Komatsu PC4000-11 T4 Hydraulic Mining shovel Shop Manual 08246-xD-GB-1 – PDF DOWNLOAD

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Komatsu PC4000-11 T4 Hydraulic Mining shovel Shop Manual 08246-xD-GB-1 – PDF DOWNLOAD

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Komatsu PC4000-11 T4 Hydraulic Mining shovel Shop Manual 08246-xD-GB-1 – PDF DOWNLOAD

SERIAL NUMBER 08246 and up

• 1.1 BEFORE READING THIS MANUAL
• This manual gives details of the methods of inspection, maintenance and troubleshooting 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 inspection, maintenance and troubleshooting of machines.
• Read, understand and follow all precautions and warnings in this manual and on the machine before performing inspection, maintenance or troubleshooting. 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 inspection, maintenance and troubleshooting 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 inspection, maintenance and troubleshooting 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. 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.

2.1 SAFETY INFORMATION

To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed.

The safety information in this manual does not replace any safety rules or laws in your area.

To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The “Safety Alert Symbol” identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.

TABLE OF CONTENTS:
Komatsu PC4000-11 T4 Hydraulic Mining shovel Shop Manual 08246-xD-GB-1 – PDF DOWNLOAD

1 INTRODUCTION 1-1
11 FOREWORD 1-2
12 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND
MAINTENANCE OF HYDRAULIC MINING SHOVELS 1-3
13 DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL 1-3
14 PROCEDURES FOR DISASSEMBLING AND ASSEMBLING IN THIS MANUAL 1-4
2 SAFETY 2-1
21 OVERVIEW 2-3
211 METHOD OF USING THIS MANUAL 2-3
22 GENERAL PRECAUTIONS 2-5
221 GENERAL 2-5
222 PERSONAL PROTECTIVE CLOTHING 2-5
223 WHEN USING A HAMMER 2-6
224 PROPER TOOLS 2-6
225 PERSONNEL 2-6
226 FIRE PREVENTION 2-7
227 UNAUTHORIZED MODIFICATION 2-7
23 PRECAUTIONS FOR MAINTENANCE AND REPAIR 2-8
231 GENERAL PRECAUTIONS 2-8
232 KEEP WORK PLACE CLEAN AND TIDY 2-8
233 PRECAUTIONS WHEN WELDING 2-9
234 PRECAUTION WITH HIGH PRESSURE FLUIDS 2-9
2341 HANDLING HIGH PRESSURE HOSES AND PIPES 2-9
235 COMPRESSED AIR 2-9
236 WASTE MATERIALS 2-10
3 SUPERSTRUCTURE 3-1
31 SUPERSTRUCTURE OVERVIEW 3-2
32 MACHINE HOUSE (T4) 3-4
