KOMATSU PC8000-6 EXCAVATOR HYDRAULIC MINING SHOVEL ASSEMBLY AND TRANSPORT MANUAL 12105 – PDF DOWNLOAD
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DESCRIPTION:
KOMATSU PC8000-6 EXCAVATOR HYDRAULIC MINING SHOVEL ASSEMBLY AND TRANSPORT MANUAL 12105 – PDF DOWNLOAD
SAFETY INFORMATION:
- To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed. - The safety information in this manual does not replace any safety rules or laws in your area.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used. - The “Safety Alert Symbol” identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
TABLE OF CONTENTS:
KOMATSU PC8000-6 EXCAVATOR HYDRAULIC MINING SHOVEL ASSEMBLY AND TRANSPORT MANUAL 12105 – PDF DOWNLOAD
2 SAFETY 11
2 1 SAFETY INFORMATION 12
2 2 OVERVIEW 13
2 2 1 NORMAL OPERATIONS 13
2 2 2 REGULAR MAINTENANCE 13
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 13
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 13
2 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 14
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 15
2 4 1 UNDERSTANDING THE MACHINE 15
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 15
2 4 3 PREPARATIONS FOR SAFE OPERATION 15
2 4 4 FIRE PREVENTION 17
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 19
2 4 6 BURN PREVENTION 21
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 21
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 22
2 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 23
2 4 10 PRECAUTIONS AT JOBSITE 24
2 4 11 STARTING ENGINE 29
2 4 12 OPERATION 30
2 5 PRECAUTION FOR MAINTENANCE 36
2 5 1 GENERAL PRECAUTIONS 36
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 44
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 45
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 49
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 49
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 49
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 49
2 7 SPECIAL SAFETY EQUIPMENT 50
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 51
2 7 2 OBJECT HANDLING 51
2 7 3 LIGHTING 51
2 7 4 WARNING BEACON 51
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 51
2 8 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLY 59
2 8 1 WHEN ASSEMBLING THE EXCAVATOR 59
2 8 2 WHEN DISASSEMBLING THE EXCAVATOR 59
2 8 3 WHEN TRANSPORTING THE DISASSEMBLED EXCAVATOR 60
3 GENERAL 61
3 1 GENERAL 62
3 1 1 DELIVERY OF THE EXCAVATOR 62
3 1 2 ASSEMBLING THE EXCAVATOR 62
3 1 3 LIFTING AND TRANSPORTATION 62
3 1 4 ELECTRICAL ENERGY 63
3 1 5 ELECTROMAGNETIC COMPATIBILITY (EMC) 63
3 1 6 MONITORING SYSTEM OF THE MACHINE 63
3 2 ASSEMBLY SITE REQUIREMENTS 64
3 2 1 CONFIGURATION OF COMPONENTS ON ERECTION SITE (EXAMPLE) 64
3 2 2 REQUIRED CRANES 65
3 2 3 MANPOWER / ASSEMBLY TIME 65
3 2 4 TOOLS AND EQUIPMENT FOR ASSEMBLY 66
3 2 5 STANDARD APPLICATION TORQUE CHART 69
3 2 6 PREPARATIONS FOR ASSEMBLY 72
3 3 LIFTING OF THE MAIN COMPONENTS 74
3 3 1 SAFETY PRECAUTIONS FOR LIFTING OF COMPONENTS 75
3 3 2 LIFTING ATTACHMENT POINTS AND WEIGHTS 75
3 3 3 CRAWLER SIDE FRAME WITHOUT TRACKS 75
3 3 4 CARBODY 77
3 3 5 SUPERSTRUCTURE PLATFORM 79
3 3 6 MACHINERY HOUSE 81
3 3 7 FACE SHOVEL BOOM 83
3 3 8 BACKHOE BOOM 85
3 3 9 COUNTERWEIGHT LIFTING FOR HORIZONTAL TRANSPORT 87
3 3 10 COUNTERWEIGHT ERECTING FOR VERTICAL TRANSPORT 89
