Komatsu PC8000-6 Shovel Operation and Maintenance Manual (GZEAM12082-0)

Komatsu PC8000-6 Shovel Operation and Maintenance Manual (GZEAM12082-0)

Komatsu PC8000-6 Shovel Index:

• 1 FOREWORD
  • 1.1 BEFORE READING THIS MANUAL
  • 1.2 DIRECTIONS OF THE MACHINE
  • 1.3 SPECIFICATION AND SERIAL PLATE
    • 1.3.1 PRODUCT IDENTIFICATION NUMBER
  • 1.4 DIVISION OF THE BINDER
  • 1.5 DESIGNATED USE OF THE SHOVEL
  • 1.6 DELIVERY OF THE SHOVEL
    • 1.6.1 SPARE PARTS
    • 1.6.2 SERVICE
  • 1.7 EXPLANATION OF ABBREVIATIONS
  • 1.8 CONTENTS
• 2 SAFETY
  • 2.1 SAFETY INFORMATION
  • 2.2 OVERVIEW
    • 2.2.1 NORMAL OPERATIONS
    • 2.2.2 REGULAR MAINTENANCE
    • 2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR
    • 2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR
  • 2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.
  • 2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
    • 2.4.1 UNDERSTANDING THE MACHINE
    • 2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR
    • 2.4.3 PREPARATIONS FOR SAFE OPERATION
    • 2.4.4 FIRE PREVENTION
    • 2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
    • 2.4.6 BURN PREVENTION
    • 2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS
    • 2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
    • 2.4.9 PRECAUTIONS AT JOBSITE
    • 2.4.10 STARTING ENGINE
    • 2.4.11 OPERATION
  • 2.5 PRECAUTION FOR MAINTENANCE
    • 2.5.1 GENERAL PRECAUTIONS
    • 2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE
    • 2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID
  • 2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
    • 2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM
    • 2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS
    • 2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR
  • 2.7 SPECIAL SAFETY EQUIPMENT
    • 2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB
    • 2.7.2 OBJECT HANDLING
    • 2.7.3 LIGHTING
    • 2.7.4 WARNING BEACON
    • 2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
  • 2.8 SAFETY WARNING SIGNS
    • 2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS
• 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 UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR
    • 3.2.6 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE
    • 3.2.7 FOLDING LADDER INSIDE OF CARBODY
    • 3.2.8 BOOM ACCESS LADDER AND WALKWAY
    • 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
    • 3.3.4 INTERFACE PANEL FOR DIAGNOSTICS
    • 3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER
  • 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR (KOMTRAX Plus)
    • 3.4.1 SEQUENCE OF DISPLAYS
    • 3.4.2 OPENING SCREEN
    • 3.4.3 MAIN GAUGE SCREENS 1-4
    • 3.4.4 FUEL CONSUMPTION SCREEN
    • 3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR
    • 3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE.
    • 3.4.7 MAINTENANCE MONITOR
    • 3.4.8 SETTINGS FOR OPERATOR
    • 3.4.9 SERVICE MENU
    • 3.4.10 AUTOMATIC MESSAGES
    • 3.4.11 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM
    • 3.4.12 TABLE OF AVAILABLE INSTRUCTION MESSAGES
  • 3.5 CAMERA SYSTEM WITH MONITORS
    • 3.5.1 LOCATION OF MONITORS AND CONTROL UNITS
  • 3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING
    • 3.6.1 DIGITAL DISPLAY
    • 3.6.2 LUMINOUS INDICATION
    • 3.6.3 AUXILIARY HEATER FOR OPERATOR’S CAB
  • 3.7 MACHINERY HOUSE
    • 3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES
    • 3.7.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE
    • 3.7.3 CENTRAL CONTROL AND FILTER PANEL
    • 3.7.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO
  • 3.8 ELECTRICAL EQUIPMENT IN CAB BASE
    • 3.8.1 STANDARD COMPONENTS IN CAB BASE
    • 3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE
    • 3.8.3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS
    • 3.8.4 BINARY FAULT CODE LIST.
    • 3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS
    • 3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE
  • 3.9 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES
    • 3.9.1 ENGINE COOLANT AND ENGINE OIL PAN HEATING SYSTEMS
    • 3.9.2 HYDRAULIC OIL, PTO GEAR OIL AND BATTERY HEATING
  • 3.10 CHECKS BEFORE STARTING THE ENGINES
    • 3.10.1 HYDRAULIC SYSTEM – CHECK OIL LEVEL
    • 3.10.2 MACHINERY HOUSE DOORS
    • 3.10.3 OPERATOR’S SEAT ADJUSTMENT
  • 3.11 STARTING THE ENGINES
    • 3.11.1 STARTING PROCEDURE
    • 3.11.2 COLD WEATHER STARTING AID
    • 3.11.3 ENGINE WARMUP LOCK ON LOW IDLE
    • 3.11.4 HYDRAULIC OIL WARM-UP
