................................................................449
		4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...............461
		4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....................................................463
		4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS..................................465
		4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE..........................................................467
		4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.........................................469
		4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES........................................471
		4.12.9 SLIP RING UNIT - LUBRICATE.......................................................................473
		4.12.10 SERVICE CRANE - LUBRICATE.......................................................................473
	4.13 EVERY 2000 OPERATING HOURS OR YEARLY...................................................................474
		4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER....................475
		4.13.2 EMERGENCY ESCAPE LADDERS - INSPECTION............................................................485
	4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR................................................490
		4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...............................................491
		4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL......................................499
		4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL................................................................503
		4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.........................................................505
	4.15 FIRE PREVENTION........................................................................................506
	4.16 WELD REPAIRS...........................................................................................508
		4.16.1 GENERAL PROTECTIVE MEASURES......................................................................509
		4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE............................511
		4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT........................513
		4.16.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...........................515
		4.16.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...........................................515

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]