Komatsu Hydraulic Mining Excavator PC8000-11 Operation & Maintenance Manual – PDF DOWNLOAD

Komatsu Hydraulic Mining Excavator PC8000-11 Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu Hydraulic Mining Excavator PC8000-11 Operation & Maintenance Manual – PDF DOWNLOAD

SERIAL NUMBER 12117

BEFORE READING THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this excavator that must
be obeyed in order to use the excavator safely. Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of excavators.
Read, understand and follow all precautions and warnings in this manual and on the excavator 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 excavator is used.
Therefore, the safety messages in this manual and on the excavator may not include all possible safety precau-
tions. 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 main-
tenance of the excavator can be hazardous and could result in serious injury or death.
If you sell the excavator, be sure to give this manual to the new owner together with the excavator.
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 excavator may lead to addi-
tional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your excavator 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: Komatsu delivers excavators that comply with all applicable regulations and standards of the country to which it has been shipped.
If the excavator 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 regula-
tions of your country, consult Komatsu or your Komatsu distributor
before operating the excavator.
Always keep the Operation and Maintenance Manual in the stor-
age 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:

Komatsu Hydraulic Mining Excavator PC8000-11 Operation & Maintenance Manual – PDF DOWNLOAD

1 FOREWORD 1-1
11BEFORE READING THIS MANUAL 1-2
12EC DECLARATION OF CONFORMITY 1-3
13PRIVACY POLICY ON EXCAVATORS EQUIPPED WITH EXCAVATOR MONITORING SYSTEMS
FOR THE EEA 1-4
14RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS 1-7
15DIRECTIONS OF THE EXCAVATOR 1-8
16SPECIFICATION AND SERIAL PLATE 1-9
161 PRODUCT IDENTIFICATION NUMBER 1-9
17DIVISION OF THE BINDER 1-10
18DESIGNATED USE OF THE EXCAVATOR 1-11
19DELIVERY OF THE EXCAVATOR 1-12
191 SPARE PARTS 1-12
192 SERVICE 1-12
110EXPLANATION OF ABBREVIATIONS 1-13
2 SAFETY 2-23
21SAFETY INFORMATION 2-24
22OVERVIEW 2-25
221 NORMAL OPERATIONS 2-25
222 REGULAR MAINTENANCE 2-25
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 2-25
224 ADDITIONAL SAFETY PRECAUTIONS 2-25
23SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 2-26
231 SOUND 2-26
232 VIBRATION 2-26
24GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 2-27
241 UNDERSTANDING THE EXCAVATOR 2-27
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 2-27
243 PREPARATIONS FOR SAFE OPERATION 2-27
244 FIRE PREVENTION 2-29
245 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR 2-32
246 BURN PREVENTION 2-33
247 PRECAUTIONS WHEN CLEANING CAB GLASS 2-34
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-34
249 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 2-35
2410 ELECTROMAGNETIC COMPATIBILITY (EMC) 2-35
2411 PRECAUTIONS AT JOBSITE 2-36
2412 STARTING MOTOR 2-42
2413 OPERATION 2-43
25PRECAUTION FOR MAINTENANCE 2-49
251 GENERAL PRECAUTIONS 2-49
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-57
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 2-58
26ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 2-63
261 INSPECTION OF THE HYDRAULIC SYSTEM 2-63
262 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS
2-63
