KOMATSU PC4000-6E EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08203 – PDF DOWNLOAD
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DESCRIPTION:
KOMATSU PC4000-6E EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08203 – PDF DOWNLOAD
DESIGNATED USE OF THE SHOVEL:
- 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.
TABLE OF CONTENTS:
KOMATSU PC4000-6E EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 08203 – PDF DOWNLOAD
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 ABBREVATIONS 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 – BASIC RESPONSIBILITIES 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) 26
2 1 10 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE 27
2 1 11 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 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 46
3 2 4 EMERGENCY ESCAPE LADDER 50
3 2 5 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN AND OPERATOR WARNING SYSTEM 52
3 2 6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 54
3 2 7 UNDERCARRIAGE 63
3 2 8 WORKING ATTACHMENT 64
3 3 OPERATOR’S CAB – CONTROLS 66
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 66
3 3 2 SAFETY CIRCUIT FOR CONTROLS 67
3 3 3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 70
3 3 4 SAFETY CIRCUIT FOR CONTROLS 71
3 3 5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK 73
3 3 6 OPERATORS CONSOLE, OVERVIEW 75
3 3 7 INTERFACE PANEL FOR DIAGNOSTICS 81
3 4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 82
3 4 1 INTRODUCTION 83
3 4 2 OPERATING THE ELECTRONIC MONITORING SYSTEM 91
3 4 3 AUTOMATIC DISPLAY OF MESSAGES 95
3 4 4 MENU CONTROL AND SERVICE FUNCTIONS 119
3 4 5 MENU CONTROL LIST 146
3 4 6 FAULT AND INFORMATION MESSAGE LIST 162
3 5 CAMERA SYSTEM WITH MONITOR 188
3 5 1 LOCATION OF MONITOR AND CONTROL UNIT 189
3 6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 196
3 7 MACHINERY HOUSE 200
3 7 1 EMERGENCY MOTOR SHUTDOWN SWITCHES 201
3 7 2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES 203
3 7 3 CENTRAL CONTROL AND FILTER PANEL 205
3 8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE 206
3 8 1 SWITCH BOARD (X2) IN CAB BASE 209
3 8 2 COMPONENTS IN THE MEDIUM VOLTAGE SWITCH CABINET 217
3 8 3 MONITOR AND CONTROL PANEL 219
3 9 HIGH VOLTAGE SWITCH CABINET 222
3 10 CHECKS BEFORE STARTING THE MOTOR 224
3 11 STARTING THE MAIN DRIVE MOTOR 228
3 11 1 STARTING PROCEDURE 231
3 12 MOVING THE SHOVEL 241
3 12 1 TRAVEL CONTROL WITH FOOT PEDALS 241
3 12 2 TRAVELLING INSTRUCTIONS 244
3 13 SLEWING AND BRAKING THE SUPERSTRUCTURE 245
3 13 1 SLEWING THE SUPERSTRUCTURE 245
3 13 2 BRAKING THE SUPERSTRUCTURE 247
3 13 3 SLEW PARKING BRAKE 248
3 14 WORKING WITH THE ATTACHMENT 250
3 14 1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM 250
3 14 2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM 251
3 14 3 BOTTOM DUMP BUCKET 252
3 14 4 DROP BALL OPERATION 253
3 14 5 COMBINED OPERATION CYCLES 256
3 15 WORKING INSTRUCTIONS 258
3 15 1 STABILITY OF THE SHOVEL 258
3 15 2 SHOVEL OPERATION 258
3 16 PARKING THE SHOVEL 261
3 17 STOPPING THE MOTOR 262
3 17 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 265
3 18 OPERATION OF THE LUBRICATION SYSTEM 266
3 18 1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT 266
3 18 2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 268
3 19 TRANSFER PUMP FOR HYDRAULIC OIL 270
3 19 1 OPERATING THE TRANSFER PUMP 271
3 19 2 FUNCTIONS OF THE TRANSFER PUMP 273
3 20 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM 276
3 20 1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS 277
3 20 2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB 281
3 20 3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM: 281
3 20 4 IN CASE OF FIRE 283
3 21 CENTRAL REFILLING SYSTEM 284
3 21 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 285
3 21 2 RECEIVER PANEL AND MONITOR BOX 285
3 21 3 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM 289
3 22 CABLE DRUM (IF SO EQUIPPED) 292
3 22 1 OPERATION OF THE CABLE DRUM 293
3 22 2 TRAVELLING INSTRUCTIONS 297
3 23 WORK ON THE LOADER ATTACHMENT 300
3 24 TRANSPORTATION AND LIFTING OF THE SHOVEL 301
3 24 1 DISASSEMBLING OF THE SHOVEL 301
3 24 2 TRANSPORTATION AND LIFTING 301
3 25 RETRIEVAL PROCEDURE 302
3 26 SHOVEL STORAGE 303
