Komatsu Hydraulic Mining Shovel PC8000E Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Mining Shovel PC8000E, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Mining Shovel PC8000E-6 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,008 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
FAMPC8000-06 - Hydraulic Mining Shovel PC8000 General Assembly Procedure.pdf
GZEAM12058 - Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual.pdf
GZEAM12062 - Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual.pdf
GZEAM12066 - Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual.pdf
Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual (SN12053).pdf
SMPC8000E-6 - Hydraulic Mining Shovel PC8000E-6 Shop Manual.pdf
MAIN SECTIONS
FAMPC8000-06 - Hydraulic Mining Shovel PC8000 General Assembly Procedure...2
GZEAM12058 - Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual...160
COVER...160
1. INTRODUCTION...162
1.1 CONTENTS OF THE BINDER...163
1.2 DIVISION OF THE BINDER...164
1.3 DESIGNATED USE OF THE SHOVEL...165
1.4 DELIVERY OF THE SHOVEL...166
1.5 EXPLANATION OF ABBREVIATIONS...167
1.6 TABLE OF CONTENTS...168
2. SAFETY...174
2.1 SAFETY INSTRUCTIONS...175
2.1.1 WARNINGS AND SYMBOLS...175
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL...175
2.1.3 ORGANIZATIONAL MEASURES...176
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...178
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES...179
2.1.6 WARNING OF SPECIAL DANGERS...182
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING...184
2.1.8 SPECIAL SAFETY EQUIPMENT...184
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...188
3. OPERATION...196
3.1 FOREWORD...197
3.2 CONSTRUCTION OF THE SHOVEL...198
3.2.1 OVERALL VIEW...198
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE...199
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...207
3.2.4 EMERGENCY ESCAPE LADDER AT THE OPERATORS CAB PLATFORM...211
3.2.5 EMERGENCY ESCAPE LADDER AT THE SUPERSTRUCTURE PLATFORM...213
3.2.6 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR...215
3.2.7 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE...217
3.2.8 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...219
3.2.9 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...221
3.2.10 ENGINE OIL MANAGEMENT SYSTEM...231
3.3 OPERATORS CAB - CONTROLS...235
3.3.1 HYDRAULIC CONTROL SYSTEM...236
3.3.2 SAFETY CIRCUIT FOR CONTROLS...236
3.3.3 OPERATORS CONSOLE...240
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS...248
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER...250
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS...251
3.4.1 INTRODUCTION...252
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM...260
3.4.3 AUTOMATIC DISPLAY OF MESSAGES...264
3.4.4 MENU CONTROL...288
3.4.5 MENU CONTROL LIST...315
3.4.6 FAULT AND INFORMATION MESSAGE LIST...333
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...357
3.5.1 AUXILIARY HEATER FOR OPERATORS CAB...360
3.6 MACHINERY HOUSE...361
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES...362
3.6.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE...364
3.6.3 CENTRAL CONTROL AND FILTER PANEL...366
3.6.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO...368
3.7 ELECTRICAL EQUIPMENT IN CAB BASE...369
3.7.1 STANDARD COMPONENTS IN CAB BASE...370
3.7.2 SWITCH BOARD (X2) IN CAB BASE...372
3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE...382
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES...385
3.9 CHECKS BEFORE STARTING THE ENGINES...389
3.10 STARTING THE ENGINES...395
3.10.1 STARTING PROCEDURE...398
3.11 MOVING THE SHOVEL...410
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS...410
3.11.2 TRAVELLING INSTRUCTIONS...413
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE...414
3.12.1 SLEWING THE SUPERSTRUCTURE...414
3.13 WORKING WITH THE ATTACHMENT...417
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM...417
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM...418
3.13.3 BOTTOM DUMP BUCKET...419
3.13.4 DROP BALL OPERATION...420
3.13.5 COMBINED OPERATION CYCLES...423
3.14 WORKING INSTRUCTIONS...425
3.14.1 STABILITY OF THE SHOVEL...425
3.14.2 SHOVEL OPERATION...425
3.15 PARKING THE SHOVEL...428
3.16 STOPPING THE ENGINES...429
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM...432
3.17 OPERATION OF THE LUBRICATION SYSTEM...433
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT...433
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS...435
3.18 TRANSFER PUMP FOR HYDRAULIC OIL...437
3.18.1 OPERATING THE TRANSFER PUMP...438
3.18.2 TRANSFUSION PROCEDURE...440