  • 3.12 MOVING THE SHOVEL
    • 3.12.1 TRAVEL CONTROL WITH FOOT PEDALS
    • 3.12.2 TRAVELLING INSTRUCTIONS
  • 3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE
    • 3.13.1 SLEWING THE SUPERSTRUCTURE
  • 3.14 WORKING WITH THE ATTACHMENT
    • 3.14.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM
    • 3.14.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM
    • 3.14.3 DROP BALL OPERATION
    • 3.14.4 COMBINED OPERATION CYCLES
  • 3.15 WORKING INSTRUCTIONS
    • 3.15.1 STABILITY OF THE SHOVEL
    • 3.15.2 SHOVEL OPERATION
  • 3.16 PARKING THE SHOVEL
    • 3.16.0.1 CLEANING THE TRACK GROUPS
  • 3.17 STOPPING THE ENGINES.
    • 3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM
  • 3.18 OPERATION OF THE LUBRICATION SYSTEM
    • 3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE
    • 3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”
  • 3.19 TRANSFER PUMP FOR HYDRAULIC OIL
    • 3.19.1 OPERATING THE TRANSFER PUMP
    • 3.19.2 TRANSFUSION PROCEDURE
  • 3.20 CENTRAL REFILLING SYSTEM
    • 3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM
    • 3.20.2 OPERATING THE HYDRAULIC SERVICE ARM
    • 3.20.3 RECEIVER PANEL WITH MONITOR BOX
    • 3.20.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS
  • 3.21 FIRE DETECTION AND SUPPRESSION SYSTEM
    • 3.21.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS
    • 3.21.1 HIGH LEVEL ALARM -FIRE-
    • 3.21.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE
    • 3.21.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS
    • 3.21.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS
    • 3.21.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF
  • 3.22 WORK ON THE LOADER ATTACHMENT
    • 3.22.1 OBSERVE THE FOLLOWING INSTRUCTIONS
  • 3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL
    • 3.23.1 DISASSEMBLING OF THE SHOVEL
    • 3.23.2 TRANSPORTATION AND LIFTING
  • 3.24 RETRIEVAL PROCEDURE
    • 3.24.1 GENERAL
  • 3.25 SHOVEL STORAGE
    • 3.25.1 GENERAL
    • 3.25.2 PREPARING FOR STORAGE
    • 3.25.3 ONE MONTH REPETITIVE SERVICE PERIOD
    • 3.25.4 SIX MONTH REPETITIVE SERVICE PERIOD
    • 3.25.5 PREPARING FOR OPERATION
  • 3.26 TROUBLE SHOOTING
    • 3.26.1 GENERAL
    • 3.26.2 ENGINE
    • 3.26.3 HYDRAULIC SYSTEM
    • 3.26.4 FINAL DRIVES AND SWING GEAR
    • 3.26.5 CRAWLER TRACKS
• 4 MAINTENANCE
  • 4.1 FOREWORD
    • 4.1.1 DEFINITIONS
    • 4.1.2 GENERAL RECOMMENDATIONS
  • 4.2 PRECAUTIONS FOR MAINTENANCE
  • 4.3 FLUIDS AND LUBRICANTS
    • 4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES
    • 4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES
  • 4.4 FILLING CAPACITIES
  • 4.5 STANDARD TORQUE LIST
  • 4.6 LUBRICATION AND MAINTENANCE SCHEDULE
    • 4.6.1 AFTER THE FIRST 250 OPERATING HOURS
    • 4.6.2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS
    • 4.6.3 PERIODIC SERVICING INTERVALS
    • 4.6.4 PERIODIC SERVICING SCHEDULE
    • 4.6.5 Lubrication Chart
    • 4.6.6 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES
    • 4.6.7 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
    • 4.6.8 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM
    • 4.6.9 ENGINE FUEL FILTER LOCATION
  • 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 SERVICE THE GREASE FILTERS FOR REFILLABLE GREASE CONTAINERS OF THE CENTRAL lUBE SYSTEM AND SWING CIRCLE PINION LUBE SYSTEM
    • 4.7.5 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 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION
    • 4.8.3 AIR CLEANER – CLEAN PRE-CLEANER
    • 4.8.4 RADIATORS – CHECK COOLANT LEVEL
    • 4.8.5 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
    • 4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION
    • 4.11.7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION
  • 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH
    • 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 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES
    • 4.12.7 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 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL
  • 4.15 FIRE PREVENTION
    • 4.15.1 PRECAUTIONS
  • 4.16 WELD REPAIRS
    • 4.16.1 GENERAL PROTECTIVE MEASURES
    • 4.16.2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR
    • 4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
    • 4.16.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
    • 4.16.5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
    • 4.16.6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE

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