Komastu Hydraulic Mining Shovel PC4000E-6 Operation & Maintenance Manual(GZAM08209-xE-GB-0) – PDF

Komastu Hydraulic Mining Shovel PC4000E-6 Operation & Maintenance Manual(GZAM08209-xE-GB-0) – PDF DOWNLOAD

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Komastu Hydraulic Mining Shovel PC4000E-6 Operation & Maintenance Manual(GZAM08209-xE-GB-0) – PDF DOWNLOAD

FOREWORD
BEFORE READING THIS MANUAL

This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundemental
safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used. Therefore,
the safety messages in this manual and on the machine may not include all possible safety precautions. If
you carry out any operation, inspection or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you
or others engage in prohibited uses or actions described in this manual. Improper operation and maintenance of
the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of publication. Continuing improvements in the design of this machine may lead to additional
changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:  > (1))
Komatsu delivers machines that comply with all applicable regulations
and standards of the country to which it has been shipped. If
the machine has been purchased in another country, it may lack
certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your
product complies with the applicable standards and regulations of
your country, consult Komatsu or your Komatsu distributor before
operating the machine.
Always keep the Operation and Maintenance Manual in the storage
space provided inside the operator’s cabin (see Fig. 1-1) so
that all relevant personnel can read it at any time. If this manual is
lost or damaged, contact your distributor immediately to arrange
for its replacement.

TABLE OF CONTENTS:

Komastu Hydraulic Mining Shovel PC4000E-6 Operation & Maintenance Manual(GZAM08209-xE-GB-0) – PDF DOWNLOAD