3.19 CENTRAL REFILLING SYSTEM...443
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...444
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM...446
3.19.3 RECEIVER PANEL WITH MONITOR BOX...448
3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS...454
3.20 WORK ON THE LOADER ATTACHMENT...455
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL...456
3.21.1 DISASSEMBLING OF THE SHOVEL...456
3.21.2 TRANSPORTATION AND LIFTING...456
3.22 RETRIEVAL PROCEDURE...457
3.23 SHOVEL STORAGE...458
3.23.1 PREPARING FOR STORAGE...458
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD...459
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD...459
3.23.4 PREPARING FOR OPERATION...460
3.24 TROUBLE SHOOTING...461
3.24.1 ENGINE...461
3.24.2 HYDRAULIC SYSTEM...462
3.24.3 FINAL DRIVES AND SWING GEAR...463
3.24.4 CRAWLER TRACKS...463
4. MAINTENANCE...464
4.1 FOREWORD...465
4.2 PRECAUTIONS FOR MAINTENANCE...466
4.3 FLUIDS AND LUBRICANTS...468
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES...468
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...469
4.4 FILLING CAPACITIES...471
4.5 STANDARD TORQUE LIST...472
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...473
4.6.1 INITIAL SERVICING...473
4.6.2 PERIODIC SERVICING INTERVALS...473
4.6.3 PERIODIC SERVICING SCHEDULE...474
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES...479
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...480
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM...484
4.6.7 MAINTENANCE OF THE ENGINES...488
4.7 WHEN NECESSARY...489
4.7.1 ENGINE AIR CLEANER MAINTENANCE...490
4.7.2 SWING CIRCLE TOOTHING LUBRICATION...494
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS...496
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...500
4.8 EVERY 10 OPERATING HOURS OR DAILY...501
4.8.1 WALK - AROUND INSPECTION...502
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...512
4.8.3 RADIATORS - CHECK COOLANT LEVEL...514
4.8.4 TRACK GROUPS - CLEAN...514
4.9 EVERY 50 OPERATING HOURS OR WEEKLY...515
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVEL...516
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...520
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...522
4.9.4 PUMP DISTRIBUTOR GEARS - CHECK OIL LEVEL...524
4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...526
4.9.6 MAIN HYDRAULIC OIL COOLER - INSPECT AND CLEAN IF NECESSARY...528
4.9.7 PTO GEAR OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...532
4.10 EVERY 250 OPERATING HOURS OR MONTHLY...533
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...534
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...536
4.10.3 DRIVE SHAFTS - LUBRICATE...536
4.10.4 SIGNAL HORN COMPRESSOR - LUBRICATE...536
4.10.5 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...538
4.10.6 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...538
4.10.7 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER...540
4.10.8 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...542
4.10.9 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL...544
4.10.10 AIR CONDITIONING FOR OPERATORS CAB - CHECK REFRIGERANT LEVEL...546
4.11 EVERY 500 OPERATING HOURS OR QUARTELY...547
4.11.1 BATTERIES - CHECK FLUID LEVEL...548
4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL...550
4.11.3 DRIVE SHAFT HOUSINGS ON PTO GEARS - CHECK OIL LEVEL...552
4.11.4 FUEL TANK - DRAIN CONDENSATION...554
4.11.5 CRAWLER TRACK - INSPECTION...556
4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION...562
4.11.7 GROUND CABLE OF OPERATORS CAB - CHECK FOR CORRECT CONNECTION...564
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...565
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...566
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE...608
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...620
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...622
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS...624
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE...626
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES...628
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES...630
4.13 EVERY 2000 OPERATING HOURS OR YEARLY...631
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...632
4.13.2 EMERGENCY ESCAPE LADDERS - INSPECTION...642
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...649
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...650
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL...658
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL...662
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...664
