Komatsu Mining Shovel PC8000-6 service & repair manual

Description Komatsu Mining Shovel PC8000-6 service & repair manual

Komatsu Mining Shovel PC8000-6 pdf workshop service manual + operation & maintenance manual

Serial numbers:
12040 and up
12071 and up

Technical data, maintenance, testing, specifications, troubleshooting, diagrams, schematics, adjusting, assembly, disassembly instructions and other information

MANUAL CONTENT:
FOREWORD
BEFORE READING THIS MANUAL
DIRECTIONS OF THE MACHINE
SPECIFICATION AND SERIAL PLATE
PRODUCT IDENTIFICATION NUMBER
DIVISION OF THE BINDER
DESIGNATED USE OF THE SHOVEL
DELIVERY OF THE SHOVEL
SPARE PARTS
SERVICE
EXPLANATION OF ABBREVIATIONS
CONTENTS

SAFETY
SAFETY INFORMATION
OVERVIEW
NORMAL OPERATIONS
REGULAR MAINTENANCE
TROUBLESHOOTING, ADJUSTMENTS AND REPAIR
ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR
SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
UNDERSTANDING THE MACHINE
PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR
PREPARATIONS FOR SAFE OPERATION
FIRE PREVENTION
PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
BURN PREVENTION
PRECAUTIONS WHEN CLEANING CAB GLASS
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
PRECAUTIONS AT JOBSITE
STARTING ENGINE
OPERATION
PRECAUTION FOR MAINTENANCE
GENERAL PRECAUTIONS
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
PRECAUTIONS WITH HIGH PRESSURE FLUID
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
INSPECTION OF THE HYDRAULIC SYSTEM
TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS
AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR
SPECIAL SAFETY EQUIPMENT
FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB
OBJECT HANDLING
LIGHTING
WARNING BEACON
SAFETY HARNESS IN CONFORMITY WITH EN 361
SAFETY WARNING SIGNS
LOCATION AND DESCRIPTION OF THE SIGNS

OPERATION
FOREWORD
CONSTRUCTION OF THE SHOVEL.
OVERALL VIEW WITH BACKHOE ATTACHMENT
OVERALL VIEW WITH BOTTOM DUMP BUCKET ATTACHMENT
SUPERSTRUCTURE
UNDERCARRIAGE
HYDRAULICALLY OPERATED ACCESS LADDER
EMERGENCY ESCAPE LADDER AT THE OPERATOR’S CAB PLATFORM
EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR
EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE
FOLDING LADDER INSIDE OF CARBODY
BOOM ACCESS LADDER AND WALKWAY
EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
OPERATOR’S CAB - CONTROLS
HYDRAULIC CONTROL SYSTEM
SAFETY CIRCUIT FOR CONTROLS
OPERATOR’S CONSOLE
INTERFACE PANEL FOR DIAGNOSTICS
ELECTRONIC MONITORING AND CONTROL SYSTEM ECS
INTRODUCTION
OPERATING THE ELECTRONIC MONITORING SYSTEM
AUTOMATIC DISPLAY OF MESSAGES
MENU CONTROL, SERVICE FUNCTIONS AND INPUTS/OUTPUTS
FAULT AND INFORMATION MESSAGE LIST
CAMERA SYSTEM WITH MONITORS (SPECIAL EQUIPMENT)
LOCATION OF MONITORS AND CONTROL UNITS
OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING
MACHINERY HOUSE
EMERGENCY MOTOR SHUTDOWN SWITCHES
BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE
CENTRAL CONTROL AND FILTER PANEL
CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO
MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE
COMPONENTS IN THE MEDIUM VOLTAGE SWITCH CABINET
SWITCH BOARD (X2) IN CAB BASE
MONITOR AND CONTROL PANEL
HIGH VOLTAGE SWITCH CABINET
CHECKS BEFORE STARTING THE MOTORS
STARTING THE MAIN DRIVE MOTORS
MOVING THE SHOVEL
TRAVEL CONTROL WITH FOOT PEDALS
TRAVELLING INSTRUCTIONS
SLEWING AND BRAKING THE SUPERSTRUCTURE
SLEWING THE SUPERSTRUCTURE
WORKING WITH THE ATTACHMENT
MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM
MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM
DROP BALL OPERATION
COMBINED OPERATION CYCLES
WORKING INSTRUCTIONS
STABILITY OF THE SHOVEL
SHOVEL OPERATION
PARKING THE SHOVEL
STOPPING THE MAIN DRIVE MOTORS
RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM
OPERATION OF THE LUBRICATION SYSTEM
CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE
SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”
FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM (SPECIAL EQUIPMENT))
CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS
PERSONNEL SAFETY
REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB
ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM
IN CASE OF FIRE
TRANSFER PUMP FOR HYDRAULIC OIL
OPERATING THE TRANSFER PUMP
TRANSFUSION PROCEDURE
CENTRAL REFILLING SYSTEM
SYSTEMS CONNECTED TO THE REFILLING SYSTEM
RECEIVER PANEL AND MONITOR BOX
REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOUSE ROOF
FOLDING PEDESTAL ON THE OPERATOR’S CAB
FOLDING PEDESTALS IN FRONT OF THE OPERATOR’S CAB
SERVICE CRANE (SPECIAL EQUIPMENT)
OPERATING THE CRANE
CABLE DRUM (SPECIAL EQUIPMENT)
OPERATION OF THE CABLE DRUM
TRAVELLING INSTRUCTIONS
CABLE GUIDE (IF SO EQUIPPED)
LIFTING DEVICE FOR THE POWER CABLE
WORK ON THE LOADER ATTACHMENT
TRANSPORTATION AND LIFTING OF THE SHOVEL
DISASSEMBLING OF THE SHOVEL
TRANSPORTATION AND LIFTING
RETRIEVAL PROCEDURE
SHOVEL STORAGE
PREPARING FOR STORAGE
ONE MONTH REPETITIVE SERVICE PERIOD
SIX MONTH REPETITIVE SERVICE PERIOD
PREPARING FOR OPERATION
TROUBLE SHOOTING
GENERAL
MAIN DRIVE ELECTRIC MOTOR
HYDRAULIC SYSTEM
FINAL DRIVES AND SWING GEAR
CRAWLER TRACKS

