Komatsu HYDRAULIC MINING SHOVEL PC4000-11 Operation & Maintenance Manual(08273-xD-GB-2) – PDF

Komatsu HYDRAULIC MINING SHOVEL PC4000-11 Operation & Maintenance Manual(08273-xD-GB-2) – PDF DOWNLOAD

DESCRIPTION:

SERIAL NUMBER 08273

Komatsu HYDRAULIC MINING SHOVEL PC4000-11 Operation & Maintenance Manual(08273-xD-GB-2) – PDF DOWNLOAD

1.1BEFORE 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 fundamental 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:
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:

Komatsu HYDRAULIC MINING SHOVEL PC4000-11 Operation & Maintenance Manual(08273-xD-GB-2) – PDF DOWNLOAD

1 FOREWORD 1-1
11 BEFORE READING THIS MANUAL 1-2
12 EC DECLARATION OF CONFORMITY 1-3
13 PRIVACY POLICY ON MACHINES EQUIPPED WITH MACHINE MONITORING SYSTEMS
FOR THE EEA 1-4
14 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS 1-7
15 DIRECTIONS OF THE MACHINE 1-8
16 SPECIFICATION AND SERIAL PLATE 1-9
161 PRODUCT IDENTIFICATION NUMBER 1-9
17 DIVISION OF THE BINDER 1-10
18 DESIGNATED USE OF THE SHOVEL 1-11
19 DELIVERY OF THE SHOVEL 1-12
191 SPARE PARTS 1-12
192 SERVICE 1-12
110 EXPLANATION OF ABBREVIATIONS 1-13
2 SAFETY 2-21
21 SAFETY INFORMATION 2-22
22 OVERVIEW 2-23
221 NORMAL OPERATIONS 2-23
222 REGULAR MAINTENANCE 2-23
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 2-23
224 ADDITIONAL SAFETY PRECAUTIONS 2-23
23 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 2-24
231 SOUND 2-24
232 VIBRATION 2-24
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 2-25
241 UNDERSTANDING THE MACHINE 2-25
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 2-25
243 PREPARATIONS FOR SAFE OPERATION 2-25
244 FIRE PREVENTION 2-27
245 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 2-30
246 BURN PREVENTION 2-31
247 PRECAUTIONS WHEN CLEANING CAB GLASS 2-32
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-32
249 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 2-33
2410 ELECTROMAGNETIC COMPATIBILITY (EMC) 2-33
2411 PRECAUTIONS AT JOBSITE 2-34
2412 STARTING MOTOR 2-40
2413 OPERATION 2-41
25 PRECAUTION FOR MAINTENANCE 2-47
251 GENERAL PRECAUTIONS 2-47
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-55
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 2-56
26 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 2-61
261 INSPECTION OF THE HYDRAULIC SYSTEM 2-61
262 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING
ADJUSTMENTS 2-61
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 2-61
27 SPECIAL SAFETY EQUIPMENT 2-62
271 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB 2-63
272 OBJECT HANDLING 2-63
273 LIGHTING 2-63
274 WARNING BEACON 2-63
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 2-63
28 SAFETY WARNING SIGNS 3-71
281 LOCATION AND DESCRIPTION OF THE SIGNS 3-72
3 OPERATION 3-1
31 FOREWORD 3-2
311 CONNECTION OF CUSTOMER ELECTRICAL INSTALLATIONS TO THE EXCAVATOR 3-2
32 CONSTRUCTION OF THE SHOVEL 3-3
321 OVERALL VIEW 3-3
322 SUPERSTRUCTURE 3-4
323 HYDRAULICALLY OPERATED ACCESS LADDER 3-14
324 EMERGENCY ESCAPE LADDERS 3-18
325 BOOM ACCESS LADDER AND WALKWAY 3-26
326 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR
WARNING SYSTEM 3-28
327 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE
STRUCTURE (FOPS) 3-30
328 UNDERCARRIAGE 3-40
329 WORKING ATTACHMENT 3-41
3210 DIESEL ENGINE TYPE SDA 16V160E-2 3-43
3211 ENGINE OIL MANAGEMENT SYSTEM 3-46
33 OPERATOR’S CAB – CONTROLS 3-50
331 CONTROLS WITH BACKHOE ATTACHMENT 3-50
332 SAFETY CIRCUIT FOR CONTROLS 3-51
333 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT 3-54
334 SAFETY CIRCUIT FOR CONTROLS 3-55
335 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK 3-57
336 OPERATOR’S CONSOLE 3-59
337 INTERFACE PANEL FOR DIAGNOSTICS 3-65
338 CONTROL MODULE FOR AUXILIARY CAB HEATER 3-67
34 VEHICLE HEALTH MONITORING SYSTEM KOMTRAX PLUS – HEALTH MONITOR 3-68
341 SEQUENCE OF DISPLAYS 3-69
342 OPENING SCREEN 3-69
343 FUNCTION CHECKING SCREEN 3-70
344 MAIN GAUGE SCREENS 1 TO 3 3-71
345 ECO GUIDANCE 3-75
346 MAINTENANCE 3-79
347 MONITOR SETTING 3-79
348 AUTOMATIC MESSAGES 3-83
35 CAMERA SYSTEMS – SPECIAL EQUIPMENT 3-86
351 CAMERA SYSTEM – TYPE 1 3-86
352 CAMERA SYSTEM – TYPE 2 (KOMVISION) 3-93