4.15 FIRE PREVENTION...665
4.16 WELD REPAIRS...667
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...670
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...672
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...674
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...676
GZEAM12062 - Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual...683
1. INTRODUCTION...685
1.1 CONTENTS OF THE BINDER...686
1.2 DIVISION OF THE BINDER...687
1.3 DESIGNATED USE OF THE SHOVEL...688
1.4 DELIVERY OF THE SHOVEL...689
1.5 EXPLANATION OF ABBREVIATIONS...690
1.6 TABLE OF CONTENTS...691
2. SAFETY...697
2.1 SAFETY INSTRUCTIONS...698
2.1.1 WARNINGS AND SYMBOLS...698
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL...698
2.1.3 ORGANIZATIONAL MEASURES...699
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...701
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES...702
2.1.6 WARNING OF SPECIAL DANGERS...705
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING...707
2.1.8 SPECIAL SAFETY EQUIPMENT...707
2.1.9 ELECTROMAGNETIC COMPATIBILITY (EMC)...709
2.1.10 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE...709
2.1.11 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...711
3. OPERATION...719
3.1 FOREWORD...720
3.2 CONSTRUCTION OF THE SHOVEL...721
3.2.1 OVERALL VIEW...721
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE...722
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...730
3.2.4 EMERGENCY ESCAPE LADDER AT THE OPERATORS CAB PLATFORM...734
3.2.5 EMERGENCY ESCAPE LADDER AT THE SUPERSTRUCTURE PLATFORM...736
3.2.6 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR...738
3.2.7 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE...740
3.2.8 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...742
3.2.9 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...744
3.2.10 ENGINE OIL MANAGEMENT SYSTEM...754
3.3 OPERATORS CAB - CONTROLS...758
3.3.1 HYDRAULIC CONTROL SYSTEM...759
3.3.2 SAFETY CIRCUIT FOR CONTROLS...759
3.3.3 OPERATORS CONSOLE...763
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS...771
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER...773
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS...774
3.4.1 INTRODUCTION...775
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM...783
3.4.3 AUTOMATIC DISPLAY OF MESSAGES...787
3.4.4 MENU CONTROL...811
3.4.5 MENU CONTROL LIST...838
3.4.6 FAULT AND INFORMATION MESSAGE LIST...856
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...880
3.5.1 AUXILIARY HEATER FOR OPERATORS CAB...883
3.6 MACHINERY HOUSE...884
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES...885
3.6.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE...887
3.6.3 CENTRAL CONTROL AND FILTER PANEL...889
3.6.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO...891
3.7 ELECTRICAL EQUIPMENT IN CAB BASE...892
3.7.1 STANDARD COMPONENTS IN CAB BASE...893
3.7.2 SWITCH BOARD (X2) IN CAB BASE...895
3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE...905
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES...908
3.9 CHECKS BEFORE STARTING THE ENGINES...912
3.10 STARTING THE ENGINES...918
3.10.1 STARTING PROCEDURE...921
3.11 MOVING THE SHOVEL...933
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS...933
3.11.2 TRAVELLING INSTRUCTIONS...936
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE...937
3.12.1 SLEWING THE SUPERSTRUCTURE...937
3.13 WORKING WITH THE ATTACHMENT...940
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM...940
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM...941
3.13.3 BOTTOM DUMP BUCKET...942
3.13.4 DROP BALL OPERATION...943
3.13.5 COMBINED OPERATION CYCLES...946
3.14 WORKING INSTRUCTIONS...948
3.14.1 STABILITY OF THE SHOVEL...948
3.14.2 SHOVEL OPERATION...948
3.15 PARKING THE SHOVEL...951
3.16 STOPPING THE ENGINES...952
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM...955
3.17 OPERATION OF THE LUBRICATION SYSTEM...956
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT...956
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS...958
3.18 TRANSFER PUMP FOR HYDRAULIC OIL...960
3.18.1 OPERATING THE TRANSFER PUMP...961
3.18.2 TRANSFUSION PROCEDURE...963
3.19 CENTRAL REFILLING SYSTEM...966
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...967
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM...969
3.19.3 RECEIVER PANEL WITH MONITOR BOX...971
3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS...977
3.20 WORK ON THE LOADER ATTACHMENT...978
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL...979
3.21.1 DISASSEMBLING OF THE SHOVEL...979