321 DISCONNECTION PLATE AT THE MACHINE HOUSE 3-6
3211 MACHINE HOUSE HOSE PORTS – PORT ALLOCATIONS 3-6
322 MACHINE HOUSE ROOF 3-8
3221 DISASSEMBLING OF THE MACHINE HOUSE ROOF COVER PLATES 3-11
3222 ASSEMBLING OF THE MACHINE HOUSE ROOF COVER PLATES 3-18
323 TRAVERSE ASSEMBLY ON MACHINE HOUSE (T4 EQUIPMENT) 3-24
3231 DISASSEMBLING OF THE COMPLETE TRAVERSE ASSEMBLY
(T4 EQUIPMENT) 3-24
3232 ASSEMBLING OF THE COMPLETE TRAVERSE ASSEMBLY
(T4 EQUIPMENT) 3-28
3233 DISASSEMBLING OF THE SCR CATALYSTS (T4 EQUIPMENT) 3-32
3234 ASSEMBLING OF THE SCR CATALYSTS (T4 EQUIPMENT) 3-36
3235 DISASSEMBLING OF THE DEF TANK ASSEMBLY (T4 EQUIPMENT) 3-41
3236 ASSEMBLING OF THE DEF TANK ASSEMBLY (T4 EQUIPMENT) 3-45
324 AIR INTAKE SYSTEM 3-48
3241 DISASSEMBLING OF THE AIR INTAKE SYSTEM 3-48
3242 ASSEMBLING OF THE AIR INTAKE SYSTEM 3-51
TOC – 2 PC4000-11 T4 SHOP-50 08246-xD-GB-0
325 DIESEL ENGINE 3-54
3251 DISASSEMBLING AND ASSEMBLING OF THE ALTERNATOR 3-54
3252 DISASSEMBLING AND ASSEMBLING OF THE STARTER MOTORS 3-54
3253 DISASSEMBLING OF THE DIESEL ENGINE 3-55
3254 ASSEMBLING OF THE DIESEL ENGINE 3-61
326 BATTERIES 3-68
3261 DISASSEMBLING OF THE BATTERIES 3-68
3262 ASSEMBLING OF THE BATTERIES 3-70
327 FLEXIBLE COUPLING 3-71
3271 DISASSEMBLING OF THE CENTAFLEX COUPLING ASSEMBLY 3-71
3272 ASSEMBLING OF THE CENTAFLEX COUPLING ASSEMBLY 3-74
3273 REPLACING THE RUBBER ROLLERS OF THE CENTAFLEX COUPLING 3-76
328 RADIATOR FAN AND FAN DRIVE ASSEMBLY 3-78
3281 DISASSEMBLING OF THE RADIATOR FAN 3-80
3282 ASSEMBLING OF THE RADIATOR FAN 3-82
3283 DISASSEMBLING OF THE RADIATOR FAN MOTOR 3-84
3284 ASSEMBLING OF THE RADIATOR FAN MOTOR 3-86
3285 DISASSEMBLING OF THE RADIATOR ASSEMBLY 3-88
3286 ASSEMBLING OF THE RADIATOR ASSEMBLY 3-93
329 MAIN PUMP ASSEMBLIES 3-98
3291 DISASSEMBLING AND ASSEMBLING OF THE AUXILIARY PUMPS 3-99
3292 DISASSEMBLING OF THE MAIN PUMP ASSEMBLIES 3-100
3293 ASSEMBLING OF THE MAIN PUMP ASSEMBLIES 3-104
3210 UNIVERSAL PTO 3-108
32101 DISASSEMBLING OF THE UNIVERSAL PTO 3-108
32102 ASSEMBLING OF THE UNIVERSAL PTO 3-111
33 HYDRAULIC SYSTEM 3-114
331 HYDRAULIC OIL COOLER ASSEMBLY 3-114
3311 DISASSEMBLING OF HYDRAULIC COOLER FAN AND MOTOR 3-115
3312 ASSEMBLING OF HYDRAULIC COOLER FAN AND MOTOR 3-118
3313 DISASSEMBLING OF THE HYDRAULIC OIL RADIATORS 3-121
3314 ASSEMBLING OF THE HYDRAULIC OIL COOLERS 3-125
3315 DISASSEMBLING OF THE HYDRAULIC OIL COOLER ASSEMBLY 3-128
3316 ASSEMBLING OF THE HYDRAULIC OIL COOLER ASSEMBLY 3-133
