Komastu Hydraulic Mining Shovel PC4000E-6 Shop Manual(08165E-GB-2) – PDF DOWNLOAD

Komastu Hydraulic Mining Shovel PC4000E-6 Shop Manual(08165E-GB-2) – PDF DOWNLOAD

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Komastu Hydraulic Mining Shovel PC4000E-6 Shop Manual(08165E-GB-2) – 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.
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.

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.
Using the Shovel for purposes other than those mentioned above
(such as object handling and use as a transport vehicle) is considered
contrary to its designated use. The manufacturer/supplier
cannot be held liable for any damage resulting from such use.
The risk of such misuse lies entirely with the user.

TABLE OF CONTENTS:

Komastu Hydraulic Mining Shovel PC4000E-6 Shop Manual(08165E-GB-2) – PDF DOWNLOAD

CONTENTS
2.1 SAFETY INFORMATION ……………………………………………………………………………………………………. 2-3
2.2 OVERVIEW……………………………………………………………………………………………………………………….. 2-4
2.2.1 NORMAL OPERATIONS …………………………………………………………………………………………. 2-4
2.2.2 REGULAR MAINTENANCE……………………………………………………………………………………… 2-4
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ………………………………………………. 2-4
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND
TRANSPORTATION OF THE EXCAVATOR………………………………………………………………. 2-4
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB. …………………………………………………….. 2-5
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………… 2-6
2.4.1 UNDERSTANDING THE MACHINE………………………………………………………………………….. 2-6
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR …………………. 2-6
2.4.2.1 ENSURING SAFE OPERATION…………………………………………………………………. 2-6
2.4.3 PREPARATIONS FOR SAFE OPERATION……………………………………………………………….. 2-6
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT…………………… 2-6
2.4.3.2 INSPECTING THE MACHINE…………………………………………………………………….. 2-6
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT……………… 2-7
2.4.3.4 KEEP MACHINE CLEAN …………………………………………………………………………… 2-7
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT…………………………….. 2-7
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT …………………………………. 2-8
2.4.3.7 IF A PROBLEM IS FOUND………………………………………………………………………… 2-8
2.4.4 FIRE PREVENTION………………………………………………………………………………………………… 2-8
2.4.4.1 PRECAUTIONS TO PREVENT FIRE ………………………………………………………….. 2-8
2.4.4.2 ACTION IF FIRE OCCURS………………………………………………………………………… 2-9
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…………………………………………. 2-10
2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS …………………………………………………….. 2-10
2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ………………………………… 2-10
2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE
MACHINE………………………………………………………………………………………………. 2-10
2.4.6.2 NO JUMPING ON OR OFF THE MACHINE……………………………………………….. 2-10
2.4.6.3 NO PEOPLE ON THE ATTACHMENT ………………………………………………………. 2-10
2.4.6.4 WORKING IN HIGH PLACES…………………………………………………………………… 2-10
2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK……………………………………………… 2-11
2.4.6.6 LEAVING THE MACHINE ………………………………………………………………………… 2-11
2.4.7 BURN PREVENTION…………………………………………………………………………………………….. 2-11
2.4.7.1 HOT COOLANT …………………………………………………………………………………….. 2-11
2.4.7.2 HOT OIL ……………………………………………………………………………………………….. 2-12
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………………………………… 2-12
2.4.8.1 UNAUTHORIZED MODIFICATION……………………………………………………………. 2-12
2.4.9 PRECAUTIONS AT JOBSITE…………………………………………………………………………………. 2-14
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT ……………………………………………………. 2-15
2.4.9.2 CAMERA SYSTEM WITH MONITORS………………………………………………………. 2-15
2.4.9.3 ENSURE GOOD VISIBILITY…………………………………………………………………….. 2-15
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS…………………………………….. 2-15
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS……………………………… 2-16
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES …………………………………… 2-16
2.4.9.7 WORKING ON LOOSE GROUND…………………………………………………………….. 2-17
2.4.9.8 GAS, DUST, STEAM AND SMOKE…………………………………………………………… 2-17
2.4.9.9 VENTILATION OF ENCLOSED AREAS…………………………………………………….. 2-18
SAFETY
2 – 3
2.4.10 STARTING ENGINE……………………………………………………………………………………………… 2-19