3.21.2 TRANSPORTATION AND LIFTING...979
3.22 RETRIEVAL PROCEDURE...980
3.23 SHOVEL STORAGE...981
3.23.1 PREPARING FOR STORAGE...981
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD...982
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD...982
3.23.4 PREPARING FOR OPERATION...983
3.24 TROUBLE SHOOTING...984
3.24.1 ENGINE...984
3.24.2 HYDRAULIC SYSTEM...985
3.24.3 FINAL DRIVES AND SWING GEAR...986
3.24.4 CRAWLER TRACKS...986
4. MAINTENANCE...987
4.1 FOREWORD...988
4.2 PRECAUTIONS FOR MAINTENANCE...989
4.3 FLUIDS AND LUBRICANTS...991
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES...991
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...992
4.4 FILLING CAPACITIES...994
4.5 STANDARD TORQUE LIST...995
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...996
4.6.1 INITIAL SERVICING...996
4.6.2 PERIODIC SERVICING INTERVALS...996
4.6.3 PERIODIC SERVICING SCHEDULE...997
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES...1002
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1003
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM...1007
4.6.7 MAINTENANCE OF THE ENGINES...1011
4.7 WHEN NECESSARY...1012
4.7.1 ENGINE AIR CLEANER MAINTENANCE...1013
4.7.2 SWING CIRCLE TOOTHING LUBRICATION...1017
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS...1019
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...1023
4.8 EVERY 10 OPERATING HOURS OR DAILY...1024
4.8.1 WALK - AROUND INSPECTION...1025
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...1035
4.8.3 RADIATORS - CHECK COOLANT LEVEL...1037
4.8.4 TRACK GROUPS - CLEAN...1037
4.9 EVERY 50 OPERATING HOURS OR WEEKLY...1038
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVEL...1039
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...1043
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...1045
4.9.4 PUMP DISTRIBUTOR GEARS - CHECK OIL LEVEL...1047
4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...1049
4.9.6 MAIN HYDRAULIC OIL COOLER - INSPECT AND CLEAN IF NECESSARY...1051
4.9.7 PTO GEAR OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...1055
4.10 EVERY 250 OPERATING HOURS OR MONTHLY...1056
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...1057
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...1059
4.10.3 DRIVE SHAFTS - LUBRICATE...1059
4.10.4 SIGNAL HORN COMPRESSOR - LUBRICATE...1059
4.10.5 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...1061
4.10.6 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...1061
4.10.7 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER...1063
4.10.8 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...1065
4.10.9 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL...1067
4.10.10 AIR CONDITIONING FOR OPERATORS CAB - CHECK REFRIGERANT LEVEL...1069
4.11 EVERY 500 OPERATING HOURS OR QUARTELY...1070
4.11.1 BATTERIES - CHECK FLUID LEVEL...1071
4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL...1073
4.11.3 DRIVE SHAFT HOUSINGS ON PTO GEARS - CHECK OIL LEVEL...1075
4.11.4 FUEL TANK - DRAIN CONDENSATION...1077
4.11.5 CRAWLER TRACK - INSPECTION...1079
4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION...1085
4.11.7 GROUND CABLE OF OPERATORS CAB - CHECK FOR CORRECT CONNECTION...1087
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...1088
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...1089
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE...1131
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...1143
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...1145
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS...1147
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE...1149
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES...1151
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES...1153
4.13 EVERY 2000 OPERATING HOURS OR YEARLY...1154
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...1155
4.13.2 EMERGENCY ESCAPE LADDERS - INSPECTION...1165
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...1172
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...1173
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL...1181
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL...1185
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...1187
4.15 FIRE PREVENTION...1188
4.16 WELD REPAIRS...1190
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...1193
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...1195
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...1197
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...1199
GZEAM12066 - Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual...1206