332 HYDRAULIC OIL TANK 3-138
3321 DISASSEMBLING OF THE MAIN SHUT-OFF VALVE 3-140
3322 ASSEMBLING OF THE MAIN SHUT-OFF VALVE 3-142
3323 DISASSEMBLING OF THE HYDRAULIC OIL TANK 3-144
3324 ASSEMBLING OF THE HYDRAULIC OIL TANK 3-149
333 MAIN CONTROL VALVE BLOCKS 3-156
3331 DISASSEMBLING OF THE MAIN CONTROL VALVE BLOCKS 3-156
3332 ASSEMBLING OF THE MAIN CONTROL VALVE BLOCKS 3-159
3333 DISASSEMBLING OF THE MRV AT THE MAIN CONTROL VALVE BLOCKS 3-162
3334 ASSEMBLING OF THE MRV AT THE MAIN CONTROL VALVE BLOCKS 3-163
3335 DISASSEMBLING OF SRV ON MAIN CONTROL VALVE BLOCK 3-164
3336 ASSEMBLING OF SRV ON MAIN CONTROL VALVE BLOCKS 3-165
3337 DISASSEMBLING OF ACV-/SRV-BLOCK ON MAIN CONTROL
VALVE BLOCKS 3-166
3338 ASSEMBLING OF ACV-/SRV-BLOCK ON MAIN CONTROL VALVE BLOCKS 3-168
SHOP-50 08246-xD-GB-0 PC4000-11 T4 TOC – 3
334 DISTRIBUTOR MANIFOLD 3-170
3341 DISASSEMBLING OF SRV-VALVE BLOCKS / RESTRICTOR BLOCKS AT
THE DISTRIBUTOR MANIFOLD 3-171
3342 ASSEMBLING OF SRV-VALVE BLOCKS / RESTRICTOR BLOCKS AT
THE DISTRIBUTOR MANIFOLD 3-173
3343 DISASSEMBLING OF ANTI CAVITATION VALVES AT THE DISTRIBUTOR
MANIFOLD 3-175
3344 ASSEMBLING OF ANTI CAVITATION VALVES AT THE DISTRIBUTOR
MANIFOLD 3-177
3345 DISASSEMBLING OF THE DIFFUSER BLOCK AT THE MANIFOLD (FSA) 3-179
3346 ASSEMBLING OF THE DIFFUSER BLOCK AT THE MANIFOLD 3-181
3347 DISASSEMBLING OF THE DISTRIBUTOR MANIFOLD 3-182
3348 ASSEMBLING OF THE DISTRIBUTOR MANIFOLD 3-185
34 SLEW SYSTEM 3-188
341 SLEW GEARS 3-188
3411 DISASSEMBLING OF THE SLEW GEAR 3-189
3412 ASSEMBLING OF THE SLEW GEAR 3-192
342 SLEW MOTOR 3-196
3421 DISASSEMBLING OF THE SLEW MOTOR 3-197
3422 ASSEMBLING OF THE SLEW MOTOR 3-200
343 SLEW PARKING BRAKE 3-202
3431 DISASSEMBLING OF THE SLEW PARKING BRAKE (L&S) 3-203
3432 ASSEMBLING OF THE SLEW PARKING BRAKE (L&S) 3-206
3433 DISASSEMBLING OF THE SLEW PARKING BRAKE (SIEBENHAAR) 3-209
3434 ASSEMBLING OF THE SLEW PARKING BRAKE (SIEBENHAAR) 3-212
344 SLEW SERVICE BRAKE VALVE 3-215
3441 DISASSEMBLING OF THE SLEW SERVICE BRAKE VALVE 3-215
3442 ASSEMBLING OF THE OF THE SLEW SERVICE BRAKE VALVE 3-217
345 SLEW CIRCLE 3-219
3451 DISASSEMBLING OF THE SLEW CIRCLE 3-219
3452 ASSEMBLING OF THE SLEW CIRCLE 3-223
346 SLEW CIRCLE LUBRICATION PINION (DUMMY WHEEL) 3-228
3461 DISASSEMBLING OF THE LUBRICATION PINION ASSEMBLY 3-228
3462 ASSEMBLING OF THE LUBRICATION PINION ASSEMBLY 3-229
35 LUBRICATION PUMPS 3-230
