Komatsu Mining Shovel PC8000E-6 service & repair manual

Description Komatsu Mining Shovel PC8000E-6 service & repair manual

Komatsu Mining Shovel PC8000E-6 pdf workshop service repair manual

Serial numbers:
12037 and up
12089 - 12093
12089 and up

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

MANUAL CONTENT:
INTRODUCTION
CONTENTS OF THE BINDER
RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION
AND MAINTENANCE OF HYDRAULIC MINING SHOVELS
EXPLANATION OF ABBREVIATIONS
DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL

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
ENSURING SAFE OPERATION
PREPARATIONS FOR SAFE OPERATION
PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT
INSPECTING THE MACHINE
WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT
KEEP MACHINE CLEAN
PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT
IF A PROBLEM IS FOUND
FIRE PREVENTION
PRECAUTIONS TO PREVENT FIRE
ACTION IF FIRE OCCURS
EMERGENCY EXIT FROM OPERATOR’S CAB
PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE
NO JUMPING ON OR OFF THE MACHINE
NO PEOPLE ON THE ATTACHMENT
WORKING IN HIGH PLACES
LEAVING OPERATOR’S SEAT WITH LOCK
LEAVING THE MACHINE
BURN PREVENTION
HOT COOLANT
HOT OIL
PRECAUTIONS WHEN CLEANING CAB GLASS
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
UNAUTHORIZED MODIFICATION
PRECAUTIONS AT JOBSITE
VISIBILITY FROM OPERATOR’S SEAT
CAMERA SYSTEM WITH MONITORS
ENSURE GOOD VISIBILITY
CHECKING SIGNS AND SIGNALMAN’S SIGNALS
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES
WORKING ON LOOSE GROUND
GAS, DUST, STEAM AND SMOKE
VENTILATION OF ENCLOSED AREAS
STARTING ENGINE
WARNING TAG
CHECKS BEFORE STARTING ENGINE
PRECAUTION WHEN STARTING ENGINE
PRECAUTION IN COLD AREAS
OPERATION
CHECKS BEFORE OPERATION
PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE
PRECAUTIONS WHEN TRAVELLING
TRAVELLING ON SLOPES
OPERATIONS ON SLOPES
PROHIBITED OPERATIONS
TRAVELLING ON FROZEN OR SNOW COVERED SURFACES
PARKING THE MACHINE
TRANSPORTATION
SPECIFICATIONS
LIFTING GEARS
SAFETY HINTS FOR SLING ACCESSORY
STANDARD TIGHTENING TORQUE CHART
CONVERSION TABLE
BLIND PLUGS
CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH
PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353

MAIN ASSEMBLY GROUPS
SUPERSTRUCTURE
MACHINE HOUSE
HYDRAULIC OIL TANK
HYDRAULIC OIL COOLER
HIGH VOLTAGE SWITCH CABINET
CAB SUPPORT
X2 - LOW VOLTAGE SWITCH BOARD (LOCATION 12)
EXTRA LOW VOLTAGE SWITCH BOARD (LOCATION 11)
SLIP RING UNIT
OPERATOR’S CAB
CONTROL BLOCKS
SWING MACHINERY
SWING MACHINERY L&S
SWING MACHINERY SIEBENHAAR
UNDERCARRIAGE
ATTACHMENTS
FRONT SHOVEL ATTACHMENT (FSA)
BACKHOE ATTACHMENT (BHA)

DRIVE
ELECTRIC DRIVE - SAFETY AND OPERATION INSTRUCTION DOCUMENTS
PRIME DRIVE ASSEMBLY
ELECTRIC MOTORS
LOCATION OF ATTACHING PARTS
MOTOR TYPE PLATE
TYPE PLATE FOR THE MOTOR BEARINGS
MOTOR BEARINGS & GREASE EQUIPMENT
MONITORING OF THE MOTOR BEARING TEMPERATURE
MONITORING OF THE MOTOR WINDING TEMPERATURE
JUNCTION BOX FOR THE MOTOR MONITORING DEVICE
CHECKING OF THE BEARING CONDITION

HYDRAULIC OIL TANK
GENERAL LAYOUT
LOCATION OF THE ELECTRIC EQUIPMENT
SUCTION OIL TANK WITH STRAINERS
RETURN OIL COLLECTOR PIPE WITH STRAINER
BACK PRESSURE VALVE
TRANSFER PUMP
RETURN AND LEAK OIL FILTER
BREATHER FILTER

HYDRAULIC OIL COOLING
OVERALL VIEW OF THE HYDRAULIC OIL COOLING
FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT
STANDARD HYDRAULIC OIL COOLING CIRCUIT
ADDITIONAL OIL COOLING CIRCUIT
ADJUSTMENT OF THE BACK PRESSURE VALVE
FAN DRIVE - STANDARD OIL COOLER
TWO STAGE COOLER FAN DRIVE RPM CONTROL
FIXED DISPLACEMENT PUMP WITH VARIABLE SETTING
PRESSURE RELIEF VALVES
SOLENOID VALVES
ADJUSTMENT OF THE COOLER FAN DRIVE SPEED
MAXIMUM SPEED
MEDIUM SPEED
FAN DRIVE - ADDITIONAL OIL COOLER
FUNCTION OF THE ADDITIONAL COOLER FAN RPM CONTROL
ADJUSTMENT OF THE ADDITIONAL COOLER FAN DRIVE SPEED