1. INTRODUCTION...1208
1.1 CONTENTS OF THE BINDER...1209
1.2 DIVISION OF THE BINDER...1210
1.3 DESIGNATED USE OF THE SHOVEL...1211
1.4 DELIVERY OF THE SHOVEL...1212
1.5 EXPLANATION OF ABBREVIATIONS...1213
1.6 TABLE OF CONTENTS...1214
2. SAFETY...1220
2.1 SAFETY INSTRUCTIONS...1221
2.1.1 WARNINGS AND SYMBOLS...1221
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL...1221
2.1.3 ORGANIZATIONAL MEASURES...1222
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...1224
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES...1225
2.1.6 WARNING OF SPECIAL DANGERS...1228
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING...1230
2.1.8 SPECIAL SAFETY EQUIPMENT...1230
2.1.9 ELECTROMAGNETIC COMPATIBILITY (EMC)...1232
2.1.10 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE...1232
2.1.11 VISIBILITY FROM OPERATORS SEAT...1234
2.1.12 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...1236
3. OPERATION...1244
3.1 FOREWORD...1245
3.2 CONSTRUCTION OF THE SHOVEL...1246
3.2.1 OVERALL VIEW WITH BACKHOE ATTACHMENT...1246
3.2.2 OVERALL VIEW WITH BOTTOM DUMP BUCKET ATTACHMENT...1247
3.2.3 SUPERSTRUCTURE...1249
3.2.4 UNDERCARRIAGE...1257
3.2.5 HYDRAULICALLY OPERATED ACCESS LADDER...1259
3.2.6 EMERGENCY ESCAPE LADDER AT THE OPERATORS CAB PLATFORM...1263
3.2.7 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR...1265
3.2.8 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE...1267
3.2.9 FOLDING LADDER INSIDE OF CARBODY...1269
3.2.10 BOOM ACCESS LADDER AND WALKWAY...1271
3.2.11 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...1273
3.2.12 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...1275
3.3 OPERATORS CAB - CONTROLS...1285
3.3.1 HYDRAULIC CONTROL SYSTEM...1286
3.3.2 SAFETY CIRCUIT FOR CONTROLS...1286
3.3.3 OPERATORS CONSOLE...1290
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS...1298
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS...1299
3.4.1 INTRODUCTION...1300
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM...1308
3.4.3 AUTOMATIC DISPLAY OF MESSAGES...1312
3.4.4 MENU CONTROL AND SERVICE FUNCTIONS...1336
3.4.5 MENU CONTROL LIST...1363
3.4.6 FAULT AND INFORMATION MESSAGE LIST...1381
3.5 CAMERA SYSTEM WITH MONITORS (SPECIAL EQUIPMENT)...1407
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS...1408
3.6 OPERATING THE HEATERS, VENTILATION AND AIR CONDITIONING...1415
3.6.1 AIR CONDITIONING AND HEATING...1416
3.6.2 A - HEATING...1416
3.6.3 B - COOLING...1416
3.6.4 COMBINED OPERATION OF AIR CONDITIONING AND HEATING...1418
3.7 MACHINERY HOUSE...1419
3.7.1 EMERGENCY MOTOR SHUTDOWN SWITCHES...1420
3.7.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE...1422
3.7.3 CENTRAL CONTROL AND FILTER PANEL...1424
3.7.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO...1426
3.8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE...1427
3.8.1 COMPONENTS IN THE MEDIUM VOLTAGE SWITCH CABINET...1430
3.8.2 SWITCH BOARD (X2) IN CAB BASE...1432
3.8.3 MONITOR AND CONTROL PANEL IN CAB BASE...1440
3.9 HIGH VOLTAGE SWITCH CABINET...1443
3.10 CHECKS BEFORE STARTING THE MOTORS...1445
3.11 STARTING THE MAIN DRIVE MOTORS...1447
3.12 MOVING THE SHOVEL...1454
3.12.1 TRAVEL CONTROL WITH FOOT PEDALS...1454
3.12.2 TRAVELLING INSTRUCTIONS...1457
3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE...1458
3.13.1 SLEWING THE SUPERSTRUCTURE...1458
3.14 WORKING WITH THE ATTACHMENT...1461
3.14.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM...1461
3.14.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM...1462
3.14.3 BOTTOM DUMP BUCKET...1463
3.14.4 DROP BALL OPERATION...1464
3.14.5 COMBINED OPERATION CYCLES...1467
3.15 WORKING INSTRUCTIONS...1469
3.15.1 STABILITY OF THE SHOVEL...1469
3.15.2 SHOVEL OPERATION...1469
3.16 PARKING THE SHOVEL...1472
3.17 STOPPING THE MAIN DRIVE MOTORS...1473
3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM...1476
3.18 OPERATION OF THE LUBRICATION SYSTEM...1477
3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT...1477
3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS...1479
3.19 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM (SPECIAL EQUIPMENT)...1481
3.19.1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS...1482
3.19.2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB...1486
3.19.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM:...1486
3.19.4 IN CASE OF FIRE...1488
3.20 TRANSFER PUMP FOR HYDRAULIC OIL...1489
3.20.1 OPERATING THE TRANSFER PUMP...1490
3.20.2 TRANSFUSION PROCEDURE...1492
3.21 CENTRAL REFILLING SYSTEM...1495
3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...1496