351 DISASSEMBLING OF THE LUBRICATION PUMP 3-230
352 ASSEMBLING OF THE LUBRICATING PUMP 3-231
36 OPERATOR’S CAB 3-232
361 DISASSEMBLING OF THE OPERATOR’S CAB 3-233
362 ASSEMBLING OF THE OPERATOR’S CAB 3-237
363 DISASSEMBLING OF THE OPERATOR’S CAB TOGETHER WITH THE CAB
SUPPORT FRAME 3-240
364 ASSEMBLING OF THE OPERATOR’S CAB TOGETHER WITH THE CAB
SUPPORT FRAME 3-244
365 CAB-MOUNTS 3-248
3651 DISASSEMBLING OF THE CAB-MOUNTS 3-248
3652 ASSEMBLING OF THE CAB-MOUNTS 3-250
366 FRONT WINDOW 3-252
3661 DISASSEMBLING OF THE FRONT WINDOW 3-252
3662 ASSEMBLING OF THE FRONT WINDOW 3-253
TOC – 4 PC4000-11 T4 SHOP-50 08246-xD-GB-0
367 OPERATOR’S SEAT 3-254
3671 DISASSEMBLING OF THE OPERATOR’S SEAT 3-254
3672 ASSEMBLING OF THE OPERATOR’S SEAT 3-255
37 CAB BASE 3-256
371 DISASSEMBLING OF THE CAB SUPPORT FRAME 3-257
372 ASSEMBLING OF THE CAB SUPPORT FRAME 3-259
373 DISASSEMBLING OF THE CAB BASE 3-261
374 ASSEMBLING OF THE CAB BASE 3-263
38 LADDERS AND PLATFORMS 3-265
381 HYDRAULIC ACCESS LADDER 3-265
3811 DISASSEMBLING OF THE HYDRAULIC ACCESS LADDER 3-265
3812 ASSEMBLING OF THE HYDRAULIC ACCESS LADDER 3-267
382 DISASSEMBLING OF THE ACCESS LADDER CYLINDER 3-269
383 ASSEMBLING OF THE ACCESS LADDER CYLINDER 3-271
384 FUEL TANK STEP 3-272
3841 DISASSEMBLING OF THE FUEL TANK STEP 3-272
3842 ASSEMBLING OF THE FUEL TANK STEP 3-274
385 STEP PLATFORMS 3-275
3851 DISASSEMBLING OF THE UPPER STEP PLATFORM AT FUEL TANK 3-275
3852 ASSEMBLING OF THE UPPER STEP PLATFORM AT FUEL TANK 3-277
3853 DISASSEMBLING OF THE LOWER STEP PLATFORM AT
MACHINE HOUSE 3-278
3854 ASSEMBLING OF THE LOWER STEP PLATFORM AT MACHINE HOUSE 3-279
386 EMERGENCY ESCAPE LADDERS 3-280
3861 DISASSEMBLING OF THE EMERGENCY ESCAPE LADDER ASSEMBLY
AT THE CAB BASE 3-280
3862 ASSEMBLING OF THE EMERGENCY ESCAPE LADDER ASSEMBLY AT
THE CAB BASE 3-282
3863 DISASSEMBLING OF THE EMERGENCY ESCAPE LADDER ASSEMBLY
AT THE MACHINE HOUSE 3-283
3864 ASSEMBLING OF THE EMERGENCY ESCAPE LADDER ASSEMBLY AT
THE MACHINE HOUSE 3-285
39 COUNTERWEIGHT 3-286
391 DISASSEMBLING OF THE COUNTERWEIGHT 3-287
392 ASSEMBLING OF THE COUNTERWEIGHT 3-289
310 FUEL TANK 3-292
3101 DISASSEMBLING OF THE FUEL TANK 3-292
3102 ASSEMBLING OF THE FUEL TANK 3-296
3103 FUEL COOLER BOX (T4 EQUIPMENT) 3-300
31031 DISASSEMBLING OF THE FUEL COOLER BOX (T4 EQUIPMENT) 3-300
31032 ASSEMBLING OF THE FUEL COOLER BOX (T4 EQUIPMENT) 3-302
311 SUPERSTRUCTURE LIFTING 3-304
3111 DISASSEMBLE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE 3-304