3 3 11 COUNTERWEIGHT LIFTING FOR VERTICAL TRANSPORT 91
3 3 12 FUEL TANK] 93
3 3 13 CAB BASE 95
3 3 14 MAIN HYDRAULIC OIL RESERVOIR 97
3 3 15 FACE SHOVEL STICK 99
3 3 16 BACKHOE STICK 101
3 3 17 FACE SHOVEL BACK WALL 103
3 3 18 FACE SHOVEL CLAM SHELL 105
3 3 19 BACKHOE BUCKET 107
3 3 20 BASIC DIMENSIONS 108
3 4 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES 110
4 ASSEMBLY SEQUENCE 113
4 1 ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES 114
4 1 1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY 115
4 1 2 STABILITY IN RELATION TO ASSEMBLY STAGE 116
4 2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES 122
4 2 1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY 123
4 3 ASSEMBLY OF UNDERCARRIAGE 124
4 3 1 ASSEMBLY OF TRACKS 125
4 3 2 ATTACH CARBODY TO SIDE FRAME 126
4 3 3 DETERMINING THE TIGHTENING TORQUE 131
4 3 4 SPECIAL HYDRAULIC TORQUE WRENCH 135
4 3 5 MOUNTING OF TRAVEL GEARS AND FINAL DRIVES 136
4 3 6 MOUNTING OF TRAVEL GEARS WITH PROTECTION KIT 140
4 3 7 CLOSING THE TRACKS 142
4 3 8 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS 143
4 3 9 HYDRAULIC TRACK TENSIONING SYSTEM 146
4 4 MOUNTING OF THE SLEW RING 148
4 5 MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE 154
4 6 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT 158
4 7 ASSEMBLY OF MACHINERY HOUSE ROOF 160
4 7 1 MOUNTING OF THE EXHAUST SYSTEM 161
4 7 2 MOUNTING OF THE AIR INTAKE SYSTEM 164
4 7 3 MOUNTING OF COOLING SYSTEM SURGE TANKS 166
4 7 4 MOUNTING OF FIRE EXTINGUISHING TANK ASSEMBLIES 168
4 8 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM 170
4 9 MOUNTING OF HYDRAULIC ACCESS LADDER 172
4 9 1 MOUNTING OF THE SWITCHING VALVE FOR EMERGENCY LOWERING OF THE ACCESS LADDER 174
4 10 CONNECTING ENGINE OIL RESERVE SYSTEM 178
4 11 PRE-ASSEMBLY OF FACE SHOVEL BOOM 182
4 11 1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM 184
4 11 2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS 186
4 11 3 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM 188
4 11 4 PREASSEMBLY OF HOSES 191
4 12 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME 194
4 12 1 INSTALLATION OF BOOM ARC HOSES 196
4 13 PRE-ASSEMBLY OF BACKHOE BOOM 198
4 13 1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM 200
4 13 2 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM 202
4 14 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME 208
4 14 1 INSTALLATION OF BOOM ARC HOSES 211
4 15 MOUNTING OF THE COUNTERWEIGHT 212
4 16 MOUNTING OF THE FUEL TANK 214
4 16 1 INSTALLATION OF FUEL FILTERS AND FUEL LINES 216
4 17 MOUNTING OF THE CAB BASE 220
4 17 1 MAKING OF ELECTRICAL CABLE CONNECTIONS 222
4 17 2 CONNECT HEATER HOSES AND ACTUATION HOSE OF FIRE SUPPRESSION SYSTEM 224
4 17 3 INSTALL CAB STAIR AND RAILINGS 226
4 18 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE 228
4 18 1 INSTALL ORBCOMM ANTENNA 230
4 18 2 INSTALL THE EMERGENCY ESCAPE LADDER ON CAB 232
4 19 MOUNTING OF FRONT ROOF AND COVERING 234
4 20 ATTACHING THE HYDRAULIC OIL RESERVOIR 236
4 20 1 INSTALL THE COMPENSATOR BETWEEN MAIN AND SUCTION OIL RESERVOIR 238
4 21 ATTACHING THE HYDRAULIC OIL COOLER 240
4 21 1 CONNECTING THE HOSE LINES TO THE COMBINED OIL COOLER FOR HYDRAULIC OIL AND PTO GEAR OIL 242
4 21 2 INSTALL AUXILIARY HYDRAULIC OIL COOLER 246
4 21 3 CONNECTING THE HYDRAULIC HOSE LINES OF MAIN OIL COOLER FAN DRIVE CIRCUIT 248