CONTROLLING
GENERAL LAYOUT
CONTROL AND FILTER PANELS – LOCATION OF COMPONENTS
MAIN VALVE CARTRIDGE BLOCK
CONTROL AND FILTER PANELS MOUNTED ON THE PTOS
PILOT PRESSURE SUPPLY AND ADJUSTMENTS
PILOT PRESSURE CIRCUIT
CHECKS AND ADJUSTMENTS OF PILOT PRESSURE
REMOTE CONTROL VALVES ARRANGEMENT
FUNCTION OF THE ELECTRO-HYDRAULIC CONTROL SYSTEM
HAND LEVER (JOYSTICK) CONTROL
FOOT PEDAL CONTROL
PROPORTIONAL AMPLIFIER MODULE
RAMP TIME MODULE
ADJUSTMENT OF AMPLIFIER MODULES
GENERAL
ADJUSTING THE AMPLIFIER MODULE, TYPE A
ADJUSTING THE AMPLIFIER MODULE, TYPE B
ADJUSTING THE RAMP TIME MODULE

COMPONENTS
MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTERS (FSA)
DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS
AND ANTI-CAVITATION VALVES
RESTRICTOR BLOCK WITH SECONDARY RELIEF VALVE
ANTI-CAVITATION VALVE (ACV) BLOCK
ACV BLOCK ON CONTROL BLOCKS
REMOTE CONTROL VALVES
4/3 DIRECTIONAL SOLENOID VALVES
PROPORTIONAL SOLENOID VALVES
HIGH-PRESSURE FILTER (SCREEN)
CONTROL BLOCKS AND VALVES
TRAVEL BRAKE VALVE
PRESSURE REDUCING VALVE
4/2 DIRECTIONAL VALVES
PRESSURE DOUBLE STAGE VALVE
HYDRAULIC CYLINDER

MAIN HYDRAULIC PUMPS AND PUMP REGULATION
GENERAL
LAYOUT
PUMP REGULATION SYSTEM ("OPEN SENSING SYSTEM")
PUMP REGULATION SYSTEM — VALVE FUNCTION
MAIN PUMPS
PUMP BEARING FLUSHING / LUBRICATION
OPERATING PRINCIPLE
CHECKS / ADJUSTMENTS
QMAX AND QMIN ADJUSTMENT BOLTS
ELECTRONIC PUMP REGULATION SYSTEM
ELECTRONIC LOAD LIMITING CONTROL – GENERAL
MICROCONTROLLER RC4-4
SIGNAL RECTIFIER MODULE
CHECKS AND ADJUSTMENTS
HYDRAULIC CONSTANT REGULATION SYSTEM (EMERGENCY MODE)
GENERAL
PUMP REGULATION SYSTEM, CHECKS AND ADJUSTMENTS
POWER CHECK
ELECTRONIC LOAD LIMIT REGULATION, XLR BASIC ADJUSTMENT
METHOD "A" WITH 24 V SUPPLY
METHOD "B" WITH BODAS SOFTWARE
ELECTRONIC LOAD LIMIT REGULATION, RC4 FUNCTION CHECK
HYDRAULIC CONTROL (EMERGENCY MODE)
PRESSURE CUT-OFF VALVE
ENERGY EFFICIENCY
GENERAL
CHECKS AND ADJUSTMENTS

OPERATING HYDRAULICS
GENERAL
FLOATING FUNCTION FOR BOOM AND STICK CYLINDER (FSA)
HYDRAULICS FOR THE ATTACHMENT CYLINDERS FSA
ELECTRIC / HYDRAULIC FLOWCHART "BOOM UP

HYDRAULIC TRACK TENSIONING SYSTEM
GENERAL
FUNCTIONAL DESCRIPTION
DOUBLE-STAGE VALVE
TENSIONING CYLINDER
ADJUSTMENTS / CHECKS
ACCESS LADDER, HYDRAULICALLY OPERATED
GENERAL
FUNCTION OF THE HYDRAULICALLY OPERATED ACCESS LADDER
ADJUSTMENTS / CHECKS

CENTRAL REFILLING SYSTEM (SERVICE ARM)
SERVICE ARM
MONITORING AND CONTROL BOX
FUNCTION
CHECKS AND ADJUSTMENTS

HINTS FOR READING THE HYDRAULIC DIAGRAM
GENERAL
HYDRAULIC SYMBOLS
LINES, UNIONS
COMPONENTS, VALVES
SENSORS
VALVES, VALVE COMPONENTS
PUMP, MOTOR, CYLINDER

HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
GENERAL
REFERENCE CODE OF THE ELECTRICAL COMPONENTS
AREA CODE
COMPONENT IDENTIFYING LETTER
GRAPHICAL SYMBOLS
DRAWING CONCEPT
CABLE MARKING

KOMTRAX PLUS & MTC CONTROL SYSTEM
GENERAL
SPECIFICATIONS FOR OPERATORS
SEQUENCE OF DISPLAYS
OPENING SCREEN
MAIN GAUGE SCREENS 1 TO 3
ENERGY CONSUMPTION SCREEN
FAILURE MESSAGE HISTORY FOR THE OPERATOR
MAIN GAUGE SCREENS - CHANGING OF TIME / SMR / DATE