3112 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE 3-307
SHOP-50 08246-xD-GB-0 PC4000-11 T4 TOC – 5
4 UNDERCARRIAGE 4-1
41 UNDERCARRIAGE OVERVIEW 4-2
42 TRAVEL SYSTEM 4-4
421 CRAWLER TRACK 4-4
4211 CHANGING OF THE CRAWLER TRACK 4-4
422 SPROCKET 4-11
4221 DISASSEMBLING OF THE SPROCKET ASSEMBLY 4-11
4222 ASSEMBLING OF THE SPROCKET ASSEMBLY 4-16
423 GUIDE WHEEL ASSEMBLY 4-19
4231 DISASSEMBLING OF THE GUIDE WHEEL ASSEMBLY 4-19
4232 ASSEMBLING OF THE GUIDE WHEEL ASSEMBLY 4-21
424 TRACK TENSIONING ACCUMULATORS 4-24
4241 DISASSEMBLING OF THE LOW PRESSURE ACCUMULATORS 4-24
4242 ASSEMBLING OF THE LOW PRESSURE ACCUMULATORS 4-26
4243 DISASSEMBLING OF THE HIGH PRESSURE ACCUMULATORS 4-28
4244 ASSEMBLING OF THE HIGH PRESSURE ACCUMULATORS 4-29
425 TRACK TENSION VALVE BLOCK 4-30
4251 DISASSEMBLING OF THE TRACK TENSIONING VALVE BLOCK 4-30
4252 ASSEMBLING OF THE TRACK TENSIONING VALVE BLOCK 4-31
426 TRACK TENSIONING CYLINDERS 4-32
4261 DISASSEMBLING OF THE TRACK TENSIONING CYLINDERS 4-32
4262 ASSEMBLING OF THE TRACK TENSIONING CYLINDERS 4-34
427 HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM 4-37
4271 PRECURSORY WORK 4-37
4272 REPLACE THE HYDRAULIC HOSES INSIDE THE CENTER BODY 4-39
4273 REPLACE THE HYDRAULIC HOSES BETWEEN CENTER BODY AND
CRAWLER FRAME 4-39
4274 REPLACE THE HYDRAULIC HOSES INSIDE THE CRAWLER FRAME 4-41
4275 SUBSEQUENT WORK 4-41
428 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE) 4-42
4281 DISASSEMBLING OF THE TRAVEL BRAKE VALVE BLOCK 4-42
4282 ASSEMBLING OF THE TRAVEL BRAKE VALVE BLOCK 4-44
429 TRAVEL MOTORS 4-46
4291 DISASSEMBLING OF THE TRAVEL MOTORS 4-46
4292 ASSEMBLING OF THE TRAVEL MOTORS 4-48
4210 TRAVEL PARKING BRAKE 4-50
42101 TRAVEL PARKING BRAKE OVERVIEW 4-50
42102 DISASSEMBLING OF THE TRAVEL PARKING BRAKE (L&S) 4-55
42103 ASSEMBLING OF THE TRAVEL PARKING BRAKE (L&S) 4-58
42104 DISASSEMBLING OF THE TRAVEL PARKING BRAKE (ZOLLERN) 4-61
42105 ASSEMBLING OF THE TRAVEL PARKING BRAKE (ZOLLERN) 4-64
4211 TRAVEL GEAR BOX 4-68
42111 DISASSEMBLING OF THE TRAVEL GEAR BOX 4-69
42112 ASSEMBLING OF THE TRAVEL GEAR BOX 4-71
4212 CARRIER ROLLER 4-74
42121 DISASSEMBLING OF THE CARRIER ROLLER ASSEMBLY 4-74
42122 ASSEMBLING OF THE CARRIER ROLLER ASSEMBLY 4-76
4213 TRACK ROLLER 4-78
42131 DISASSEMBLING OF THE TRACK ROLLER ASSEMBLY 4-78
42132 ASSEMBLING OF THE TRACK ROLLER ASSEMBLY 4-80
TOC – 6 PC4000-11 T4 SHOP-50 08246-xD-GB-0
