KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:8172) KOMATSU PC4000 6
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KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:8172) KOMATSU PC4000 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 PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:8172) KOMATSU PC4000 6
MAIN MENU....................................................................................................... 0 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 MINING 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 SUPERSTRUCTURE.................................................................................... 40 3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER.............................................................. 50 3.2.4 EMERGENCY ESCAPE LADDER........................................................................... 54 3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.............................. 56 3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)......................... 58 3.2.7 UNDERCARRIAGE..................................................................................... 69 3.2.8 WORKING ATTACHMENT................................................................................ 70 3.2.9 DIESEL ENGINE TYPE SDA 16V160..................................................................... 72 3.2.10 ENGINE OIL MANAGEMENT SYSTEM..................................................................... 74 3.3 OPERATOR’S CAB - CONTROLS............................................................................... 78 3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.................................................................. 78 3.3.2 SAFETY CIRCUIT FOR CONTROLS....................................................................... 79 3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT....................................................... 82 3.3.4 SAFETY CIRCUIT FOR CONTROLS....................................................................... 83 3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK....................................................... 85 3.3.6 OPERATOR’S CONSOLE................................................................................ 87 3.3.7 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING..................... 93 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTHMONITOR.................................................. 96 3.4.1 INITIALIZATION SCREEN NO. 0.0..................................................................... 96 3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1............................................................... 96 3.4.3 STANDARD MONITOR 1 (NO. 1.2)...................................................................... 97 3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM..................................................111 3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES...........................................................120 3.5 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING..................................................122 3.5.1 A - HEATING.......................................................................................123 3.5.2 B - COOLING.......................................................................................123 3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING................................................123 3.5.4 AUXILIARY HEATER FOR OPERATOR’S CAB...............................................................125 3.6 POWER HOUSE.............................................................................................126 3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES................................................................127 3.6.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES...............................................129 3.6.3 CENTRAL CONTROL AND FILTER PANEL..................................................................131 3.7 ELECTRICAL EQUIPMENT IN CAB BASE........................................................................134 3.7.1 STANDARD COMPONENTS IN CAB BASE...................................................................135 3.7.2 SWITCH BOARD (X2) IN CAB BASE.....................................................................137 3.7.3 COMPONENTS OF ELECTRICAL PRE-HEATING SYSTEM LOCATED IN THE CAB BASE...............................147 3.8 CHECKS BEFORE STARTING THE ENGINE.......................................................................154 3.9 STARTING THE ENGINE.....................................................................................160 3.9.1 STARTING PROCEDURE................................................................................163 3.9.2 ENGINE WARM-UP....................................................................................167 3.9.3 HYDRAULIC OIL WARM-UP.............................................................................167 3.10 MOVING THE SHOVEL......................................................................................169 3.10.1 TRAVEL CONTROL WITH FOOT PEDALS..................................................................169 3.10.2 TRAVELLING INSTRUCTIONS..........................................................................172 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE.................................................................173 3.11.1 SLEWING THE SUPERSTRUCTURE.......................................................................173 3.11.2 BRAKING THE SUPERSTRUCTURE.......................................................................175 3.11.3 SLEW PARKING BRAKE...............................................................................176 3.12 WORKING WITH THE ATTACHMENT............................................................................178 3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM.....................................................178 3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM......................................................179 3.12.3 BOTTOM DUMP BUCKET...............................................................................180 3.12.4 DROP BALL OPERATION..............................................................................181 3.12.5 COMBINED OPERATION CYCLES........................................................................184 3.13 WORKING INSTRUCTIONS...................................................................................186 3.13.1 STABILITY OF THE SHOVEL..........................................................................186 3.13.2 SHOVEL OPERATION.................................................................................186 3.14 PARKING THE SHOVEL.....................................................................................189 3.15 STOPPING THE ENGINE....................................................................................190 3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.........................................................193 3.16 OPERATION OF THE LUBRICATION SYSTEM....................................................................194 3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”.................................................................194 3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”.....................................................196 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM..................................................................198 3.17.1 HIGH LEVEL ALARM ”FIRE”..........................................................................201 3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE............................................201 3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM...................................................201 3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S.......203 3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER.......205 3.18 TRANSFER PUMP FOR HYDRAULIC OIL........................................................................206 3.18.1 OPERATING THE TRANSFER PUMP......................................................................207 3.18.2 FUNCTIONS OF THE TRANSFER PUMP...................................................................209 3.19 CENTRAL REFILLING SYSTEM...............................................................................212 3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM........................................................213 3.19.2 OPERATING THE HYDRAULIC SERVICE ARM..............................................................215 3.19.3 RECEIVER PANEL WITH MONITOR BOX..................................................................217 3.19.