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 2-63
27SPECIAL SAFETY EQUIPMENT 2-64
271 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB 2-65
272 OBJECT HANDLING 2-65
273 LIGHTING 2-65
274 WARNING BEACON 2-65
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 2-65
28SAFETY WARNING SIGNS 2-73
281 LOCATION AND DESCRIPTION OF THE SIGNS 2-74
3 OPERATION 3-93
31FOREWORD 3-94
32CONSTRUCTION OF THE EXCAVATOR 3-95
321 OVERALL VIEW 3-95
322 UNDERCARRIAGE AND SUPERSTRUCTURE 3-96
323 UNDERCARRIAGE TRACK SLIDERS 3-102
324 HYDRAULICALLY OPERATED ACCESS/INGRESS STAIRWAY 3-108
325 EMERGENCY ESCAPE LADDERS 3-112
326 FOLDING LADDER INSIDE OF CARBODY 3-122
327 BOOM ACCESS LADDER AND WALKWAY 3-124
328 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE
(FOPS) 3-128
33OPERATOR’S CAB – CONTROLS 3-138
331 CONTROLS WITH BACKHOE ATTACHMENT 3-138
332 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 3-142
333 OPERATOR’S CONSOLE 3-147
334 INTERFACE PANEL FOR DIAGNOSTICS 3-155
335 CONTROL MODULE FOR AUXILIARY CAB HEATER 3-157
34KOMTRAX (MACHINE) MONITOR 3-158
341 SEQUENCE OF DISPLAYS 3-159
342 OPENING SCREEN 3-159
343 MAIN GAGE SCREENS 1-4 3-160
344 FUEL CONSUMPTION SCREEN 3-167
345 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR 3-167
346 MAIN SCREEN – CHANGE >TIME >SMR >DATE 3-168
347 MAINTENANCE MONITOR 3-168
348 SETTINGS FOR OPERATOR 3-169
349 SERVICE MENU 3-173
3410 AUTOMATIC MESSAGES 3-173
35MODULE TO MONITOR DIESEL EXHAUST FLUID/CATALYTIC REDUCTION (DEF/SCR) 3-178
351 LOCATION ON OPERATOR’S CONSOLE 3-178
352 DISPLAY ON OPERATOR’S CONSOLE 3-179
36CAMERA SYSTEM KOMVISION 3-180
37OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 3-184
371 DIGITAL DISPLAY 3-184
372 LUMINOUS INDICATION 3-186
373 AUXILIARY HEATER FOR OPERATOR’S CAB 3-189
38MACHINERY HOUSE 3-190
381 EMERGENCY ENGINE STOP SWITCHES 3-191
382 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE 3-193
383 CENTRAL CONTROL AND FILTER PANEL 3-195
384 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO 3-197
39ELECTRICAL EQUIPMENT IN CAB BASE 3-198
391 STANDARD COMPONENTS IN CAB BASE 3-199
392 PREHEATING SYSTEM (WHEN EQUIPPED) 3-201
310CHECKS BEFORE STARTING THE ENGINES 3-204
3101 HYDRAULIC SYSTEM – CHECK OIL LEVEL 3-209
311STARTING THE ENGINES 3-210
3111 STARTING PROCEDURE 3-213
3112 COLD WEATHER STARTING AID 3-213
3113 ENGINE WARMUP LOCK ON LOW IDLE 3-215
3114 HYDRAULIC OIL WARM-UP 3-221
312MOVING THE EXCAVATOR 3-223
3121 TRAVEL CONTROL WITH FOOT PEDALS 3-223
3122 TRAVELING INSTRUCTIONS 3-225
3123 UNDERCARRIAGE TRACK SLIDERS 3-228
313SLEWING AND BRAKING THE SUPERSTRUCTURE 3-230
3131 SLEWING THE SUPERSTRUCTURE 3-230
314WORKING WITH THE ATTACHMENT 3-233
3141 COMBINED OPERATION CYCLES 3-235
315WORKING INSTRUCTIONS 3-237
3151 STABILITY OF THE EXCAVATOR 3-237
3152 FURTHER OPERATING PRACTICES 3-239
3153 LOADING TRUCKS 3-243
316PARKING THE EXCAVATOR 3-244
317STOPPING THE ENGINES 3-246
3171 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 3-249
318OPERATION OF THE LUBRICATION SYSTEM 3-250
3181 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE 3-250
3182 SLEW CIRCLE PINION LUBRICATION SYSTEM ”SLS” 3-252
319TRANSFER PUMP FOR HYDRAULIC OIL 3-254
3191 OPERATING THE TRANSFER PUMP 3-255
3192 TRANSFUSION PROCEDURE 3-257
320SERVICE CENTER 3-260
3201 SYSTEMS CONNECTED TO THE SERVICE CENTER 3-261
3202 OPERATING THE HYDRAULIC SERVICE ARM 3-263
3203 SERVICE CENTER WITH MONITOR BOX 3-265
3204 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION
SYSTEMS MOUNTED ON THE POWER HOUSE ROOF 3-271
321FIRE DETECTION AND SUPPRESSION SYSTEM 3-272