43 UNDERCARRIAGE CENTER BODY 4-82
431 DISASSEMBLING OF THE UNDERCARRIAGE CENTER BODY AND THE
CRAWLER CARRIERS 4-82
432 ASSEMBLING OF THE UNDERCARRIAGE CENTER BODY AND THE
CRAWLER CARRIERS 4-87
4321 INSTALL CRAWLER CARRIER MOUNTING BOLTS 4-93
433 ROTARY JOINT 4-94
4331 DISASSEMBLING OF THE ROTARY JOINT 4-94
4332 ASSEMBLING OF THE ROTARY JOINT 4-98
5 ATTACHMENT 5-1
51 REPAIR PROCEDURES 5-2
511 REPLACEMENT OF BUSHINGS AT THE ATTACHMENT 5-2
5111 DISASSEMBLING OF THE BUSHINGS 5-2
5112 INSTALLATION OF THE BUSHINGS 5-3
512 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS 5-4
52 BACKHOE ATTACHMENT (BHA) 5-6
521 OVERVIEW 5-6
522 PIN SEALING BUCKET – STEERING ROD – BUCKET LINK ROD 5-8
523 BOOM ASSEMBLY 5-10
5231 DISASSEMBLING OF THE BOOM 5-10
5232 ASSEMBLING OF THE BOOM 5-12
5233 DISASSEMBLING OF THE BOOM CYLINDERS 5-15
5234 ASSEMBLING OF THE BOOM CYLINDERS 5-20
524 STICK ASSEMBLY 5-25
5241 DISASSEMBLING OF THE STICK 5-25
5242 ASSEMBLING OF THE STICK 5-30
5243 DISASSEMBLING OF THE STICK CYLINDERS 5-34
5244 ASSEMBLING OF THE STICK CYLINDERS 5-38
525 BUCKET AND STEERING 5-43
5251 DISASSEMBLING OF THE BUCKET 5-43
5252 ASSEMBLING OF THE BUCKET 5-47
5253 DISASSEMBLING OF THE BUCKET CYLINDERS 5-50
5254 ASSEMBLING OF THE BUCKET CYLINDERS 5-57
5255 DISASSEMBLING OF THE BUCKET LINK ROD 5-64
5256 ASSEMBLING OF THE BUCKET LINK ROD 5-67
5257 DISASSEMBLING OF THE STEERING RODS 5-70
5258 ASSEMBLING OF THE STEERING RODS 5-76
526 HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT 5-81
5261 REPLACING OF THE BOOM ARC HOSES 5-81
5262 REPLACING OF THE LUBRICATION HOSES 5-84
5263 REPLACING OF THE BOOM CYLINDER HOSES 5-85
5264 REPLACING OF THE STICK CYLINDER HOSES 5-88
5265 REPLACING OF THE BUCKET CYLINDER HOSES 5-91
SHOP-50 08246-xD-GB-0 PC4000-11 T4 TOC – 7
53 FRONT SHOVEL ATTACHMENT (FSA) 5-94
531 OVERVIEW 5-94
532 USING THE CYLINDER MOUNTING DEVICE FOR FRONT SHOVEL
ATTACHMENTS (PN 967 000 40) 5-96
5321 DESIGNATED USAGE 5-97
5322 NON-DESIGNATED USAGE 5-97
533 BOOM ASSEMBLY 5-98
5331 DISASSEMBLING OF THE BOOM 5-98
5332 ASSEMBLING OF THE BOOM 5-101
5333 DISASSEMBLING OF THE BOOM CYLINDERS 5-104
5334 ASSEMBLING OF THE BOOM CYLINDERS 5-109
534 STICK ASSEMBLY 5-114
5341 DISASSEMBLING OF THE STICK 5-114
5342 ASSEMBLING OF THE STICK 5-119
5343 DISASSEMBLING OF THE STICK CYLINDERS 5-124
5344 ASSEMBLING OF THE STICK CYLINDERS 5-128
535 BULL CLAM BUCKET 5-132
5351 DISASSEMBLING OF THE BULL CLAM BUCKET 5-132