110 CONTENTS
1 FOREWORD 1-1
11 BEFORE READING THIS MANUAL 1-2
12 SAFETY INFORMATION 1-3
13 DIRECTIONS OF THE MACHINE 1-4
14 SPECIFICATION AND SERIAL PLATE 1-5
141 PRODUCT IDENTIFICATION NUMBER 1-5
15 SERVICE METER LOCATION 1-6
16 DIVISION OF THE BINDER 1-7
17 DESIGNATED USE OF THE SHOVEL 1-8
18 DELIVERY OF THE SHOVEL 1-9
181 SPARE PARTS 1-9
182 SERVICE 1-9
19 EXPLANATION OF ABBREVIATIONS 1-10
110 CONTENTS 1-11
2 SAFETY 2-1
21 SAFETY INFORMATION 2-3
22 OVERVIEW 2-4
221 NORMAL OPERATIONS 2-4
222 REGULAR MAINTENANCE 2-4
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 2-4
224 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING
AND TRANSPORTATION OF THE EXCAVATOR 2-4
23 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 2-5
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 2-6
241 UNDERSTANDING THE MACHINE 2-6
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 2-6
243 PREPARATIONS FOR SAFE OPERATION 2-6
244 FIRE PREVENTION 2-8
245 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 2-10
246 BURN PREVENTION 2-11
247 PRECAUTIONS WHEN CLEANING CAB GLASS 2-12
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-13
249 PRECAUTIONS AT JOBSITE 2-14
2410 STARTING ENGINE 2-19
2411 OPERATION 2-20
25 PRECAUTION FOR MAINTENANCE 2-26
251 GENERAL PRECAUTIONS 2-26
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-33
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 2-34
26 ADDITIONAL SAFETY INFORMATION FOR
TROUBLESHOOTING AND ADJUSTMENTS 2-39
261 INSPECTION OF THE HYDRAULIC SYSTEM 2-39
262 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING
ADJUSTMENTS 2-39
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 2-39
27 SPECIAL SAFETY EQUIPMENT 2-40
271 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 2-41
272 OBJECT HANDLING 2-41
273 LIGHTING 2-41
274 WARNING BEACON 2-41
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 2-41
3 OPERATION 3-1
31 FOREWORD 3-2
32 CONSTRUCTION OF THE SHOVEL 3-3
321 OVERALL VIEW 3-3
322 SUPERSTRUCTURE 3-4
323 HYDRAULICALLY OPERATED ACCESS LADDER 3-10
324 EMERGENCY ESCAPE LADDER 3-14
325 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN AND OPERATOR
WARNING SYSTEM 3-16
326 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE
STRUCTURE (FOPS) 3-18
327 UNDERCARRIAGE 3-27
328 WORKING ATTACHMENT 3-28
33 OPERATOR’S CAB – CONTROLS 3-30
331 CONTROLS WITH BACKHOE ATTACHMENT 3-30
332 SAFETY CIRCUIT FOR CONTROLS 3-31
333 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 3-34
334 SAFETY CIRCUIT FOR CONTROLS 3-35
335 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK 3-37
336 OPERATORS CONSOLE, OVERVIEW 3-39
337 INTERFACE PANEL FOR DIAGNOSTICS 3-45
34 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 3-46
341 INTRODUCTION 3-47
342 OPERATING THE ELECTRONIC MONITORING SYSTEM 3-55
343 AUTOMATIC DISPLAY OF MESSAGES 3-59
344 MENU CONTROL 3-83
345 MENU CONTROL LIST 3-109
346 FAULT AND INFORMATION MESSAGE LIST 3-124
35 CAMERA SYSTEM WITH MONITOR 3-150
351 LOCATION OF MONITOR AND CONTROL UNIT 3-151
36 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 3-158
361 DIGITAL DISPLAY 3-158
362 LUMINOUS INDICATION 3-160
363 ADDITIONAL AIR CONDITIONING/HEATER UNIT IN OPERATOR’S CAB 3-163
37 MACHINERY HOUSE 3-164
371 EMERGENCY MOTOR SHUTDOWN SWITCHES 3-165
372 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES 3-167
373 CENTRAL CONTROL AND FILTER PANEL 3-169
38 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE 3-170
FOREWORD CONTENTS
1 – 13
381 SWITCH BOARD (X2) IN CAB BASE 3-173
382 COMPONENTS IN THE MEDIUM VOLTAGE SWITCH CABINET 3-181
383 MONITOR AND CONTROL PANEL 3-183
384 PREHEATING SYSTEM 3-187
39 HIGH VOLTAGE SWITCH CABINET 3-190
310 CHECKS BEFORE STARTING THE MOTOR 3-192
3101 HYDRAULIC SYSTEM – CHECK OIL LEVEL 3-195
3102 MACHINERY HOUSE DOORS 3-195
3103 OPERATOR’S SEAT ADJUSTMENT 3-195
311 STARTING THE MAIN DRIVE MOTOR 3-196
3111 STARTING PROCEDURE 3-199
312 MOVING THE SHOVEL 3-209
3121 TRAVEL CONTROL WITH FOOT PEDALS 3-209
3122 TRAVELLING INSTRUCTIONS 3-211
313 SLEWING AND BRAKING THE SUPERSTRUCTURE 3-212
3131 SLEWING THE SUPERSTRUCTURE 3-212
314 WORKING WITH THE ATTACHMENT 3-215
3141 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM 3-215
3142 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM 3-216
3143 DROP BALL OPERATION 3-218
3144 COMBINED OPERATION CYCLES 3-221
315 WORKING INSTRUCTIONS 3-223
3151 STABILITY OF THE SHOVEL 3-223
3152 SHOVEL OPERATION 3-223
316 STOPPING THE MOTOR 3-226
3161 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 3-229
317 OPERATION OF THE LUBRICATION SYSTEM 3-230
3171 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND
ATTACHMENT 3-230
3172 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM 3-231
3173 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 3-232
318 TRANSFER PUMP FOR HYDRAULIC OIL 3-234
3181 OPERATING THE TRANSFER PUMP 3-235
3182 FUNCTIONS OF THE TRANSFER PUMP 3-237
319 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM 3-240
3191 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION
SYSTEMS 3-241
3192 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB 3-245
3193 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM: 3-245
3194 IN THE CASE OF A FIRE 3-247
320 CENTRAL REFILLING SYSTEM 3-248
3201 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 3-249
3202 RECEIVER PANEL AND MONITOR BOX 3-249