36 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 3-98
361 DIGITAL DISPLAY 3-98
362 AUXILIARY HEATER FOR OPERATOR’S CAB 3-103
37 MACHINERY HOUSE 3-104
371 EMERGENCY ENGINE SHUTDOWN SWITCHES 3-105
372 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES 3-107
373 CENTRAL CONTROL AND FILTER PANEL 3-109
38 ELECTRICAL EQUIPMENT IN CAB BASE 3-110
381 STANDARD COMPONENTS IN CAB BASE 3-111
382 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE (WHEN
INSTALLED) 3-115
39 CHECKS BEFORE STARTING THE ENGINE 3-122
391 OPERATOR’S SEAT ADJUSTMENT 3-127
310 STARTING THE ENGINE 3-128
3101 STARTING PROCEDURE 3-131
3102 ENGINE WARM-UP 3-141
3103 HYDRAULIC OIL WARM-UP 3-141
311 MOVING THE SHOVEL 3-143
3111 TRAVEL CONTROL WITH FOOT PEDALS 3-143
3112 TRAVELING INSTRUCTIONS 3-145
312 SLEWING AND BRAKING THE SUPERSTRUCTURE 3-148
3121 SLEWING THE SUPERSTRUCTURE 3-148
3122 BRAKING THE SUPERSTRUCTURE 3-149
3123 SLEW PARKING BRAKE 3-149
313 WORKING WITH THE ATTACHMENT 3-151
3131 COMBINED OPERATION CYCLES 3-153
314 WORKING INSTRUCTIONS 3-155
3141 STABILITY OF THE SHOVEL 3-155
3142 FURTHER OPERATING PRACTICES 3-157
3143 LOADING TRUCKS 3-161
315 PARKING THE SHOVEL 3-162
316 STOPPING THE ENGINE 3-164
3161 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 3-167
317 OPERATION OF THE LUBRICATION SYSTEM 3-168
3171 CENTRAL LUBRICATION SYSTEM ”CLS” 3-168
3172 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 3-169
318 FIRE DETECTION AND SUPPRESSION SYSTEMS 3-174
3181 DISPLAY MODULE 3-179
3182 INTERFACE CONTROL MODULE 3-181
3183 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS
CARTRIDGES ON MACHINERY HOUSE ROOF 3-183
319 TRANSFER PUMP FOR HYDRAULIC OIL 3-184
3191 OPERATING THE TRANSFER PUMP 3-185
3192 FUNCTIONS OF THE TRANSFER PUMP 3-187
320 CENTRAL REFILLING SYSTEM 3-190
3201 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 3-191
3202 OPERATING THE HYDRAULIC SERVICE ARM 3-193
3203 RECEIVER PANEL WITH MONITOR BOX 3-195
3204 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM
AND SWING CIRCLE PINION LUBRICATION SYSTEM 3-199
321 WORK ON THE LOADER ATTACHMENT 3-202
322 TRANSPORTATION AND LIFTING OF THE SHOVEL 3-203
3221 DISASSEMBLING OF THE SHOVEL 3-203
3222 TRANSPORTATION AND LIFTING 3-203
323 RETRIEVAL PROCEDURE 3-204
324 SHOVEL STORAGE 3-205
3241 PREPARING FOR STORAGE 3-205
3242 ONE MONTH REPETITIVE SERVICE PERIOD 3-205
3243 SIX MONTH REPETITIVE SERVICE PERIOD 3-205
3244 PREPARING FOR OPERATION 3-206
325 TROUBLE SHOOTING 3-207
3251 ENGINE 3-207
3252 HYDRAULIC SYSTEM 3-208
3253 FINAL DRIVES AND SWING MACHINERY 3-209
3254 CRAWLER TRACKS 3-209
4 MAINTENANCE 4-1
41 FOREWORD 4-2
411 DEFINITIONS 4-2
412 GENERAL RECOMMENDATIONS 4-2
42 SAFETY 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
44 FILLING CAPACITIES 4-10
45 STANDARD TORQUE LIST 4-11
451 TORQUE FOR FLANGE JOINTS 4-12
452 TORQUES FOR SPECIAL COMPONENTS 4-13
46 LUBRICATION AND MAINTENANCE SCHEDULE 4-15
461 INITIAL SERVICING 4-15
462 SERVICING THE CRITICAL BOLT CONNECTIONS 4-16
463 PERIODIC SERVICING INTERVALS 4-16
464 PERIODIC SERVICING SCHEDULE 4-17
465 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS
OF THE HYDRAULIC SYSTEM 4-22
47 SAFETY CRITICAL PARTS 4-24
471 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 4-24
472 INSPECTION OF HOSE LINES 4-24
473 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 4-24
474 VENTING THE AIR FROM THE FUEL FILTERS 4-27
48 INITIAL SERVICING 4-28
481 INITIAL CHECKS FOR PROPER LUBRICATION 4-29
482 SWING CIRCLE – CHECK GREASE INJECTORS 4-31
483 SWING CIRCLE TOOTHING LUBRICATION 4-33
484 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS 4-35
485 SWING CIRCLE – CHECK TORQUE OF BOLT CONNECTIONS 4-37
486 RETIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS 4-39
49 EXTENDED SERVICE INTERVALS 4-45
491 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM 4-45
492 MAINTENANCE OF THE ENGINE 4-49
410 ENGINE FUEL FILTER LOCATION 4-50
4101 FUEL LINE CONNECTIONS ON THE ENGINE 4-51
411 WHEN NECESSARY 4-52
4111 ENGINE AIR CLEANER SERVICE 4-53
4112 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS 4-57
4113 TRACK ROLLERS – REPLACE FLOATING SEALS 4-61
4114 GUIDE WHEELS – REPLACE FLOATING SEALS 4-61
412 EVERY 10 OPERATING HOURS OR DAILY 4-62