MAINTENANCE
FOREWORD
SAFETY PRECAUTIONS FOR MAINTENANCE
FLUIDS AND LUBRICANTS
LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES
FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES
MAIN DRIVE ELECTRIC MOTORS – BEARING LUBRICATION
FILLING CAPACITIES
STANDARD TORQUE LIST
LUBRICATION AND MAINTENANCE SCHEDULE
INITIAL SERVICING
PERIODIC SERVICING INTERVALS
PERIODIC SERVICING SCHEDULE
MAINTENANCE OF THE MAIN DRIVE ELECTRIC MOTORS
REPLACEMENT OF HYDRAULIC HOSE LINES
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
WHEN NECESSARY
SWING CIRCLE TOOTHING LUBRICATION
AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS
SERVICE THE GREASE FILTERS FOR REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM
TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS
EVERY 10 OPERATING HOURS OR DAILY
WALK - AROUND INSPECTION
CLEANING THE TRACK GROUPS
EVERY 50 OPERATING HOURS OR WEEKLY
SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVEL
TRAVEL GEARS MADE BY L&S, CHECK OIL LEVEL IN GEAR BOXES, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS
TRAVEL GEARS MADE BY ZOLLERN, CHECK OIL LEVEL IN GEAR BOXES AND MOTOR ADAPTER HOUSINGS
FINAL DRIVE HOUSINGS - CHECK OIL LEVEL
PUMP DISTRIBUTOR GEARS - CHECK OIL LEVEL
HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR
HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY
PTO GEAR OIL COOLERS - INSPECT AND CLEAN IF NECESSARY
EVERY 250 OPERATING HOURS OR MONTHLY
UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE
HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
SIGNAL HORN COMPRESSOR - LUBRICATE
AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER
CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT
WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL
AIR CONDITIONING FOR OPERATOR’S CAB - VERSION "KYSOR"
AIR CONDITIONING FOR ELECTRICAL SWITCH CABINETS - CHECK REFRIGERANT LEVEL
EVERY 500 OPERATING HOURS OR MONTHLY
BATTERIES - CHECK FLUID LEVEL
DRIVE SHAFT HOUSINGS ON PTO GEARS - CHECK OIL LEVEL
CRAWLER TRACK - INSPECTION
GROUND CABLE OF OPERATOR’S CAB - CHECK FOR CORRECT CONNECTION
EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH
HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD
HYDRAULIC SYSTEM - FILTER SERVICE
PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS
SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE
HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS
HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES
MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES
SLIP RING UNIT - LUBRICATE
EVERY 2000 OPERATING HOURS OR YEARLY
HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
EMERGENCY ESCAPE LADDERS - INSPECTION
EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL
TRAVEL GEARS MADE BY L&S, CHANGE OIL IN GEAR BOXES, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS
TRAVEL GEARS MADE BY ZOLLERN, CHANGE OIL IN GEAR BOXES AND MOTOR ADAPTER HOUSINGS
FINAL DRIVE HOUSINGS - CHANGE OIL
PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL
FIRE PREVENTION
PRECAUTIONS
WELD REPAIRS
GENERAL PROTECTIVE MEASURES
WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR
PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE

Specification

Structure, Function
Introduction
Specifications
Main assembly groups
Drive
Hydraulic oil tank
Hydraulic oil cooling
Controlling
Components
Main hydraulic pumps and pump regulation
Operating hydraulics
Hydraulic track tensioning system
Access ladder, hydraulically operated
Central refilling system (service arm)
Hints for reading the hydraulic diagram
Hints for reading the electric wiring diagram
KOMTRAX Plus
Lubrication system

Troubleshooting
Introduction & General Information for Troubleshooting
Overview
General Precautions
Preparations For Work
Precautions During Work
Precautions When Carrying Out Any Operation
Fundamental Requirements for Troubleshooting
Points To Remember When Trouble- shooting
Sequence Of Events In Troubleshooting
Checks Before Troubleshooting
Handling Of Electric Equipment And Hydraulic Components
General working procedures
Cylinder bypass test
Information about MTC & Nodes
Basics about "How to crimp"
Cable Shielding
KOMTRAX Plus vs. VHMS
Mounting Locations and Connector Types
Standard Value Table for Electrical Components
References for Troubleshooting (CAN Bus & Node Outputs)
Tables for Testing and Troubleshooting
Troubleshooting by Trouble Code
Troubleshooting by Symptoms

Assembly & Disassembly
Introduction
Contents of the binder
Foreword

Safety and standards
Safety instructions
Torque charts according to DIN
Blind plugs
Conversion table
Tools
Explanation of Abbreviations

Superstructure
Superstructure overview
Special preparatory work
Diesel engine
Radiators (engine coolant)
Torsion type coupling
PTO
Hydraulics
Slew system
Lubrication system
Operator’s cab
Cab base
Access ladder
Counterweight
Superstructure lifting
Fuel tank

Undercarriage
Travel system
Car body

Attachment
Face Shovel (FSA)
Metering valves (grease injectors) at the attachment
Cylinder bypass test

Service information
Fluids and lubricants
Filling capacities
Work Instructions
Used special tools (overview)