4 21 4 CONNECTING THE HYDRAULIC HOSE LINES OF AUXILIARY OIL COOLER CIRCUIT 250
4 21 5 CONNECTING THE HYDRAULIC HOSE LINES OF AUXILIARY OIL COOLER FAN MOTORS 252
4 21 6 CONNECTING THE RETURN OIL HOSE LINES OF COOLANT RADIATOR FAN MOTORS 254
4 21 7 CONNECTING THE RETURN AND PRESSURE OIL HOSE LINES OF MAIN CONTROL VALVES 256
4 21 8 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP 258
4 22 ATTACHING THE HANDRAILS, CATWALKS AND STEPS 260
4 23 ATTACHING THE SERVICE CRANE 264
4 24 ATTACHING THE CENTRAL LUBRICATION UNIT 266
4 24 1 CONNECTING THE HYDRAULIC LINES AND GREASE LINES 268
4 24 2 INSTALL LUBRICATION PINIONS OF SWING CIRCLE 270
4 24 3 CONNECT CABLE HARNESS OF CENTRAL LUBRICATION UNIT 272
4 24 4 CONNECTING GREASE LINES OF THE CENTRAL LUBRICATION SYSTEM 274
4 25 CENTRAL REFILLING SYSTEM 276
4 25 1 CONNECTING THE REFILLING LINES 277
4 26 MOUNTING CAN-NODE BOXES ON MACHINERY HOUSE ROOF 280
4 26 1 CONNECTING THE CABLES TO THE CAN-NODES 281
4 27 PRE-CHECKS PRIOR TO INITIAL START UP 282
4 28 FILLING AND BLEEDING THE HYDRAULIC SYSTEM 284
4 28 1 FILLING THE HYDRAULIC SYSTEM 285
4 28 2 BLEEDING THE HYDRAULIC SYSTEM 286
4 29 BLEEDING GEAR PUMPS FOR PTO GEAR LUBRICATION 292
4 30 ASSEMBLY FACE SHOVEL ATTACHMENT 294
4 30 1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM 295
4 30 2 ATTACHING THE STICK TO THE BOOM 297
4 30 3 CONNECTING HOSE LINES TO BUCKET CYLINDERS 299
4 30 4 CONNECTING STICK CYLINDERS TO THE STICK 300
4 31 BLEEDING THE HYDRAULIC CIRCUITS 302
4 31 1 BLEEDING THE SWING PARKING BRAKE CIRCUIT 303
4 31 2 BLEEDING THE TRAVEL GEAR PARKING BRAKE CIRCUIT 303
4 31 3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT 305
4 31 4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER 306
4 31 5 BLEEDING HYDRAULIC CIRCUIT OF SERVICE ARM 306
4 31 6 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS 306
4 31 7 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS 307
4 32 ATTACHING FACE SHOVEL TO THE STICK 308
4 32 1 ATTACHING BUCKET BACK WALL TO THE STICK 309
4 32 2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM CYLINDERS 311
4 32 3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL 313
4 32 4 CONNECTING GREASE LINES OF THE FACE SHOVEL ATTACHMENT 315
4 32 5 CONNECTING GREASE LINES ON THE BUCKET 317
4 32 6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS 317
4 33 ATTACHING THE BACKHOE STICK TO THE BOOM 318
4 33 1 ATTACHING THE STICK TO THE BOOM 319
4 33 2 CONNECTING HOSE LINES FROM BOOM TO BUCKET CYLINDERS 321
4 34 BLEEDING THE HYDRAULIC CIRCUITS 322
4 34 1 BLEEDING THE SWING PARKING BRAKE CIRCUIT 323
4 34 2 BLEEDING THE TRAVEL GEAR PARKING BRAKE CIRCUIT 323
4 34 3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT 325
4 34 4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER 326
4 34 5 BLEEDING HYDRAULIC CIRCUIT OF SERVICE ARM 326
4 34 6 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS 326
4 34 7 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS 327
4 35 ATTACHING BACKHOE BUCKET TO THE STICK 328
4 35 1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT 333
4 36 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS 334
5 FINAL CHECKS AND ADJUSTMENTS 335
5 0 1 COMMISSIONING CHECK LIST 337
5 0 2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS 337
5 0 3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE 339