4121 WALK-AROUND INSPECTION 4-63
4122 AIR CLEANER – CLEAN PRE-CLEANER 4-67
4123 RADIATOR – CHECK COOLANT LEVEL 4-69
4124 TRACK GROUPS – CLEAN 4-69
4125 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER 4-71
4126 BOOM – CHECK LADDER AND WALKWAY 4-73
4127 ELECTRICAL EQUIPMENT – CHECK VISUALLY 4-73
4128 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 4-75
413 EVERY 50 OPERATING HOURS OR WEEKLY 4-76
4131 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 4-77
4132 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL 4-83
4133 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL 4-89
4134 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 4-91
4135 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 4-95
414 EVERY 250 OPERATING HOURS OR MONTHLY 4-96
4141 AIR CONDITIONING 4-97
4142 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 4-97
4143 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 4-101
4144 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 4-103
4145 SIGNAL HORN COMPRESSOR – LUBRICATE 4-103
4146 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE 4-103
4147 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE 4-103
4148 AUTOMATIC LUBRICATION SYSTEMS – CLEAN BREATHER FILTER 4-105
4149 CABIN AIR FILTERS – INSPECT 4-107
41410 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 4-109
41411 CABIN HEATER FILTER – INSPECT 4-111
415 EVERY 500 OPERATING HOURS OR MONTHLY 4-112
4151 BATTERIES – CHECK FLUID LEVEL 4-113
4152 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS
– CHECK OIL LEVEL 4-115
4153 FUEL TANK – DRAIN CONDENSATION 4-117
4154 CRAWLER TRACK – INSPECTION 4-119
4155 GROUND CABLES OF ENGINE, PRELUBRICATION PUMP AND ALTERNATOR
– CHECK FOR CORRECT CONNECTION 4-125
4156 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION 4-127
4157 EMERGENCY LOWERING OF ACCESS LADDER – TEST FUNCTIONALITY 4-131
4158 EMERGENCY ESCAPE LADDERS 4-133
4159 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 4-135
416 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS 4-136
4161 CRITICAL BOLT CONNECTIONS 4-137
4162 HYDRAULIC SYSTEM – FILTER SERVICE 4-143
4163 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS – OIL
SAMPLE ANALYSIS 4-157
4164 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 4-159
4165 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS 4-161
4166 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 4-163
4167 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 4-165
4168 ALL OTHER HINGES AND AREAS TO LUBRICATE 4-167
4169 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 4-169
41610 ENGINE SHUTDOWN PULL CHAINS – TEST FUNCTIONALITY 4-171
41611 ELECTRICAL EQUIPMENT – MAINTENANCE 4-173
41612 CABIN AIR FILTER – REPLACE PRIMARY FILTER 4-175
417 EVERY 2000 OPERATING HOURS OR YEARLY 4-176
4171 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND
PULSATION DAMPER 4-177
4172 FILLING THE HYDRAULIC SYSTEM 4-187
4173 BLEEDING THE HYDRAULIC SYSTEM 4-189
4174 GEAR PUMP FOR PTO GEAR LUBRICATION 4-191
4175 EMERGENCY ESCAPE LADDERS – INSPECTION 4-193
4176 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 4-195
4177 HYDRAULIC HOSES – CHECK CONDITION 4-197
4178 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 4-199
418 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 4-200
4181 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 4-201
4182 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 4-221
4183 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD 4-223
4184 CABIN HEATER FILTER – REPLACE FILTER ELEMENT 4-257
4185 OIL SEPARATOR ELEMENT – REPLACE (IF SO EQUIPPED) 4-259
419 EVERY 6000 OPERATING HOURS OR AT LEAST ONCE A YEAR 4-260
4191 AUTOMATIC LUBRICATION SYSTEMS – REPLACE GREASE FILTERS 4-261
420 FIRE PREVENTION 4-262
4201 PRECAUTIONS 4-263
421 WELD REPAIRS 4-264
4211 GENERAL PROTECTIVE MEASURES 4-265
4212 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
UNDERCARRIAGE 4-267
4213 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER
ATTACHMENT 4-269
4214 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
SUPERSTRUCTURE 4-271
4215 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 4-272

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