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB.......223 3.20 WORK ON THE LOADER ATTACHMENT..........................................................................226 3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL...............................................................227 3.21.1 DISASSEMBLING OF THE SHOVEL......................................................................227 3.21.2 TRANSPORTATION AND LIFTING.......................................................................227 3.22 RETRIEVAL PROCEDURE....................................................................................228 3.23 SHOVEL STORAGE.........................................................................................229 3.23.1 PREPARING FOR STORAGE............................................................................229 3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD..............................................................230 3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD..............................................................230 3.23.4 PREPARING FOR OPERATION..........................................................................231 3.24 TROUBLE SHOOTING.......................................................................................232 3.24.1 ENGINE...........................................................................................232 3.24.2 HYDRAULIC SYSTEM.................................................................................233 3.24.3 FINAL DRIVES AND SWING MACHINERY.................................................................234 3.24.4 CRAWLER TRACKS...................................................................................234 4. MAINTENANCE.................................................................................................235 4.1 FOREWORD................................................................................................236 4.2 PRECAUTIONS FOR MAINTENANCE.............................................................................237 4.3 FUEL AND LUBRICANTS.....................................................................................239 4.4 FILLING CAPACITIES......................................................................................241 4.5 STANDARD TORQUE LIST....................................................................................242 4.6 LUBRICATION AND MAINTENANCE SCHEDULE....................................................................243 4.6.1 INITIAL SERVICING.................................................................................243 4.6.2 PERIODIC SERVICING INTERVALS......................................................................243 4.6.3 PERIODIC SERVICING SCHEDULE.......................................................................244 4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM.................251 4.6.5 MAINTENANCE OF THE ENGINE.........................................................................253 4.7 WHEN NECESSARY..........................................................................................254 4.7.1 ENGINE AIR CLEANER SERVICE........................................................................255 4.7.2 SWING CIRCLE TOOTHING LUBRICATION.................................................................259 4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS.................................................261 4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...........................................265 4.8 EVERY 10 OPERATING HOURS OR DAILY.......................................................................266 4.8.1 WALK-AROUND INSPECTION............................................................................267 4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...................................................................277 4.8.3 RADIATOR - CHECK COOLANT LEVEL....................................................................279 4.8.4 TRACK GROUPS - CLEAN..............................................................................279 4.8.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER.........................................................281 4.9 EVERY 50 OPERATING HOURS OR WEEKLY......................................................................282 4.9.1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....................................283 4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS........................287 4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL............................................................289 4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL...................................291 4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....................................................293 4.9.6 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY............................................295 4.10 EVERY 250 OPERATING HOURS OR MONTHLY...................................................................296 4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...........................................297 4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE........................................................299 4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE...............................................................299 4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER..........299 4.10.5 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.......................299 4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER......................................301 4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT................................................305 4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL.....................................................307 4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL....................................309 4.11 EVERY 500 OPERATING HOURS OR MONTHLY...................................................................310 4.11.1 BATTERIES - CHECK FLUID LEVEL....................................................................311 4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL........................................................313 4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL.....................315 4.11.4 FUEL TANK - DRAIN CONDENSATION...................................................................317 4.11.5 CRAWLER TRACK - INSPECTION.......................................................................319 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH............................................................324 4.12.1 HIGH STRENGTH BOLT CONNECTIONS...................................................................325 4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE................................................................367 4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS - OIL SAMPLE ANALYSIS..............379 4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....................................................381 4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS...........................................383 4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE..........................................................385 4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.........................................387 4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES........................................389 4.13 EVERY 2000 OPERATING HOURS OR YEARLY...................................................................390 4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER....................391 4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.............................................................403 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR................................................404 4.14.1 SWING MACHINERY AND MOTOR ADAPTER HOUSING - CHANGE OIL...........................................405 4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL......................................413 4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL................................................................417 4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.........................................................419 4.15 FIRE PREVENTION........................................................................................420 4.16 WELD REPAIRS...........................................................................................422 4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE............................425 4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT........................427 4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...........................429 4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...........................................430
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