Komatsu PC8000-6 Hydraulic Mining Shovel Operation and Maintenance Manual (OG_PC8000-6_12046)

Komatsu PC8000-6 Hydraulic Mining Shovel Index:

• COVER
• 1. INTRODUCTION
  • 1.1 CONTENTS OF THE BINDER
  • 1.2 DIVISION OF THE BINDER
  • 1.3 DESIGNATED USE OF THE SHOVEL
  • 1.4 DELIVERY OF THE SHOVEL
  • 1.5 EXPLANATION OF ABBREVIATIONS
  • 1.6 TABLE OF CONTENTS
• 2. SAFETY
  • 2.1 SAFETY INSTRUCTIONS
    • 2.1.1 WARNINGS AND SYMBOLS
    • 2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL
    • 2.1.3 ORGANIZATIONAL MEASURES
    • 2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASICRESPONSIBILITIES
    • 2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES
    • 2.1.6 WARNING OF SPECIAL DANGERS
    • 2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING
    • 2.1.8 SPECIAL SAFETY EQUIPMENT
    • 2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEANSTANDARD)
• 3. OPERATION
  • 3.1 FOREWORD
  • 3.2 CONSTRUCTION OF THE SHOVEL
    • 3.2.1 OVERALL VIEW
    • 3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE
    • 3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER
    • 3.2.4 EMERGENCY ESCAPE LADDER AT THE OPERATOR’S CAB PLATFORM
    • 3.2.5 EMERGENCY ESCAPE LADDER AT THE SUPERSTRUCTURE PLATFORM
    • 3.2.6 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR
    • 3.2.7 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE
    • 3.2.8 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
    • 3.2.9 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
    • 3.2.10 ENGINE OIL MANAGEMENT SYSTEM
  • 3.3 OPERATOR’S CAB – CONTROLS
    • 3.3.1 HYDRAULIC CONTROL SYSTEM
    • 3.3.2 SAFETY CIRCUIT FOR CONTROLS
    • 3.3.3 OPERATOR’S CONSOLE
  • 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS
    • 3.4.1 INTRODUCTION
    • 3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM
    • 3.4.3 AUTOMATIC DISPLAY OF MESSAGES
    • 3.4.4 MENU CONTROL
    • 3.4.5 MENU CONTROL LIST
    • 3.4.6 FAULT AND INFORMATION MESSAGE LIST
  • 3.5 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING
    • 3.5.1 A – HEATING
    • 3.5.2 B – COOLING
    • 3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING
  • 3.6 MACHINERY HOUSE
    • 3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES
    • 3.6.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE
    • 3.6.3 CENTRAL CONTROL AND FILTER PANEL
    • 3.6.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO
  • 3.7 ELECTRICAL EQUIPMENT IN CAB BASE
    • 3.7.1 SWITCH BOARD (X2) IN CAB BASE
  • 3.8 CHECKS BEFORE STARTING THE ENGINES
  • 3.9 STARTING THE ENGINES
    • 3.9.1 STARTING PROCEDURE
  • 3.10 MOVING THE SHOVEL
    • 3.10.1 TRAVEL CONTROL WITH FOOT PEDALS
    • 3.10.2 TRAVELLING INSTRUCTIONS
  • 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE
    • 3.11.1 SLEWING THE SUPERSTRUCTURE
  • 3.12 WORKING WITH THE ATTACHMENT
    • 3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM
    • 3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM
    • 3.12.3 BOTTOM DUMP BUCKET
    • 3.12.4 DROP BALL OPERATION
    • 3.12.5 COMBINED OPERATION CYCLES
  • 3.13 WORKING INSTRUCTIONS
    • 3.13.1 STABILITY OF THE SHOVEL
    • 3.13.2 SHOVEL OPERATION
  • 3.14 PARKING THE SHOVEL
  • 3.15 STOPPING THE ENGINES
  • 3.16 OPERATION OF THE LUBRICATION SYSTEM
    • 3.16.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT
    • 3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”
  • 3.17 TRANSFER PUMP FOR HYDRAULIC OIL
    • 3.17.1 OPERATING THE TRANSFER PUMP
    • 3.17.2 TRANSFUSION PROCEDURE
  • 3.18 CENTRAL REFILLING SYSTEM
    • 3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM
    • 3.18.2 OPERATING THE HYDRAULIC SERVICE ARM
    • 3.18.3 RECEIVER PANEL WITH MONITOR BOX
    • 3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS
  • 3.19 WORK ON THE LOADER ATTACHMENT
  • 3.20 TRANSPORTATION AND LIFTING OF THE SHOVEL
    • 3.20.1 DISASSEMBLING OF THE SHOVEL
    • 3.20.2 TRANSPORTATION AND LIFTING
  • 3.21 RETRIEVAL PROCEDURE
  • 3.22 SHOVEL STORAGE