3203 REFILLING PROCEDURE: 3-251
3204 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION
SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM 3-253
321 CABLE DRUM (IF SO EQUIPPED) 3-256
3211 OPERATION OF THE CABLE DRUM 3-257
3212 TRAVELLING INSTRUCTIONS 3-261
322 CABLE GUIDE (IF SO EQUIPPED) 3-265
3221 LIFTING DEVICE FOR THE POWER CABLE 3-265
323 WORK ON THE LOADER ATTACHMENT 3-266
3231 OBSERVE THE FOLLOWING INSTRUCTIONS 3-266
324 TRANSPORTATION AND LIFTING OF THE SHOVEL 3-267
3241 DISASSEMBLING OF THE SHOVEL 3-267
3242 TRANSPORTATION AND LIFTING 3-267
325 RETRIEVAL PROCEDURE 3-268
326 SHOVEL STORAGE 3-269
3261 PREPARING FOR STORAGE 3-269
3262 ONE MONTH REPETITIVE SERVICE PERIOD 3-269
3263 SIX MONTH REPETITIVE SERVICE PERIOD 3-269
3264 PREPARING FOR OPERATION 3-270
327 TROUBLE SHOOTING 3-271
3271 HYDRAULIC SYSTEM 3-272
3272 FINAL DRIVES AND SWING GEAR 3-273
3273 CRAWLER TRACKS 3-273
4 MAINTENANCE 4-1
41 FOREWORD 4-2
42 PRECAUTIONS FOR MAINTENANCE 4-3
43 FLUIDS AND LUBRICANTS 4-4
431 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 4-4
432 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 4-5
433 MAIN DRIVE ELECTRIC MOTOR – BEARING LUBRICATION 4-6
44 FILLING CAPACITIES 4-7
45 STANDARD TORQUE LIST 4-8
46 LUBRICATION AND MAINTENANCE SCHEDULE 4-9
461 INITIAL SERVICING 4-9
462 PERIODIC SERVICING INTERVALS 4-9
463 PERIODIC SERVICING SCHEDULE 4-10
464 MAINTENANCE OF THE MAIN DRIVE ELECTRIC MOTOR 4-13
465 REPLACEMENT OF HYDRAULIC HOSE LINES 4-16
466 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4-16
47 WHEN NECESSARY 4-18
471 SWING CIRCLE TOOTHING LUBRICATION 4-19
472 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS 4-21
473 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS 4-25
48 EVERY 10 OPERATING HOURS OR DAILY 4-26
481 WALK-AROUND INSPECTION 4-27
482 CLEANING THE TRACK GROUPS 4-35
49 EVERY 50 OPERATING HOURS OR WEEKLY 4-36
491 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 4-37
492 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS
MANUFACTURED BY “L&S” – CHECK OIL LEVELS 4-41
493 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 4-43
494 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED
BY “ZOLLERN” – CHECK OIL LEVELS 4-45
495 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 4-47
496 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL 4-49
497 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 4-51
498 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 4-53
410 EVERY 250 OPERATING HOURS OR MONTHLY 4-54
4101 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 4-55
4102 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE
AND CLEAN BREATHER FILTER 4-55
4103 SIGNAL HORN COMPRESSOR – LUBRICATE 4-55
4104 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER 4-57
4105 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 4-61
4106 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT (HEAVY DUTY
VERSION, SPECIAL EQUIPMENT) 4-63
4107 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL 4-65
4108 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 4-67
4109 AIR CONDITIONING FOR ELECTRICAL SWITCH CABINETS – CHECK
REFRIGERANT LEVEL 4-69
41010 AIR CONDITIONER UNIT FOR MEDIUM VOLTAGE AND HIGH
VOLTAGE SWITCH CABINETS 4-71
411 EVERY 500 OPERATING HOURS OR MONTHLY 4-72
4111 BATTERIES – CHECK FLUID LEVEL 4-73
4112 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT
HOUSINGS – CHECK OIL LEVEL 4-75
4113 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL 4-77
4114 CRAWLER TRACK – INSPECTION 4-79
4115 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT
CONNECTION 4-85
412 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4-86
4121 HIGH STRENGTH BOLT CONNECTIONS 4-87
4122 HYDRAULIC SYSTEM – FILTER SERVICE 4-135
4123 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL
GEARS – OIL SAMPLE ANALYSIS 4-149
4124 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 4-151
4125 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS 4-153
4126 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 4-155
4127 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 4-157
4128 SLIP RING UNIT – LUBRICATE 4-159
413 EVERY 2000 OPERATING HOURS OR YEARLY 4-160
4131 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND
PULSATION DAMPER 4-161
4132 BLEEDING THE HYDRAULIC SYSTEM 4-173
4133 GEAR PUMP FOR PTO GEAR LUBRICATION 4-175
4134 EMERGENCY ESCAPE LADDER – INSPECTION 4-177
414 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4-178
4141 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 4-179
4142 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED
BY “L&S”- CHANGE OIL 4-187
4143 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED
BY “ZOLLERN”- CHANGE OIL 4-193
4144 FINAL DRIVE HOUSINGS – CHANGE OIL 4-197
4145 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 4-199
415 FIRE PREVENTION 4-200
4151 PRECAUTIONS 4-201
416 WELD REPAIRS 4-202
4161 GENERAL INFORMATION 4-203
4162 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL 4-203
4163 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
UNDERCARRIAGE 4-205
4164 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
LOADER ATTACHMENT 4-207
4165 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
SUPERSTRUCTURE 4-209

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