KOMATSU PC8000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:12053) KOMATSU PC8000-6 – PDF DOWNLOAD

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KOMATSU PC8000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:12053) KOMATSU PC8000-6

KOMATSU PC8000-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:12053) KOMATSU PC8000-6 – PDF DOWNLOAD:

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KOMATSU PC8000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:12053) KOMATSU PC8000-6

• This machine has been manufactured in accordance with advanced and up-to-date technology standards including recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the 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 affecting the safety of the machine, should, therefore, be 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 company’s safety instructions. Short traveling distances 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 considered 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 (SN:12053) KOMATSU PC8000-6

COVER...................................................................................................  1
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 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEANSTANDARD).............................. 29
3. OPERATION........................................................................................... 37
	3.1 FOREWORD........................................................................................ 38
	3.2 CONSTRUCTION OF THE SHOVEL...................................................................... 39
		3.2.1 OVERALL VIEW.............................................................................. 39
		3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE.......................................................... 40
		3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...................................................... 48
		3.2.4 EMERGENCY ESCAPE LADDER AT THE OPERATOR’S CAB PLATFORM.................................... 52
		3.2.5 EMERGENCY ESCAPE LADDER AT THE SUPERSTRUCTURE PLATFORM.................................... 54
		3.2.6 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR................. 56
		3.2.7 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE........................... 58
		3.2.8 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...................... 60
		3.2.9 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)................. 62
		3.2.10 ENGINE OIL MANAGEMENT SYSTEM............................................................. 72
	3.3 OPERATOR’S CAB - CONTROLS....................................................................... 76
		3.3.1 HYDRAULIC CONTROL SYSTEM.................................................................. 77
		3.3.2 SAFETY CIRCUIT FOR CONTROLS............................................................... 77
		3.3.3 OPERATOR’S CONSOLE........................................................................ 81
		3.3.4 INTERFACE PANEL FOR DIAGNOSTICS........................................................... 89
		3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER................................................... 91
	3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS.................................................... 92
		3.4.1 INTRODUCTION.............................................................................. 93
		3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM................................................101
		3.4.3 AUTOMATIC DISPLAY OF MESSAGES.............................................................105
		3.4.4 MENU CONTROL..............................................................................129
		3.4.5 MENU CONTROL LIST.........................................................................156
		3.4.6 FAULT AND INFORMATION MESSAGE LIST........................................................174
	3.5 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING..........................................198
		3.5.1 AUXILIARY HEATER FOR OPERATOR’S CAB.......................................................201
	3.6 MACHINERY HOUSE.................................................................................202
		3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES........................................................203
		3.6.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE...................................205
		3.6.3 CENTRAL CONTROL AND FILTER PANEL..........................................................207
		3.6.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO...........................................209
	3.7 ELECTRICAL EQUIPMENT IN CAB BASE................................................................210
		3.7.1 STANDARD COMPONENTS IN CAB BASE...........................................................211
		3.7.2 SWITCH BOARD (X2) IN CAB BASE.............................................................213
		3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE....................................223
	3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES...............................................226
	3.9 CHECKS BEFORE STARTING THE ENGINES..............................................................230
	3.10 STARTING THE ENGINES...........................................................................236
		3.10.1 STARTING PROCEDURE.......................................................................239
	3.11 MOVING THE SHOVEL..............................................................................247
		3.11.1 TRAVEL CONTROL WITH FOOT PEDALS..........................................................247
		3.11.2 TRAVELLING INSTRUCTIONS..................................................................250
	3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE.........................................................251
		3.12.1 SLEWING THE SUPERSTRUCTURE...............................................................251
	3.13 WORKING WITH THE ATTACHMENT....................................................................254
		3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM.............................................254
		3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM..............................................255
		3.13.3 BOTTOM DUMP BUCKET.......................................................................256
		3.13.4 DROP BALL OPERATION......................................................................257
		3.13.5 COMBINED OPERATION CYCLES................................................................260
	3.14 WORKING INSTRUCTIONS...........................................................................262
		3.14.1 STABILITY OF THE SHOVEL..................................................................262
		3.14.2 SHOVEL OPERATION.........................................................................262
	3.15 PARKING THE SHOVEL.............................................................................265
	3.16 STOPPING THE ENGINES...........................................................................266
		3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.................................................269
	3.17 OPERATION OF THE LUBRICATION SYSTEM............................................................270
		3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT.......................270
		3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”.............................................272
	3.18 TRANSFER PUMP FOR HYDRAULIC OIL................................................................274
		3.18.1 OPERATING THE TRANSFER PUMP..............................................................275
		3.18.2 TRANSFUSION PROCEDURE....................................................................277
	3.19 CENTRAL REFILLING SYSTEM.......................................................................280
		3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM................................................281
		3.19.2 OPERATING THE HYDRAULIC SERVICE ARM......................................................283
		3.19.3 RECEIVER PANEL WITH MONITOR BOX..........................................................285
		3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS........................291
	3.20 WORK ON THE LOADER ATTACHMENT..................................................................292
	3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL.......................................................293
		3.21.1 DISASSEMBLING OF THE SHOVEL..............................................................293
		3.21.2 TRANSPORTATION AND LIFTING...............................................................293