3.21.2 RECEIVER PANEL AND MONITOR BOX...1496
3.21.3 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOU....1500
3.22 FOLDING PEDESTAL ON THE OPERATORS CAB...1501
3.23 SERVICE CRANE (SPECIAL EQUIPMENT)...1505
3.23.1 OPERATING THE CRANE...1506
3.24 CABLE DRUM (SPECIAL EQUIPMENT)...1509
3.24.1 OPERATION OF THE CABLE DRUM...1510
3.24.2 TRAVELLING INSTRUCTIONS...1514
3.25 WORK ON THE LOADER ATTACHMENT...1517
3.26 TRANSPORTATION AND LIFTING OF THE SHOVEL...1518
3.26.1 DISASSEMBLING OF THE SHOVEL...1518
3.26.2 TRANSPORTATION AND LIFTING...1518
3.27 RETRIEVAL PROCEDURE...1519
3.28 SHOVEL STORAGE...1520
3.28.1 PREPARING FOR STORAGE...1520
3.28.2 ONE MONTH REPETITIVE SERVICE PERIOD...1520
3.28.3 SIX MONTH REPETITIVE SERVICE PERIOD...1521
3.28.4 PREPARING FOR OPERATION...1521
3.29 TROUBLE SHOOTING...1522
3.29.1 MAIN DRIVE ELECTRIC MOTOR...1522
3.29.2 HYDRAULIC SYSTEM...1523
3.29.3 FINAL DRIVES AND SWING GEAR...1524
3.29.4 CRAWLER TRACKS...1524
4. MAINTENANCE...1526
4.1 FOREWORD...1527
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE...1528
4.3 FLUIDS AND LUBRICANTS...1530
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES...1530
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...1531
4.3.3 MAIN DRIVE ELECTRIC MOTORS BEARING LUBRICATION...1532
4.4 FILLING CAPACITIES...1533
4.5 STANDARD TORQUE LIST...1534
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...1535
4.6.1 INITIAL SERVICING...1535
4.6.2 PERIODIC SERVICING INTERVALS...1535
4.6.3 PERIODIC SERVICING SCHEDULE...1536
4.6.4 MAINTENANCE OF THE MAIN DRIVE ELECTRIC MOTORS...1540
4.6.5 REPLACEMENT OF HYDRAULIC HOSE LINES...1542
4.6.6 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1543
4.7 WHEN NECESSARY...1545
4.7.1 SWING CIRCLE TOOTHING LUBRICATION...1546
4.7.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS...1548
4.7.3 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...1552
4.8 EVERY 10 OPERATING HOURS OR DAILY...1553
4.8.1 WALK - AROUND INSPECTION...1554
4.8.2 CLEANING THE TRACK GROUPS...1562
4.9 EVERY 50 OPERATING HOURS OR WEEKLY...1563
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVEL...1564
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...1568
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...1570
4.9.4 PUMP DISTRIBUTOR GEARS - CHECK OIL LEVEL...1572
4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...1574
4.9.6 MAIN HYDRAULIC OIL COOLER - INSPECT AND CLEAN IF NECESSARY...1576
4.9.7 PTO GEAR OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...1580
4.10 EVERY 250 OPERATING HOURS OR MONTHLY...1581
4.10.1 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...1582
4.10.2 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...1582
4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE...1582
4.10.4 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER...1584
4.10.5 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...1586
4.10.6 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL...1588
4.10.7 AIR CONDITIONING FOR OPERATORS CAB - VERSION "KYSOR"...1590
4.10.8 AIR CONDITIONING FOR ELECTRICAL SWITCH CABINETS - CHECK REFRIGERANT LEVEL...1592
4.11 EVERY 500 OPERATING HOURS OR MONTHLY...1595
4.11.1 BATTERIES - CHECK FLUID LEVEL...1596
4.11.2 DRIVE SHAFT HOUSINGS ON PTO GEARS - CHECK OIL LEVEL...1598
4.11.3 CRAWLER TRACK - INSPECTION...1600
4.11.4 GROUND CABLE OF OPERATORS CAB - CHECK FOR CORRECT CONNECTION...1606
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...1607
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...1608
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE...1654
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...1666
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...1668
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS...1670
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE...1672
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES...1674
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES...1676
4.12.9 SLIP RING UNIT - LUBRICATE...1678
4.12.10 SERVICE CRANE - LUBRICATE...1678
4.13 EVERY 2000 OPERATING HOURS OR YEARLY...1679
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...1680
4.13.2 EMERGENCY ESCAPE LADDERS - INSPECTION...1690
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...1695
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...1696
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL...1704
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL...1708
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...1710
4.15 FIRE PREVENTION...1711
4.16 WELD REPAIRS...1713
4.16.1 GENERAL PROTECTIVE MEASURES...1714