2.4.10.1 WARNING TAG ……………………………………………………………………………………… 2-19
2.4.10.2 CHECKS BEFORE STARTING ENGINE …………………………………………………… 2-19
2.4.10.3 PRECAUTION WHEN STARTING ENGINE……………………………………………….. 2-19
2.4.10.4 PRECAUTION IN COLD AREAS………………………………………………………………. 2-20
2.4.11 OPERATION………………………………………………………………………………………………………… 2-20
2.4.11.1 CHECKS BEFORE OPERATION ……………………………………………………………… 2-20
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE…………… 2-21
2.4.11.3 PRECAUTIONS WHEN TRAVELLING………………………………………………………. 2-22
2.4.11.4 TRAVELLING ON SLOPES……………………………………………………………………… 2-23
2.4.11.5 OPERATIONS ON SLOPES…………………………………………………………………….. 2-24
2.4.11.6 PROHIBITED OPERATIONS……………………………………………………………………. 2-24
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES………………….. 2-25
2.4.11.8 PARKING THE MACHINE ……………………………………………………………………….. 2-25
2.4.11.9 TRANSPORTATION……………………………………………………………………………….. 2-25
2.5 PRECAUTION FOR MAINTENANCE…………………………………………………………………………………. 2-26
2.5.1 GENERAL PRECAUTIONS……………………………………………………………………………………. 2-26
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC
RESPONSIBILITIES ……………………………………………………………………………….. 2-27
2.5.1.2 STOP ENGINE FOR MAINTENANCE……………………………………………………….. 2-28
2.5.1.3 WARNING TAG ……………………………………………………………………………………… 2-28
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY……………………………………………………. 2-29
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS ………………………………. 2-30
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS
RUNNING ……………………………………………………………………………………………… 2-30
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…………………………. 2-30
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR
EQUIPMENT………………………………………………………………………………………….. 2-31
2.5.1.9 NOISE…………………………………………………………………………………………………… 2-31
2.5.1.10 WHEN USING A HAMMER ……………………………………………………………………… 2-31
2.5.1.11 PROPER TOOLS……………………………………………………………………………………. 2-32
2.5.1.12 ACCUMULATOR ……………………………………………………………………………………. 2-32
2.5.1.13 PERSONNEL …………………………………………………………………………………………. 2-32
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE………………………………………… 2-32
2.5.2.1 PRECAUTION WHEN WELDING……………………………………………………………… 2-32
2.5.2.2 BATTERY HANDLING…………………………………………………………………………….. 2-33
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID……………………………………………………… 2-34
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE………………………………………… 2-34
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…………………………………… 2-34
2.5.3.3 REPLACEMENT OF HOSE LINES……………………………………………………………. 2-34
2.5.3.4 INSPECTION OF HOSE LINES………………………………………………………………… 2-35
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ………………………. 2-35
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE……………………………………………………… 2-36
2.5.3.7 AIR CONDITIONING MAINTENANCE ………………………………………………………. 2-36
2.5.3.8 COMPRESSED AIR………………………………………………………………………………… 2-36
2.5.3.9 WASTE MATERIALS………………………………………………………………………………. 2-37
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND
ADJUSTMENTS………………………………………………………………………………………………………………. 2-38
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM …………………………………………………………. 2-38
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING
ADJUSTMENTS……………………………………………………………………………………………………. 2-38
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR……………………………….. 2-38
2.7 SPECIAL SAFETY EQUIPMENT……………………………………………………………………………………….. 2-40
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ……………. 2-41
2.7.2 OBJECT HANDLING …………………………………………………………………………………………….. 2-41
2.7.3 LIGHTING ……………………………………………………………………………………………………………. 2-41
2.7.4 WARNING BEACON……………………………………………………………………………………………… 2-41
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ……….. 2-41
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361
(EUROPEAN STANDARD) ………………………………………………………………………. 2-41
2.7.5.2 INSTRUCTIONS FOR USE ……………………………………………………………………… 2-43
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL ……………………. 2-45
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), ……………………………… 2-45
2.7.5.5 INSTRUCTIONS FOR USE ……………………………………………………………………… 2-47

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