5352 ASSEMBLING OF THE BULL CLAM BUCKET 5-136
5353 DISASSEMBLING OF THE BUCKET CYLINDERS 5-140
5354 ASSEMBLING OF THE BUCKET CYLINDERS 5-146
5355 DISASSEMBLING OF THE CLAM CYLINDERS 5-152
5356 ASSEMBLING OF THE CLAM CYLINDERS 5-157
536 HYDRAULIC HOSES AT THE FACESHOVEL ATTACHMENT 5-163
5361 REPLACING OF THE BOOM ARC HOSES 5-163
5362 REPLACING OF THE LUBRICATION HOSES 5-166
5363 REPLACING OF THE BOOM CYLINDER HOSES 5-167
5364 REPLACING OF THE STICK ARC HOSES 5-170
5365 REPLACING OF THE STICK CYLINDER HOSES 5-173
5366 REPLACING OF THE BUCKET CYLINDER HOSES 5-176
5367 REPLACING OF THE CLAM CYLINDER HOSES 5-178
54 METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT 5-184
541 DISASSEMBLING OF THE METERING VALVES (GREASE INJECTORS) 5-184
542 ASSEMBLING OF THE METERING VALVES (GREASE INJECTORS) 5-186
55 GROUND ENGAGING TOOLS (GET) 5-187
551 DISASSEMBLING AND ASSEMBLING OF THE GET 5-187
56 CYLINDER BYPASS TEST 5-189
6 SERVICE INFORMATION 6-1
61 FLUIDS AND LUBRICANTS 6-2
62 LIFTING GEARS 6-2
63 SAFETY HINTS FOR SLING ACCESSORY 6-4
64 WEIGHT TABLES 6-5
641 SUPERSTRUCTURE 6-5
642 UNDERCARRIAGE 6-7
643 BACKHOE ATTACHMENT (BHA) 6-8
644 FACE SHOVEL ATTACHMENT (FSA) 6-9
TOC – 8 PC4000-11 T4 SHOP-50 08246-xD-GB-0
65 TORQUE CHARTS ACCORDING TO KOMATSU COMPANY STANDARD 6-10
651 METRIC STANDARD THREAD 6-10
652 METRIC FINE THREAD 6-11
653 CUMMINS MOTOR TORQUES – METRIC 6-12
654 CUMMINS MOTOR TORQUES – US CUSTOMARY 6-12
655 SAE-FLANGE CONNECTIONS 6-13
66 BLIND PLUGS 6-14
661 DUMMY PLATES FOR SAE–FLANGES 6-14
662 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH 6-16
663 PLUGS AND FITTINGS ACCORDING TO DIN 2353 6-17
67 CONVERSION TABLE 6-18
671 METHOD OF USING THE CONVERSATION TABLE 6-18
672 MILLIMETER – INCH & KILOGRAM – POUND 6-19
673 LITER – US GALLON & LITER – UK GALLON 6-20
674 NM- FTLB 6-21
675 BAR – PSI – KPA – MPA 6-22
676 TEMPERATURE 6-23
68 TOOLS 6-24
681 STANDARD TOOL CASE 6-24
682 USED SPECIAL TOOLS (OVERVIEW) 6-26
69 WORK INSTRUCTIONS 6-29
691 BLEEDING THE TRACK TENSIONING SYSTEM 6-29
692 HINTS FOR HYDRAULIC HOSE INSTALLATION 6-31
693 REMOVE / INSTALL THE CRAWLER CARRIER 6-34
694 REPAIR PROCEDURE FOR THE RADIATOR ASSEMBLY 6-35
7 PARTS & SERVICE NEWS 7-1
71 LIST OF RELEVANT PARTS AND SERVICE NEWS 7-2

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• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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