5 0 4 PRESSURE COMPENSATION OF SEALED COMPONENTS 339
5 1 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE 340
5 1 1 ARRANGEMENT OF EXTINGUISHING TANKS AND EXPELLANT GAS CARTRIDGES ON MACHINERY HOUSE ROOF 345
5 1 2 PROTRACTING ACTUATION DEVICE (PAD) 346
5 1 3 TESTING AND TROUBLE SHOOTING OF THE CHECKFIRE RELEASE CIRCUIT 349
5 1 4 FIRE WIRE ROUTING IN MACHINERY HOUSE 351
5 1 5 INSTALL THE PROTRACTING ACTUATION DEVICE (PAD) IN THE MANUAL/AUTOMATIC ACTUATOR 353
5 1 6 CONTROL MODULE – LED INDICATIONS 354
5 1 7 MAINTENANCE SCHEDULE 355
5 2 COMMISSIONING OF THE AIR CONDITIONING 356
5 3 PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC MANUAL 360
5 3 1 VISUAL INSPECTION 361
5 3 2 TRAVELLING INSTRUCTIONS 361
5 4 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING 362
6 ORBCOMM INITIALIZATION 363
6 1 ORBCOMM TERMINAL ACTIVATION 364
6 1 1 APPLICATION FORM FOR TERMINAL ACTIVATION 365
6 2 WEBCARE BASIC INFORMATION FOR MACHINE REGISTRATION 366
7 DISASSEMBLY OF THE MACHINE 369
7 0 1 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES 370
7 0 2 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE 371
7 0 3 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES 372
7 0 4 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE 373
7 0 5 DISPOSAL OF WASTE MATERIAL 374
7 0 6 LIFTING AND TRANSPORTATION OF MAIN COMPONENTS 374
8 LIFTING AND TRANSPORTATION OF MAIN COMPONENTS 375
8 1 LIFTING OF THE MAIN COMPONENTS 376
8 1 1 SAFETY PRECAUTIONS FOR LIFTING OF COMPONENTS 377
8 1 2 LIFTING ATTACHMENT POINTS AND WEIGHTS 377
8 1 3 CRAWLER SIDE FRAME WITHOUT TRACKS 377
8 1 4 CARBODY [DIESEL DRIVE] 379
8 1 5 CARBODY [ELECTRIC DRIVE] 381
8 1 6 SUPERSTRUCTURE PLATFORM 383
8 1 7 MACHINERY HOUSE [DIESEL DRIVE] 385
8 1 8 MACHINERY HOUSE [ELECTRIC DRIVE] 387
8 1 9 FACE SHOVEL BOOM 389
8 1 10 BACKHOE BOOM 391
8 1 11 COUNTERWEIGHT LIFTING FOR HORIZONTAL TRANSPORT 393
8 1 12 COUNTERWEIGHT ERECTING FOR VERTICAL TRANSPORT 395
8 1 13 COUNTERWEIGHT LIFTING FOR VERTICAL TRANSPORT 397
8 1 14 FUEL TANK [DIESEL DRIVE] 399
8 1 15 HIGH VOLTAGE SWITCH CABINET [ELECTRIC DRIVE] 401
8 1 16 CAB BASE 403
8 1 17 MAIN HYDRAULIC OIL RESERVOIR 405
8 1 18 FACE SHOVEL STICK 407
8 1 19 BACKHOE STICK 409
8 1 20 FACE SHOVEL BACK WALL 411
8 1 21 FACE SHOVEL CLAM SHELL 413
8 1 22 BACKHOE BUCKET 415
8 2 TRANSPORTATION OF THE MAIN COMPONENTS 416
8 2 1 SAFETY PRECAUTIONS FOR TRANSPORTATION OF THE MAIN COMPONENTS 416
8 2 2 TIE-DOWN OF UNPACKED EXCAVATOR TRANSPORT UNITS 416
8 2 3 CRAWLER TRACKS [1900 mm] 419
8 2 4 CRAWLER TRACKS [1500 mm] 421
8 2 5 CRAWLER SIDE FRAME WITHOUT TRACKS 423
8 2 6 CARBODY [DIESEL DRIVE] 425
8 2 7 CARBODY [DIESEL DRIVE] 427
8 2 8 CARBODY [ELECTRIC DRIVE] 429
8 2 9 CARBODY [ELECTRIC DRIVE] 431
8 2 10 SUPERSTRUCTURE PLATFORM 433
8 2 11 MACHINERY HOUSE [DIESEL DRIVE] 435
8 2 12 MACHINERY HOUSE [ELECTRIC DRIVE] 437
8 2 13 FACE SHOVEL BOOM 439
8 2 14 BACKHOE BOOM 441
8 2 15 COUNTERWEIGHT 443
8 2 16 FUEL TANK [DIESEL DRIVE] 445
8 2 17 HIGH VOLTAGE SWITCH CABINET [ELECTRIC DRIVE] 447
8 2 18 CAB BASE 449
8 2 19 MAIN HYDRAULIC OIL RESERVOIR 451
8 2 20 FACE SHOVEL STICK 453
8 2 21 BACKHOE STICK 455
8 2 22 FACE SHOVEL BACK WALL 457
8 2 23 FACE SHOVEL CLAM SHELL 459
8 2 24 BACKHOE BUCKET 461
8 2 25 COMPONENTS DELIVERED IN TRANSPORT BOXES 461
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