    • 3.22.1 PREPARING FOR STORAGE
    • 3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD
    • 3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD
  • • 3.22.4 PREPARING FOR OPERATION
  • 3.23 TROUBLE SHOOTING
    • 3.23.1 ENGINE
    • 3.23.2 HYDRAULIC SYSTEM
    • 3.23.3 FINAL DRIVES AND SWING GEAR
    • 3.23.4 CRAWLER TRACKS
• 4. MAINTENANCE
  • 4.1 FOREWORD
  • 4.2 PRECAUTIONS FOR MAINTENANCE
  • 4.3 FUEL AND LUBRICANTS
  • 4.4 FILLING CAPACITIES
  • 4.5 STANDARD TORQUE LIST
  • 4.6 LUBRICATION AND MAINTENANCE SCHEDULE
    • 4.6.1 INITIAL SERVICING
    • 4.6.2 PERIODIC SERVICING INTERVALS
    • 4.6.3 PERIODIC SERVICING SCHEDULE
    • 4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM
    • 4.6.5 MAINTENANCE OF THE ENGINES
  • 4.7 WHEN NECESSARY
    • 4.7.1 ENGINE AIR CLEANER MAINTENANCE
    • 4.7.2 SWING CIRCLE TOOTHING LUBRICATION
    • 4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS
    • 4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS
  • 4.8 EVERY 10 OPERATING HOURS OR DAILY
    • 4.8.1 WALK – AROUND INSPECTION
    • 4.8.2 AIR CLEANER – CLEAN PRE-CLEANER
    • 4.8.3 RADIATORS – CHECK COOLANT LEVEL
    • 4.8.4 TRACK GROUPS – CLEAN
  • 4.9 EVERY 50 OPERATING HOURS OR WEEKLY
    • 4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL
    • 4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS
    • 4.9.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL
    • 4.9.4 PUMP DISTRIBUTOR GEARS – CHECK OIL LEVEL
    • 4.9.5 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR
    • 4.9.6 MAIN HYDRAULIC OIL COOLER – INSPECT AND CLEAN IF NECESSARY
    • 4.9.7 PTO GEAR OIL COOLERS – INSPECT AND CLEAN IF NECESSARY
  • 4.10 EVERY 250 OPERATING HOURS OR MONTHLY
    • 4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION
    • 4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE
    • 4.10.3 DRIVE SHAFTS – LUBRICATE
    • 4.10.4 SIGNAL HORN COMPRESSOR – LUBRICATE
    • 4.10.5 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
    • 4.10.6 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
    • 4.10.7 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER
    • 4.10.8 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT
    • 4.10.9 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL
    • 4.10.10 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL
  • 4.11 EVERY 500 OPERATING HOURS OR QUARTELY
    • 4.11.1 BATTERIES – CHECK FLUID LEVEL
    • 4.11.2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL
    • 4.11.3 DRIVE SHAFT HOUSINGS ON PTO GEARS – CHECK OIL LEVEL
    • 4.11.4 FUEL TANK – DRAIN CONDENSATION
    • 4.11.5 CRAWLER TRACK – INSPECTION
  • 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH
    • 4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD
    • 4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE
    • 4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS
    • 4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE
    • 4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS
    • 4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE
    • 4.12.7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES
    • 4.12.8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES
  • 4.13 EVERY 2000 OPERATING HOURS OR YEARLY
    • 4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
    • 4.13.2 EMERGENCY ESCAPE LADDERS – INSPECTION
  • 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
    • 4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL
    • 4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL
    • 4.14.3 FINAL DRIVE HOUSINGS – CHANGE OIL
    • 4.14.4 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL
  • 4.15 FIRE PREVENTION
  • 4.16 WELD REPAIRS
    • 4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
    • 4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
    • 4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
    • 4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE

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