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...1716
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...1718
4.16.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...1720
4.16.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...1720
Hydraulic Mining Shovel PC8000-6 Operation & Maintenance Manual (SN12053)...1728
COVER...1728
1. INTRODUCTION...1730
1.1 CONTENTS OF THE BINDER...1731
1.2 DIVISION OF THE BINDER...1732
1.3 DESIGNATED USE OF THE SHOVEL...1733
1.4 DELIVERY OF THE SHOVEL...1734
1.5 EXPLANATION OF ABBREVIATIONS...1735
1.6 TABLE OF CONTENTS...1736
2. SAFETY...1742
2.1 SAFETY INSTRUCTIONS...1743
2.1.1 WARNINGS AND SYMBOLS...1743
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL...1743
2.1.3 ORGANIZATIONAL MEASURES...1744
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...1746
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES...1747
2.1.6 WARNING OF SPECIAL DANGERS...1750
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING...1752
2.1.8 SPECIAL SAFETY EQUIPMENT...1752
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...1756
3. OPERATION...1764
3.1 FOREWORD...1765
3.2 CONSTRUCTION OF THE SHOVEL...1766
3.2.1 OVERALL VIEW...1766
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE...1767
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...1775
3.2.4 EMERGENCY ESCAPE LADDER AT THE OPERATORS CAB PLATFORM...1779
3.2.5 EMERGENCY ESCAPE LADDER AT THE SUPERSTRUCTURE PLATFORM...1781
3.2.6 EMERGENCY ESCAPE LADDER AT THE UPPER DECK AND MACHINERY HOUSE ESCAPE DOOR...1783
3.2.7 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE...1785
3.2.8 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...1787
3.2.9 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...1789
3.2.10 ENGINE OIL MANAGEMENT SYSTEM...1799
3.3 OPERATORS CAB - CONTROLS...1803
3.3.1 HYDRAULIC CONTROL SYSTEM...1804
3.3.2 SAFETY CIRCUIT FOR CONTROLS...1804
3.3.3 OPERATORS CONSOLE...1808
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS...1816
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER...1818
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS...1819
3.4.1 INTRODUCTION...1820
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM...1828
3.4.3 AUTOMATIC DISPLAY OF MESSAGES...1832
3.4.4 MENU CONTROL...1856
3.4.5 MENU CONTROL LIST...1883
3.4.6 FAULT AND INFORMATION MESSAGE LIST...1901
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...1925
3.5.1 AUXILIARY HEATER FOR OPERATORS CAB...1928
3.6 MACHINERY HOUSE...1929
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES...1930
3.6.2 BATTERY MAIN SWITCHES AND SAFETY SWITCH FOR MAINTENANCE...1932
3.6.3 CENTRAL CONTROL AND FILTER PANEL...1934
3.6.4 CONTROL AND FILTER PANEL ON FRONT- AND REAR PTO...1936
3.7 ELECTRICAL EQUIPMENT IN CAB BASE...1937
3.7.1 STANDARD COMPONENTS IN CAB BASE...1938
3.7.2 SWITCH BOARD (X2) IN CAB BASE...1940
3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE...1950
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES...1953
3.9 CHECKS BEFORE STARTING THE ENGINES...1957
3.10 STARTING THE ENGINES...1963
3.10.1 STARTING PROCEDURE...1966
3.11 MOVING THE SHOVEL...1974
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS...1974
3.11.2 TRAVELLING INSTRUCTIONS...1977
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE...1978
3.12.1 SLEWING THE SUPERSTRUCTURE...1978
3.13 WORKING WITH THE ATTACHMENT...1981
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM...1981
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM...1982
3.13.3 BOTTOM DUMP BUCKET...1983
3.13.4 DROP BALL OPERATION...1984
3.13.5 COMBINED OPERATION CYCLES...1987
3.14 WORKING INSTRUCTIONS...1989
3.14.1 STABILITY OF THE SHOVEL...1989
3.14.2 SHOVEL OPERATION...1989
3.15 PARKING THE SHOVEL...1992
3.16 STOPPING THE ENGINES...1993
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM...1996
3.17 OPERATION OF THE LUBRICATION SYSTEM...1997
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT...1997
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS...1999
3.18 TRANSFER PUMP FOR HYDRAULIC OIL...2001
3.18.1 OPERATING THE TRANSFER PUMP...2002
3.18.2 TRANSFUSION PROCEDURE...2004
3.19 CENTRAL REFILLING SYSTEM...2007
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...2008
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM...2010
3.19.3 RECEIVER PANEL WITH MONITOR BOX...2012
3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS...2018
3.20 WORK ON THE LOADER ATTACHMENT...2019
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL...2020
3.21.1 DISASSEMBLING OF THE SHOVEL...2020
3.21.2 TRANSPORTATION AND LIFTING...2020