3211 DISPLAY MODULE 3-277
3212 INTERFACE CONTROL MODULE 3-279
3213 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT
GAS CARTRIDGES ON POWER HOUSE ROOF 3-281
322WORK ON THE LOADER ATTACHMENT 3-282
3221 OBSERVE THE FOLLOWING INSTRUCTIONS 3-282
323TRANSPORTATION AND LIFTING OF THE EXCAVATOR 3-283
3231 DISASSEMBLING OF THE EXCAVATOR 3-283
3232 TRANSPORTATION AND LIFTING 3-283
324RETRIEVAL PROCEDURE 3-284
3241 GENERAL 3-284
325EXCAVATOR STORAGE 3-285
3251 GENERAL 3-285
3252 PREPARING FOR STORAGE 3-285
3253 ONE MONTH REPETITIVE SERVICE PERIOD 3-285
3254 SIX MONTH REPETITIVE SERVICE PERIOD 3-285
3255 PREPARING FOR OPERATION 3-286
326TROUBLE SHOOTING 3-287
3261 GENERAL 3-287
3262 ENGINE 3-287
3263 HYDRAULIC SYSTEM 3-288
3264 FINAL DRIVES AND SLEW GEAR 3-289
3265 CRAWLER TRACKS 3-289
4 MAINTENANCE 4-291
41FOREWORD 4-292
411 GENERAL RECOMMENDATIONS 4-292
42PRECAUTIONS FOR MAINTENANCE 4-293
43FLUIDS AND LUBRICANTS 4-294
431 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 4-294
432 DIESEL EXHAUST FLUID (DEF) 4-295
433 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 4-298
44FILLING CAPACITIES 4-299
45STANDARD TORQUE LIST 4-301
451 TORQUE FOR FLANGE JOINTS 4-302
452 TORQUES FOR SPECIAL COMPONENTS 4-303
46LUBRICATION AND MAINTENANCE SCHEDULE 4-306
461 INITIAL SERVICING 4-306
462 SERVICING THE CRITICAL BOLT CONNECTIONS 4-307
463 PERIODIC SERVICING INTERVALS 4-307
464 PERIODIC SERVICING SCHEDULE 4-307
465 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF
THE HYDRAULIC SYSTEM 4-314
47SAFETY CRITICAL PARTS 4-316
471 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 4-316
472 INSPECTION OF HOSE LINES 4-317
473 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 4-317
48EXTENDED SERVICE INTERVALS 4-319
481 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM 4-319
482 MAINTENANCE OF THE ENGINE 4-323
483 ENGINE FUEL FILTER LOCATION 4-325
484 VENTING THE AIR FROM THE FUEL FILTERS 4-329
49INITIAL SERVICING 4-330
491 WORKING ATTACHMENT (CLS 1)- INITIAL CHECKS FOR PROPER LUBRICATION 4-330
492 ATTACHMENT (CLS 1)- CHECK GREASE INJECTORS AND GREASE CONNECTIONS 4-331
493 CAR BODY AND RACEWAY OF SLEW RING (CLS 2)- CHECK GREASE INJECTORS
AND GREASE CONNECTIONS 4-332
494 SLEW CIRCLE PINION (SLS)- CHECK GREASE INJECTORS AND GREASE
CONNECTIONS 4-333
495 SLEW CIRCLE TOOTHING LUBRICATION 4-335
496 SLEW CIRCLE – CHECK TORQUE OF BOLT CONNECTIONS 4-336
497 RE-TIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS 4-337
410WHEN NECESSARY 4-340
4101 ENGINE AIR CLEANER MAINTENANCE 4-341
4102 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 4-345
4103 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 4-347
4104 SERVICE THE GREASE FILTERS FOR REFILLABLE GREASE CONTAINERS 4-349
4105 GUIDE WHEELS – REPLACE FLOATING SEALS 4-349
411EVERY 10 OPERATING HOURS OR DAILY 4-350
4111 WALK – AROUND INSPECTION 4-351
4112 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL CHECK 4-355
4113 AIR CLEANER – CLEAN 4-359
4114 EXPANSION TANK OF RADIATORS- CHECK COOLANT LEVEL 4-361
4115 TRACK GROUPS – REMOVE DIRT 4-361
4116 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 4-365
412EVERY 50 OPERATING HOURS OR WEEKLY 4-366
4121 SLEW GEARS 4-367
4122 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 4-369
4123 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 4-371
4124 PUMP DISTRIBUTOR GEARS 4-373
4125 HYDRAULIC ACCESS/INGRESS STAIRWAY – CHECK SAFETY SENSOR 4-375
4126 MAIN HYDRAULIC OIL & PTO COOLER- INSPECT AND CLEAN 4-377
413EVERY 250 OPERATING HOURS OR MONTHLY 4-378