3 26 1 PREPARING FOR STORAGE 303
3 26 2 ONE MONTH REPETITIVE SERVICE PERIOD 303
3 26 3 SIX MONTH REPETITIVE SERVICE PERIOD 304
3 26 4 PREPARING FOR OPERATION 304
3 27 TROUBLE SHOOTING 305
3 27 1 MAIN DRIVE ELECTRIC MOTOR 305
3 27 2 HYDRAULIC SYSTEM 306
3 27 3 FINAL DRIVES AND SWING GEAR 307
3 27 4 CRAWLER TRACKS 307
4 MAINTENANCE 309
4 1 FOREWORD 310
4 2 PRECAUTIONS FOR MAINTENANCE 311
4 3 FLUIDS AND LUBRICANTS 313
4 3 1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 313
4 3 2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 314
4 3 3 MAIN DRIVE ELECTRIC MOTOR – BEARING LUBRICATION 315
4 4 FILLING CAPACITIES 316
4 5 STANDARD TORQUE LIST 317
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 318
4 6 1 INITIAL SERVICING 318
4 6 2 PERIODIC SERVICING INTERVALS 318
4 6 3 PERIODIC SERVICING SCHEDULE 319
4 6 4 MAINTENANCE OF THE MAIN DRIVE ELECTRIC MOTOR 323
4 6 5 REPLACEMENT OF HYDRAULIC HOSE LINES 325
4 6 6 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 326
4 7 WHEN NECESSARY 328
4 7 1 SWING CIRCLE TOOTHING LUBRICATION 329
4 7 2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS 331
4 7 3 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS 335
4 8 EVERY 10 OPERATING HOURS OR DAILY 336
4 8 1 WALK-AROUND INSPECTION 337
4 8 2 CLEANING THE TRACK GROUPS 345
4 9 EVERY 50 OPERATING HOURS OR WEEKLY 346
4 9 1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 347
4 9 2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S” – CHECK OIL LEVELS 351
4 9 3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 353
4 9 4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN” – CHECK OIL LEVELS 355
4 9 5 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 357
4 9 6 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL 359
4 9 7 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 361
4 9 8 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 363
4 10 EVERY 250 OPERATING HOURS OR MONTHLY 364
4 10 1 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 365
4 10 2 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 365
4 10 3 SIGNAL HORN COMPRESSOR – LUBRICATE 365
4 10 4 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER 367
4 10 5 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 371
4 10 6 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL 375
4 10 7 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 377
4 10 8 AIR CONDITIONING FOR ELECTRICAL SWITCH CABINETS – CHECK REFRIGERANT LEVEL 379
4 11 EVERY 500 OPERATING HOURS OR MONTHLY 382
4 11 1 BATTERIES – CHECK FLUID LEVEL 383
4 11 2 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL 385
4 11 3 CRAWLER TRACK – INSPECTION 387
4 11 4 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 393
4 12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 394
4 12 1 HIGH STRENGTH BOLT CONNECTIONS 395
4 12 2 HYDRAULIC SYSTEM – FILTER SERVICE 443
4 12 3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 457
4 12 4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 459
4 12 5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS 461
4 12 6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 463
4 12 7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 465
4 12 8 SLIP RING UNIT – LUBRICATE 467
4 13 EVERY 2000 OPERATING HOURS OR YEARLY 468
4 13 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 469
4 13 2 BLEEDING THE HYDRAULIC SYSTEM 481
4 13 3 GEAR PUMP FOR PTO GEAR LUBRICATION 483
4 13 4 EMERGENCY ESCAPE LADDER – INSPECTION 485
4 14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 486
4 14 1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 487
4 14 2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S”- CHANGE OIL 495
4 14 3 FINAL DRIVE HOUSINGS – CHANGE OIL 499
4 14 4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN”- CHANGE OIL 501
4 14 5 FINAL DRIVE HOUSINGS – CHANGE OIL 505
4 14 6 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 507
4 15 FIRE PREVENTION 508
4 16 WELD REPAIRS 510
4 16 1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 513
4 16 2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 515
4 16 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 517
4 16 4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 518
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