3.22 RETRIEVAL PROCEDURE...2021
3.23 SHOVEL STORAGE...2022
3.23.1 PREPARING FOR STORAGE...2022
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD...2023
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD...2023
3.23.4 PREPARING FOR OPERATION...2024
3.24 TROUBLE SHOOTING...2025
3.24.1 ENGINE...2025
3.24.2 HYDRAULIC SYSTEM...2026
3.24.3 FINAL DRIVES AND SWING GEAR...2027
3.24.4 CRAWLER TRACKS...2027
4. MAINTENANCE...2028
4.1 FOREWORD...2029
4.2 PRECAUTIONS FOR MAINTENANCE...2030
4.3 FLUIDS AND LUBRICANTS...2032
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES...2032
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...2033
4.4 FILLING CAPACITIES...2035
4.5 STANDARD TORQUE LIST...2036
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...2037
4.6.1 INITIAL SERVICING...2037
4.6.2 PERIODIC SERVICING INTERVALS...2037
4.6.3 PERIODIC SERVICING SCHEDULE...2038
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES...2043
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2044
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM...2048
4.6.7 MAINTENANCE OF THE ENGINES...2052
4.7 WHEN NECESSARY...2053
4.7.1 ENGINE AIR CLEANER MAINTENANCE...2054
4.7.2 SWING CIRCLE TOOTHING LUBRICATION...2058
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS...2060
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...2064
4.8 EVERY 10 OPERATING HOURS OR DAILY...2065
4.8.1 WALK - AROUND INSPECTION...2066
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...2076
4.8.3 RADIATORS - CHECK COOLANT LEVEL...2078
4.8.4 TRACK GROUPS - CLEAN...2078
4.9 EVERY 50 OPERATING HOURS OR WEEKLY...2079
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVEL...2080
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...2082
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...2084
4.9.4 PUMP DISTRIBUTOR GEARS - CHECK OIL LEVEL...2086
4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...2088
4.9.6 MAIN HYDRAULIC OIL COOLER - INSPECT AND CLEAN IF NECESSARY...2090
4.9.7 PTO GEAR OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...2094
4.10 EVERY 250 OPERATING HOURS OR MONTHLY...2095
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...2096
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...2098
4.10.3 DRIVE SHAFTS - LUBRICATE...2098
4.10.4 SIGNAL HORN COMPRESSOR - LUBRICATE...2098
4.10.5 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...2100
4.10.6 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...2100
4.10.7 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER...2102
4.10.8 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...2104
4.10.9 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL...2106
4.10.10 AIR CONDITIONING FOR OPERATORS CAB - CHECK REFRIGERANT LEVEL...2108
4.11 EVERY 500 OPERATING HOURS OR QUARTELY...2109
4.11.1 BATTERIES - CHECK FLUID LEVEL...2110
4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL...2112
4.11.3 DRIVE SHAFT HOUSINGS ON PTO GEARS - CHECK OIL LEVEL...2114
4.11.4 FUEL TANK - DRAIN CONDENSATION...2116
4.11.5 CRAWLER TRACK - INSPECTION...2118
4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION...2124
4.11.7 GROUND CABLE OF OPERATORS CAB - CHECK FOR CORRECT CONNECTION...2126
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...2127
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...2128
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE...2170
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...2182
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...2184
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS...2186
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE...2188
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES...2190
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES...2192
4.13 EVERY 2000 OPERATING HOURS OR YEARLY...2193
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...2194
4.13.2 EMERGENCY ESCAPE LADDERS - INSPECTION...2204
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...2211
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...2212
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL...2216
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL...2220
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...2222
4.15 FIRE PREVENTION...2223
4.16 WELD REPAIRS...2225
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...2228
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...2230
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...2232
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...2234
SMPC8000E-6 - Hydraulic Mining Shovel PC8000E-6 Shop Manual...2241