4131 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 4-379
4132 SIGNAL HORN COMPRESSOR – LUBRICATE 4-381
4133 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP
STATION 4-383
4134 CABIN AIR CLEANER – INSPECT 4-385
4135 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL 4-387
4136 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 4-389
4137 ADDITIONAL AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT
LEVEL 4-391
4138 CABIN HEATER FILTER – INSPECT 4-393
414EVERY 500 OPERATING HOURS OR QUARTELY 4-394
4141 BATTERIES – CHECK FLUID LEVEL 4-395
4142 CYLINDER ROD PROTECTION (IF EQUIPPED), INSPECT 4-399
4143 DRIVE SHAFT HOUSINGS ON PTO GEARS – CHECK OIL LEVEL 4-401
4144 FUEL TANK – DRAIN CONDENSATION 4-403
4145 CRAWLER TRACK – INSPECTION 4-405
4146 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK
FOR CORRECT CONNECTION 4-411
4147 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 4-413
4148 EMERGENCY LOWERING OF ACCESS/INGRESS STAIRWAY – TEST
FUNCTIONALITY 4-415
415EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 4-416
4151 CRITICAL BOLT CONNECTIONS 4-417
4152 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 4-423
4153 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST
FUNCTIONALITY 4-425
4154 ELECTRICAL EQUIPMENT – MAINTENANCE 4-427
4155 HYDRAULIC SYSTEM – FILTER SERVICE 4-429
4156 HIGH PRESSURE SCREENS 4-431
4157 PTO’S (PUMP DISTRIBUTOR GEARS), SLEW GEARS AND TRAVEL GEARS – OIL
SAMPLE ANALYSIS 4-441
4158 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 4-443
4159 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 4-445
41510 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 4-447
41511 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 4-449
41512 ALL OTHER HINGES AND AREAS TO LUBRICATE 4-451
41513 CABIN AIR CLEANER – REPLACE FILTER 4-453
41514 CRITICAL BOLT CONNECTIONS – VISUAL CHECK 4-455
416EVERY 2000 OPERATING HOURS OR YEARLY 4-456
4161 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND
PULSATION DAMPER 4-457
4162 EMERGENCY ESCAPE LADDERS – INSPECTION 4-467
4163 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 4-473
4164 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 4-475
417EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4-476
4171 SLEW GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 4-477
4172 TRAVEL GEARS, CHANGE OIL IN GEAR BOXES, BRAKE HOUSINGS AND MOTOR
ADAPTER HOUSINGS 4-485
4173 TRAVEL GEARS, TYPE 631053, CHANGE OIL IN GEAR BOXES AND MOTOR
ADAPTER HOUSINGS 4-489
4174 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 4-493
4175 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD 4-495
4176 CABIN HEATER FILTER – REPLACE FILTER ELEMENT 4-529
4177 DEF TANK – DRAIN 4-531
4178 DEF TANK – REPLACE SUCTION AND VENT FILTERS 4-533
4179 OIL SEPARATOR ELEMENT – REPLACE (IF SO EQUIPPED) 4-537
41710 CHECKING THE STEEL STRUCTURES 4-539
418EVERY 6000 HOURS HOWEVER AT LEAST ONCE A YEAR 4-540
4181 AUTOMATIC LUBRICATION SYSTEMS – REPLACE PUMP OUTLET GREASE
’ FILTERS 4-541
4182 HIGH PRESSURE FILTERS – REPLACE 4-543
419FIRE PREVENTION 4-544
4191 PRECAUTIONS 4-545
420WELD REPAIRS 4-546
4201 GENERAL PROTECTIVE MEASURES 4-547
4202 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 4-547
4203 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
UNDERCARRIAGE 4-549
4204 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER
ATTACHMENT 4-551
4205 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
SUPERSTRUCTURE 4-553
4206 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 4-557

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