	3.22 RETRIEVAL PROCEDURE............................................................................294
	3.23 SHOVEL STORAGE.................................................................................295
		3.23.1 PREPARING FOR STORAGE....................................................................295
		3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD......................................................296
		3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD......................................................296
		3.23.4 PREPARING FOR OPERATION..................................................................297
	3.24 TROUBLE SHOOTING...............................................................................298
		3.24.1 ENGINE...................................................................................298
		3.24.2 HYDRAULIC SYSTEM.........................................................................299
		3.24.3 FINAL DRIVES AND SWING GEAR..............................................................300
		3.24.4 CRAWLER TRACKS...........................................................................300
4. MAINTENANCE.........................................................................................301
	4.1 FOREWORD........................................................................................302
	4.2 PRECAUTIONS FOR MAINTENANCE.....................................................................303
	4.3 FLUIDS AND LUBRICANTS...........................................................................305
		4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES......................................305
		4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES.......................................306
	4.4 FILLING CAPACITIES..............................................................................308
	4.5 STANDARD TORQUE LIST............................................................................309
	4.6 LUBRICATION AND MAINTENANCE SCHEDULE............................................................310
		4.6.1 INITIAL SERVICING.........................................................................310
		4.6.2 PERIODIC SERVICING INTERVALS..............................................................310
		4.6.3 PERIODIC SERVICING SCHEDULE...............................................................311
		4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES...................................316
		4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.............................................317
		4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM..................321
		4.6.7 MAINTENANCE OF THE ENGINES................................................................325
	4.7 WHEN NECESSARY..................................................................................326
		4.7.1 ENGINE AIR CLEANER MAINTENANCE............................................................327
		4.7.2 SWING CIRCLE TOOTHING LUBRICATION.........................................................331
		4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS......................................333
		4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...................................337
	4.8 EVERY 10 OPERATING HOURS OR DAILY...............................................................338
		4.8.1 WALK - AROUND INSPECTION..................................................................339
		4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...........................................................349
		4.8.3 RADIATORS - CHECK COOLANT LEVEL...........................................................351
		4.8.4 TRACK GROUPS - CLEAN......................................................................351
	4.9 EVERY 50 OPERATING HOURS OR WEEKLY..............................................................352
		4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVEL..................................353
		4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS................355
		4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL....................................................357
		4.9.4 PUMP DISTRIBUTOR GEARS - CHECK OIL LEVEL..................................................359
		4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.............................................361
		4.9.6 MAIN HYDRAULIC OIL COOLER - INSPECT AND CLEAN IF NECESSARY................................363
		4.9.7 PTO GEAR OIL COOLERS - INSPECT AND CLEAN IF NECESSARY.....................................367
	4.10 EVERY 250 OPERATING HOURS OR MONTHLY...........................................................368
		4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...................................369
		4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE................................................371
		4.10.3 DRIVE SHAFTS - LUBRICATE.................................................................371
		4.10.4 SIGNAL HORN COMPRESSOR - LUBRICATE.......................................................371
		4.10.5 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER..........373
		4.10.6 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER......................373
		4.10.7 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER....375
		4.10.8 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT........................................377
		4.10.9 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL..........................................379
		4.10.10 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL...........................381
	4.11 EVERY 500 OPERATING HOURS OR QUARTELY..........................................................382
		4.11.1 BATTERIES - CHECK FLUID LEVEL............................................................383
		4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL...............................................385
		4.11.3 DRIVE SHAFT HOUSINGS ON PTO GEARS - CHECK OIL LEVEL......................................387
		4.11.4 FUEL TANK - DRAIN CONDENSATION...........................................................389
		4.11.5 CRAWLER TRACK - INSPECTION...............................................................391
		4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION....397
		4.11.7 GROUND CABLE OF OPERATOR’S CAB - CHECK FOR CORRECT CONNECTION............................399
	4.12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH....................................................400
		4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD.......................................401
		4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE........................................................443
		4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS.......455
		4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.............................................457
		4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS..........................459
		4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE..................................................461
		4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.................................463
		4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES................................465
	4.13 EVERY 2000 OPERATING HOURS OR YEARLY...........................................................466
		4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER............467
		4.13.2 EMERGENCY ESCAPE LADDERS - INSPECTION....................................................477
	4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR........................................484
		4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL.......................................485
		4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL..............................489
		4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL........................................................493
		4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.................................................495
	4.15 FIRE PREVENTION................................................................................496
	4.16 WELD REPAIRS...................................................................................498
		4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE....................501
		4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT................503
		4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...................505
		4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...................................507

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